Hoshizaki KML-200MAE Service Manual
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Hoshizaki KML-200MAE Service Manual

Hoshizaki KML-200MAE Service Manual

Modular crescent cuber
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MODULAR CRESCENT CUBER
KML-200MAE
KML-200MWE
SERVICE MANUAL
HOSHIZAKI
MODEL
NO.:
73095
ISSUED:
FEB. 4, 1998
REVISED:
NOV. 29, 2000

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  • Page 1 HOSHIZAKI MODULAR CRESCENT CUBER MODEL KML-200MAE KML-200MWE SERVICE MANUAL NO.: 73095 ISSUED: FEB. 4, 1998 REVISED: NOV. 29, 2000...
  • Page 2 No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker. Should the reader have any questions or concerns which have not been satisfactorily ad- dressed, please call or write to the HOSHIZAKI Care Department for assistance.

  • Page 3: Table Of Contents

    I. SPECIFICATIONS ... 5 1. KML-200MAE (Air-cooled) ... 5 2. KML-200MWE (Water-cooled) ... 6 II. GENERAL INFORMATION ... 7 1. CONSTRUCTION ... 7 [a] KML-200MAE (Air-cooled) ... 7 [b] KML-200MWE (Water-cooled) ... 8 2. CONTROLLER BOARD ... 9 [a] SOLID-STATE CONTROL ... 9 [b] CONTROLLER BOARD ...
  • Page 4 V. REMOVAL AND REPLACEMENT OF COMPONENTS... 33 1. SERVICE FOR REFRIGERANT LINES ... 33 [a] REFRIGERANT RECOVERY ... 33 [b] EVACUATION AND RECHARGE ... 33 2. BRAZING ... 34 3. REMOVAL AND REPLACEMENT OF COMPRESSOR... 34 4. REMOVAL AND REPLACEMENT OF DRIER ... 36 5.

  • Page 5: Specifications

    I. SPECIFICATIONS 1. KML-200MAE AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROX. ICE PRODUCTION PER 24 HR. lbs./day ( kg./day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W ( KWH/100 lbs.

  • Page 6: Kml-200Mwe (Water-Cooled)

    2. KML-200MWE AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROX. ICE PRODUCTION PER 24 HR. lbs./day ( kg./day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W ( KWH/100 lbs. ) WATER gal./24 HR.

  • Page 7: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] KML-200MAE...

  • Page 8: [B] Kml-200Mwe (Water-Cooled)

    [b] KML-200MWE...

  • Page 9: Controller Board

    2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KML-200 Series Modular Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system. 3) All models are pre-tested and factory-adjusted.
  • Page 10 (2) Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle. But the Defrost Timer does not start counting until the Ther- mistor senses 48°F at the Evaporator outlet. The period from the end of the freeze cycle up to the point of the Thermistor's sensing varies depending on the ambient and water temperatures.
  • Page 11 Connector K1 Pin #1 thru #10 #1, 9 Magnetic Contactor Hot Gas Valve Line Valve Pump Motor (icemaking) Pump Motor (drain) Water Valve #7, 10 Power (line, Bin Control) Open Dip Switch Defrost Timer, Drain Timer & Drain Counter Connector K5 Float Switch Connector K4 Open...

  • Page 12: [C] Sequence

    [c] SEQUENCE 1st Cycle 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 2. After 1 minute, Defrost cycle starts. 5. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens.
  • Page 13 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. 10/20 second Drain Timer starts counting. & LINE VALVE 5.
  • Page 14 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. 4. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens.

  • Page 15: [D] Controls And Adjustments

    [d] CONTROLS AND ADJUSTMENTS (Alpine/Alpine “C” Board) The Dip Switch is factory-adjusted to the following positions: DIP SWITCH NO. KML-200MAE, KML-200MWE Switch Nos. 1 and 2: Used for adjustment of the Defrost Timer. The Defrost Timer starts counting when the Thermistor reads a certain temperature at the Evaporator outlet.
  • Page 16 1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor. The resistance varies depending on the Suction Line temperatures. The Thermistor detects the temperature of the Evaporator outlet to start the Defrost Timer. No adjustment is required. If neces- sary, check for resistance between Thermistor leads, and visually check the Thermistor mounting, located on the Suction Line next to the Evaporator outlet.
  • Page 17 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING Dip Switch No. 3 T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Drain Counter Do not adjust the Drain Counter, or the Evaporator may freeze up. Except for some B-type models, the Drain Counter is factory-adjusted to drain the Water Tank every 10 cycles, and no adjustment is required.

  • Page 18: [E] Checking Controller Board

    5) Bin Control When the ambient temperature is below 45°F, the Bin Control Thermostat operates to stop the icemaker even if the Ice Storage Bin is empty. When the Thermostat is set in the prohibited range, the icemaker operates continuously even if the Ice Storage Bin is filled with ice. Setting in the prohibited range might cause severe damage to the icemaker resulting in failure.
  • Page 19 The unit should start the freeze cycle after 1 minute ± 5 seconds from the resistor connection. 3) Check the Controller Board by using test program of the Controller Board. (i) Disconnect the Connector K1 from the Controller Board. Set the Dip Switch No. 7 and 8 on the Controller Board to the “ON”...

  • Page 20: Switches

    3. SWITCHES Two control switches are used to control operation in the KML Series Modular Crescent Cubers. These switches are referred to as the “Control Switch” and the “Service Switch.” [a] CONTROL SWITCH The Control Switch is located on the lower left section of the control box when facing the front of the machine.

  • Page 21: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KML-200MAE...

  • Page 22: [B] Kml-200Mwe (Water-Cooled)

    [b] KML-200MWE...

  • Page 23: Wiring Diagrams

    Note: KML-200MAE Pressure Switch 2. WIRING DIAGRAMS Cut-out 384 ± 21.3 PSIG [a] KML-200MAE, KML-200MWE Cut-in 284.5 ± 21.3 PSIG KML-200MWE Pressure Switch Cut-out 355.6 ± 21.3 PSIG Cut-in 256 ± 21.3 PSIG...

  • Page 24: Timing Chart

    3. TIMING CHART When Control Sw. is turned OFF, Pressure Sw. is OFF, or Thermistor Temp. exceeds t1. Control Sw. in Thermo- stat ON Pressure Sw. ON Overheat Protect Reset (KM-1200MAE/SAE) (KM-1200MRE/SRE, KM-2000SRE3) *NOTE: The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...
  • Page 25 To Stand-by Cycle (When Control Sw. is turned OFF, Pressure Sw. is OFF, or Thermistor Temp. exceeds t1.) To Freeze Cycle From Freeze Cycle Min. 3 min (KM-1200MAE/SAE) (KM-1200MRE/SRE, KM-2000SRE3) *1 The Pump Motor waits for 2 seconds before starting a drain cycle. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...

  • Page 26: Performance Data

    4. PERFORMANCE DATA [a] KML-200MAE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg./day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day (m /day) FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG SUCTION PRESSURE PSIG (kg/cm TOTAL HEAT OF REJECTION Note: Pressure data is recorded first 5 minutes in freezing cycle.

  • Page 27: [B] Kml-200Mwe (Water-Cooled)

    [b] KML-200MWE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg./day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day (m /day) FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG SUCTION PRESSURE PSIG HEAT OF REJECTION FROM CONDENSER HEAT OF REJECTION FROM COMPRESSOR WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE...

  • Page 28: Service Diagnosis

    IV. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION PROBLEM [1] The icemaker a) Power Supply will not start b) Fuse (Inside Fused Disconnect, if any) c) Control Switch d) Bin Control Thermostat e) High Pressure Control f) Transformer g) Wiring to Controller Board h) Thermistor i) Hot Gas Solenoid...
  • Page 29 PROBLEM l) Controller Board [2] Water a) Float switch continues to be supplied, and the ice- maker will not b) Controller Board start. [3] Compressor a) Control Switch b) High Pressure Controller c) Water Regulator d) Overload Protector e) Starter f) Start Capacitor or Run Capacitor g) Magnetic Contactor...
  • Page 30 PROBLEM [4] Water a) Water Solenoid continues to Valve be supplied in b) Controller Board freeze cycle. [5] No water a) Water Supply Line comes from Spray Tubes. Water Pump b) Water Solenoid will not start, or Valve freeze cycle time is too c) Water System short.

  • Page 31: Evaporator Is Frozen Up

    2. EVAPORATOR IS FROZEN UP PROBLEM [1] Freeze cycle a) Float Switch time is too long. b) Water Solenoid Valve c) Controller Board [2] All ice formed a) Evaporator on Evaporator b) Water Supply Line does not fall into bin in c) Water Solenoid harvest cycle.

  • Page 32: Abnormal Ice

    4. ABNORMAL ICE PROBLEM [1] Small Cube a) Ice Cube Guide b) See chart 1 - [5], and check water supply line, Water Solenoid Valve, water system, Pump Motor or Controller Board. c) Drain Valve [2] Cloudy or a) See chart 2 - [1] and - [3], and check Float Switch, Water Solenoid Valve, irregular cube Controller Board, Spray Tubes, water system, refrigerant charge or Expansion Valve.

  • Page 33: Removal And Replacement Of Components

    5) Disconnect the Vacuum Pump, and attach a Refrigerant Service Cylinder to the Low- side line. Remember to loosen the connection, and purge the air from the Hose. See the Nameplate for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

  • Page 34: Brazing

    2. BRAZING 1. Refrigerant R22 itself is not flammable, explosive or poisonous. How- ever, when exposed to an open flame, R22 creates Phosgene gas, hazardous in large amounts. 2. Always recover the refrigerant and store it in an approved container. Do not discharge the refrigerant into the atmosphere.
  • Page 35 7) Slide and remove the Compressor. Unpack the new Compressor package. Install the new Compressor. 8) Attach the Rubber Grommets of the prior Compressor. 9) Sandpaper the Suction, Discharge and Process Pipes. 10) Place the Compressor in position, and secure it using the Bolts and Washers. 11) Remove plugs from the Suction, Discharge and Process Pipes.

  • Page 36: Removal And Replacement Of Drier

    4. REMOVAL AND REPLACEMENT OF DRIER Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. 1) Turn off the power supply. 2) Remove the panels.

  • Page 37: Removal And Replacement Of Hot Gas Valve And .............................. Line Valve

    4) Remove the insulation and the Expansion Valve Bulb on the suction line. 5) Remove the Expansion Valve Cover, and disconnect the Expansion Valve using brazing equipment. 6) Braze the new Expansion Valve, with nitrogen gas flowing at the pressure of 3 - 4 PSIG.
  • Page 38 Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. 1) Turn off the power supply. 2) Remove the panels. 3) Recover the refrigerant and store it in an approved container. 4) Remove the screw and the Solenoid.

  • Page 39: Removal And Replacement Of Evaporator

    7. REMOVAL AND REPLACEMENT OF EVAPORATOR Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repairs or replacement have been made. 1) Turn off the power supply. 2) Remove the panels and the Top Insulation over the Evaporator.

  • Page 40: Removal And Replacement Of Water-Regulating Valve

    8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE - WATER-COOLED MODEL ONLY Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. 1) Turn off the power supply.

  • Page 41: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    9. ADJUSTMENT OF WATER REGULATING VALVE - WATER-COOLED MODEL ONLY The Water Regulating Valve (also called “WATER REGULATOR”) is factory-adjusted. No adjustment is required under normal use. Adjust the Water Regulator, if necessary, using the following procedures. 1) Attach a pressure gauge to the high-side line of the system. Or prepare a thermometer to check for the condenser drain temperature.

  • Page 42: Removal And Replacement Of Thermistor

    10. REMOVAL AND REPLACEMENT OF THERMISTOR 1. Fragile, handle very carefully. 2. Always use a recommended sealant (High Thermal Conductive Type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 or equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent.

  • Page 43: Removal And Replacement Of Fan Motor

    10) Secure the insulation using the Plastic Cable Ties. 11) Connect the Thermistor leads through the bushing of the Control Box to the K3 Connector on the Controller Board. Note: Do not cut the leads of the Thermistor while installing it. 12) Replace the Control Box Cover and the panels in their correct positions.

  • Page 44: Removal And Replacement Of Water Valve

    12. REMOVAL AND REPLACEMENT OF WATER VALVE 1) Turn off the power supply. 2) Close the Water Supply Line Shut-off Valve. 3) Remove the Front Panel. 4) Remove the Valve Outlet Tubing by releasing the Clamp. 5) Remove the Bracket from the unit. 6) Remove the Fitting Nut and Water Valve.

  • Page 45: Removal And Replacement Of Spray Tube

    14. REMOVAL AND REPLACEMENT OF SPRAY TUBE 1) Turn off the power supply. 2) Remove the Front Panel and the Insulation Panel. 3) Release the Clamps, and disconnect the Rubber Hoses. 4) Remove the Spray Tubes by squeezing the side tabs. 5) Install the new Spray Tubes, and replace the removed parts in the reverse order of which they were removed.

  • Page 46: Cleaning And Maintenance Instructions

    VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. PREPARING THE ICEMAKER FOR LONG STORAGE When shutting off the icemaker for an extended time, drain out all water from the water line and remove the ice from the Storage Bin. The Storage Bin should be cleaned and dried.
  • Page 47 [2] Remove the water from the potable water supply line: 1) Turn off the power supply and remove the Front Panel. 2) Move the Control Switch, on the Control Box, to the “OFF” position. 3) Wait 3 minutes. 4) Close the Potable Water Supply Line Shut-off Valve and open the Potable Water Supply Line Drain Valve.

  • Page 48: Cleaning

    This will prevent irritation in case the solution contacts with skin. 1) Dilute approximately 10.5 fl. oz. of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY,” (Economics Laboratory, Inc.) with 2 gal. of water. 2) Remove all ice from the Evaporator and the Storage Bin.
  • Page 49 11) Replace the Insulation Panel and the Front Panel in their correct positions. 12) Turn on the power supply and start the washing process. 13) Turn off the power supply after 30 minutes. 14) Remove the Front Panel. 15) Move the Service Switch to the “DRAIN” position. 16) Replace the Front Panel and turn on the power supply for 2 minutes.

  • Page 50: Sanitizing

    1) Dilute IMS-II Sanitizer or a 5.25% Sodium Hypochlorite solution with water (Add 1.0 fl. oz. to 2 gal. of water). Note: IMS-II Sanitizer, Part #SA0004, is available through your Hoshizaki Dealer. 2) Remove the Insulation Panel. 3) Pour the sanitizing solution into the Water Tank.

  • Page 51: Maintenance

    4. MAINTENANCE This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. 1) Stainless Steel Exterior To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2) Storage Bin and Scoop •...

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Kml-200mwe

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