Hoshizaki KM-1601SWH Service Manual
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Hoshizaki KM-1601SWH Service Manual

Stackable crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Stackable Crescent Cuber
Models
KM-1601SWH
KM-1601SWH3
KM-1601SRH
KM-1601SRH3
SERVICE MANUAL
™
Number: 73145
Issued: 10-31-2006
Revised: 10-4-2007

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Summary of Contents for Hoshizaki KM-1601SWH

  • Page 1 Hoshizaki Hoshizaki America, Inc. Stackable Crescent Cuber Models KM-1601SWH KM-1601SWH3 KM-1601SRH KM-1601SRH3 SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com ™ Number: 73145 Issued: 10-31-2006 Revised: 10-4-2007...
  • Page 2 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 addressed, please call, write, or send an e-mail message to the HOSHIZAKI Technical Support Department for assistance. HOSHIZAKI AMERICA, INC.

  • Page 3: Table Of Contents

    B. Condensing Unit ......................11 1. URC-21F ....................... 11 II. General Information ......................13 A. Construction ........................ 13 1. KM-1601SWH, KM-1601SWH3 (water-cooled) ............. 13 2. KM-1601SRH, KM-1601SRH3 (remote air-cooled) ..........14 B. Sequence of Operation ....................15 1. One Minute Fill Cycle .................... 15 2.
  • Page 4 1. KM-1601SWH, KM-1601SWH3 (water-cooled) ............. 25 2. KM-1601SRH, KM-1601SRH3 (remote air-cooled) ..........26 B. Wiring Diagrams ......................27 1. KM-1601SWH (water-cooled), KM-1601SRH (remote air-cooled) ......27 2. KM-1601SWH3 (water-cooled), KM-1601SRH3 (remote air-cooled) ....28 C. Performance Data ....................... 29 1. KM-1601SWH (water-cooled) ................29 2.

  • Page 5: Specifications

    I. Specifications A. Icemaker 1. KM-1601SWH (water-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 13.4 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.

  • Page 6: Km-1601Swh3 (Water-Cooled)

    2. KM-1601SWH3 (water-cooled) AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 9.0 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *1555 (705) 1558 (707)

  • Page 7: 3A. Km-1601Srh (Remote Air-Cooled) (Auxiliary Codes: R-0; R-1; Some S-1)

    3a. KM-1601SRH (remote air-cooled) (auxiliary codes: R-0; R-1; some S-1) This data applies to units with an 8 l/min water valve. The 8 l/min water valve is part number 3U0111-02 and has J248-032 stamped on the side of the valve facing the rear of the unit.

  • Page 8: 3B. Km-1601Srh (Remote Air-Cooled) (Auxiliary Codes: Some S-1; S-2 And Later)

    3b. KM-1601SRH (remote air-cooled) (auxiliary codes: some S-1; S-2 and later) This data applies to units with a 15 l/min or 11 l/min water valve. The 15 l/min water valve is part number 3U0111-01 and has J248-030 stamped on the side of the valve facing the rear of the unit.

  • Page 9: 4A. Km-1601Srh3 (Remote Air-Cooled) (Auxiliary Codes: R-0; R-1; Some S-1)

    4a. KM-1601SRH3 (remote air-cooled) (auxiliary codes: R-0; R-1; some S-1) This data applies to units with an 8 l/min water valve. The 8 l/min water valve is part number 3U0111-02 and has J248-032 stamped on the side of the valve facing the rear of the unit.

  • Page 10: 4B. Km-1601Srh3 (Remote Air-Cooled) (Auxiliary Codes: Some S-1; S-2 And Later)

    4b. KM-1601SRH3 (remote air-cooled) (auxiliary codes: some S-1; S-2 and later) This data applies to units with a 15 l/min or 11 l/min water valve. The 15 l/min water valve is part number 3U0111-01 and has J248-030 stamped on the side of the valve facing the rear of the unit.

  • Page 11: Condensing Unit

    B. Condensing Unit 1. URC-21F Unit: mm (inches)
  • Page 12 SPECIFICATIONS MODEL: URC-21F AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 2.6FLA 130W EXTERIOR DIMENSIONS (WxDxH) 46-3/8" x 15-11/16" x 25-15/16" (1178 x 398 x 659 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 48-7/16" x 18-1/8" x 40-7/8" (1230 x 460 x 1039 mm) EXTERIOR FINISH Galvanized Steel WEIGHT...

  • Page 13: General Information

    II. General Information A. Construction 1. KM-1601SWH, KM-1601SWH3 (water-cooled) Spray Tubes Inlet Water Expansion Valves Valve Evaporator Assembly Water Supply Inlet Junction Box Hot Gas Valve Check Valves Cleaning Valve Water Regulator Check Valve (water) Water Pump Water-cooled Float Switch...

  • Page 14: Km-1601Srh, Km-1601Srh3 (Remote Air-Cooled)

    2. KM-1601SRH, KM-1601SRH3 (remote air-cooled) Spray Tubes Expansion Valves Inlet Water Valve Water Supply Inlet Evaporator Assembly Hot Gas Valve Junction Boxes Cleaning Valve Check Valves Check Valve (water) Water Pump Receiver Tank Float Switch Compressor Control Box Drier Bin Control Thermostat Control Switch Transformer Box Liquid Line Valve...

  • Page 15: Sequence Of Operation

    B. Sequence of Operation The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. 1.

  • Page 17: Control Board

    C. Control Board • A HOSHIZAKI exclusive solid-state control is employed in KM-1601SWH, KM-1601SWH3, KM-1601SRH, and KM-1601SRH3 Stackable Crescent Cubers. • All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 18: Control Board Layout

    1. Control Board Layout Control Products "E" Control Board Output Test Switch (used to test relays on board) Dip Switch Alarm Reset Switch Backup Freeze Timer LED Connector K3 Harvest Control (thermistor) Backup Harvest Connector K4 Timer LED Open (not connected) Alarm Buzzer Microprocessor Power LED...

  • Page 19: Features

    2. Features a) Maximum Water Supply Period – 6 minutes Inlet water valve opening, in the harvest cycle, is limited by the harvest timer. The water valve cannot remain open longer than the maximum period. The water valve can close in less than six minutes if the harvest cycle is completed.

  • Page 20: F) Led Lights And Audible Alarm Safeties

    f) LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power is turned off. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below.

  • Page 21: Controls And Adjustments

    However, a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning. Before changing this setting, call the HOSHIZAKI Technical Support Department at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production.

  • Page 22: C) Pump-Out Timer (Dip Switch 3 & 4)

    c) Pump-Out Timer (dip switch 3 & 4) When a freeze cycle is completed, the pump motor stops, and the icemaker resumes operation in 2 seconds. Then, during cycles when a pump out is called for, the pump motor drains the water tank for the time determined by the pump-out timer. The pump- out timer also acts in place of the harvest timer during cycles with a pump out.

  • Page 23: E) Freeze Timer (Dip Switch 9 & 10)

    e) Freeze Timer (dip switch 9 & 10) CAUTION Adjust to proper specification, or the unit may not operate correctly. The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest cycle.

  • Page 24: Control Board Replacement

    5. Control Board Replacement The application switch located between relay X3 & X4 must be set to match the original board application. Place this switch in the "ALP" position if there is no white wire supplied to the K1 connector. If there is a white wire, place the switch in the "C" position. If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch in the "OFF"...

  • Page 25: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-1601SWH, KM-1601SWH3 (water-cooled)

  • Page 26: Km-1601Srh, Km-1601Srh3 (Remote Air-Cooled)

    2. KM-1601SRH, KM-1601SRH3 (remote air-cooled)

  • Page 27: Wiring Diagrams

    B. Wiring Diagrams 1. KM-1601SWH (water-cooled), KM-1601SRH (remote air-cooled) * Pressure Switch Water-Cooled Model Remote Model Cut-out 384± PSIG 412± PSIG Cut-in 284±21 PSIG 327±21 PSIG...

  • Page 28: Km-1601Swh3 (Water-Cooled), Km-1601Srh3 (Remote Air-Cooled)

    2. KM-1601SWH3 (water-cooled), KM-1601SRH3 (remote air-cooled) * Pressure Switch Water-Cooled Model Remote Model Cut-out 384± PSIG 412± PSIG Cut-in 284±21 PSIG 327±21 PSIG...

  • Page 29: Performance Data

    C. Performance Data 1. KM-1601SWH (water-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 1492 1501 1419 80/27 1499 1513 1378 90/32 1501 1523 1408 lbs./day kg./day 100/38 1453 1496 1303 APPROXIMATE ELECTRIC...

  • Page 30: Km-1601Swh3 (Water-Cooled)

    2. KM-1601SWH3 (water-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 1555 1558 1466 80/27 1557 1562 1417 90/32 1558 1565 1440 lbs./day kg./day 100/38 1507 1536 1326 APPROXIMATE ELECTRIC 70/21 2270 2311 2332 CONSUMPTION...

  • Page 31: 3A. Km-1601Srh (Remote Air-Cooled) (Auxiliary Codes: R-0; R-1; Some S-1)

    3a. KM-1601SRH (remote air-cooled) (auxiliary codes: R-0; R-1; some S-1) This data applies to units with an 8 l/min water valve. The 8 l/min water valve is part number 3U0111-02 and has J248-032 stamped on the side of the valve facing the rear of the unit.

  • Page 32: 3B. Km-1601Srh (Remote Air-Cooled) (Auxiliary Codes: Some S-1; S-2 And Later)

    3b. KM-1601SRH (remote air-cooled) (auxiliary codes: some S-1; S-2 and later) This data applies to units with a 15 l/min or 11 l/min water valve. The 15 l/min water valve is part number 3U0111-01 and has J248-030 stamped on the side of the valve facing the rear of the unit.

  • Page 33: 4A. Km-1601Srh3 (Remote Air-Cooled) (Auxiliary Codes: R-0; R-1; Some S-1)

    4a. KM-1601SRH3 (remote air-cooled) (auxiliary codes: R-0; R-1; some S-1) This data applies to units with an 8 l/min water valve. The 8 l/min water valve is part number 3U0111-02 and has J248-032 stamped on the side of the valve facing the rear of the unit.

  • Page 34: 4B. Km-1601Srh3 (Remote Air-Cooled) (Auxiliary Codes: Some S-1; S-2 And Later)

    4b. KM-1601SRH3 (remote air-cooled) (auxiliary codes: some S-1; S-2 and later) This data applies to units with a 15 l/min or 11 l/min water valve. The 15 l/min water valve is part number 3U0111-01 and has J248-030 stamped on the side of the valve facing the rear of the unit.

  • Page 35: Service Diagnosis

    IV. Service Diagnosis A. 10-Minute KM Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70°F or warmer air and 50°F or warmer water temperatures.

  • Page 36: Diagnostic Charts

    2, 5, or 10 cycles. The factory default for KM-1601SWH/3 is every 10 cycles and the factory default for KM-1601SRH/3 depends on the water valve installed. See "II.C.3.a) Default Dip Switch Settings.") The unit always restarts at the 1 minute fill cycle.
  • Page 37 Problem Possible Cause Remedy [1] The icemaker will not e) High Pressure Control 1. Bad contacts. 1. Check for continuity and start. (continued) replace. 2. Dirty air filter or 2. Clean. condenser. 3. Ambient or condenser 3. Reduce temperature. water temperature too warm.
  • Page 38 Problem Possible Cause Remedy [1] The icemaker will not k) Inlet Water Valve 2. Coil winding opened. 2. Replace. start. (continued) (continued) 3. Wiring to water valve. 3. Check for loose connection or open, and replace. l) Control Board 1. Defective. 1.
  • Page 39 Problem Possible Cause Remedy [5] No water comes from c) Water System 1. Water leaks. 1. Check connections for spray tubes. Water water leaks, and replace. pump will not start, or 2. Clogged. 2. Clean. freeze cycle time is 3. Pump out check valve 3.

  • Page 40: Evaporator Is Frozen Up

    2. Evaporator is Frozen Up Problem Possible Cause Remedy [1]Freeze cycle time is a) Float Switch 1. Leads short-circuit or 1. Check and replace. too long. defective switch. 2. Float does not move 2. Clean or replace. freely. b) Inlet Water Valve 1.

  • Page 41: Low Ice Production

    Problem Possible Cause Remedy [3]Other. (continued) g) Water Supply Line 1. Too small; requires 1. Increase water line size. 1/2" OD line dedicated per machine. h) Water Filter 1. Flow rate too small. 1. Replace with filter that has larger flow rate. 3.

  • Page 42: Other

    5. Other Problem Possible Cause Remedy [1] Icemaker will not stop a) Bin Control Thermostat 1. Set too cold. 1. Adjust warmer. when bin is filled with 2. Defective. 2. Replace. ice. [2] Abnormal noise. a) Pump Motor 1. Bearings worn out. 1.

  • Page 43: Removal And Replacement Of Components

    V. Removal and Replacement of Components IMPORTANT 1. Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced. 2. The Polyol Ester (POE) oils used in R-404A units can absorb moisture quickly. Therefore it is important to prevent moisture from entering the system when replacing or servicing parts.

  • Page 44: Evacuation And Recharge (R-404A)

    For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

  • Page 45: Removal And Replacement Of Compressor

    B. Removal and Replacement of Compressor IMPORTANT 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. Note: When replacing a compressor with a defective winding, be sure to install the new start capacitor and start relay supplied with the replacement compressor.

  • Page 46: Removal And Replacement Of Expansion Valve

    C. Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration circuit exceeds the drier capacity and freezes up at the expansion valve. 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.

  • Page 47: Removal And Replacement Of Hot Gas Valve And Line Valve

    D. Removal and Replacement of Hot Gas Valve and Line Valve IMPORTANT 1. Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. 2. Always install a new drier every time the sealed refrigeration system is opened.

  • Page 48: Removal And Replacement Of Evaporator

    E. Removal and Replacement of Evaporator IMPORTANT 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 49: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve. 5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out.

  • Page 50: Removal And Replacement Of Headmaster (Condensing Pressure Regulator - C

    H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.) - Remote Air-Cooled Model Only IMPORTANT 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.

  • Page 51: Removal And Replacement Of Thermistor

    I. Removal and Replacement of Thermistor IMPORTANT 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 equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent.

  • Page 52: Removal And Replacement Of Fan Motor

    J. Removal and Replacement of Fan Motor Note: When replacing a fan motor with defective winding, it is recommended that a new capacitor be installed. 1) Turn off the power supply. 2) Remove the panels. 3) Remove the junction box cover from the remote condenser unit (remote air-cooled model).

  • Page 53: Removal And Replacement Of Pump Motor

    L. Removal and Replacement of Pump Motor 1) Turn off the power supply. 2) Remove the front panel. 3) Drain the water tank by removing the cap located on the front bottom part of the ice dropping hole. See Fig. 3. Fig.

  • Page 54: Cleaning And Maintenance

    A. Cleaning and Sanitizing Instructions WARNING 1. HOSHIZAKI recommends cleaning this icemaker at least once a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.

  • Page 55: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 27 fl. oz. (800 ml) of recommended cleaner Hoshizaki "Scale Away" or "LIME-A- WAY" (Economics Laboratory, Inc.) with 5 gal. (19 l) of warm water. 2) Remove all ice from the evaporator and the storage bin.

  • Page 56: Sanitizing Procedure - Following Cleaning Procedure

    18) Replace the front panel in its correct position. 19) Turn on the power supply to fill the water tank with water. 20) Turn off the power supply after 3 minutes. 21) Remove the front panel and fully open the cleaning valve. 22) Move the control switch to the "WASH"...

  • Page 57: Maintenance

    B. Maintenance IMPORTANT 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, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2.
  • Page 58 2. Remove the water from the icemaker water supply line: 1) If you have not already done so, turn off the power supply and remove the front panel. 2) Close the icemaker water supply line shut-off valve and open the icemaker water supply line drain valve.

This manual is also suitable for:

Km-1601swh3Km-1601srhKm-1601srh3

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