Related Manuals for Hoshizaki KM-280MAF-E
Summary of Contents for Hoshizaki KM-280MAF-E
- Page 1 89/336 NUMBER: 73089 73/23 ISSUED: JULY 13, 2001 REVISED: APRIL 22, 2003 MODULAR CRESCENT CUBER KM-280MAF-E KM-280MWF-E KM-500MAF-E KM-500MWF-E KM-630MAF-E KM-630MWF-E SERVICE MANUAL FOR QUALIFIED SERVICE PERSON HOSHIZAKI...
- Page 2 No 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 addressed, please call HOSHIZAKI CARE for assistance.
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Page 3: Table Of Contents
This manual should be made available to the technician prior to service or maintenance. CONTENTS PAGE I. SPECIFICATIONS ....................5 1. KM-280MAF-E (Air-cooled) ................. 5 2. KM-280MWF-E (Water-cooled) ................6 3. KM-500MAF-E (Air-cooled) ................. 7 4. KM-500MWF-E (Water-cooled) ................8 5. KM-630MAF-E (Air-cooled) ................. 9 6. - Page 4 4. PERFORMANCE DATA ..................50 [a] KM-280MAF-E ....................50 [b] KM-280MWF-E ....................51 [c] KM-500MAF-E ....................52 [d] KM-500MWF-E ....................53 [e] KM-630MAF-E ....................54 [f] KM-630MWF-E ....................55 IV. SERVICE DIAGNOSIS ................... 56 1. NO ICE PRODUCTION..................56 2. EVAPORATOR IS FROZEN UP ................59 3.
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Page 5: Specifications
I. SPECIFICATIONS 1. KM-280MAF-E (Air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 6: Km-280Mwf-E (Water-Cooled)
2. KM-280MWF-E (Water-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 7: Km-500Maf-E (Air-Cooled)
3. KM-500MAF-E (Air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 8: Km-500Mwf-E (Water-Cooled)
4. KM-500MWF-E (Water-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 9: Km-630Maf-E (Air-Cooled)
5. KM-630MAF-E (Air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 10: Km-630Mwf-E (Water-Cooled)
6. KM-630MWF-E (Water-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. -
Page 11: General Information
II. GENERAL INFORMATION 1. DIMENSIONS [a] KM-280MAF-E... -
Page 12: [B] Km-280Mwf-E
[b] KM-280MWF-E... - Page 13 [c] KM-500MAF-E...
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Page 14: [D] Km-500Mwf-E
[d] KM-500MWF-E... -
Page 15: [E] Km-630Maf-E
[e] KM-630MAF-E... -
Page 16: [F] Km-630Mwf-E
[f] KM-630MWF-E... -
Page 17: Construction
2. CONSTRUCTION [a] KM-280MAF-E Transformer Spray Tube Water Supply Inlet Control Switch Condenser Bin Control Thermostat Hot Gas Valve Expansion Valve Fan Motor, Condenser Compressor Drier Float Switch Control Box Water Pump... - Page 18 [b] KM-280MWF-E Transformer Spray Tube Water Supply Inlet Control Switch Water Regulator Bin Control Thermostat Expansion Valve Hot Gas Valve Compressor Float Switch Drier Water Pump Control Box...
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Page 19: [C] Km-500Maf-E
[c] KM-500MAF-E Transformer Spray Tubes Water Supply Inlet Control Switch Condenser Bin Control Thermostat Hot Gas Valve Expansion Valve Fan Motor Condenser Compressor Drier Float Switch Control Box Water Pump... -
Page 20: [C] Km-500Maf-E
[d] KM-500MWF-E Transformer Spray Tubes Water Supply Inlet Control Switch Water Regulator Bin Control Thermostat Expansion Valve Hot Gas Valve Compressor Float Switch Drier Water Pump Control Box... -
Page 21: [D] Km-500Mwf-E
[e] KM-630MAF-E... -
Page 22: [E] Km-630Maf-E
[f] KM-630MWF-E... -
Page 23: Controller Board
3. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM “F” Series -E Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system. 3) All models are pretested and factory-adjusted. - Page 24 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 Thermistor senses 9°C at the Evapora- tor 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 25 The green LED’s 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows: Sequence Step LED’s on Length: Min. Max. Avg. 1 Minute Fill Cycle LED4 60 sec. Harvest Cycle LED1, 4, & 2 2 min.
- Page 26 The dip switches should be adjusted as per the adjustment chart on page 30. Switches 7 & 8 must remain in the OFF position. (Control Products HOS-001A Board)
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Page 27: [C] Sequence
[c] SEQUENCE KM-280M_F-E, KM-500M_F-E, KM-630M_F-E 1st Cycle 1. Unit energized and Control Switch to “ICE” 3. Thermistor reads 9°C. position. Water supply cycle starts. Defrost Timer starts counting. 2. After 1 minute, Defrost cycle starts. IMPORTANT Water Valve opening is limited to 6 minutes. - Page 28 KM-280M_F-E, KM-500M_F-E, KM-630M_F-E 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 2. Drain timer stops counting. 1. Float Switch opens and signals to complete Pump drain is completed freeze cycle.
- Page 29 KM-280M_F-E, KM-500M_F-E, KM-630M_F-E 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 2. Thermistor reads 9°C. 1. Float Switch opens and signals to complete Defrost Timer starts counting. freeze cycle.
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Page 30: [D] Controls And Adjustments
[d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: DIP SWITCH NO. KM-280MAF-E OFF OFF OFF KM-280MWF-E OFF OFF OFF OFF OFF KM-500MAF-E OFF OFF OFF OFF OFF KM-500MWF-E OFF OFF OFF OFF OFF KM-630MAF-E OFF OFF... - Page 31 Switch Nos. 9 and 10: Used for adjustment of Freeze Timer. The Freeze Timer determines maximum freeze cycle time. Upon termination of Freeze Timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. 1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor.
- Page 32 2) Defrost Timer No adjustment is required under normal use, as the Defrost Timer is adjusted to the suitable position. However, if necessary when all the ice formed on the Evaporator does not fall into the bin in the harvest cycle, adjust the Defrost Timer to a longer setting by adjusting the Dip Switch (No.
- Page 33 4) Drain Counter CAUTION Do not adjust the Drain Counter, or the Evaporator may freeze up. The Drain Counter is factory-adjusted to drain the Water Tank every 10 cycles, and no adjustment is required. However, where water quality is bad and the icemaker needs a pump drain more often, the Drain Counter can be adjusted as shown in the table below: SETTING FREQUENCY...
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Page 34: [E] Checking Controller Board
6) Bin Control CAUTION When the ambient temperature is below 45°F (7°C), 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. - Page 35 (iv) After Step (iii), de-energize the unit and confirm that the Defrost Timer is in the minimum position. Disconnect the resistor from the Controller Board, and ener- gize the unit. After the 1 minute water supply cycle, the defrost cycle starts. Re-connect a 1.5 K ohm - 3.5 K ohm resistor to the Connector K3 (pins #1 and #2) after the first 2 minutes of the defrost cycle.
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Page 36: Technical Information
III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-280MAF-E... - Page 37 [b] KM-280MWF-E...
- Page 38 [c] KM-500MAF-E, KM-630MAF-E...
- Page 39 [d] KM-500MWF-E (line valve added at serial # J-1..)
- Page 40 [e] KM-630MWF-E...
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Page 41: Wiring Diagrams
2. WIRING DIAGRAMS [a] KM-280MAF-E, KM-280MWF-E with serial #’s beginning with J-0 KM-280MAF-E KM-280MWF-E Pressure Switch Pressure Switch Cut-out 412 ± 21.3 PSIG Cut-out 384 ± 21.3 PSIG 28.03 ± 1.5 BAR 26.12 ± 1.5 BAR Cut-in 327 ± 21.3 PSIG Cut-in 284 ±... - Page 42 [b] KM-280MAF-E, KM-280MWF-E with serial #’s beginning with J-1 and beyond KM-280MAF-E KM-280MWF-E Pressure Switch Pressure Switch Cut-out 412 ± 21.3 PSIG Cut-out 384 ± 21.3 PSIG 28.03 ± 1.5 BAR 26.12 ± 1.5 BAR Cut-in 327 ± 21.3 PSIG Cut-in 284 ±...
- Page 43 [c] KM-500MAF-E with serial #’s beginning with J-0, J-1, K-0, and L-0, KM-500MWF-E with serial #’s beginning with J-0 only KM-500MAF-E KM-500MWF-E Pressure Switch Pressure Switch Cut-out 412 ± 21.3 PSIG Cut-out 384 ± 21.3 PSIG 28.03 ± 1.5 BAR 26.12 ±...
- Page 44 [d] KM-500MAF-E with serial #’s beginning with L-1 and beyond KM-500MAF-E Pressure Switch Cut-out 412 ± 21.3 PSIG 28.03 ± 1.5 BAR Cut-in 327 ± 21.3 PSIG 22.2 ± 1.5 BAR...
- Page 45 [e] KM-500MWF-E with serial #’s beginning with J-1 and beyond KM-500MWF-E Pressure Switch Cut-out 384 ± 21.3 PSIG 26.12 ± 1.5 BAR Cut-in 284 ± 21.3 PSIG 19.32 ± 1.5 BAR...
- Page 46 [e] KM-630MAF-E, KM-630MWF-E with serial #’s beginning with J-0, J-1, and K-0 KM-630MAF-E KM-630MWF-E Pressure Switch Pressure Switch Cut-out 412 ± 21.3 PSIG Cut-out 384 ± 21.3 PSIG 28.03 ± 1.5 BAR 26.12 ± 1.5 BAR Cut-in 327 ± 21.3 PSIG Cut-in 284 ±...
- Page 47 [f] KM-630MAF-E, KM-630MWF-E with serial #’s beginning with L-0 and beyond KM-630MAF-E KM-630MWF-E Pressure Switch Pressure Switch Cut-out 412 ± 21.3 PSIG Cut-out 384 ± 21.3 PSIG 28.03 ± 1.5 BAR 26.12 ± 1.5 BAR Cut-in 327 ± 21.3 PSIG Cut-in 284 ±...
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Page 48: Timing Chart
3. TIMING CHART *1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”... - Page 49 *1 The Pump Motor waits for 2 seconds before starting a drain cycle. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” *2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...
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Page 50: Performance Data
4. PERFORMANCE DATA [a] KM-280MAF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 51: [B] Km-280Mwf-E
[b] KM-280MWF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 52: [C] Km-500Maf-E
[c] KM-500MAF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 53: [D] Km-500Mwf-E
[d] KM-500MWF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 54: [E] Km-630Maf-E
[e] KM-630MAF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 55: [F] Km-630Mwf-E
[f] KM-630MWF-E Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. -
Page 56: Service Diagnosis
IV. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker a) Power Supply 1. “OFF” position. 1. Move to “ON” position will not start 2. Loose connections. 2. Tighten 3. Bad contacts. 3. Check for continuity and replace. - Page 57 PROBLEM POSSIBLE CAUSE REMEDY [2] Water a) Float switch 1. Connector disconnected. 1. Place in position. continues to 2. Leads opened or defective 2. Check and replace. be supplied, switch. and the ice- 3. Float does not move freely. 3. Clean or replace. maker will not b) Controller Board 1.
- Page 58 PROBLEM POSSIBLE CAUSE REMEDY [4] Water a) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks continues to Valve with icemaker off. be supplied in b) Controller Board 1. Defective. 1. See “II.2.[e] CHECKING freeze cycle. CONTROLLER BOARD.” [5] No water a) Water Supply Line 1.
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Page 59: Evaporator Is Frozen Up
2. EVAPORATOR IS FROZEN UP PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) Float Switch 1. Leads short-circuit or 1. Check and replace. time is too defective switch. long. 2. Float does not move freely. 2. Clean or replace. b) Water Solenoid 1. -
Page 60: Low Ice Production
3. LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) See chart 1 - [3], and check dirty Air Filter or Condenser, ambient or water time is long. temperature, water pressure, Water Regulator or refrigerant charge. b) See chart 2 - [1], and check Float Switch, Water Solenoid Valve or Controller Board. -
Page 61: Removal And Replacement Of Components
4) Close the Low-side Valve and High-side Valve on the Service Manifold. 5) Disconnect the Vacuum Pump, and attach a Refrigerant Charging Cylinder to accu- rately weigh in the liquid charge. Remember to purge any air from the charging Hose. See the Nameplate for the required refrigerant charge. Hoshizaki... -
Page 62: Brazing
recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used. 6) Open the High-side Valve on the gauge Manifold, and accurately measure in the liquid charge. Close the valve on the Charging Cylinder before closing the High- side Manifold Valve. -
Page 63: Removal And Replacement Of Compressor
3. 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 repairs or replacements have 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 64: Removal And Replacement Of Drier
15) Evacuate the system, and charge it with refrigerant. (See “1. [b] EVACUATION AND RECHARGE”.) 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Refit the panels in their correct positions. 18) Plug in the icemaker. Turn on the power supply. 4. -
Page 65: Removal And Replacement Of Expansion Valve
5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant 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 repairs or replacements have been made. -
Page 66: Removal And Replacement Of Hot Gas Valve
6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND/OR LINE VALVE IMPORTANT Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened. -
Page 67: Removal And Replacement Of Evaporator
12) Refit the panels in their correct positions. 13) Plug in the icemaker. Turn on the power supply. 7. 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 replace- ments have been made. -
Page 68: Removal And Replacement Of Water-Regulating Valve
8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE– WATER-COOLED MODELS ONLY 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 replace- ments have been made. 1) Turn off the power supply. -
Page 69: Adjustment Of Water-Regulating Valve
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 thermom- eter to check for the condenser drain temperature. -
Page 70: Removal And Replacement Of Thermistor
10. REMOVAL AND REPLACEMENT OF THERMISTOR CAUTION 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 71: Removal And Replacement Of Fan Motor
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) Refit the Control Box Cover and the panels in their correct positions. 13) Plug in the icemaker. -
Page 72: Removal And Replacement Of Water Valve
12. REMOVAL AND REPLACEMENT OF WATER VALVE 1) Turn off the power supply. Unplug the icemaker. 2) Close the Water Supply Line Shut-off Valve. 3) Remove the Top and Front Panels. 4) Remove the Valve Outlet Tubing by releasing the Clamp. 5) Remove the Bracket from the unit. -
Page 73: Removal And Replacement Of Pump Motor
13. REMOVAL AND REPLACEMENT OF PUMP MOTOR Note: When replacing a Pump Motor with defective winding, it is recommended that a new capacitor be installed. 1) Turn off the power supply. Unplug the icemaker. 2) Remove the Front Panel. 3) Remove the Base Cover. 4) Drain the Water Tank by removing one end of the Pump Tubing. -
Page 74: Removal And Replacement Of Float Switch
14. REMOVAL AND REPLACEMENT OF FLOAT SWITCH 1) Go through the steps 1) through 4) in “13. REMOVAL AND REPLACEMENT OF PUMP MOTOR.” 2) Remove the black rubber Connector from the base of the Float Switch. 3) Remove the screws securing the Float Switch Bracket and the stainless steel adjusting guide. -
Page 75: Removal And Replacement Of Transformer
16. REMOVAL AND REPLACEMENT OF TRANSFORMER 1) Turn off the power supply. Unplug the icemaker. 2) Remove the Panels. 3) Remove the closed end connectors from the Transformer leads. 4) Remove the transformer Cover. 5) Remove the Transformer. 6) Install the new Transformer. 7) Replace the Transformer Cover. -
Page 76: Cleaning And Maintenance Instructions
VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. PREPARING THE ICEMAKER FOR LONG STORAGE WARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice from the Storage Bin. The Storage Bin should be cleaned and dried. Drain the icemaker to prevent damage to the water supply line at sub-freezing temperatures, using air or carbon dioxide. -
Page 77: Cleaning And Sanitizing Procedures
6. Wipe off any splashed or spilt cleaner/sanitizer immediately. [a] CLEANING PROCEDURE 1) Mix 3 gallons (11.4 L) of water with Hoshizaki “Scale-Away” (or “LIME-A-WAY,” Eco- nomics Laboratory, Inc.) or Hoshizaki Cleaner (Rector Seal Corp.) using a mixing rate as... - Page 78 2) Remove all ice from the Evaporator and the Storage Bin. Note: To remove cubes on the Evaporator, turn off the power supply and turn it on after 3 minutes. The defrost cycle starts and the cubes will be re- moved from the Evaporator.
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Page 79: [B] Sanitizing Procedure
[b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Mix 3 gallons (11.4 L) of water and a 5.25% Sodium Hypochlorite solution or dilute IMS-II sanitizer or other recommended Hoshizaki sanitizer as directed on the package. Note: IMS-II Sanitizer, Part # SA0004, is available through your Hoshizaki Dealer. -
Page 80: Maintenance
11) Move the Control Switch to the “ICE” position. 12) Replace the Front Panel and the Base Cover in their correct positions. 13) Clean the Storage Bin with water. 14) Turn on the power supply, and start the automatic icemaking process. 3.