Hoshizaki KM-600MAH Service Manual
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Hoshizaki KM-600MAH Service Manual

Modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Modular Crescent Cuber
Model
KM-600MAH
SERVICE MANUAL
1
™
Number: 73167
Issued: 8-12-2008
Revised: 8-25-2008

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  • Page 1 Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Model KM-600MAH SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com ™ Number: 73167 Issued: 8-12-2008 Revised: 8-25-2008...
  • 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

    IMPORTANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety.
  • Page 4 IV. Service Diagnosis ......................23 A. 10-Minute KM Diagnostic Procedure ................23 B. Diagnostic Charts ......................25 1. No Ice Production ....................25 2. Evaporator is Frozen Up ..................28 3. Low Ice Production ....................29 4. Abnormal Ice ......................30 5.

  • Page 5: Specifications

    I. Specifications A. Icemaker KM-600MAH (air-cooled) AC SUPPLY VOLTAGE 115-120/60/1 AMPERAGE 12.0 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR.

  • Page 6: General Information

    II. General Information A. Construction 1. KM-600MAH (air-cooled) Spray Tubes Water Supply Pipe Bin Control Thermostat Condenser Control Box Control Switch Fan Motor Expansion Valve Hot Gas Valve Float Switch Drier Compressor Water Pump...

  • Page 7: Sequence Of Operation

    B. Sequence of Operation The steps in the sequence are as outlined below. When power is supplied, the red "POWER OK" LED on the control board comes on. 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 8: Normal Harvest Cycle

    5. Normal Harvest Cycle LEDs 1, 4, and 2 are on. Comp and HGV remain energized. PM stops and WV energizes. The control board monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), the control board reads a 3.9 kΩ...

  • Page 10: Control Board

    C. Control Board • A Hoshizaki exclusive solid-state control is employed in the KM-600MAH Modular Crescent Cuber. • All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit before handling or replacing the board.

  • Page 11: Control Board Layout

    1. Control Board Layout Control Products "E" Control Board "OUTPUT TEST" Switch (used to test relays on board) S4 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...

  • Page 12: Features

    2. Features a) Maximum Water Supply Period – 6 minutes The inlet water valve will be open during harvest for 6 minutes or the length of harvest whichever is shorter. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete.

  • Page 13: 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 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 14: 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, contact Hoshizaki Technical Support 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 15: C) Pump-Out Timer (S4 Dip Switch 3 & 4)

    c) Pump-Out Timer (S4 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 16: F) Freeze Timer (S4 Dip Switch 9 & 10)

    f) Freeze Timer (S4 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, the control board initiates the harvest cycle.

  • Page 17: Control Board Replacement

    5. Control Board Replacement The application switch located between relay X3 & X4 must be set to the "ALP" position. The dip switches should be adjusted to the factory default settings. See "II.C.3.a) Default Dip Switch Settings." S4 dip switch 8 must remain off. D.

  • Page 18: Float Switch Cleaning

    5) Wipe down the float switch housing, shaft, float, retainer rod, and rubber boot with a mixture of 1 part of recommended cleaner Hoshizaki "Scale Away" or "LIME-A-WAY" (Economics Laboratory, Inc.) and 25 parts of warm water. Rinse the parts thoroughly with clean water.

  • Page 19: Bin Control

    F. 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 20: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-600MAH (air-cooled) Spray Tubes Condenser Inlet Water Valve High Pressure Water Supply Switch Evaporator Drier Heat Exchanger Thermistor Cleaning Valve Hot Gas Suction Line Valve Access Valve Strainer Access Water Pump...

  • Page 21: Wiring Diagram

    B. Wiring Diagram 1. KM-600MAH (air-cooled)

  • Page 22: Performance Data

    C. Performance Data 1. KM-600MAH (air-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 90/32 lbs./day kg./day 100/38 APPROXIMATE ELECTRIC 70/21 1040 1084 1102 CONSUMPTION 80/27 1073 1142 1137 90/32 1084...

  • Page 23: 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 (21°C) or warmer air and 50°F (10°C) or warmer water temperatures.
  • Page 24 5) Freeze Cycle – LED 1 is on. Compressor remains energized, pump motor, and fan motor energize. The inlet water valve and hot gas valve de-energize. The unit is held in freeze by a 5 minute short cycle protection timer. After the 5 minute short cycle protection timer terminates, the freeze cycle operation is transferred to the float switch for freeze termination.

  • Page 25: Diagnostic Charts

    B. Diagnostic Charts 1. No Ice Production Problem Possible Cause Remedy [1] The icemaker will not a) Power Supply 1. Off, blown fuse, or 1. Turn on, replace, or reset. start. tripped breaker. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3.
  • Page 26 Problem Possible Cause Remedy [1] The icemaker will not j) Thermistor 1. Leads shorted or 1. See "II.D. Harvest Control start. (continued) opened and high – Thermistor." temperature or harvest backup timer safety operates. (1 beep or 2 beep alarm) k) Hot Gas Valve 1.
  • Page 27 Problem Possible Cause Remedy [4] Water continues to a) Water Pressure 1. Too high. 1. Reduce. be supplied in freeze b) Inlet Water Valve 1. Diaphragm does not 1. Check for water leaks with cycle. close. icemaker off. c) Control Board 1.

  • Page 28: 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 29: Low Ice Production

    Problem Possible Cause Remedy [3]Other. (continued) e) Hot Gas Valve 1. Coil winding opened. 1. Replace. 2. Plunger does not 2. Replace. move. 3. Wiring to hot gas 3. Check for loose valve. connection or open, and replace. f) Ice Cube Guide 1.

  • Page 30: Abnormal Ice

    4. Abnormal Ice Problem Possible Cause Remedy [1] Small cubes. a) Pump Out Check Valve 1. Dirty or worn and 1. Clean or replace. leaking by. b) Ice Cube Guide 1. Out of position. 1. Place in position. Circulated water falls into bin.
  • Page 31 Problem Possible Cause Remedy [3] Ice in storage bin a) Drain Line(s) 1. Plugged. 1. Clean. often melts. b) Icemaker and Bin 1. Drains not run 1. Separate the drain lines. separately. c) Ice Cube Guide 1. Out of position. 1.

  • Page 32: 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 33: Evacuation And Recharge (R-404A)

    5) Disconnect the vacuum pump and attach a refrigerant service cylinder to the high-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 700 (latest edition) be used.

  • Page 34: 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 35: 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 36: Removal And Replacement Of Hot Gas Valve

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

  • Page 37: 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 front and top insulation.

  • Page 38: Removal And Replacement Of Thermistor

    F. Removal and Replacement of Thermistor IMPORTANT 1. Fragile, handle very carefully. 2. Always use the 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 the recommended foam insulation (non-absorbent type) or equivalent.

  • Page 39: Removal And Replacement Of Fan Motor

    G. 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) Disconnect the fan motor wires. 4) Remove the fan motor bracket and fan motor.

  • Page 40: Removal And Replacement Of Pump Motor

    I. Removal and Replacement of Pump Motor 1) Turn off the power supply. 2) Remove the front panel. 3) Remove the base cover. 4) Drain the water tank by removing one end of the pump tubing. See Fig. 3. 5) Disconnect the pump suction and discharge hoses. 6) Remove the closed end connectors from the pump motor leads.

  • Page 41: Cleaning And Maintenance

    Ensure all components, fasteners, and thumbscrews are securely in place after any cleaning or maintenance is done to the equipment. A. Cleaning and Sanitizing Instructions Hoshizaki recommends cleaning this icemaker at least once a year. More frequent cleaning, however, may be required in some existing water conditions. WARNING 1.

  • Page 42: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 16 fl. oz. (473 ml) of Hoshizaki "Scale Away" with 3 gal. (11 l) of warm water. 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 back on after 3 minutes.

  • Page 43: Sanitizing Procedure - Following Cleaning Procedure

    20) Remove the front panel and fully open the cleaning valve. 21) Move the control switch to the "WASH" position. 22) Replace the front panel in its correct position. 23) Turn on the power supply to rinse off the cleaning solution. 24) Turn off the power supply after 5 minutes.

  • Page 44: 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 45 5) Make sure at least 3 minutes have elapsed since you turned off the power supply. Make sure the control switch is in the "ICE" position. Replace the front panel in its correct position and turn on the power supply. 6) Blow the icemaker water supply line out using the compressed air or carbon dioxide supply.

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