Hoshizaki KM-500MAF Service Manual
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Hoshizaki KM-500MAF Service Manual

Hoshizaki KM-500MAF Service Manual

Modular crescent cuber
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MODULAR CRESCENT CUBER
KM-500MAF
KM-500MWF
KM-500MRF
SERVICE MANUAL
HOSHIZAKI
MODEL
NO.:
73086
ISSUED:
APRIL 9, 1999
REVISED:
DEC. 16, 2003

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Summary of Contents for Hoshizaki KM-500MAF

  • Page 1 NO.: 73086 ISSUED: APRIL 9, 1999 REVISED: DEC. 16, 2003 HOSHIZAKI MODULAR CRESCENT CUBER MODEL KM-500MAF KM-500MWF KM-500MRF SERVICE MANUAL...
  • 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 or write to the HOSHIZAKI Technical Support Department for assistance.

  • Page 3: Table Of Contents

    [a] KM-500MAF (Air-cooled) ................25 [b] KM-500MWF (Water-cooled) ..............26 [c] KM-500MRF (Remote air-cooled) ............... 27 2. WIRING DIAGRAMS..................28 [a] KM-500MAF (Air-cooled) and KM-500MWF (Water-cooled) ....... 28 [b] KM-500MRF (Remote air-cooled) ............... 29 3. TIMING CHART ....................30 4. PERFORMANCE DATA..................32 [a] KM-500MAF (Air-cooled) ................
  • Page 4 V. REMOVAL AND REPLACEMENT OF COMPONENTS .......... 40 1. SERVICE FOR REFRIGERANT LINES ............... 40 [a] REFRIGERANT RECOVERY ................ 40 [b] EVACUATION AND RECHARGE ..............40 2. BRAZING ......................41 3. REMOVAL AND REPLACEMENT OF COMPRESSOR ........42 4. REMOVAL AND REPLACEMENT OF DRIER ............. 44 5.

  • Page 5: Specifications

    I. SPECIFICATIONS 1. KM-500MAF Note: We reserve the right to make changes in specifications and design without prior notice.

  • Page 6: Km-500Mwf (Water-Cooled)

    2. KM-500MWF Note: We reserve the right to make changes in specifications and design without prior notice.

  • Page 7: Km-500Mrf (Remote Air-Cooled)

    3. KM-500MRF Note: We reserve the right to make changes in specifications and design without prior notice.

  • Page 8: Condenser Unit, Urc-6F

    4. CONDENSER UNIT URC-6F 24" (610 mm.) 23-1/32" (585 mm.) 19-11/16" 6/16" x 3/4" (10 mm. x 20 mm.) (500 mm.) 4 x 2 (SLOTTED HOLES) 18-1/8" (460 mm.) 20-15/32" (520 mm.) 21-15/16" (557 mm.) 7/8" DIA. HOLE (23 mm. DIA.) 6-5/16"...
  • Page 9 SPECIFICATIONS MODEL: URC-6F EXTERIOR Galvanized Steel DIMENSIONS (W x D x H) 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 453.8 mm.) REFRIGERANT CHARGE R404A 1 lb. 2 oz. (505 g) WEIGHT Net 61 lbs. (28 kg) Shipping 68 lbs. (31 kg) CONNECTIONS REFRIGERANT One Shot Couplings (Aeroquip)

  • Page 10: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] KM-500MAF 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 11: [B] Km-500Mwf (Water-Cooled)

    [b] KM-500MWF 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 12: [C] Km-500Mrf (Remote Air-Cooled)

    [c] KM-500MRF Spray Tubes Water Supply Inlet Control Switch Junction Box Bin Control Thermostat Expansion Valve Receiver Tank Compressor Float Switch Drier Water Pump Hot Gas Valves Control Box...

  • Page 13: Controller Board

    2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-500MAF, KM-500MWF, and KM-500MRF Modular 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 14 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 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 15: Led Lights And Audible Alarm Safeties

    problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned ON or OFF. 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:...
  • Page 16 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 ener- gized with the control switch OFF or the unit will not start. The dip switches should be adjusted per the adjustment chart published in the Tech Specs book.

  • Page 17: [C] Sequence

    [c] SEQUENCE 1st Cycle 1. Unit energized and Control Switch to “ICE” 3. Thermistor reads 48° F. 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 18 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 19 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 48° F. 1. Float Switch opens and signals to complete Defrost Timer starts counting. freeze cycle.

  • Page 20: [D] Controls And Adjustments

    [d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: DIP SWITCH NO. KM-500MAF OFF OFF KM-500MWF OFF OFF KM-500MRF OFF OFF 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 21 1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor. The resistance var- ies depending on the Suction Line temperatures. The Thermistor detects the tempera- ture of the Evaporator outlet to start the Defrost Timer. No adjustment is required. If necessary, check for resistance between Thermistor leads, and visually check the Thermistor mounting, located on the Suction Line next to the Evaporator outlet.
  • Page 22 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 10 seconds 150 seconds 10 seconds 180 seconds 10 seconds 120 seconds 20 seconds 180 seconds T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Drain Counter CAUTION...

  • Page 23: [E] Checking Controller Board

    5) Freeze Timer CAUTION Adjust to proper specification, or the unit may not operate correctly. Two new dip switches numbered 9 and 10 have been added to the improved “E” board to better prevent possible freeze ups. These settings come factory set to the default setting of 60 min.
  • Page 24 After the 1 minute ± 5 second water supply cycle and the 2 minute ± 10 second defrost cycle, the unit should start the freeze cycle. (ii) After the above step (i), disconnect the Float Switch leads from the Controller Board within the first 5 minutes of the freeze cycle.

  • Page 25: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-500MAF...

  • Page 26: [B] Km-500Mwf (Water-Cooled)

    [b] KM-500MWF...

  • Page 27: [C] Km-500Mrf (Remote Air-Cooled)

    [c] KM-500MRF...

  • Page 28: Wiring Diagrams

    2. WIRING DIAGRAMS [a] KM-500MAF and KM-500MWF Note: Pressure Switch Cut-out 412 ± PSIG Cut-in 327 ± 21 PSIG...

  • Page 29: [B] Km-500Mrf (Remote Air-Cooled)

    [b] KM-500MRF Note: Pressure Switch Cut-out 412 ± PSIG Cut-in 327 ± 21 PSIG U1GMA0179608...

  • Page 30: Timing Chart

    3. TIMING CHART When Control Sw. is turned OFF, Pressure Sw. is OFF, or Thermistor Temp. exceeds t1. From Defrost Cycle To Defrost Cycle If Float Sw. is OFF Hi Temp Mid Temp Lo Temp Too Lo Temp Normal Too Hi Temp Lo Water Time Up (60 sec) Control Sw.
  • Page 31 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 Control Sw. in WASH Min. Max. Max. 3 min 6 min 6 min Max. 20 min *1 The Pump Motor waits for 2 seconds before starting a drain cycle.

  • Page 32: Performance Data

    4. PERFORMANCE DATA [a] KM-500MAF 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 33: [B] Km-500Mwf (Water-Cooled)

    [b] KM-500MWF 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 34: [C] Km-500Mrf (Remote Air-Cooled)

    [c] KM-500MRF 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 35: 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 36 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective 1. See “II.2[e] CHECKING CONTROLLER BOARD.” m) Interlock Switch 1. “OFF” position. 1. Move to “ON” position. (Cleaning Valve) 2. Bad contacts. 2. Check for continuity and replace. [2] Water a) Float switch 1.
  • Page 37 PROBLEM POSSIBLE CAUSE REMEDY [5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get comes from water level in Water Tank recommended pressure. Spray Tubes. too low. Water Pump b) Water Solenoid 1. Dirty mesh filter or orifice 1.

  • Page 38: 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 39: Abnormal Ice

    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 40: Removal And Replacement Of Components

    V. REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. 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 41: Brazing

    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 refriger- ant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

  • Page 42: 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 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 43 15) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment. 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Replace the panels in their correct positions.

  • Page 44: Removal And Replacement Of Drier

    4. REMOVAL AND REPLACEMENT OF DRIER 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. 1) Turn off the power supply. 2) Remove the panels.

  • Page 45: Removal And Replacement Of Hot Gas Valve And ............................... Line Valve

    3) Recover the refrigerant and store it in an approved container. 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 46 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. 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 47: Removal And Replacement Of Evaporator

    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 replacement have been made. 1) Turn off the power supply. 2) Remove the panels and the Top Insulation over the Evaporator.

  • Page 48: Removal And Replacement Of Water-Regulating Valve

    8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE - WATER-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. 1) Turn off the power supply.

  • Page 49: 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 50: Removal And Replacement Of Condensing Pressure

    10. REMOVAL AND REPLACEMENT OF 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

    11. 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 52: Removal And Replacement Of Fan Motor

    Note: For models with the Liquid Bypass, the Thermistor should be located upstream from the Liquid Bypass outlet, and its end should be 4-3/4" or more away from the outlet. See Fig. 3. Min. 4-3/4" Liquid Bypass Flow Fig. 3 10) Secure the insulation using the Plastic Cable Ties.

  • Page 53: Removal And Replacement Of Water Valve

    6) Install the new Fan Motor, and replace the removed parts in the reverse order of which they were removed. 7) Replace the panels in their correct positions. 8) Replace the Junction Box Cover in its correct position (Remote Air-cooled model). 9) Turn on the power supply.

  • Page 54: Removal And Replacement Of Spray Tubes

    3) Remove the Base Cover. 4) Drain the Water Tank by removing one end of the Pump Tubing. 5) Replace the removed parts in their correct positions. 6) Disconnect the Pump Suction and Discharge Hoses. 7) Remove the screws and the Pump Motor Bracket. 8) Remove the closed end connectors from the Pump Motor leads.

  • Page 55: Maintenance And Cleaning Instructions

    VI. MAINTENANCE AND CLEANING INSTRUCTIONS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. 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.
  • Page 56 [2] Remove the water from the potable water supply line: 1) Remove the Front Panel. (Except water-cooled model) 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 57: Cleaning And Sanitizing Procedures

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

  • Page 58: [A] Cleaning Procedure

    [a] CLEANING PROCEDURE 1) Dilute 16 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 3 gal. of 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 on after 3 minutes.
  • Page 59 19) Replace the Front Panel in its correct position. 20) Turn on the power supply to fill the Water Tank with water. 21) Turn off the power supply after 3 minutes. 22) Remove the Front Panel, and fully open the Cleaning Valve. 23) Move the Control Switch to the “Wash”...

  • Page 60: [B] Sanitizing Procedure

    [b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute a 5.25 % Sodium Hypochlorite solution (chlorine bleach) with water (Add 1.5 fl. oz. of sanitizer to 3 gal. of water). 2) Remove the Insulation Panel, if it is in its usual position. 3) Pour the sanitizing solution into the Water Tank.

  • Page 61: Maintenance

    3. 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 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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