Hoshizaki KM-320MAH-E Service Manual
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Hoshizaki KM-320MAH-E Service Manual

Modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
89/336
73/23
Modular Crescent Cuber
Models
KM-320MAH-E
KM-515MAH-E
KM-650MAH-E
SERVICE MANUAL
Number: 73170
Issued: 11-13-2008
Revised: 3-22-2012

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Summary of Contents for Hoshizaki KM-320MAH-E

  • Page 1 Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models KM-320MAH-E KM-515MAH-E KM-650MAH-E SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73170 89/336 Issued: 11-13-2008 73/23 Revised: 3-22-2012...
  • Page 2 WARNING Only qualified service technicians should install and service the icemaker. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki-europe.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and...

  • Page 3: Table Of Contents

    Retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information ....................5 I. Specifications ........................7 A. KM-320MAH-E ......................7 B. KM-515MAH-E ......................8 C. KM-650MAH-E ......................9 II. General Information ......................10 A. Construction ........................ 10 1.
  • Page 4 B. Wiring Diagram ......................30 1. Thermostatic Bin Control ..................30 2. Mechanical Bin Control ..................31 C. Performance Data ....................... 32 1. KM-320MAH-E ....................... 32 2. KM-515MAH-E ...................... 33 3. KM-650MAH-E ...................... 34 IV. Service Diagnosis ......................35 A. Diagnostic Procedure ....................35 B.

  • Page 5: Important Safety Information

    Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the icemaker, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury.
  • Page 6 WARNING, continued • Before servicing the icemaker, move the control switch to the "OFF" position. Unplug the icemaker from the mains socket. • Do not use an extension cord. • Do not use an icemaker with a damaged power cord. The power cord should not be altered, jerked, bundled, weighed down, pinched, or tangled. Such actions could result in electric shock or fire. To unplug the icemaker, be sure to pull the plug, not the cord, and do not jerk the cord.

  • Page 7: Specifications

    I. Specifications A. KM-320MAH-E AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 3.5 A (5 Min. Freeze at 109°F/WT 59°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp. (°F) lbs./day (kg/day)

  • Page 8: Km-515Mah-E

    B. KM-515MAH-E AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 7.14 A ( 5 Min. Freeze AT 109°F / WT 59°F) MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *513 (233) 482 (219) 441 (200)

  • Page 9: Km-650Mah-E

    C. KM-650MAH-E AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 6.8 A ( 5 Min. Freeze AT 109°F / WT 59°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *653 (296) 610 (277) 558 (253)

  • Page 10: General Information

    II. General Information A. Construction 1. KM-320MAH-E Main Transformer (230V→115V) Water Supply Pipe Spray Tubes Inlet Water Valve Hot Gas Valve Strainer Control Switch Condenser Expansion Valve Evaporator High-Pressure Switch Control Box Power Cord with Thermistor Fused Plug (250V, 13A fuse)

  • Page 11: Km-515Mah-E

    2. KM-515MAH-E Main Transformer (230V→115V) Spray Tubes Water Supply Pipe Expansion Valve Hot Gas Valve Strainer Inlet Water Valve Condenser Control Switch High-Pressure Evaporator Switch Control Box Power Cord with Fused Plug Thermistor (250V, 13A fuse) Fan Motor Liquid Line Valve Drier Float Switch Water Pump...

  • Page 12: Km-650Mah-E

    3. KM-650MAH-E Main Transformer (230V→115V) Spray Tubes Water Supply Pipe Inlet Water Valve High-Pressure Switch Evaporator Condenser Control Box Power Cord with Control Switch Fused Plug (250V, 13A fuse) Thermostatic Strainer Expansion Valve Fan Motor Thermistor Hot Gas Valve Float Switch Drier Water Pump Compressor...

  • Page 13: Sequence Of Operation

    B. Sequence of Operation 1. Sequence Cycles and Shutdown a) "E" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier The steps in the sequence are as outlined below. When power is supplied, CB red "POWER OK"...
  • Page 14 The 1st pump-out occurs after the 1st freeze cycle, then every 10th cycle thereafter (KM-320MAH-E) or every cycle thereafter (KM-515MAH-E and KM-650MAH-E). The pump-out frequency control is factory set, and generally no adjustment is required. However, the pump-out frequency control (S4 dip switch 5 &...

  • Page 15: B) "G" Control Board

    "G" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later The steps in the sequence are as outlined below. When power is supplied, the red "POWER OK" LED and the green "BC CLOSED" LED on CB turn on (If yellow "BC OPEN"...
  • Page 16 The 1st pump-out occurs after the 11th freeze cycle, then every 10th cycle thereafter (KM-320MAH-E) or every cycle thereafter (KM-515MAH-E and the KM-650MAH-E). The pump-out frequency control is factory set, and generally no adjustment is required. However, the pump-out frequency control (S4 dip switch 5 & 6) can be set to have a pump-out occur every cycle, or every 2, 5, or 10 cycles.

  • Page 17: Sequence Flow Chart

    2. Sequence Flow Chart a) "E" Control Board: KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier...

  • Page 18: B) "G" Control Board

    "G" Control Board: KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later...

  • Page 19: Control Board

    C. Control Board • A Hoshizaki exclusive control board is employed in Hoshizaki icemakers. • All models are pretested and factory adjusted. • For a control board check procedure, see "IV.B. Control Board Check." NOTICE • Fragile, handle very carefully. • 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 icemaker when handling or replacing the control board.

  • Page 20: Control Board Layout

    1. Control Board Layout a) "E" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier "E" Control Board • "OUTPUT TEST" Button • "ALARM RESET" Button (used to test relays on control board) •...

  • Page 21: B) "G" Control Board

    "G" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later "G" Control Board • Bin Control Switch Closed LED (green) • "OUTPUT TEST" Button • S4 Dip Switch • "ALARM RESET" Button...

  • Page 22: Led Lights And Audible Alarm Safeties

    2. LED Lights and Audible Alarm Safeties a) "E" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when power is turned off. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs.

  • Page 23: B) "G" Control Board

    "G" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs.

  • Page 24: Controls And Adjustments

    Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact your Hoshizaki Service Center. a) Default Dip Switch Settings The dip switches are factory-adjusted to the following positions for both the "E" and "G"...

  • Page 25: B) Harvest Timer (S4 Dip Switch 1 & 2)

    Before changing this setting, contact your Hoshizaki Service Office for recommendations. Keep in mind that setting the harvest timer to a longer setting decreases 24-hour production. Note that the pump-out timer (S4 dip switch 3 & 4) acts in place of the harvest timer during cycles with a pump out.

  • Page 26: D) Pump-Out Frequency Control (S4 Dip Switch 5 & 6)

    The pump-out frequency control is factory set to drain the water tank every 10 cycles on the KM-320MAH-E and every cycle on the KM-515MAH-E and the KM-650MAH-E, and generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump-out frequency can be adjusted.

  • Page 27: F) Factory Use (S4 Dip Switch 8)

    (2) Harvest Pump Timer, "G" Control Board KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later Factory set for proper operation. Do not adjust. Depending on the harvest pump timer setting, the pump motor energizes and runs the last 0 or 50 seconds of harvest. The...

  • Page 28: H) Float Switch Selector (S5 Dip Switch 1): "G" Control Board

    h) Float Switch Selector (S5 dip switch 1): "G" Control Board NOTICE Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly. i) Refill Counter (S5 dip switch 2 through 5): "G" Control Board NOTICE Do not adjust.

  • Page 29: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-320MAH-E, KM-515MAH-E, and KM-650MAH-E Spray Tubes Condenser Inlet Water Valve Drier High-Pressure Evaporator Water Supply Switch Liquid Line Valve (KM-515MAH-E) Heat Thermistor Exchanger Suction Line Strainer Water Pump Float Switch...

  • Page 30: Wiring Diagram

    B. Wiring Diagram 1. Thermostatic Bin Control KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier...

  • Page 31: Mechanical Bin Control

    2. Mechanical Bin Control KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later...

  • Page 32: Performance Data

    C. Performance Data 1. KM-320MAH-E 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 CONSUMPTION 80/27 90/32 watts 100/38 APPROXIMATE WATER 70/21 0.44 0.37 0.34 CONSUMPTION PER 24 HR.

  • Page 33: Km-515Mah-E

    2. KM-515MAH-E 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 1080 70/21 1115 1150 CONSUMPTION 80/27 1107 1161 1189 1200 90/32 1115 1231 watts 100/38 1118 1207 1260...

  • Page 34: Km-650Mah-E

    3. KM-650MAH-E 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 1090 1122 1164 CONSUMPTION 1115 1165 80/27 1205 90/32 1122 1200 1242 watts 100/38 1130 1210 1280...

  • Page 35: Service Diagnosis

    IV. Service Diagnosis WARNING • This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the dispenser icemaker/storage bin.
  • Page 36 4) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV remains energized, Comp and HGV energize. CB monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 &...
  • Page 37 6) Pump-Out Cycle – (10/20 second pump-out) – LEDs 1, 3, and 2 are on. LED 4 is on when S4 dip switch 3 & 4 are set to 3 off and 4 on (KM-320MAH-E). Comp remains energized, HGV energizes. WV energizes if S4 dip switch 3 off and 4 on.
  • Page 38 Cycle." 8) Shutdown a) Thermostatic Bin Control: KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier When the icemaker is running hold ice in contact with the thermostatic bulb, TBC switch opens within 10 seconds, shutting down the icemaker. TBC is factory set, and generally no adjustment is required.

  • Page 39: Control Board Check

    B. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB while CB is beeping.

  • Page 40: Bin Control Check

    C. Bin Control Check 1. Thermostatic Bin Control Check KM-320MAH-E and KM-650MAH-E Auxiliary Code U-0 and Earlier KM-515MAH-E Auxiliary Code U-1 and Earlier TBC switch is a temperature controlled switch used to control the level of ice in the bin. It is in line with the power supply to the control switch.

  • Page 41: Mechanical Bin Control Check And Cleaning

    2. Mechanical Bin Control Check and Cleaning KM-320MAH-E and KM-650MAH-E Auxiliary Code U-1 and Later KM-515MAH-E Auxiliary Code U-2 and Later a) Mechanical Bin Control Check This icemaker uses a MBC with a lever-actuated proximity switch to control the ice level in the storage bin.

  • Page 42: B) Mechanical Bin Control Cleaning

    5) Remove the actuator paddle from the switch mount. See Fig. 2. 6) Wipe down MBC with a mixture of 1 part of Hoshizaki "Scale Away" and 25 parts of warm water. Rinse the parts thoroughly with clean water.

  • Page 43: Float Switch Check And Cleaning

    D. Float Switch Check and Cleaning F/S is used to determine that there is sufficient water in the water tank after the 1-minute fill cycle and after each harvest cycle. F/S is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle. No adjustment is required.

  • Page 44: Float Switch Cleaning

    F/S assembly. See Fig. 4. 4) Remove the retainer rod from the bottom of F/S housing, then remove the float. Be careful not to bend the retainer rod excessively when removing it. 5) Wipe down F/S housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Clean the inside of the rubber boot and hose with cleaning solution. Rinse the parts thoroughly with clean water.

  • Page 45: Thermistor Check

    E. Thermistor Check To check thermistor resistance, follow the steps below. 1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the icemaker from the mains socket. 2) Remove the control box cover. 3) Remove the thermistor. 4) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes.

  • Page 46: Diagnostic Charts

    (230VAC/115VAC) 4. Fuse (Control Box) a) Blown. 5. Thermostatic Bin Control a) Tripped with bin filled with ice. (KM-320MAH-E and b) Ambient temperature too cool. KM-650MAH-E c) Set too warm. Aux. Code U-0 and Earlier; d) Bulb out of position.

  • Page 47: Freeze-Up

    Defrost and clean the icemaker prior to diagnosing freeze-up. See "VI.A. Cleaning and Sanitizing Instructions." Fill out a freeze-up checklist. The freeze-up checklist can be found in the Hoshizaki America Technician's Pocket Guide or contact your local distributor for a copy of the freeze-up checklist.
  • Page 48 Freeze-Up - Possible Cause 6. Float Switch a) Dirty, sticking. See "IV.D. Float Switch Check b) Defective. and Cleaning" 7. Refrigerant Charge a) Low. 8. Control Board a) Harvest timer (S4 dip switch 1 & 2) set too short. See "II.C.3. Controls and b) Harvest pump timer (S4 dip switch 7) not in factory default position.

  • Page 49: Low Ice Production

    3. Low Ice Production Low Ice Production - Possible Cause Long Harvest Cycle 1. Evaporator a) Scaled up. 2. Spray Tubes and/or Spray a) Dirty. Guides b) Out of position. 3. Refrigerant Charge a) Low. 4. Water Supply a) Low water pressure. b) External water filters clogged.

  • Page 50: Replacement Of Components

    V. Replacement of Components WARNING • This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the control switch to the "OFF" position, then unplug the icemaker from the mains socket before servicing. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the storage bin.

  • Page 51: Brazing

    2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. • Do not use silver alloy or copper alloy containing arsenic. • Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing. 1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.

  • Page 52: Evacuation And Recharge (R-404A)

    Remember to loosen the connection and purge the air from the hose. See the nameplate on the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

  • Page 53: Important Notes For Component Replacement

    Install a new capacitor. Pump Motor Install a new capacitor. Thermistor • Attach the new thermistor to the suction line in the same location as the previous thermistor. • The thermistor should be at the 12 o'clock position on the tube. • Smoothly fill the recessed area of the thermistor holder with high thermal conductive type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound 10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu Silicones), or equivalent are recommended. • Secure the thermistor with the holder, then insulate it. • Be very careful to prevent damage to the leads.

  • Page 54: Cleaning And Maintenance

    VI. Cleaning and Maintenance This icemaker must be cleaned and maintained in accordance with the instruction manual and labels provided with the icemaker. Consult with your local Hoshizaki service center about cleaning and maintenance service. WARNING • Only qualified service technicians should service this icemaker. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after any cleaning or maintenance is done to the icemaker.

  • Page 55: 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, remove the front panel and move the control switch to the "OFF" position. Wait 3 minutes, then move the control switch back to the "ICE"...

  • Page 56: Sanitizing Procedure - Following Cleaning Procedure

    16) Move the control switch to the "WASH" position to rinse off the cleaning solution. 17) Replace the front panel in its correct position. 18) After 5 minutes, remove the front panel. 19) Move the control switch to the "OFF" position, then unplug the icemaker from the mains socket.

  • Page 57: Maintenance

    B. Maintenance This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. WARNING • Only qualified service technicians should service this icemaker. • Move the control switch to the "OFF" position and unplug the icemaker from the mains socket before servicing to prevent the power supply from being turned back on inadvertently.

  • Page 58: Preparing The Icemaker For Periods Of Non-Use

    C. Preparing the Icemaker for Periods of Non-Use NOTICE • When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. • To prevent damage to the water pump seal, do not operate the icemaker with the control switch in the "WASH" position when the water tank is empty. When the icemaker is not used for two or three days under normal conditions, it is sufficient to move the control switch to the "OFF"...

  • Page 59: Disposal

    VII. Disposal This icemaker contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.

This manual is also suitable for:

Km-515mah-eKm-650mah-e

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