Hoshizaki KML-631MAH Service Manual
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Hoshizaki KML-631MAH Service Manual

Low-profile modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Low-Profile Modular Crescent Cuber
Models
KML-631MAH
KML-631MWH
KML-631MRH
SERVICE MANUAL
™
Number: 73150
Issued: 5-9-2007
Revised: 2-18-2008

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Summary of Contents for Hoshizaki KML-631MAH

  • Page 1 Hoshizaki Hoshizaki America, Inc. Low-Profile Modular Crescent Cuber Models KML-631MAH KML-631MWH KML-631MRH SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com ™ Number: 73150 Issued: 5-9-2007 Revised: 2-18-2008...
  • 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

    Please retain this booklet for any further reference that may be necessary. CONTENTS I. Specifications ........................6 A. Icemaker ........................6 1. KML-631MAH (air-cooled) ..................6 2. KML-631MWH (water-cooled) ................. 7 3. KML-631MRH (remote air-cooled) ................8 B. Condenser Unit ......................9 1. URC-9F ........................9 II.
  • Page 4 3. KML-631MRH (remote air-cooled) ................ 27 B. Wiring Diagrams ......................28 1. KML-631MAH, KML-631MWH and KML-631MRH (auxiliary codes: S-0 and S-2) 28 2. KML-631MAH and KML-631MWH (auxiliary codes: T-0 and later) ......29 3. KML-631MRH (auxiliary codes: T-0 and later) ............30 C.
  • Page 5 VI. Cleaning and Maintenance Instructions ................. 52 A. Cleaning and Sanitizing Procedures ................52 1. Cleaning Procedure ....................52 2. Sanitizing Procedure – Following Cleaning Procedure .......... 53 B. Maintenance ........................ 54 C. Preparing the Icemaker for Long Storage ..............54...

  • Page 6: Specifications

    I. Specifications A. Icemaker 1. KML-631MAH (air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 7.6 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 7: Kml-631Mwh (Water-Cooled)

    2. KML-631MWH (water-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 6.8 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.

  • Page 8: Kml-631Mrh (Remote Air-Cooled)

    3. KML-631MRH (remote air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 7.8 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 9: Condenser Unit

    B. Condenser Unit 1. URC-9F Unit: mm [inches]...
  • Page 10 AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 1.3FLA EXTERIOR DIMENSIONS (WxDxH) 32-3/16" x 15-11/16" x 21-15/16" (817 x 398 x 558 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 34-5/16" x 18-1/8" x 36-15/16" (871 x 460 x 938 mm) EXTERIOR FINISH Galvanized Steel WEIGHT...

  • Page 11: General Information

    II. General Information A. Construction 1. KML-631MAH (air-cooled) Water Supply Condenser Inlet Fan Motor Spray Tubes Hot Gas Valve Wash Valve Inlet Water Junction Box Valve Condenser Drain Valve Expansion Valve Control Box Water Pump Drier Float Switch Control Compressor...

  • Page 12: Kml-631Mwh (Water-Cooled)

    2. KML-631MWH (water-cooled) Water Supply Inlet Hot Gas Valve Spray Tubes Wash Valve Junction Box Inlet Water Water Valve Regulator Drain Valve Condenser Expansion Valve Control Box Drier Water Pump Compressor Float Switch Control Switches Auxiliary Code S-0 Auxiliary Codes T-0 and later Bin Control Thermostat...

  • Page 13: Kml-631Mrh (Remote Air-Cooled)

    3. KML-631MRH (remote air-cooled) Water Supply Inlet Spray Tubes Hot Gas Valve Wash Valve Inlet Water Valve Junction Boxes Drain Valve Receiver Tank Expansion Control Box Valve Line Valve Drier Compressor Water Pump Crankcase Heater Control Float Switch Switches Auxiliary Code S-0 Auxiliary Codes S-2 and later Bin Control...

  • Page 14: 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 16: Control Board

    C. Control Board • A HOSHIZAKI exclusive solid-state control is employed in KML-631MAH, KML-631MWH and KML-631MRH Modular 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 17: 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 18: 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 19: 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 switch is turned OFF. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below.

  • Page 20: 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 21: 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 22: 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 23: Harvest Control - Thermistor

    D. Harvest Control – Thermistor A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest 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 24: Service Switch

    2. Service Switch When the control switch is in the "SERVICE" position, the control switch supplies power to the service switch and the machine is in service mode. The service switch has three positions: "DRAIN," "CIRCULATE," and "WASH." See the information below for details of each function.

  • Page 25: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KML-631MAH (air-cooled)

  • Page 26: Kml-631Mwh (Water-Cooled)

    2. KML-631MWH (water-cooled)

  • Page 27: Kml-631Mrh (Remote Air-Cooled)

    3. KML-631MRH (remote air-cooled)

  • Page 28: Wiring Diagrams

    B. Wiring Diagrams 1. KML-631MAH, KML-631MWH and KML-631MRH (auxiliary codes: S-0 and S-2)

  • Page 29: Kml-631Mah And Kml-631Mwh (Auxiliary Codes: T-0 And Later)

    2. KML-631MAH and KML-631MWH (auxiliary codes: T-0 and later)

  • Page 30: Kml-631Mrh (Auxiliary Codes: T-0 And Later)

    3. KML-631MRH (auxiliary codes: T-0 and later)

  • Page 31: Performance Data

    C. Performance Data 1. KML-631MAH (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 1250 1262 1273 CONSUMPTION 80/27 1259 1277 1286 90/32 1262...

  • Page 32: Kml-631Mwh (Water-Cooled)

    2. KML-631MWH (water-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 1140 1146 1144 CONSUMPTION 80/27 1144 1154 1146 90/32 1146 1160 1155 watts 100/38 1142 1159...

  • Page 33: Kml-631Mrh (Remote Air-Cooled)

    3. KML-631MRH (remote 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 1250 1265 1277 CONSUMPTION 80/27 1261 1284 1292 90/32 1265 1300 1310 watts 100/38 1265...

  • Page 34: Service Diagnosis

    IV. Service Diagnosis A. 10-Minute 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 35: Diagnostic Charts

    unit remains in freeze with the float switch removed, replace the board. Note: Normal freeze cycle will last 20 to 40 minutes depending on model and conditions. Cycle times and pressures should follow performance data provided in this manual. 6) Pump-Out Cycle (10/20 second pump out) – The compressor remains energized, the hot gas valve energizes, and the fan motor de-energizes.
  • Page 36 Problem Possible Cause Remedy [1] The icemaker will not e) High Pressure Control 3. Ambient or condenser 3. Reduce temperature. start. (continued) (continued) water temperature too warm. 4. Refrigerant 4. Recharge. overcharged. 5. Fan not operating. 5. See chart 1.[6] (except water-cooled model) 6.
  • Page 37 Problem Possible Cause Remedy [1] The icemaker will not m)Control Switch 1. SERVICE position. 1. Move to ICE position. start. (continued) 2. Bad contacts. 2. Check and replace. [2] Water continues to a) Float Switch 1. Connector 1. Place in position. be supplied, and the disconnected.
  • Page 38 Problem Possible Cause Remedy [5] No water comes from d) Pump Motor 3. Bearing worn out. 3. Replace. spray tubes. Water (continued) 4. Wiring to pump motor. 4. Check for loose pump will not start, or connection or open, and freeze cycle time is replace.

  • Page 39: 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 40: Low Ice Production

    Problem Possible Cause Remedy [3]Other (continued) g) Water Supply Line 1. Too small; requires 1. Increase water line size. 3/8" OD line dedicated per machine. h) Water Filter 1. Flow rate too small. 1. Replace with filter that has larger flow rate. 3.
  • Page 41 Problem Possible Cause Remedy [2] Abnormal noise. c) Compressor 2. Mounting pad out of 2. Reinstall. (continued) (continued) position. d) Refrigerant Lines 1. Rub or touch other 1. Replace. lines or surfaces. [3] Ice in storage bin a) Drain Line(s) 1.

  • Page 42: 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 43: Evacuation And Recharge (R-404A)

    Remember to loosen the connection, and purge the air from the hose. 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.

  • Page 44: 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 45: 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 46: Removal And Replacement Of Evaporator

    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. 5) Disconnect the valve. If replacing the hot gas valve, also remove the strainer. 6) Place the new valve and strainer, if applicable, in position.

  • Page 47: Removal And Replacement Of Water Regulating Valve - Water Cooled Model Only

    8) Remove the drier, then place the new drier in position. 9) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 10) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 11) Evacuate the system, and charge it with refrigerant.

  • Page 48: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    G. 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) Prepare a thermometer to check the condenser drain temperature. Attach a pressure gauge to the high-side line of the system.

  • Page 49: Removal And Replacement Of Thermistor

    7) Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. CAUTION Always protect the headmaster body by using a damp cloth to prevent it from overheating. Do not braze with the headmaster body exceeding 250°F (121°C). 8) Remove the drier in the icemaker, then place the new drier in position.

  • Page 50: Removal And Replacement Of Fan Motor

    9) Attach the new thermistor to the suction pipe in the same position as the previous thermistor. Be very careful to prevent damage to the leads. Secure it using the thermistor holder and recommended foam insulation. 10) Secure the insulation using the plastic cable ties. 11) Connect the thermistor leads through the bushing of the control box to the K3 connector on the control board.

  • Page 51: 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) Remove the three screws and the float switch assembly. 4) Disconnect the pump motor wiring connector and the ground wire. 5) Disconnect the hoses attached to the pump motor assembly. 6) Remove the four screws and the pump motor.

  • Page 52: Cleaning And Maintenance Instructions

    1. Cleaning Procedure 1) Dilute approximately 13.5 fl. oz. (400 ml) of Hoshizaki "Scale Away" with 2.5 gallons (9.5 l) of warm water. 2) Remove all ice from the evaporator and the storage bin.

  • Page 53: Sanitizing Procedure - Following Cleaning Procedure

    15) Move the service switch to the "DRAIN" position. 16) Replace the front panel in its correct position and turn on the power supply for 2 minutes. 17) Turn off the power supply and remove the front panel. 18) Move the control switch to the "ICE" position. 19) Replace the front panel in its correct position.

  • Page 54: Maintenance

    12) Remove the front panel. 13) Repeat steps 18 through 31 in "1. Cleaning Procedure" two times to rinse thoroughly. 14) Move the control switch to the "ICE" position. 15) Replace the front panel in its correct position. 16) Clean the storage bin with water. 17) Turn on the power supply, and start the automatic icemaking process.
  • Page 55 1. On water-cooled model only, first remove the water from the water-cooled condenser: 1) Turn off the power supply and remove the front panel and right side panel. 2) Close the condenser water supply line shut-off valve. 3) Open the condenser water supply line drain valve. 4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.
  • Page 56 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON KML-451MWH B-1 and Later ON OFF OFF OFF ON ON OFF OFF OFF ON KML-631MAH B-1 and Later ON OFF OFF OFF ON ON OFF OFF OFF ON KML-631MWH C-0 and Later...
  • Page 57 B. Wiring Diagram 1. KML-631MAH B-1 and Later and KML-631MWH C-0 and Later...
  • Page 58 2. KML-631MRH C-0 and Later...

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