Hoshizaki KM-1601MRH/3 Service Manual
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Hoshizaki KM-1601MRH/3 Service Manual

Modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Modular Crescent Cuber
Models
KM-1601MRH/3
SERVICE MANUAL
Number: 73129
Issued: 6-16-2006
Revised: 3-28-2011

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Summary of Contents for Hoshizaki KM-1601MRH/3

  • Page 1 Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models KM-1601MRH/3 SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73129 Issued: 6-16-2006 Revised: 3-28-2011...
  • 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. Please retain this booklet for any further reference that may be necessary.
  • Page 4 III. Technical Information ...................... 22 A. Water Circuit and Refrigeration Circuit ................ 22 B. Wiring Diagrams ......................23 1. KM-1601MRH ......................23 2. KM-1601MRH3 ...................... 24 C. Performance Data ....................... 25 1. KM-1601MRH with URC-21F ................. 25 2. KM-1601MRH with URC-22F ................. 26 3.

  • 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, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. CAUTION Indicates a situation which could result in damage to the unit.

  • Page 6: Specifications

    I. Specifications A. Icemaker 1. KM-1601MRH with URC-21F AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 11.6 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: Km-1601Mrh With Urc-22F

    2. KM-1601MRH with URC-22F AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 11.6 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 8: Km-1601Mrh3 With Urc-21F

    3. KM-1601MRH3 with URC-21F AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 8.4 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. Temp.(°F) lbs./day ( kg/day ) *1471 (667)

  • Page 9: Km-1601Mrh3 With Urc-22F

    4. KM-1601MRH3 with URC-22F AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 8.4 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. Temp.(°F) lbs./day ( kg/day ) *1486 (674)

  • Page 10: Condenser Unit

    B. Condenser Unit 1. URC-21F, URC-22F AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 2.6FLA 130W EXTERIOR DIMENSIONS (WxDxH) 46-3/8" x 15-11/16" x 25-15/16" (1178 x 398 x 659 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 48-7/16" x 18-1/8" x 40-7/8" (1230 x 460 x 1039 mm) EXTERIOR FINISH Galvanized Steel WEIGHT...

  • Page 11: General Information

    II. General Information A. Construction 1. KM-1601MRH, KM-1601MRH3 Inlet Water Valve Spray Tube Water Supply Inlet Hot Gas Valve Junction Box Check Valve Evaporator Expansion Valve Cleaning Valve Control Box Line Valve Control Switch Receiver Bin Control Thermostat Capacitor Box Float Switch (KM-1601MRH) Water Pump...

  • Page 12: Urc-21F, Urc-22F

    2. URC-21F, URC-22F Fan Blade Condenser Fan Motors Fan Blade Condenser Headmaster (C.P.R.) Junction Box Discharge Line Connection Liquid Line Connection...

  • Page 13: Sequence Of Operation

    B. Sequence of Operation 1. Sequence Cycles and Shutdown 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 control board is 1, 4, 3, 2.

  • Page 14: E) Normal Harvest Cycle

    e) Normal Harvest Cycle LEDs 1, 4, and 2 are on. Comp and FMR continue to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is shorter.

  • Page 15: Sequence Flow Chart

    2. Sequence Flow Chart...

  • Page 16: Control Board

    C. Control Board • A Hoshizaki exclusive solid-state control is employed in KM-1601MRH and KM-1601MRH3 Modular Crescent Cubers. • All models are pretested and factory-adjusted. CAUTION 1. The control board is fragile; handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 17: Control Board Layout

    1. Control Board Layout "E" Control Board Output Test Switch (used to test relays on control Dip Switch Alarm Reset Switch board) Backup Freeze Timer LED Connector K3 Harvest Control (thermistor) Backup Harvest Connector K4 Timer LED Open (not connected) Alarm Buzzer Power LED Microprocessor...

  • Page 18: Led Lights And Audible Alarm Safeties

    2. 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 control 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 19: 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 20: 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 21: F) Freeze Timer (Dip Switch 9 & 10)

    f) 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. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem.

  • Page 22: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-1601MRH, KM-1601MRH3...

  • Page 23: Wiring Diagrams

    B. Wiring Diagrams 1. KM-1601MRH...

  • Page 24: Km-1601Mrh3

    2. KM-1601MRH3...

  • Page 25: Performance Data

    C. Performance Data 1. KM-1601MRH with URC-21F APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 1508 1483 1399 80/27 1489 1450 1338 90/32 1483 1422 1320 lbs./day kg./day 100/38 1449 1398 1227 APPROXIMATE ELECTRIC 70/21 2450...

  • Page 26: Km-1601Mrh With Urc-22F

    2. KM-1601MRH with URC-22F APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 1493 1471 1410 80/27 1476 1441 1364 90/32 1471 1417 1346 lbs./day kg./day 100/38 1449 1400 1280 APPROXIMATE ELECTRIC 70/21 2590 2634 2687...

  • Page 27: Km-1601Mrh3 With Urc-21F

    3. KM-1601MRH3 with URC-21F APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 1471 70/21 1448 1354 80/27 1453 1417 1290 1392 90/32 1448 1277 lbs./day kg./day 100/38 1408 1365 1171 APPROXIMATE ELECTRIC 2410 70/21 2477 2503...

  • Page 28: Km-1601Mrh3 With Urc-22F

    4. KM-1601MRH3 with URC-22F APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 1486 70/21 1458 1366 80/27 1465 1422 1300 90/32 1458 1391 1280 lbs./day kg./day 100/38 1422 1365 1178 APPROXIMATE ELECTRIC 70/21 2460 2513 2553...

  • Page 29: Service Diagnosis

    IV. Service Diagnosis WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices.
  • Page 30 4) Initial Harvest Cycle – Inlet water valve remains energized, contactor coil energizes to start the compressor (and fan motor on a remote condenser unit), and the hot gas valve energizes. The evaporator warms and the thermistor senses 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ...

  • Page 31: Control Board Check

    B. Control Board Check Before replacing a control board 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 the control board is in alarm (beeping), press the "ALARM RESET" button on the control board while the control board is beeping. WARNING! Risk of electric shock.

  • Page 32: Bin Control Check

    C. Bin Control Check To check the thermostatic bin control, follow the steps below. CAUTION When the ambient temperature is below 45°F (7°C), the thermostatic bin control switch opens and shuts down the icemaker even if the ice storage bin is empty.

  • Page 33: Float Switch Check And Cleaning

    D. Float Switch Check and Cleaning The float switch is used to determine that there is sufficient water in the tank after the 1-minute fill cycle and after each harvest cycle. The float switch is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle.

  • Page 34: Float Switch Cleaning

    Be careful not to bend the retainer rod excessively when removing it. 7) Wipe down the float switch assembly'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 35: Thermistor Check

    E. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes.

  • Page 36: Diagnostic Charts

    F. Diagnostic Charts Before consulting the diagnostic charts, check for correct installation, proper voltage per unit nameplate, and adequate water supply. Check CB using the steps in "IV.B. Control Board Check." Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10, are in the factory default position. S4 dip switch 1, 2, 5, 6 are cleaning adjustments and the settings are flexible. For factory default settings, see "II.C.3.a) Default Dip Switch Settings." 1. No Ice Production Problem Possible Cause Remedy...
  • Page 37 Problem Possible Cause Remedy [1] The icemaker will not f) Transformer 1. Coil winding opened 1. Replace. start. (continued). or shorted. g)Wiring to Control Board 1. Loose connections or 1. Check for continuity and open. replace. h)Thermistor 1. Leads shorted or 1.
  • Page 38 Problem Possible Cause Remedy [3] Compressor will a)Magnetic Contactor 1. Bad contacts. 1. Check for continuity and not start or stops replace. operating. 2. Coil winding opened. 2. Replace. b)Start Capacitor or Run 1. Defective. 1. Replace. Capacitor c) Internal Overload 1.

  • Page 39: Evaporator Is Frozen Up

    Problem Possible Cause Remedy [6] Fan motor will a)Fan Motor 1. Motor winding opened. 1. Replace. not start, or is not operating. 2. Bearing worn out. 2. Replace. 3. Wiring to fan motor. 3. Check for loose connection or open, and replace.

  • Page 40: Low Ice Production

    Problem Possible Cause Remedy [2]All ice formed on g) Thermistor 1. Out of position or 1. See "V.B. Important ecaorator does not loose attachment. Notes for Component fall into bin in harvest. Replacement." (continued). h) Control Board 1. Harvest timer is set 1.

  • Page 41: Abnormal Ice

    4. Abnormal Ice Problem Possible Cause Remedy [1] Small cubes. a) Ice Cube Guide 1. Out of position. 1. Place in position. Circulated water falls into bin. b) See chart 1.[5] and check water supply line, inlet water valve, water system, pump motor, and control board.

  • Page 42: Replacement Of Components

    V. Replacement of Components WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently.

  • Page 43: Brazing

    2. Brazing WARNING 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). 2. 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.
  • Page 44 5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For refrigerant charge, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

  • Page 45: 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 46: Cleaning And Maintenance Instructions

    WARNING 1. Hoshizaki recommends cleaning this unit at least once a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.

  • Page 47: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 27 fl. oz. (800 ml) of Hoshizaki "Scale Away" with 5 gal. (19 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 on after 3 minutes. The harvest cycle starts and the cubes will be removed from the evaporator.

  • Page 48: Sanitizing Procedure - Following Cleaning Procedure

    16) Move the control switch to the "ICE" position. 17) Close the cleaning valve. Note: The icemaker will not operate unless the cleaning valve is completely closed. 18) Replace the front panel in its correct position. 19) Turn on the power supply to fill the water tank with water. 20) Turn off the power supply after 3 minutes.

  • Page 49: 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 and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2.
  • Page 50 6) Attach compressed air or carbon dioxide supply to the potable water line drain valve. 7) Move the control switch to the "ICE" position. 8) Blow the potable water line out using compressed air or carbon dioxide. 2. Drain the potable water tank: 1) Turn off the power supply. 2) Move the control switch to the "OFF" position.

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