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25

III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

[a] KM-150BAF

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Summary of Contents for KM-150BAF

Page 1: ... SERVICE MANUAL ISSUED FEB 27 1998 KM 150BAF KM 150BWF CRESCENT CUBER Reliability is a beautiful thingTM REVISED DEC 14 2003 NUMBER 73066 ...

Page 2: ... 800 233 1940TechnicalService 770 487 2331 Fax 770 487 3360 NOTE Toexpediteassistance allcorrespondence communicationMUST includethefollowing information Model Number Serial Number Completeanddetailedexplanationoftheproblem 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...

Page 3: ...FORMATION 7 1 CONSTRUCTION 7 a KM 150BAF 7 b KM 150BWF 8 2 CONTROLLER BOARD 9 a SOLID STATE CONTROL 9 b CONTROLLER BOARD 9 c SEQUENCE 16 d CONTROLS AND ADJUSTMENTS 18 e CHECKING THE CONTROLLER BOARD 21 3 SWITCHES 24 III TECHNICAL INFORMATION 25 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 25 a KM 150BAF Air cooled 25 b KM 150BWF Water cooled 26 2 WIRING DIAGRAM 27 3 TIMING CHART 28 4 PERFORMANCE DATA 3...

Page 4: ...ER REGULATING VALVE WATER COOLED MODEL ONLY 44 9 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY 45 10 REMOVAL AND REPLACEMENT OF THERMISTOR 46 11 REMOVAL AND REPLACEMENT OF FAN MOTOR EXCEPT WATER COOLED MODEL 47 12 REMOVAL AND REPLACEMENT OF WATER VALVE 47 13 REMOVAL AND REPLACEMENT OF PUMP MOTOR 48 14 REMOVAL AND REPLACEMENT OF FLOAT SWITCH 49 15 REMOVAL AND REPLACEMENT OF SPRAY TUB...

Page 5: ...5 I SPECIFICATIONS 1 KM 150BAF ...

Page 6: ...6 2 KM 150BWF ...

Page 7: ...7 II GENERAL INFORMATION 1 CONSTRUCTION a KM 150BAF ...

Page 8: ...8 b KM 150BWF ...

Page 9: ...ich are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit when handling or replacing the board 3 Do not touch the electronic devices on the board or the back of the board to prevent damage to the board 4 Do not change wiring and connections Especially never misconnect K3 K4 and K5 because the same connector is used for the Thermistor and ...

Page 10: ... cycle is completed 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 3 High Temperature Safety 127 7 F...

Page 11: ...ler Board changes to the ice making cycle If the Float Switch is in the down position electrical circuit open the Controller Board changes to a one minute water fill cycle before starting the ice making cycle This method allows for a Low Water Safety shut down to protect the Water Pump from mechanical seal failure For water cooled model if the water is shut off the unit is protected by the High Pr...

Page 12: ...3 Line Valve 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line Bin Control 8 Open Dip Switch Defrost Timer Drain Timer Drain Counter Connector K5 Float Switch Connector K4 Open not connected Connector K3 Defrost Control Thermistor Alpine C Alpine Board ...

Page 13: ...sor 3 beeps every 3 sec Freeze Back Up Timer Freeze 60 minutes Yellow LED marked 60 MIN energizes Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge or inefficient compressor To manually reset the above safeties depress white alarm reset button with the power supply ON 6 beeps every 3 sec Low Voltage Voltage is 92 Vac or less 7 beeps every 3 sec High Vol...

Page 14: ...14 Control Products HOSHIZAKI001 Board ...

Page 15: ...15 Control Products HOS 001A Board ...

Page 16: ...tops counting Defrost cycle is completed and freeze cycle starts IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 3 Thermistor reads 48 F 9 C Defrost Timer ad...

Page 17: ...rost cycle is completed and freeze cycle starts IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 2 Thermistor reads 48 F 9 C Defrost Timer adjustable from 1 t...

Page 18: ...le i e the minimum defrost time Switch Nos 5 and 6 Used for adjustment of the Drain Counter The Pump Motor drains the Water Tank at the frequency determined by the Drain Counter Switch Nos 7 and 8 Used only for checking the Controller Board Usually set in OFF position Switch Nos 9 and 10 Used for adjustment of Freeze Timer The Freeze Timer determines maximum freeze cycle time Upon termination of F...

Page 19: ...the connector K3 on the board ii Remove the Thermistor See V 10 REMOVAL AND REPLACEMENT OF THERMISTOR iii Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes iv Check for a resistance between Thermistor leads Normal reading is within 3 5 to 7 kΩ Replace the Thermistor if it exceeds the normal reading 2 Defrost Timer No adjustment is required under normal us...

Page 20: ...AUTION 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 OFF OFF Check the adjustment chart published in the Tech Specs for proper settings If the old board does not have these two dip switches only ...

Page 21: ... after the first 2 minutes of the defrost cycle The unit should start the freeze cycle after 1 minute 5 seconds from the resistor connection 5 Bin Control CAUTION When the ambient temperature is below 45 F 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 Ic...

Page 22: ...and the contacts close See the following chart and check OPEN and CLOSE of Pins of the Connector K1 at each step iii If the checks are completed turn off the icemaker plug the Connector K1 into the Controller Board as before and set the Dip Switch No 7 and 8 to the OFF position CONTROL PRODUCTS BOARD ONLY The Output Test Switch S3 provides a relay sequence test With power OFF place S3 on and switc...

Page 23: ...23 TEST PROGRAM OF ALPINE CONTROLLER BOARD ...

Page 24: ...lectrical shock disconnect the power before servicing 2 ICE This position applies power to the unit causing the automatic ice making cycle to begin The Water Valve is energized and the 1 minute water fill cycle starts Refer to II 2 c SEQUENCE for further details 3 WASH When the Control Switch is placed in the WASH position power is supplied to the Pump Motor and Cleaning Water Valve This allows cl...

Page 25: ...25 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a KM 150BAF ...

Page 26: ...26 b KM 150BWF ...

Page 27: ...27 Note Pressure Switch HI KM 150BAF Cut out 412 5 PSIG Cut in 327 1 21 3 PSIG 21 3 0 2 WIRING DIAGRAM KM 150BAF KM 150BWF KM 150BWF Cut out 376 9 PSIG Cut in 270 2 21 3 PSIG 21 3 0 ...

Page 28: ...28 3 TIMING CHART 1 The Pump Motor for KM 150B series does not have drain cycle 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II 2 d CONTROLS AND ADJUSTMENTS ...

Page 29: ...29 1 The Pump Motor for KM 150B series does not have drain cycle 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II 2 d CONTROLS AND ADJUSTMENTS ...

Page 30: ...30 4 PERFORMANCE DATA a KM 150BAF Air cooled ...

Page 31: ...31 b KM 150BWF Water cooled ...

Page 32: ...e f Transformer 1 Thermal fuse blown out1 Replace or coil winding opened g Wiring to 1 Loose connections or 1 Check for continuity and Controller Board open replace h Thermistor 1 Leads short circuit or 1 See II 2 d CONTROLS open and High AND ADJUSTMENTS 1 Temperature Safety Defrost Control operates If open unit will start but have long harvest i Hot Gas Solenoid 1 Continues to open in 1 Check for...

Page 33: ... 5 Fan not operating Except 5 See chart 1 6 water cooled model 6 Refrigerant line or 6 Clean and replace Drier components plugged c Overload Protector 1 Bad contacts 1 Check for continuity and replace 2 Voltage too low 2 Increase voltage 3 Refrigerantoverchargedor 3 Recharge undercharged d Starter 1 Bad contacts 1 Check and replace 2 Coil winding opened 2 Replace e Start Capacitor 1 Defective 1 Re...

Page 34: ...ive 1 See II 2 e CHECKING CONTROLLER BOARD 6 Fan Motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is 2 Bearing worn out 2 Replace not operating 3 Wiring to Fan Motor 3 Check for loose connection or open and replace 4 Fan blade bound 4 Check and replace b ControllerBoard 1 Defective 1 See II 2 e CHECKING CONTROLLER BOARD 7 All components a Refrigerant 1 Undercharged 1 Check for ...

Page 35: ...e e Thermistor 1 Out of position or loose 1 See V 10 REMOVAL attachment AND REPLACEMENT OF THERMISTOR f ControllerBoard 1 Defrost Timer is set too 1 Adjust longer referring short to II 2 d CONTROLS AND ADJUSTMENTS 2 Defrost Timer 2 Defective 2 See II 2 e CHECKING CONTROLLER BOARD 3 Others a Spray Tubes 1 Clogged 1 Clean 2 Out of position 2 Place in position b Water System 1 Dirty 1 Clean c Refrige...

Page 36: ...r pressure or refrigerant charge b See chart 2 1 and check Float Switch Water Solenoid Valve or Controller Board 2 Harvest cycle a See chart 2 2 and check Controller Board Thermistor Evaporator ambient time is long and or water temperature water supply line or Water Solenoid Valve 5 OTHERS PROBLEM POSSIBLE CAUSE REMEDY 1 Icemaker will a Bin Control 1 Set too cold 1 Adjust warmer not stop when Ther...

Page 37: ... side and one on the high side line Using proper refrigerant practices recover the refrigerant from the Access Valves and store it in an approved container Do not discharge the refrigerant into the atmosphere b EVACUATION AND RECHARGE R 404A 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system Be sure to connect charging hoses to both High and Low side Access Valves IMPORTANT...

Page 38: ... coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove coating 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...

Page 39: ...ker 2 Remove the Front Panel and slide out the refrigeration base 3 Recover the refrigerant and store it in an approved container 4 Remove the Terminal Cover on the Compressor and disconnect the Compressor Wiring 5 Remove the Discharge and Suction Pipes using brazing equipment 6 Remove the Hold down Bolts Washers and Rubber Grommets 7 Slide and remove the Compressor Unpack the new Compressor packa...

Page 40: ... replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply and unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Drier 5 Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubings 6 Che...

Page 41: ...connect the Expansion Valve using brazing equipment 6 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING 1 Do not heat the wall Place a steel barrier for protection 2 Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 7 Install the new Drier 8 Check for leaks using nitro...

Page 42: ... Hot Gas Valve using brazing equipment 6 Install the new valve WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant cha...

Page 43: ...through the molded chassis 5 Remove the Insulation Tube and disconnect the Evaporator Inlet Tubing at the Tee next to the Expansion Valve 6 Remove the screws holding the Evaporator to the plastic Rear Panel 7 Lift up the Evaporator and disconnect the Evaporator Outlet Tubing 8 Install the new Evaporator 9 Install the new Drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evac...

Page 44: ...er 5 Disconnect the Capillary Tube at the Condenser outlet using brazing equipment 6 Disconnect the Flare connections of the valve 7 Remove the screws and the valve from the Bracket 8 Install the new valve and braze the Capillary Tube 9 Install the new Drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the Nameplate for t...

Page 45: ...he system or prepare a thermometer to check for the condenser drain temperature 2 Rotate the adjustment screw by using a flat blade screwdriver so that the pressure gauge shows 270 PSIG or the thermometer reads 104 115 F 5 minutes after a freeze cycle or icemaking process starts When the pressure exceeds 270 PSIG or the condenser drain temperature exceeds 115 F rotate the adjustment screw counterc...

Page 46: ... icemaker 2 Remove the panels 3 Remove the Control Box Cover at the rear of the unit 4 Disconnect the Thermistor leads from the K3 Connector on the Controller Board 5 Remove the Plastic Cable Ties Foam Insulation Thermistor Holder and Thermistor See Fig 2 6 Scrape away the old sealant on the Thermistor Holder and the Suction Pipe 7 Wipe off moisture or condensation on the Suction Pipe 8 Smoothly a...

Page 47: ...replace the Front Panel in its correct position 10 Plug in the icemaker and turn on the power supply 12 REMOVAL AND REPLACEMENT OF WATER VALVE 1 Turn off the power supply and unplug the icemaker 2 Close the Water Supply Line Shut off Valve 3 Disconnect the water supply piping 4 Remove the Top Panel 5 Disconnect the Valve Outlet Tubing by releasing the Clamp 6 Disconnect the Terminals from the Wate...

Page 48: ...ove the screw and the Pump Motor Bracket 8 Lift up the Pump Motor with the Pump Motor Bracket 9 Release the Hose Clamp and disconnect the Hose for the Cleaning Water Valve 10 Remove the four screws and the Pump Motor 11 Install the new Pump Motor and replace the removed parts in the reverse order of which they were removed 7 Remove the Fitting and the Gasket 8 Release the Hose Clamp and disconnect...

Page 49: ...ch they were removed 8 Go through the steps 12 through 14 in 13 REMOVAL AND REPLACEMENT OF PUMP MOTOR 15 REMOVAL AND REPLACEMENT OF SPRAY TUBE 1 Turn off the power supply and unplug the icemaker 2 Remove the Top Panel and Top Insulation 3 Disconnect the Hoses 4 Lift off the Spray Tube 5 Install the new Spray Tube Note Place the Spray Tube so that the holding tabs on both sides are in position 6 Co...

Page 50: ...ree days it is sufficient to only move the Control Switch to the OFF position unless the icemaker will be at sub freezing temperatures 1 On water cooled model only first remove the water from the water cooled condenser 1 Remove the Front Panel 2 Move the Control Switch on the Control Box to the OFF position 3 Wait 3 minutes 4 Move the Control Switch to the ICE position 5 Allow 5 minutes for the ic...

Page 51: ... 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 3 Drain the Potable Water Tank 1 Disconnect the power supply 2 Move the Control Switch to the OFF position 3 Open the Door 4 Remove the Cube Guide and the Overflow Pipe to drain the Water Tank See Fig 3 5 Place the Overflow Pipe and the Cube Gui...

Page 52: ...ns come into contact with skin a CLEANING PROCEDURE 1 Dilute approximately 5 fl oz 148 ml of recommended cleaner Hoshizaki Scale Away or Lime A Way Economics Laboratory Inc with 1 gal 3 8 l of warm water 2 Remove the Front Panel 3 Remove all ice from the Evaporator and the Storage Bin Note To remove cubes on the Evaporator move the Control Switch on the Control Box to the OFF position and move it ...

Page 53: ...n the Water Tank Place the Overflow Pipe and Cube Guide in their correct positions 16 Repeat the above steps 11 through 15 three more times to rinse thoroughly 17 Remove one end of the Tank Drain Hose and remove the Thumbscrew at the front of the Water Tank Remove the Water Tank by pulling it toward you slightly and lowering it See Fig 4 18 Remove the Water Tank Brackets and the Thermostat Bracket...

Page 54: ... 5 Remove the Cube Guide 6 Pour the sanitizing solution into the Water Tank 7 Place the Cube Guide in its correct position 8 Move the Control Switch to the WASH position 9 Shut the Door 10 After 15 minutes move the Control Switch to the OFF position 11 Open the Door 12 Remove the Cube Guide and the Overflow Pipe to drain the Water Tank Place the Overflow Pipe and the Cube Guide in position 13 Repe...

Page 55: ...n the bin Keep the scoop clean Clean it by using a neutral cleaner and rinse thoroughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Air Filter Air cooled model only A plastic mesh air filter removes dirt or dust from the air and keeps the Condenser from getting clogged As the filter gets clogged the icemaker s performance will be reduced Check the filter at lea...

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