Hoshizaki KM-300BAJ Service Manual Download

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IMPORTANT

This manual should be read carefully before the appliance is serviced. Read the

warnings and guidelines contained in this manual carefully as they provide essential

information for the continued safe use, service, and maintenance of the appliance.

Retain this manual for any further reference that may be necessary.

CONTENTS

Important Safety Information ..........................................................................................4

I. Construction and Water/Refrigeration Circuit Diagram ...............................................6

A. Construction ...........................................................................................................6

1. KM-230BAJ, KM-300BAJ .................................................................................6

2. KM-300BWJ .....................................................................................................7

3. Icemaking Compartment ..................................................................................8

B. Water/Refrigeration Circuit Diagram ......................................................................9

1. KM-230BAJ ......................................................................................................9

2. KM-300BAJ ....................................................................................................10

3. KM-300BWJ ...................................................................................................

II. Sequence of Operation and Service Diagnosis ........................................................12

A. Sequence of Operation ........................................................................................12

1. Flow Chart ......................................................................................................12

2. Timing Chart ...................................................................................................13

3. Details ............................................................................................................14

B. Service Diagnosis ................................................................................................16

C. Control Board Check ...........................................................................................18

D. Bin Control Check and Cleaning .........................................................................18

1. Bin Control Check ..........................................................................................19

2. Bin Control Cleaning ......................................................................................19

E. Float Switch Check and Cleaning ........................................................................21

1. Float Switch Check.........................................................................................21

2. Float Switch Cleaning ....................................................................................22

F. Thermistor Check .................................................................................................23

G. Diagnostic Tables ................................................................................................24

1. No Ice Production ...........................................................................................24

2. Freeze-Up ......................................................................................................27

3. Low Ice Production .........................................................................................28

4. Abnormal Ice ..................................................................................................28

5. Other ..............................................................................................................29

III. Controls and Adjustments........................................................................................30

A. Control Board Layout ...........................................................................................31

B. LED Lights and Audible Alarm Safeties ...............................................................32

C. Settings and

Adjustments ....................................................................................33

1. Default Dip Switch Settings ............................................................................33

2. Harvest Timer .................................................................................................33

3. Pump-Out Timer .............................................................................................34

4. Pump-Out Frequency Control ........................................................................34

Summary of Contents for KM-300BAJ

Page 1: ...Service Manual Number F111 1006 Issued 03 15 2018 hoshizakiamerica com Models KM 230BAJ KM 300BAJ BWJ Self Contained Crescent Cuber ...

Page 2: ...mage due to improper installation is not covered under warranty Hoshizaki provides this manual primarily to assist qualified service technicians in the maintenance and service of the product Should the reader have any questions or concerns which have not been satisfactorily addressed please call send an e mail message or write to the Hoshizaki Technical Support Department for assistance Phone 1 80...

Page 3: ...BAJ 9 2 KM 300BAJ 10 3 KM 300BWJ 11 II Sequence of Operation and Service Diagnosis 12 A Sequence of Operation 12 1 Flow Chart 12 2 Timing Chart 13 3 Details 14 B Service Diagnosis 16 C Control Board Check 18 D Bin Control Check and Cleaning 18 1 Bin Control Check 19 2 Bin Control Cleaning 19 E Float Switch Check and Cleaning 21 1 Float Switch Check 21 2 Float Switch Cleaning 22 F Thermistor Check ...

Page 4: ...mation 40 A Refrigeration Circuit Service Information 40 1 Refrigerant Recovery 41 2 Brazing 41 3 Evacuation and Recharge R 404A 41 B Component Service Information 42 C Water Tank 43 D Separator 44 E Door 45 F Adjustment of Water Regulating Valve Water Cooled Model 46 V Maintenance 47 A Maintenance Schedule 47 VI Preparing the Appliance for Periods of Non Use 48 VII Disposal 49 VIII Technical Info...

Page 5: ...independent power supply of proper capacity See the nameplate for electrical specifications Failure to use an independent power supply of proper capacity can result in a tripped breaker blown fuse damage to existing wiring or component failure This could lead to heat generation or fire THE APPLIANCE MUST BE GROUNDED The appliance is equipped with a NEMA 5 15 three prong grounding plug to reduce th...

Page 6: ...uals or damage to the appliance NOTICE Protect the floor when moving the appliance to prevent damage to the floor Follow the water supply drain connection and maintenance instructions carefully to reduce the risk of costly water damage In areas where water damage is a concern install in a contained area with a floor drain Install the appliance in a location that stays above freezing Normal operati...

Page 7: ...ir Filter Louver Leg Side Panel R Power Supply Cord Top Cover Hot Gas Valve Thermistor Drain Valve Evaporator Condenser Fan Motor Cleaning Valve Separator Compressor Water Tank Water Valve Expansion Float Switch Valve Overflow Pipe Drier Pump Motor Control Switch Service Switch Control Box Front View Rear View Bin Control Switch With Tank Removed ...

Page 8: ... Leg Top Cover Drain Valve Hot Gas Valve Thermistor Cleaning Valve Water Regulating Evaporator Valve Condenser Separator Water Tank Compressor Expansion Valve Water Valve Overflow Pipe Drier Control Switch Float Switch Service Switch Control Box Front View Rear View Bin Control Switch With Tank Removed ...

Page 9: ...8 3 Icemaking Compartment Spray Tube Evaporator Water Supply Pipe Separator Cube Guide Water Tank Overflow Pipe Drain Valve Cleaning Valve Separator Water Valve Pump Motor Float Switch ...

Page 10: ...r Valve Spray Tube Fan Condenser Expansion Valve Compressor Access Valve Strainer Hot Gas Valve High Pressure Switch Refrigerant Circuit Water Circuit Discharge Line Insulation Tube Pump Motor Water Tank Drain Drain Valve Cleaning Valve B Water Refrigeration Circuit Diagram 1 KM 230BAJ ...

Page 11: ...ine Evaporator Float Switch Cube Guide Drier Thermistor Suction Line Water Supply Water Valve Spray Tube Fan Condenser High Pressure Switch Refrigerant Circuit Water Circuit Insulation Tube Pump Motor Water Tank Drain Drain Valve Cleaning Valve Strainer Hot Gas Valve ...

Page 12: ...Valve Water Supply Water Valve Spray Tube Strainer Hot Gas Valve Float Switch Thermistor Expansion Valve Compressor Access Valve Refrigerant Circuit Water Circuit Discharge Line Pump Motor Water Tank Drain Evaporator Cube Guide Drier Suction Line Insulation Tube Cleaning Valve Drain Valve ...

Page 13: ...ee positions DRAIN CIRCULATE and WASH See the information below for details of each function DRAIN Power is supplied to the pump and drain valve This drains the water tank CIRCULATE Power is supplied to the pump only This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator WASH Power is supplied to the pump and cleaning valve This oper...

Page 14: ...est cycle FREEZE CYCLE HARVEST CYCLE 6min OFF 3min 1 C COMPRESSOR ON OFF FAN MOTOR KM 230BAJ 300BAJ ON 60sec HOT GAS VALVE ON OFF WATER VALVE ON OFF PUMP MOTOR KM 230BAJ 30sec KM 300BAJ BWJ 10sec ON 6min DRAIN VALVE ON OFF CLEANING VALVE ON OFF FLOAT SWITCH ON OFF BIN CONTROL SWITCH ON OFF CONTROLLER BOARD RELAY X1 COMP ON OFF RELAY X2 HV FM ON OFF RELAY X3 PM ON OFF RELAY X4 WV ON OFF RELAY X6 DV...

Page 15: ...adjustable by S1 dip switch 7 8 whichever is shorter LED 8 goes off when WV closes PM energizes and runs for the last 0 10 30 or 50 seconds of harvest depending on S1 dip switch 7 8 setting LED 7 comes on when PM energizes At the end of harvest the control board checks the position of F S and proceeds to the freeze cycle if it is closed or calls for a 1 minute fill if it is open c Freeze Cycle LED...

Page 16: ... is activated BC open the POWER OK LED flashes There is a delay before the shutdown sequence begins The delay varies depending on the cycle the icemaker is in at the time of activation For details see the table below Cycle at Bin Control Activation Delay Before Shutdown Sequence Begins Fill Cycle 15 seconds Harvest Cycle 15 seconds after the next freeze cycle starts Freeze Cycle 15 seconds if BC i...

Page 17: ...e checkout check for correct installation proper voltage per unit nameplate and adequate water supply As you go through the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect 1 Remove the louver Move the control switch to the OFF position then unplug the appliance Access the control box Clear any ice from the bin control act...

Page 18: ...first 5 minutes of freeze confirm that the evaporator temperature drops After the minimum freeze period disconnect the float switch at the 2 pin connector attached to the red wires The unit should immediately switch to the pump out cycle Diagnosis If the evaporator is not cold check to see if the hot gas valve is still open or if the expansion valve is not opening properly if the water valve is co...

Page 19: ...he control switch to the ICE position while pressing the OUTPUT TEST button WARNING Risk of electric shock Care should be taken not to touch live terminals The correct lighting sequence should be 5 6 7 8 9 4 Some components e g the compressor will cycle during test Each LED comes on for 5 seconds LED 5 is on while LED 6 is on Following the output test sequence the icemaker will resume normal opera...

Page 20: ...OFF position then unplug the appliance Access the control box 2 Clear any ice away from the bin control 3 Disconnect the bin control at the 2 pin connector attached to the black wires coming from the K1 connector pins 4 5 on the control board 4 Check for continuity across the bin control leads When calling for ice the bin control proximity switch should be closed If open replace the bin control Ac...

Page 21: ...ontrol switch to the OFF position then unplug the appliance 2 Remove the water tank see IV C WATER TANK The bin control switch is located as shown below when viewed from the front 3 Remove the top panel and the rear panel 4 Disconnect the connector of the bin control switch lead black covered with a silicone hose and remove the lead wire from the grommet 5 Loosen the thumbscrew on the right side 6...

Page 22: ...tch in the DRAIN position until the tank is empty 3 Move the control switch to the OFF position then unplug the appliance 4 Remove the top panel rear panel and right side panel 5 Disconnect the connector of the FS lead 6 Check for continuity across FS leads With the water tank empty FS should be open If open continue to step 7 If closed follow the steps in II E 2 Float Switch Cleaning After cleani...

Page 23: ...oard FS float switch 2 Float Switch Cleaning Depending on local water conditions scale may build up on FS Scale on the switch can cause the float to stick In this case FS should be cleaned 1 Remove the louver 2 Drain out the water tank by leaving the control switch in the SERVICE position and the service switch in the DRAIN position until the tank is empty 3 Move the control switch to the OFF posi...

Page 24: ...r during the freeze cycle 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 Temperature F Temperature C Resistance kΩ 0 18 14 401 10 12 10 613 32 0 6 000 50 10 3 871 70 21 2 474 90 32 1 633 Check a thermistor for resistance by using the following procedure 1 Remov...

Page 25: ...eplace g Wiring to Control Board 1 Loose connections or open 1 Check for continuity and replace h Thermistor 1 Leads shorted or open and high temperature safety operates If open unit will start but have long harvest cycle 1 See II F Thermistor Check i Hot Gas Solenoid Valve 1 Continues to open in freeze cycle and high temperature safety operates 1 Check for power off in freeze cycle and replace j ...

Page 26: ...denser water temperature too warm water cooled model 6 Check and get recommended temperature 7 Refrigerant line or components plugged 7 Clean and replace drier c Overload Protector 1 Bad contacts 1 Check for continuity and replace 2 Voltage too low 2 Increase voltage 3 Refrigerant overcharged or undercharged 3 Recharge d Starter 1 Bad contacts 1 Check and replace 2 Coil winding open 2 Replace e St...

Page 27: ...ump Motor 1 Motor winding open 1 Replace 2 Bearing worn out 2 Replace 3 Wiring to pump motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Defective or bound impeller 5 Replace and clean e Control Board 1 Defective 1 See II C Control Board Check 6 Fan Motor will not start or is not operating a Fan Motor 1 Motor winding open 1 Replace 2 Bearing worn out 2 Replac...

Page 28: ... not close 2 Check for water leaks with icemaker off Replace if necessary d Ambient and or water temperature 1 Too cool 1 Increase temperature e Thermistor 1 Out of position or loose attachment 1 See II F Thermistor Check f Control Board 1 Harvest timer is set too short 1 Adjust longer referring to III C 2 Harvest Timer 2 Defective 2 See II C Control Board Check 3 Others a Spray Tubes 1 Clogged 1 ...

Page 29: ...ply line and inlet water valve 4 Abnormal Ice PROBLEM POSSIBLE CAUSE REMEDY 1 Small cubes a Cube Guide Water Tank 1 Out of position Circulated water falls into bin 1 Check that cube guide is properly installed on water tank and tank is fixed securely with snaps b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board 2 Cloudy or irregular cubes a See ...

Page 30: ...6 Magnet disconnected from detector 6 Place in position b Control Board 1 Defective 1 See II C Control Board Check 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not move freely 3 Replace c Compressor 1 Bearings worn out or cylinder valve broken 1 Replace 2 Mounting pad out of position ...

Page 31: ...ated 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 Do not touch the electronic devices on the control board or the back of the control board Do not change wiring and connections Do not short out power supply to test for voltage Always replace the whole control board a...

Page 32: ... below LED 5 X1 Relay Compressor Comp Fan Motor Remote FMR LED 4 X6 Relay Drain Valve DV LED 8 X4 Relay Inlet Water Valve WV WV1 on units with inlet water valves K7 Connector Transformer K3 Connector Magnetic Contactor LED 7 X3 Relay Pump Motor PM LED 6 X2 Relay Hot Gas Valve HGV Fan Motor FM Liquid Line Valve LLV FM and LLV off when LED on LED 9 X5 Relay Inlet Water Valve WV on units with inlet w...

Page 33: ...Pump Out Cycle 5 6 4 7 Comp HGV DV PM 10 seconds 20 seconds factory default setting The built in safeties shut down the unit and have alarms as listed below No of Beeps every 3 sec Type of Alarm Notes 1 High Evaporator Temp temperature 127 F 53 C Check for harvest problem stuck HGV or relay hot water entering unit stuck HM or shorted thermistor 2 Harvest Backup Timer harvest 20 min for two cycles ...

Page 34: ...efault position or the unit will not operate properly The S2 dip switch No 6 is factory adjusted to the ON position for the auxiliary codes G1 and H0 Change it to the OFF position when replacing the control board This does not affect the product performance but prevents cloudy ice even in poor water quality areas Fig 4 Fig 5 Freeze Timer 9 10 Harvest Pump Timer 7 8 Pump Out Frequency Control 5 6 P...

Page 35: ...4 When a pump out is called for the pump motor stops for 2 seconds then the pump motor and drain valve energize Water is removed from the bottom of the water tank and sent down the drain The pump out 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 The pump out timer is factory set and gener...

Page 36: ...nd runs for the time determined by the harvest pump timer setting The harvest pump timer is factory adjusted and no adjustment is required Dip Switch Setting Time seconds No 7 No 8 OFF OFF 0 ON OFF 10 OFF ON 30 ON ON 50 6 Freeze Timer S1 dip switch 9 10 NOTICE Adjust to proper specification or the unit may not operate correctly The freeze timer setting determines the maximum allowed freeze time to...

Page 37: ...emove If the harvest cycle exceeds 6 minutes the pump motor starts to operate for a maximum of 3 minutes S2 Dip Switch Setting Harvest Promotion Control No 2 OFF Activated ON Deactivated 9 Refill Counter S2 dip switch 3 Do not adjust This must be left in the factory default position or the unit will not operate properly The KM 230BAJ and KM 300BAJ BWJ do not refill 10 Harvest Completion Detection ...

Page 38: ...arvest cycle starts If the evaporator outlet temperature is more than 3 5 C but not more than 5 C at the end of harvest cycle the harvest cycle is extended for 50 seconds before moving on to the freeze cycle If the evaporator outlet temperature is 3 5 C or less another harvest cycle starts The harvest cycle does not repeat more than three times The freeze cycle starts even if the evaporator outlet...

Page 39: ...and SERVICE lower position 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 Note 1 When the service switch is activated power is supplied to the water pump in all three po...

Page 40: ...ner for extended periods of time over the outside surface of the evaporator 3 WASH This machine utilizes a solenoid operated wash bypass valve When the service switch is active and placed in the WASH position power is supplied to the pump and cleaning valve This operation is used to circulate cleaner and sanitizer over both the inside and outside of the evaporator ...

Page 41: ...d by properly trained and EPA certified service personnel 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 NOTICE Always recover the refrigerant and store it in an approved contai...

Page 42: ...t is important to make connections outside the evaporator case when possible If it is necessary to braze inside the evaporator case use sandpaper to remove the coating from the brazing connections before unbrazing the components NOTICE 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 I...

Page 43: ... Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge manifold 7 Allow the system to charge with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side NOTICE To prevent compressor damage use a thr...

Page 44: ...icones or equivalent are recommended Attach the new thermistor in position and press down the thermistor holder over the thermistor Be very careful to prevent damage to the leads C Water Tank 1 Drain out the water tank by leaving the control switch in the SERVICE position and the service switch in the DRAIN position until the tank is empty 2 Move the control switch to the OFF position then unplug ...

Page 45: ...r separators Do not attach the separators upside down or inside out Make sure that the side printed with THIS SIDE UP faces up and the side printed with EVAPORATOR SIDE faces the evaporator 1 Move the control switch to the OFF position then unplug the appliance 2 Remove the top panel rear panel and side panels 3 Remove the top cover and front cover See Fig 8 Fig 8 Spray Tube Front Separator Pin Si...

Page 46: ...on the groove in the evaporator bracket Remove the rear separator by lifting it up and down See Fig 8 7 Refit the separators in the reverse order of the removal procedure Check that the separators are fit correctly and can swing like a pendulum 8 Plug in the appliance then move the control switch to the ICE position E Door 1 Open the door 2 Unscrew and remove the hinges on both sides and remove th...

Page 47: ...ressure gauge to the high side line of the system 2 Five minutes after a freeze cycle starts confirm that the thermometer reads 104 F to 115 F 40 C to 46 C If it does not rotate the adjustment screw by using a flat blade screwdriver until the temperature is in the proper range See Fig 10 Next check that the reference pressure is in the range indicated in the Head Pressure table See VIII B Performa...

Page 48: ...nment and local sanitation regulations Maintenance Schedule Frequency Area Task Daily Scoop Clean the ice scoop using a neutral cleaner Rinse thoroughly after cleaning Bi Weekly Air Filter Inspect Wash with warm water and neutral cleaner if dirty Monthly External Water Filters Check for proper pressure and change if necessary Icemaker Exterior Wipe down with a clean soft cloth Use a damp cloth con...

Page 49: ...rom the icemaker water supply line 1 Remove the louver if it has not already been removed 2 Move the control switch to the OFF position 3 Wait 3 minutes 4 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 5 Allow the line to drain by gravity 6 Attach compressed air or carbon dioxide supply to the icemaker water supply line drain valve 7 Move th...

Page 50: ...denser return line drain valve 5 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 6 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 7 Close the condenser water ...

Page 51: ...zed Steel Rear WEIGHT Net 137 lbs 62 kg Shipping 165 lbs 75 kg CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermeti...

Page 52: ...T Net 154 lbs 70 kg Shipping 187 lbs 85 kg CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic Model SC10CL CONDE...

Page 53: ...HT Net 154 lbs 70 kg Shipping 187 lbs 85 kg CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT CONDENSER WATER Inlet 1 2 FPT Outlet 1 2 FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL Pressure Regulator BIN CONTROL SYSTEM Mechanical L...

Page 54: ...3 6 52 3 6 90 32 49 3 5 53 3 7 54 3 8 PSIG kg cm2 G 100 38 49 3 5 53 3 7 54 3 8 Note Pressure data is recorded at 5 minutes into freezing cycle We reserve the right to make changes in specifications and design without prior notice 21 22 24 2 0 2 0 2 0 2 0 2 0 2 0 2 0 20 APPROXIMATE ICE PRODUCTION PER 24 HR APPROXIMATE ELECTRIC CONSUMPTION APPROXIMATE WATER CONSUMPTION PER 24 HR FREEZING CYCLE TIME...

Page 55: ...2 48 3 4 80 27 46 3 2 47 3 3 49 3 5 90 32 46 3 2 48 3 4 50 3 5 PSIG kg cm2 G 100 38 46 3 3 48 3 4 52 3 7 Note Pressure data is recorded at 5 minutes into freezing cycle We reserve the right to make changes in specifications and design without prior notice TOTAL HEAT OF REJECTION FROM CONDENSER 4 200 BTU h AT 90ºF 32ºC WT 70ºF 21ºC TOTAL HEAT OF REJECTION FROM COMPRESSOR 750 BTU h AT 90ºF 32ºC WT 7...

Page 56: ...3 4 50 3 5 PSIG kg cm2 G 100 38 49 3 4 48 3 4 51 3 6 Note Pressure data is recorded at 5 minutes into freezing cycle We reserve the right to make changes in specifications and design without prior notice 25 25 27 2 0 2 0 2 0 2 0 2 0 2 0 2 0 24 APPROXIMATE ICE PRODUCTION PER 24 HR APPROXIMATE ELECTRIC CONSUMPTION APPROXIMATE WATER CONSUMPTION PER 24 HR FREEZING CYCLE TIME WATER TEMP ºF ºC AMBIENT T...

Page 57: ...56 C Wiring Diagram ...

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