Hoshizaki KM-590DJ Service Manual Download Page 6

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I. Construction and Water/Refrigeration Circuit Diagram

A. KM Construction

KM-590DJ

Evaporator Assembly

Spray Tubes

Inlet Water Valve

Water Supply Inlet

Hot Gas Valve

Junction Box

Condenser

Check Valves

(refrigeration)

Control Box

Drier

Control Switch

Compressor

Cleaning Valve

Float Switch

Water Pump

Check Valve

(water)

Thermostatic Expansion Valves

Liquid Line Valve

Fan Motor

Fan Blade

Low-Side Service Valve

High-Side Service Valve

High-Pressure

Switch

Transformer Box

Summary of Contents for KM-590DJ

Page 1: ...MODULAR CRESCENT CUBER SERVICE MANUAL KM 590DJ F137 1057 073019 ...

Page 2: ...ments 28 A Control Board Layout 29 B LED Lights and Audible Alarm Safeties 30 C Settings and Adjustments 31 1 Default Dip Switch Settings 31 2 Harvest Time S4 dip switch 1 2 32 3 Pump Out Time Harvest Time During Pump Out S4 dip switch 3 4 32 4 Pump Out Frequency Control S4 dip switch 5 33 5 Harvest Pump Time Harvest Assist S4 dip switch 6 33 6 Harvest Pump Time Harvest Assist S4 dip switch 7 34 7...

Page 3: ...mation 37 A Refrigeration Circuit Service Information 37 B Component Service Information 40 V Maintenance 41 VI Preparing the Icemaker for Periods of Non Use 42 VII Disposal 43 VIII Technical Information 44 A Dimensions Speciﬁcations 44 B Wiring Diagram 45 ...

Page 4: ...this appliance The appliance must be installed in accordance with applicable national state and local codes and regulations Failure to meet these code requirements could result in death electric shock serious injury ﬁre or damage to the appliance Electrical connection must be hard wired and must meet national state and local electrical code requirements Failure to meet these code requirements coul...

Page 5: ...d the appliance clean Dirt dust or insects in the appliance could cause harm to individuals or damage to the appliance NOTICE Follow the instructions in this manual 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 operating ambient temperatu...

Page 6: ...Water Supply Inlet Hot Gas Valve Junction Box Condenser Check Valves refrigeration Control Box Drier Control Switch Compressor Cleaning Valve Float Switch Water Pump Check Valve water Thermostatic Expansion Valves Liquid Line Valve Fan Motor Fan Blade Low Side Service Valve High Side Service Valve High Pressure Switch Transformer Box ...

Page 7: ...ness Connector B Upper Unit Wire Harness Connector A Upper Unit Wire Harness Connector B not used Wire Harness Connector A Bin Control Cable Connector Connection Detail Control Board Red K4 Connector Bin Control Assembly Thumbscrews Bin Control Bracket Bin Control Cable Bracket Control Board Red K4 Connector Wire Harness Wire Bin Control Cable Bin Control Cable Connector to Wire Harness Connector ...

Page 8: ...es Compressor Hot Gas Valve Check Valves High Pressure Switch Strainer Drier Condenser Evaporator Service Valve Discharge Line Suction Line Water Pump Thermistor Spray Tubes Inlet Water Valve Pump Out Water Tank Service Valve Refrigeration Circuit Water Circuit Liquid Line Valve Spray Tubes Fan Heat Exchanger Freeze Harvest Pump Timer ...

Page 9: ...rol switch is placed in the ICE position Operation Flow Chart 1 1 Minute Fill Cycle Cycle Steps 2 Harvest Cycle WV time 6 min or the length of harvest minus HPT setting S4 dip switch 6 whichever is shorter Max harvest time 20 min Thermistor in control 3 Freeze Cycle Min freeze time 5 min Max freeze time freeze timer setting S4 dip switch 9 10 FS in control 4 Pump Out Cycle Factory set for every 10...

Page 10: ...cle protection timer terminates Otherwise at the end of the next harvest cycle Shutdown and Restart BC Operation BC open BC actuator paddle engaged Green BC CLOSED LED oﬀ Yellow BC OPEN LED on Yellow BC OPEN LED continues All components de energized 2 Icemaker Oﬀ All components de energized 3 Ice Level Lowered Icemaker starts at 1 1 Minute Fill Cycle BC closed BC actuator paddle disengaged Green B...

Page 11: ...for correct installation proper voltage per nameplate and adequate water supply Check CB using the steps in II C Control Board Check Check dip switch settings to assure that S4 dip switch 3 4 7 8 9 10 and S5 dip switch 1 through 5 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 III C 1 Default Dip Swit...

Page 12: ...lace CT b HPS Diagnosis Conﬁrm condenser coil is not clogged or restricted Let refrigeration circuit pressures equalize If HPS does not reset and pressures are equalized replace HPS If pressures are not equalized reclaim refrigerant and diagnose refrigeration circuit restriction Check that there are no restrictions in the refrigeration circuit Harvest Cycle HGV strainer or check valve Freeze Cycle...

Page 13: ...LV 3b Harvest Pump Time Harvest Assist LEDs 1 3 and 2 are on When the thermistor reaches 9 C CB reads 3 9 kΩ from the thermistor and turns harvest termination over to the harvest timer S4 dip switch 1 2 and S5 dip switch 4 When WV de energizes LED 4 turns oﬀ X11 relay de energizes and LED 3 turns on PM energizes Comp HGV and X10 relay continue Diagnosis Place a thermometer on the suction line next...

Page 14: ...ized not bypassing LLV and FM energize TXV operates correctly Comp is eﬃcient and refrigerant charge is correct See VIII A Speciﬁcation and Performance Data b Comp Diagnosis If Comp de energizes once freeze begins check that appliance has not shut oﬀ on HPS POWER OK LED oﬀ If so check 3 b HPS Diagnosis above If POWER OK LED is on check for 115VAC at CB K1 1 V or 9 V to neutral W If 115VAC is not p...

Page 15: ...nual See VIII A Speciﬁcation and Performance Data h Short Freeze Cycle Diagnosis Conﬁrm water tank ﬁlls and overﬂows during ﬁll and harvest cycles If not check water supply ﬁlters shut oﬀ valve WV screen If water tank empties before 5 min timer terminates and freeze cycle is short check that CV is not leaking by water ﬂowing down the potable drain If CV is leaking by remove and clean CV replace ru...

Page 16: ...6 DBU and not on terminal 2 DBU replace X10 relay If PM is energized and rotating in pump out rotation make sure the drain line is not clogged and that CV is clean and operating properly Conﬁrm FM and LLV de energize If FM is energized conﬁrm where FM is connected on CB If connected to CB K1 connector pin 9 FM should be energized If connected to CB K1 connector pin 3 and FM is energized replace CB...

Page 17: ... CT primary circuit Check for 115VAC at CB K1 connector pin 10 LBU to neutral W for 115VAC Always choose a white W neutral wire to establish a good neutral connection when checking voltages For additional checks see II H 1 No Ice Production 3 The OUTPUT TEST button provides a relay sequence test Make sure the control switch is in the ICE position then press the OUTPUT TEST button For the correct l...

Page 18: ...ill reads open replace BC 7 Press and hold the actuator paddle check for continuity across the wires of BC connector When the actuator paddle is engaged BC switch is open If closed check that the actuator paddle is not restricted Clean if necessary See II D Bin Control Cleaning If BC switch still reads closed replace BC 8 Reconnect BC connector to CB K4 connector then move the control switch to th...

Page 19: ... switch mount See Fig 2 6 Wipe down BC with a mixture of 1 part of Hoshizaki Scale Away and 25 parts of warm water Rinse the parts thoroughly with clean water 7 Reassemble BC and replace it in its correct position Note If the magnet was removed for cleaning be sure to replace it in its correct position 8 Reconnect BC connector to CB K4 connector then move the control switch to the ICE position 9 R...

Page 20: ...econnect FS connector to CB K5 connector then replace the control box cover in its correct position 9 Move the control switch to the ICE position Replace the insulation panel and front panel in their correct positions then turn on the power supply After 1 min the 1 min ﬁll cycle should end and the initial harvest cycle should begin If the initial harvest cycle begins FS is good and the check is co...

Page 21: ...assembly See Fig 4 6 Remove the retainer rod from the bottom of FS housing then remove the ﬂoat Be careful not to bend the retainer rod excessively when removing it 7 Wipe down FS 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 8 ...

Page 22: ...t Service Information 8 Reconnect the thermistor connector to CB K3 connector 9 Replace the control box cover in its correct position 10 Move the control switch to the ICE position 11 Replace the front panel in its correct position 12 Turn on the power supply 13 Once the harvest cycle starts Comp energizes begin timing the harvest cycle 14 The harvest timer and harvest cycle should terminate withi...

Page 23: ... a Tripped with bin ﬁlled with ice b Actuator does not move freely c Defective 9 Water Supply a Water supply oﬀ or improper water pressure b External water ﬁlters clogged 10 Inlet Water Valve a Screen or oriﬁce clogged b Coil winding open c Water valve open in freeze cycle 11 Float Switch See II E Float Switch Check and Cleaning a Float does not move freely b Defective 12 Compressor a Compressor r...

Page 24: ...ter ﬁlters clogged c Insuﬃcient water line size Minimum 3 8 Nominal ID 10 mm Nominal OD in the EU water tubing or equivalent d Too cold 5 Control Board See II C Control Board Check a Thermistor connection loose K3 b Defective 6 Thermistor See II F Thermistor Check a Loose disconnected or defective 7 Hot Gas Valve a Erratic or closed 8 Inlet Water Valve a Screen or oriﬁce clogged 9 Compressor a Ine...

Page 25: ...ost and clean the icemaker prior to diagnosing freeze up Fill out a freeze up checklist See II I Freeze Up Check List the Hoshizaki America Technician s Pocket Guide or contact your local distributor for a copy of the freeze up checklist Freeze Up Possible Cause Harvest Cycle 1 Evaporator a Scaled up b Damaged 2 Cube Guides or Splash Guards a Out of position b Damaged 3 Spray Tubes and or Spray Gu...

Page 26: ...mostatic Expansion Valve a Defective 12 Hot Gas Valve a Closed or restricted 13 Liquid Line Valve a Open Freeze Cycle 1 Evaporator a Scaled up b Damaged 2 Spray Tubes and or Spray Guides a Dirty b Out of position 3 Refrigerant Charge a Low 4 Control Board See II C Control Board Check a Freeze timer S4 dip switch 9 10 set incorrectly b Defective 5 Inlet Water Valve a Leaking by 6 Float Switch See I...

Page 27: ...27 I Freeze Up Check List ...

Page 28: ...e 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 misconnect K3 WHITE K4 RED and K5 BLACK because the same connector is used for the thermistor mechanical bin control ...

Page 29: ...3 X3 Relay LED 3 on K1 Connector Pin 5 LED 3 oﬀ K1 Connector Pin 4 energized in freeze LED 4 X4 Relay K1 Connector Pin 6 LED 1 X1 Relay K1 Connector Pin 1 9 K2 Connector Control Transformer 10 5VAC S5 Dip Switch ALARM RESET Button S4 Dip Switch OUTPUT TEST Button used to test relays on control K3 white Connector Thermistor harvest control and high temperature safety K5 black Connector Float Switch...

Page 30: ...Alarms Type Alarm Notes 1 Beep High Evaporator Temp temperature 53 C Check for harvest problem stuck HGV or relay hot water entering unit stuck HM or shorted thermistor 2 Beep Harvest Backup Timer harvest 20 min for two cycles in a row Check thermistor open HGV not opening TXV or LLV leaking by low charge ineﬃcient Comp 3 Beep Freeze Timer freeze freeze timer setting for two cycles in a row Check ...

Page 31: ...No 1 2 3 4 5 6 7 8 9 10 KM 590DJ OFF OFF ON ON ON ON ON OFF ON ON S5 Dip Switch Do Not Adjust S5 Dip Switch No 1 2 3 4 5 KM 590DJ OFF OFF OFF OFF OFF Freeze Timer 9 10 Pump Out Frequency Control 5 Pump Out Time Harvest Time During Pump Out 3 4 Harvest Timer 1 2 Factory Use 8 Harvest Pump Time Harvest Assist 7 Do Not Adjust S4 Dip Switch J Control Board S5 Dip Switch Do Not Adjust J Control Board R...

Page 32: ...n pump out rotation in this setting When a pump out is called for the pump motor stops for 2 sec then energizes in the reverse direction taking water from the bottom of the water tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain At the same time water ﬂows through the small tube to power ﬂush the ﬂoat switch The pump motor drains...

Page 33: ...N Every cycle After 2nd freeze cycle 5 Harvest Pump Time Harvest Assist S4 dip switch 6 NOTICE Factory set for proper operation Do not adjust Adjustment outside of the factory default setting may result in damage to the appliance Harvest pump time harvest assist is only active when S4 dip switch 7 is in the ON position In the factory default position the harvest pump time harvest assist starts wit...

Page 34: ...sition and harvest begins X11 and X10 relays energize A latching circuit is created through the X11 and X10 relays For further details see VIII B Wiring Diagrams In the factory default position 50 sec before harvest termination LED 4 turns oﬀ inlet water valve and X11 relay de energize X10 relay remains energized through the latching circuit Next LED 3 turns on and control board K1 connector pin 5...

Page 35: ...plications where reﬁll is required in the freeze cycle Reﬁlls set by S5 dip switch 2 and 3 Note In single ﬂoat switch with upper ﬂoat operation only 1 reﬁll allowed Single ﬂoat switch application With S5 dip switch 1 in the OFF position control board monitors the lower ﬂoat switch for reﬁll operation With S5 dip switch 1 in the ON position the control board monitors the upper ﬂoat switch for reﬁll...

Page 36: ... S5 Dip Switch Setting Minimum Harvest Timer No 4 OFF 120 sec ON 70 sec 12 Slush Control S5 dip switch 5 NOTICE Factory set for proper operation Do not adjust Adjustment outside the factory default setting may result in damage to the appliance This dip switch setting provides slush control during the freeze cycle When the evaporator temperature reaches 2 2 C the control board reads a 5 8kΩ signal ...

Page 37: ...ystem if using an electronic leak detector and then raise the pressure using nitrogen gas 0 97MPa 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 container Do not discharge the refrigerant into the atmosphere Do not leave the system open for longer than 15 min when replacing or servicing parts The Polyol Ester P...

Page 38: ...arrow on the drier in the direction of the refrigerant ﬂow When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 121 C 2 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 0 97MPa Do not use...

Page 39: ... 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 throttling valve or liquid dispensing device to add the rem...

Page 40: ...then insulate it Hot Gas Valves Liquid Line Valves Replace the strainer if applicable Use copper tube of the same diameter and length when replacing valve lines Fan Motors 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 ...

Page 41: ...le Frequency Area Task Daily Scoop Clean the ice scoop using a neutral cleaner Rinse thoroughly after cleaning Bi Weekly Air Filters 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 containing a neutral cleaner to wipe oﬀ oil or dirt build u...

Page 42: ...ine to drain by gravity 5 Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve 6 Move the control switch to the ICE position 7 Replace the front panel in its correct position then turn on the power supply 8 Blow the icemaker water supply line out using the compressed air or carbon dioxide supply 9 Close the icemaker water supply line drain valve 2 Drain th...

Page 43: ...sposal The appliance 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 ...

Page 44: ...44 VIII Technical Information We reserve the right to make changes in speciﬁcations and design without prior notice A Dimensions Speciﬁcations 1 KM 590DJ ...

Page 45: ...45 B Wiring Diagram 1 KM 590DJ High Pressure Switch Air Cooled Model Cut out 412 22 PSIG Cut in 327 22 PSIG 0 ...

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