Hoshizaki KMD-201AA Service Manual Download | Manualshive

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7) Remove the front panel then remove the front insulation (the large insulation panel in front

of the evaporator) by lifting up the panel slightly and pulling it towards you.

8) In bad or severe water conditions, clean the float switch as described below. Otherwise,

continue to step 9.

a. Loosen the two thumbscrews securing the pump motor bracket.

b. Disconnect the discharge hose.

c. Disconnect the pump motor connector and the float switch connector from the side of the

control box.

d. Keep pushing up the snapping tab at the right side of the pump motor bracket.

e. Pull out the water tank, cube guide, pump motor bracket, pump motor and float switch

together.

f. Remove the pump motor bracket securing the pump motor and the float switch. Remove

the float switch from the pump motor bracket.

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Summary of Contents for KMD-201AA

Page 1: ... 26 02 8 5 5 6 17 8 5 0 0 0 0 ...

Page 2: ...i ...

Page 3: ... b FEATURES 10 c CONTROLS AND ADJUSTMENTS 12 d CONTROL BOARD CHECK PROCEDURE 17 e CONTROL BOARD REPLACEMENT 17 4 HARVEST CONTROL THERMISTOR 18 5 FLOAT SWITCH 19 a EXPLANATION OF OPERATION 19 b CLEANING 19 c FLOAT SWITCH CHECK PROCEDURE 19 6 BIN CONTROL 20 a EXPLANATION OF OPERATION 20 b BIN CONTROL CHECK PROCEDURE 20 7 SWITCHES 21 a CONTROL SWITCH 21 b SERVICE SWITCH 21 III TECHNICAL INFORMATION 2...

Page 4: ... MOTOR 43 11 PUMP MOTOR 44 12 WATER VALVE 45 13 DRAIN VALVE CLEANING VALVE 45 14 WATER TANK 46 15 FLOAT SWITCH 47 16 BIN CONTROL SWITCH 48 17 THERMISTOR 49 18 CONTROL BOX 50 a CONTROL SERVICE SWITCH 52 b FUSE 52 c FUSE HOLDER 52 d CONTROL BOARD 52 e MAGNETIC CONTACTOR 52 f CONTROL BOARD TRANSFORMER 52 g STARTER 53 h RUN CAPACITOR 53 i START CAPACITOR 53 j CAPACITOR FOR PUMP MOTOR 53 19 SPRAY TUBE ...

Page 5: ...ONTROL 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 NT6217GKV CONDENSER Air Cooled Fin and tube type EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Va...

Page 6: ... WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond 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 N A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic Model NT6217GKV CONDENSER Water Cooled Tube in tube type E...

Page 7: ...r Tank Cube Guide Pump Motor Float Switch Condenser Fan Motor Hot Gas Valve Compressor Control Box Expansion Valve Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder Fuse Bin Control Switch Drier Thermistor Access Valve Low Side Access Valve High Side Water Supply Tube Cleaning Valve ...

Page 8: ... Motor Float Switch Water Regulator Condenser Hot Gas Valve Compressor Control Box Expansion Valve Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder Fuse Bin Control Switch Drier Thermistor Access Valve Low Side Access Valve High Side Water Supply Tube Cleaning Valve ...

Page 9: ...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 LF 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 LEDs 5 7 are on Comp continues to run PM and FMS energize HGV closes and th...

Page 10: ...e if it is closed or calls for a 1 minute fill if it is open The unit continues to cycle through c d and e sequence until the bin control is activated and shuts the unit down When the bin control is activated the POWER OK LED flashes Note To prevent incomplete batches of ice from foaming on the evaporator the control board will only shut down the machine within the first 5 minutes of the freeze cy...

Page 11: ...k refill 1 minute maximum fill time Factory set for every 10 th cycle S1 dip Switch 5 6 Pump motor stops for 2 sec and then runs for 10 20 sec S1 dip switch 3 4 0 0 30 or 50 sec HWV energized COMP energized HGV energized HWV continues FWV de energized DV de energized COMP continues PM continues FWV energized de energized for refill only FMS energized HGV de energized PM de energizes 0 2 sec energi...

Page 12: ...rated circuits which 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 5 Always replace the whole board assembly if it goes bad 6 Do not short out power ...

Page 13: ...9 a CONTROL BOARD LAYOUT 4 Harvest Water Valve 5 Freeze Water Valve 1 2 3 Float Switch Control Board Auxiliary Code V1 or Earlier V2 or Later Part Number P00013 02 P01771 02 Type HKM2006V003 ...

Page 14: ...n to reset the safety d Low Water Safety The control board checks the position of the lower float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle If the lower float switch is in the up position electrical circuit closed the control board changes to the next cycle If the lower float switch is in the down position electrical circuit open the control ...

Page 15: ...DV energizes for a maximum of 5 minutes to drain the water tank At startup a 5 second delay occurs to stabilize the circuit LEDs 4 through 8 energize and sequence from initial startup as listed in the table below Note that the order of the LEDs from the outer edge of the board is 5 6 8 9 4 7 For more information see 2 SEQUENCE OF OPERATION 5 7 and 9 at refill Comp PM FMS FWV at refill HWV HGV Comp...

Page 16: ...witch These must be left in the factory default position or the unit will not operate properly b Harvest Timer S1 dip switch 1 2 Used for adjustment of the harvest timer The harvest timer starts counting when the thermistor reads a certain temperature at the evaporator outlet Control Board Program Ver S2 Dip Switch No 1 2 3 4 5 6 KMD 410MAH ON OFF ON OFF OFF ON P00013 02 2 5 or earlier KMD 410MWH ...

Page 17: ...ins at the frequency set by the drain frequency control The drain frequency control is factory adjusted to drain the water tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a drain more often the drain frequency can be adjusted as shown in the table below e Water Saver Timer S1 dip switch 7 8 The water saver timer allows the water valve to...

Page 18: ...0 ON 2 Control Board P00013 02 h Refill Counter S2 dip switch 2 3 4 Program Ver 2 5 or earlier Do not adjust These must be left in the factory default position or the unit will not operate properly The KMD 410MAH and KMD 410MWH refill 1 time i Factory Use S2 dip switch 5 Program Ver 2 5 or earlier Must remain off j Anti Slush Control S2 dip switch 6 Program Ver 2 5 or earlier The anti slush contro...

Page 19: ...properly It is deactivated on the KMD 410 series When activated this control determines whether ice remains on the evaporator at the end of a harvest cycle and at the beginning of a freeze cycle If ice drops and activates the bin control switch in the last 10 seconds of a harvest cycle the control determines that ice still remains on the evaporator and extends the harvest cycle for 30 seconds If t...

Page 20: ...ard to de energize the pump motor for 10 seconds and energize it for 50 seconds repeatedly When 34 F 1 C is reached a 5 9 k signal causes the control board to de energize the pump motor for 10 seconds energize it for 50 seconds de energize it again for 10 seconds then energize it continuously S2 Dip Switch Setting No 6 Anti Slush Control OFF Activated Ver 2 0 ON Deactivated p Anti Slush Control S2...

Page 21: ... control voltage is good If the POWER OK LED is off check the control transformer circuit If no voltage is present check the power supply circuit 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 The correct lighting sequence should be 5 6 7 8 9 4 Some components e g the compressor will cycle during the tes...

Page 22: ... thermistor leads and visually check the thermistor mounting located on the suction line next to the evaporator outlet Check a thermistor for resistance by using the following procedure 1 Disconnect the thermistor orange wires at the 2 pin connector on the control box See Fig below 2 Remove the thermistor See V 17 THERMISTOR 3 Immerse the thermistor sensor portion in a glass containing ice and wat...

Page 23: ...ND MAINTENANCE INSTRUCTIONS c FLOAT SWITCH CHECK PROCEDURE Before replacing a float switch that you suspect is bad make sure the float switch has been cleaned This procedure will help you verify your diagnosis The float switch has three wires The black wire is common The blue wire is for the lower float switch contact and the red wire is for the upper float switch contact 1 Disconnect the black fl...

Page 24: ... the machine to complete the freeze cycle and the following harvest cycle before shutting down the machine b BIN CONTROL CHECK PROCEDURE 1 Clear any ice away from the bin control 2 Make sure the control switch is in the ICE position 3 Check that the POWER OK LED on the control board is on 4 Activate the bin control actuator press the actuator in Check that the POWER OK LED flashes 5 Disconnect the...

Page 25: ...plied to the water pump in all three positions 2 When the control switch is in the OFF position or in the ICE position the service switch has no power and can be left in any position 1 DRAIN The KMD 410M_H series utilizes a pump out drain system When the service switch is active and placed in the DRAIN position power is supplied to the pump and drain valve 2 CIRCULATE When the service switch is ac...

Page 26: ...22 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT ...

Page 27: ...23 2 WIRING DIAGRAM The magnetic contactor wiring depends on the contactor model 428393 01 VC20 1a1b 449000 01 G7L 1A TUB See above 449000 01 only ...

Page 28: ...ACT ON OFF OFF UPPER FLOAT CONTACT ON OFF BIN CONTROL SWITCH ON FREEZE CYCLE ON OFF ON OFF ON OFF ON OFF CONTROLLER BOARD OFF ON OFF ON RELAY X5 FWV RELAY X6 DV RELAY X1 COMP RELAY X2 HGV FM RELAY X3 PM FREEZE CYCLE HARVEST CYCLE Thermistor senses 9 C after more than 8 min 50 sec in harvest cycle HARVEST CYCLE Thermistor senses 9 C after 6 min to 8 min 50 sec in harvest cycle Max 6 min 5 sec 50 se...

Page 29: ...21 27 29 32 80 27 28 31 34 FREEZING CYCLE TIME 90 32 29 34 37 min 100 38 29 34 40 70 21 3 0 2 7 2 6 80 27 2 8 2 3 2 4 HARVEST CYCLE TIME 90 32 2 7 2 0 2 0 min 100 38 2 4 2 0 2 0 70 21 216 15 2 237 16 7 261 18 4 80 27 232 16 3 265 18 6 287 20 2 HEAD PRESSURE 90 32 237 16 7 288 20 2 311 21 9 PSIG kg cm2 G 100 38 240 16 9 293 20 6 333 23 4 70 21 45 3 2 48 3 3 52 3 6 80 27 47 3 3 51 3 6 55 3 9 SUCTION...

Page 30: ...8 80 27 25 27 30 FREEZING CYCLE TIME 90 32 26 29 31 min 100 38 26 29 33 70 21 2 3 2 2 2 2 80 27 2 2 2 1 2 1 HARVEST CYCLE TIME 90 32 2 2 2 0 2 0 min 100 38 2 1 2 0 2 0 70 21 239 16 8 240 16 8 243 17 1 80 27 239 16 8 240 16 9 246 17 3 HEAD PRESSURE 90 32 240 16 8 241 16 9 246 17 3 PSIG kg cm2 G 100 38 241 17 0 242 17 0 250 17 6 70 21 43 3 0 44 3 1 48 3 4 80 27 44 3 1 46 3 3 51 3 6 SUCTION PRESSURE ...

Page 31: ...filter no water flow If unit fails to start harvest check for open float switch or bad 1 minute timer in board 4 Initial Harvest Cycle The harvest 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 thermisto...

Page 32: ...sconnect the 3 pin float switch connector from the control box 15 seconds after disconnecting the 3 pin float switch connector LED 5 comes on and refill begins Connect the 3 pin float switch connector back on the control box When the refill is finished LED 5 goes off disconnect the 3 pin float switch connector again If 5 or more minutes have elapsed in the freeze cycle the unit should switch out o...

Page 33: ...29 2 DIAGNOSTIC CHARTS a NO ICE PRODUCTION 2 See II 6 b Bin Control Check Procedure 5 See chart a 7 ...

Page 34: ...30 1 See II 4 Harvest Control Thermistor 1 See II 3 d Control Board Check Procedure 1 See II 3 d Control Board Check Procedure ...

Page 35: ... II 3 d Control Board Check Procedure 1 See II 3 d Control Board Check Procedure 1 See II 3 d Control Board Check Procedure 1 See II 3 d Control Board Check Procedure 1 See II 3 d Control Board Check Procedure ...

Page 36: ...EVAPORATOR IS FROZEN UP 1 Adjust or replace See V 9 Adjustment of Water Regulating Valve 1 See V 17 Thermistor 1 See II 3 c Controls and Adjustments b Harvest Timer 1 See II 3 d Control Board Check Procedure ...

Page 37: ...ty air filter or condenser ambient or water temperature refrigerant charge water pressure and condenser water regulating valve water cooled model only a See chart b 2 and check evaporator water supply line harvest water valve ambient and or water temperature line valve if applicable thermistor control board and hot gas valve a Ice Cube Guide Water Tank Deflector 1 See II 3 d Control Board Check Pr...

Page 38: ...hart b 1 3 and check float switch fill and harvest water valves control board spray tubes water system refrigerant charge and expansion valve 1 See II 6 b Bin Control Check Procedure c Ice Cube Guide Water Tank Deflector ...

Page 39: ...f Handy Flux R404A Repair of the refrigerant circuit requires brazing It is no problem to use the same handy flux that has been used for the current refrigerants However its entrance into the refrigerant circuit should be avoided as much as possible 4 Oil for Processing of Copper Tubing R404A When processing the copper tubing for service wipe off oil if any used by using alcohol or the like Do not...

Page 40: ... to the system Be sure to connect charging hoses to both high and low side access valves 2 Turn on the vacuum pump Open the service manifold valves Never allow the oil in the vacuum pump to flow backwards 3 Allow the vacuum pump to pull down to a 760 mmHg vacuum Evacuating period depends on pump capacity 4 Close the low side valve and high side valve on the service manifold 5 Disconnect the vacuum...

Page 41: ... inside the bin are clear coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove the coating 3 COMPRESSOR 1 Turn off the power supply 2 Remove the panels and water tank See V 14 WATER TANK ...

Page 42: ...ector 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 970 kPa DO NOT use R 404A as a mixture with pressurized air for leak testing 14 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the nameplate for the required refrigerant charge 15 Connect...

Page 43: ...t with refrigerant see V 1 c EVACUATION AND RECHARGE 9 Refit the panels in their correct positions 10 Turn on the power supply Note Always use a drier of the correct capacity and refrigerant type 5 HOT GAS VALVE 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Disconnect the hot gas valve leads 5 Remove the screw and the solenoid coi...

Page 44: ...ant and store it in an approved container 4 Remove the insulation and the expansion valve bulb on the suction line 5 Remove the expansion valve cover and disconnect the expansion valve Place the new expansion valve in position 6 Remove the drier then place the new drier in position 7 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 8 Use an electronic leak d...

Page 45: ...notch where the refrigeration tubing passes through the molded chassis 5 Disconnect the evaporator tubing 6 Remove the pop rivets securing the evaporator then lift out the evaporator 7 Install the new evaporator 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 20 to 30 kPa 10 Use an electronic leak detector or soa...

Page 46: ...sconnect the capillary tube at the condenser outlet 8 Disconnect the flare connections of the valve 9 Remove the screws and the valve from the bracket 10 Install the new valve 11 Remove the drier then place the new drier in position 12 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 13 Use an electronic leak detector or soap bubbles to check for leaks Add a...

Page 47: ...justment screw by using a flat blade screwdriver until the temperature is in the proper range See Fig below Next check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section If it is not in the proper range verify the refrigerant charge 3 Check that the condenser drain temperature is stable 10 FAN MOTOR 1 Turn off the power supply 2 Remove ...

Page 48: ...insulation 3 Disconnect the connector of the pump motor lead 4 Remove the thumbscrew securing the pump motor 5 Remove the hose band connecting the discharge hose 6 Slide the pump motor at right slightly and lift it up towards you Screw Fan Blade Cover Screw Loosen Screw Remove Fan Motor Fan Motor Bracket Thumbscrew Pump Motor Hose Band Discharge Hose ...

Page 49: ...er 5 Disconnect the terminals from the valve 6 Remove the bracket and valve from the unit 7 Install the new valve Replace the removed parts in the reverse order of which they were removed If replacing the harvest and or fill water valve make sure the washer is in place in the fitting nut 8 If replacing the harvest and or fill water valve close the icemaker water supply line drain valve Open the ic...

Page 50: ... Loosen the two thumbscrews securing the pump motor bracket 3 Move the control switch to the SERVICE position Move the service switch to the DRAIN position 4 Let the icemaker run for 2 minutes 5 Move the control switch to the OFF position 6 Turn off the power supply 7 Disconnect the pump motor and float switch connector from the side of the control box 8 Keep pushing up the snapping tab at the rig...

Page 51: ... the panels in their correct positions 12 Turn on the power supply 15 FLOAT SWITCH 1 Remove the pump motor bracket See V 14 WATER TANK 2 Pull up the pump motor bracket from the water tank 3 Flip over the pump motor bracket assembly then twist off the float switch and pull out towards you ...

Page 52: ...de the bin control switch towards you 4 Take out the bin control 5 Install the new bin control switch 6 Pass the bin control connector through the hole from the bottom to the top of the unit 7 While pulling up the bin control lead hook the bin control on the right side interior wall Then push the bin control up against the bottom of the unit and slide to the back until it snaps in place Make sure ...

Page 53: ... and float switch connector 12 Replace the front insulation and front panel in their correct positions 13 Turn on the power supply 17 THERMISTOR 1 Turn off the power supply 2 Remove the panels 3 Disconnect the connector of the thermistor lead orange 4 Remove the ties insulation thermistor holder and thermistor in this order 5 Remove the old sealant from the thermistor holder and suction pipe 6 Wip...

Page 54: ...lder is fitted do not pull the thermistor lead to move the thermistor 9 Refit the removed parts in the reverse order of the removal procedure 10 Turn on the power supply 18 CONTROL BOX 1 Turn off the power supply 2 Remove the front panel 3 Remove the one mounting screw and pull the control box cover 4 Remove the two mounting screws and pivot the control box to the left side slightly and pull the c...

Page 55: ...cially make sure that the harness does not press the push buttons on the control board Control Box Cover Control Box Screw Screws Controller Board Control Switch Service Switch Fuse Fuse Holder Starter Transformer Capacitor for Pump Motor Magnetic Contactor Push Buttons Run Capacitor Start Capacitor Noise Suppression Capacitor ...

Page 56: ...he four board supports secured to the control box to release the control board 3 Install the new control board in the reverse order of the removal procedure 4 Check the dip switch for proper setting 5 When reconnecting the connectors do not push them too hard The control board may be damaged e MAGNETIC CONTACTOR 1 Disconnect the tab terminals remove the mounting screw or pull the tub of bracket to...

Page 57: ...ng label i START CAPACITOR 1 Disconnect the terminals on the starter and remove the nut securing the run capacitor 2 Install the new run capacitor in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label j CAPACITOR FOR PUMP MOTOR 1 Disconnect the tab terminals remove the screw 2 Install the new capacitor in the reve...

Page 58: ... guide is located under the water supply tube Pull off the spray guide from the evaporator 11 Refit the removed parts in the reverse order of the removal procedure Check for water leaks IMPORTANT Fit the spray guide securely and tightly on the evaporator fin Otherwise cloudy or irregular ice cubes or performance reduction may be caused Hose Band Hose Tabs Spray Tube Hose Band Water Supply Tube und...

Page 59: ... the storage bin dispenser unit 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 3 Turn off the power supply 4 Remove the front panel and move the control switch to the SERVICE position Move the service switch to the DRAIN position 5 Replace the front panel in its correct posit...

Page 60: ...en the two thumbscrews securing the pump motor bracket b Disconnect the discharge hose c Disconnect the pump motor connector and the float switch connector from the side of the control box d Keep pushing up the snapping tab at the right side of the pump motor bracket e Pull out the water tank cube guide pump motor bracket pump motor and float switch together f Remove the pump motor bracket securin...

Page 61: ... 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 20 Turn on the power supply to fill the water tank with water 21 Turn off the power supply after 3 minutes 22 Remove the front panel 23 Move the control switch to the...

Page 62: ...ront panel in their correct positions 6 Turn on the power supply to start the sanitizing process 7 Turn off the power supply after 15 minutes 8 Remove the front panel 9 Move the service switch to the DRAIN position 10 Replace the front panel in its correct position and turn on the power supply for 2 minutes 11 Turn off the power supply 12 Remove the front panel 13 Repeat steps 18 through 31 in a C...

Page 63: ...d dust from the air and keep the condenser from getting clogged As the filters get clogged the icemaker s performance will be reduced Check the filters at least twice a month When clogged use warm water and a neutral cleaner to wash the filters d CONDENSER AIR COOLED MODEL ONLY Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be re...

Page 64: ... 2 Remove the water from the icemaker water supply line 1 Turn off the power supply and remove the front panel 2 Move the control switch on the control box to the OFF position 3 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 4 Allow the line to drain by gravity 5 Attach compressed air or carbon dioxide supply to the icemaker water supply lin...

Page 65: ...ont panel 5 Move the control switch to the OFF position 6 Replace the front panel in its correct position 7 Remove all ice from the storage bin dispenser unit and clean the storage bin dispenser unit 8 Close the icemaker water supply line drain valve ...

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