Hoshizaki KM-1300SAH-E Service Manual Download

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SERVICE MANUAL

STACKABLE CRESCENT CUBER

FOR QUALIFIED SERVICE PERSON

89/336
73/23

HOSHIZAKI

NUMBER:

73124

ISSUED: December 17, 2004

KM-1300SAH-E

Summary of Contents for KM-1300SAH-E

Page 1: ...SERVICE MANUAL STACKABLE CRESCENT CUBER FOR QUALIFIED SERVICE PERSON 89 336 73 23 HOSHIZAKI NUMBER 73124 ISSUED December17 2004 KM 1300SAH E ...

Page 2: ...many TEL 49 0 215492810 FAX 49 0 2154928128 France TEL 33 0 148137130 FAX 33 0 148130992 Note To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should ...

Page 3: ... 30 1 Refrigerant Recovery 30 2 Evacuation and Recharge R 404A 30 B Brazing 30 C Removal and Replacement of Compressor 32 D Removal and Replacement of Drier 33 E Removal and Replacement of Expansion Valve 34 F Removal and Replacement of Hot Gas Valve 35 G Removal and Replacement of Evaporator 36 H Removal and Replacement of Thermistor 37 I Removal and Replacement of Fan Motor 38 J Removal and Repl...

Page 4: ...g and Maintenance Instructions 42 A Preparing the Icemaker for Long Storage 42 B Cleaning and Sanitizing Procedures 44 1 Cleaning Procedure 44 2 Sanitizing Procedure Following Cleaning Procedure 46 C Maintenance 47 ...

Page 5: ... EXTERIOR FINISH Stainless Steel Galvanized Steel Rear WEIGHT Net 275 lbs 125 kg Shipping 315 lbs 143 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT CONDENSATE DRAIN 3 8 OD Pipe 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 ...

Page 6: ...6 II General Information A Construction KM 1300SAH E ...

Page 7: ...ecause the same connector is used for the thermistor and float switch K4 is not connected 5 Always replace the whole board assembly when it goes bad 6 Do not short out power supply to test for voltage Features of Control Products E Controller Board a Maximum Water Supply Period 6 minutes Water solenoid valve opening in the defrost harvest cycle is limited by the defrost timer The water valve canno...

Page 8: ...t the end of the initial one minute water fill cycle and at the end of each defrost cycle If the float switch is in the up position electrical circuit closed the controller 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...

Page 9: ...30 to 35 minutes Reverse Pump Out 1 3 and 2 10 seconds 20 seconds factory setting Time LEDs are Lit LED Sequence Step No of Beeps every 3 sec Type of Alarm Notes 1 High Evaporator Temp temperature 53 C Check for defrost problem stuck HGV or relay hot water entering unit stuck headmaster or shorted thermistor 2 Defrost Backup Timer defrost 20 min Orange LED marked 20 MIN lights up Check for open th...

Page 10: ...1 connector If there is a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch OFF or the unit will not start The dip switches should be adjusted per the adjustment chart published in the Tech Specs book 7 8 must remain in the OFF position Control Products HOS 001A Board ...

Page 11: ...cle Ready to complete freeze cycle when float switch circuit opens 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 9 C Defrost timer starts counting IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in fr...

Page 12: ...unting IMPORTANT Water valve opening is limited to 6 minutes 5 After the first 5 minutes in freeze cycle Ready to complete freeze cycle whenfloat switch circuit opens 4 Defrost timer stops 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 si...

Page 13: ... limited to 6 minutes 4 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when float switch circuit opens 3 Defrost timer stops 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 def...

Page 14: ... Then the pump motor drains the water tank for the time determined by the drain timer The drain timer also determines the time to restrain completion of a defrost cycle 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...

Page 15: ...oval and Replacement of Thermistor 3 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 4 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 b Defrost Timer No adjustment is required under normal use as the defrost timer is adjusted to the suitable position However if...

Page 16: ...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 pump drain more often the drain counter can be adjusted as shown in the table below No 3 No 4 T1 T2 OFF OFF 10 150 ON OFF 10 180 OFF ON 10 120 ON ON 20 180 Dip Switch Setting Time seconds No 5 No 6 OFF OFF every cycle ON OFF every 2 cycles OFF ON eve...

Page 17: ... the icemaker resulting in failure No adjustment is required under normal use as the bin control is factory adjusted Adjust it if necessary so that the icemaker stops automatically within 10 seconds after ice contacts the bin control thermostat bulb 5 Checking the Controller Board 1 Visually check the sequence with the icemaker operating 2 Visually check the controller board by using the following...

Page 18: ... the defrost timer is in the minimum position Disconnect the resistor from the controller board and energize the unit After the 1 minute water supply cycle the defrost cycle starts Re connect a 1 5 kΩ 3 5 kΩ resistor to the connector K3 pins 1 and 2 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 3 Check th...

Page 19: ...19 III Technical Information A Water Circuit and Refrigerant Circuit KM 1300SAH E ...

Page 20: ...20 B Wiring Diagram KM 1300SAH E Pressure Switch Cut out 412 psig 28 4 bar Cut in 327 21 psig 22 5 1 5 bar 21 0 1 5 0 ...

Page 21: ...21 C Timing Chart 1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II B 4 Controls and Adjustments ...

Page 22: ... pump motor waits for 2 seconds before starting a drain cycle See II B 4 Controls and Adjustments 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II B 4 Controls and Adjustments ...

Page 23: ...26 0 86 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 240 16 9 268 18 8 287 20 2 80 27 261 18 4 304 21 4 313 22 0 90 32 268 18 8 335 23 6 348 24 5 PSIG kg cm2 G 100 38 265 18 6 338 23 8 360 25 3 70 21 50 3 5 51 3 6 54 3 8 80 27 51 3 6 53 3 8 56 3 9 90 32 51 3 6 55 3 9 58 4 1 PSIG kg cm2 G 100 38 52 3 7 56 3 9 60 4 2 4 4 3 5 26 28 29 33 35 40 WATER TEMP F C AMBIENT TEMP F C 50 10 ...

Page 24: ...l 2 Increase ambient temperature 3 Set too warm 3 See II B 4 Controls and Adjustments f Bin Control 4 Bulb out of position 4 Place in position 5 Bad contacts or leaks in bulb 5 Check for continuity and replace e High Pressure Control 1 Bad contacts 1 Check for continuity and replace f Transformer 1 Thermal fuse blown or coil winding opened 1 Replace g Wiring to Controller Board 1 Loose connections...

Page 25: ...efective 1 See II B 5 Checking the Controller Board 2 a Float Switch 1 Connector disconnected 1 Place in position 2 Leads opened or defective switch 2 Check and replace 3 Float does not move freely 3 Clean or replace b Controller Board 1 Defective 1 Replace c Contactor 1 Open coil or contacts worn 1 Replace 3 a Wash Switch 1 WASH position 1 Move to ICE position 2 Bad contacts 2 Check and replace b...

Page 26: ...ace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature h Controller Board 1 Defective 1 See II B 5 Checking the Controller Board 4 a Water Solenoid Valve 1 Diaphragm does not close 1 Check for water leaks with icemaker off b Controller Board 1 Defective 1 See II B 5 Checking the Controller Board 5 a Water Supply Line 1 Water pressure too low and water level in water tank too low 1 Chec...

Page 27: ...tion or open and replace 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace b Controller Board 1 Defective 1 See II B 5 Checking the Controller Board 7 a Refrigerant 1 Undercharged 1 Check for leaks and recharge 2 Air or moisture trapped 2 Replace drier and recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Solenoid Valve 1 Continues to open in freeze cycle 1 Check and ...

Page 28: ...rvest cycle 1 Check operation in harvest cycle and replace g Thermistor 1 Out of position or loose attachment 1 See V H Removal and Replacement of Thermistor h Controller Board 1 Defrost timer is set too short 1 Adjust longer referring to II B 4 Controls and Adjustments b Defrost Timer 2 Defective 2 See II B 5 Checking the Controller Board 3 Other a Spray Tubes 1 Clogged 1 Clean 2 Out of position ...

Page 29: ... valve water system pump motor and controller board See chart B 1 and B 3 and check float switch water solenoid valve controller board spray tubes water system refrigerant charge and expansion valve Problem Possible Cause Remedy 1 a Bin Control Thermostat 1 Set too cold 1 Adjust warmer 2 Defective 2 Replace 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out...

Page 30: ... 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 2 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 The ...

Page 31: ...he hoses and service manifold 10 Cap the access valves to prevent a possible leak B Brazing DANGER 1 Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 80 C 2 Refrigerant 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 h...

Page 32: ... 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 package Install the new compressor 8 Attach the rubber grommets of the prior compressor 9 Sandpaper the su...

Page 33: ...de 1 Turn off the power supply 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 a pressure of 3 to 4 psig 21 to 28 bar when brazing the tubings 6 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 7 Evacuate the...

Page 34: ...valve using brazing equipment 6 Braze the new expansion valve with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar 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 121 C 7 Install the new drier 8 Check for leaks using nitrogen gas ...

Page 35: ...nnect the hot gas valve or line valve using brazing equipment 6 Install the new valve with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar 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 121 C 7 Install the new drier 8 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles ...

Page 36: ...ation tube and disconnect the evaporator inlet tubing at the tee next to the expansion valve 6 Lift up the evaporator and disconnect the evaporator outlet tubing 7 Install the new evaporator with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar 8 Install the new drier 9 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 10 Evacuate the system and charge it with ...

Page 37: ...hermistor See Fig 1 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 apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 9 Attach the new thermistor to the suction pipe very carefully to prevent damage to the leads Secure it using the thermistor holder and...

Page 38: ...nstalled 1 Turn off the power supply 2 Remove the panels 3 Remove the closed end connectors from the fan motor leads 4 Remove the fan motor bracket and fan motor 5 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 6 Replace the panels in their correct positions 7 Turn on the power supply ...

Page 39: ... removed 9 Open the water supply line shut off valve 10 Turn on the power supply 11 Check for leaks 12 Replace the top and front panels in their correct positions K Removal and Replacement of Pump Motor Note When replacing a pump motor with defective winding it is recommended that a new capacitor be installed 1 Turn off the power supply 2 Remove the front panel 3 Drain the water tank by removing t...

Page 40: ...check for leaks 13 Replace the front panel in its correct position L Removal and Replacement of Float Switch 1 Go through the steps 1 through 6 in K Removal and Replacement of Pump Motor 2 Remove the connectors of the float switch 3 Remove the screw and the float switch bracket 4 Remove the two screws and the float switch 5 Take off the hose sleeving the float switch leads 6 Sleeve the leads of th...

Page 41: ...ubber hoses from the spray tubes water supply pipe 4 Release the clamps and disconnect the rubber hoses 5 Remove the spray tubes by squeezing the side tabs 6 Install the new spray tubes and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply ...

Page 42: ...g Storage WARNING When shutting off the icemaker for an extended time drain out all water from the water tank and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed Note When the ice...

Page 43: ...n the water tank by removing the insulation panel and the cap located on the front bottom part of the ice dropping hole See Fig 3 4 Replace the removed parts in their correct positions 5 Remove all ice from the storage bin and clean the storage bin 6 Replace the front panel in its correct position 7 Close the drain valve ...

Page 44: ... of the ice dropping hole See Fig 4 6 After tank has drained replace the removed parts in their correct positions 7 Pour the cleaning solution into the water tank 8 Move the control switch on the control box to the WASH position 9 Replace the insulation panel and the front panel in their correct positions B Cleaning and Sanitizing Procedures IMPORTANT Ensure all components fasteners and thumbscrew...

Page 45: ...ff the power supply after 3 minutes 20 Remove the front panel 21 Move the control switch to the WASH position 22 Replace the front panel in its correct position 23 Turn on the power supply to rinse off the cleaning solution 24 Turn off the power supply after 5 minutes 25 Remove the front panel and insulation panel 26 Drain the water tank by removing the cap located on the front bottom part of the ...

Page 46: ...the WASH position 5 Turn on the power supply and start the sanitizing process 6 Turn off the power supply after 15 minutes 7 Remove the front panel and if necessary the insulation panel 8 Drain the water tank See step 5 in 1 Cleaning Procedure 9 Replace the removed parts and the insulation panel in their correct positions 10 Repeat the above steps 15 through 27 in 1 Cleaning Procedure two times to...

Page 47: ... store anything else in 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 Condenser Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker 4 Air Filters Plastic mesh ai...

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