Hoshizaki KMH-2100SRJ Service Manual Download

Page: 1 / 57

Models
KMH-2100SWJ3, SRJ/3

Stackable Crescent Cuber

Service Manual

Number: 73226
Issued: 7-5-2018

hoshizakiamerica.com

Summary of Contents for KMH-2100SRJ

Page 1: ...Models KMH 2100SWJ3 SRJ 3 Stackable Crescent Cuber Service Manual Number 73226 Issued 7 5 2018 hoshizakiamerica com ...

Page 2: ...er installation is the responsibility of the installer Product failure or property damage due to improper installation is not covered under warranty Hoshizaki provides this manual primarily to assist qualified service technicians in the installation maintenance and service of the appliance Should the reader have any questions or concerns which have not been satisfactorily addressed please call sen...

Page 3: ...ection Chart 14 B Service Diagnosis 15 C Freeze Time Correction Cycle 90 min 22 D Control Board Check 24 E Bin Control Check 25 1a Single Thermostatic Bin Control Layout 26 1b Stacked Thermostatic Bin Control Layout 26 F Float Switch Check and Cleaning 27 1 Float Switch Check 27 2 Float Switch Cleaning 28 G Thermistor Check 29 H Control Switch 29 I Diagnostic Tables 30 J Freeze Up Check List 34 IM...

Page 4: ...itch 7 41 7 Factory Use S4 dip switch 8 41 8 Freeze Timer S4 dip switch 9 10 42 9 Float Switch Selector S5 dip switch 1 42 10 Refill Counter S5 dip switch 2 and 3 42 IV Refrigeration Circuit and Component Service Information 44 A Refrigeration Circuit Service Information 44 B Component Service Information 47 C Water Regulating Valve Adjustment water cooled models 48 V Maintenance 49 VI Preparing t...

Page 5: ...uld install and service 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 the...

Page 6: ...n death or serious injury Wire routing conduit and disconnect if required must meet national state and local electrical code requirements Failure to meet these code requirements could result in death electric shock serious injury fire or damage Move the icemaker control switch to the OFF position and turn off the power supply to the icemaker before servicing the remote condenser unit Lockout Tagou...

Page 7: ... Inlet Junction Boxes Liquid Line Valve Control Box Drier Control Switch Bin Control Thermostat Cleaning Valve Float Switch Water Pump Check Valve water High Side Service Valve High Pressure Switch Main Transformer Box 3 phase models Hot Gas Valve Thermostatic Expansion Valves Check Valves Compressor Low Side Service Valve Strainer Water Regulating Valve Condenser ...

Page 8: ...Switch Bin Control Thermostat Compressor Cleaning Valve Float Switch Water Pump Check Valve water High Side Service Valve High Pressure Switch Main Transformer Box 3 phase models Receiver Hot Gas Valve Thermostatic Expansion Valves Check Valves Compressor Crankcase Heater Low Side Service Valve Discharge Service Valve Liquid Line Service Valve Strainer ...

Page 9: ...e 1b Stacked Thermostatic Bin Control Z Bracket Used for Hoshizaki B 1300 B 1500 B 1650 and Non Hoshizaki Ice Stoarage Bin Bin Control Bulb Holder C Bin Control Extension Bracket Silicone Hose Upper Bin Control Bulb Holder Lower Bin Control Bulb Holder Lower Bin Control Bulb Holder Upper Bin Control Bulb Holder Bin Control Bulb Holder E Bin Control Bulb Holder F Spacer Bin Control Bulb Holder G Bi...

Page 10: ... 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 Water Supply Drain Return Water Regulating Valve Heat Exchanger Freeze Harvest Pump Timer ...

Page 11: ...iner Drier Condenser Evaporator Service Valve Discharge Line Suction Line Water Pump Thermistor Spray Tubes Inlet Water Valve Freeze Harvest Pump Timer Pump Out Water Tank Service Valve Refrigeration Circuit Water Circuit Fan Headmaster C P R Liquid Line Valve Receiver Fusible Plug Service Valve Spray Tubes Heat Exchanger KM 2500SRH3 Headmaster located in icemaker ...

Page 12: ... 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 10th cycle S4 dip switch 5 Pump motor stops for 2 sec then reve...

Page 13: ...n Ice contacts BC bulb 2 Icemaker Off All components de energized 3 Ice Level Lowered No ice touching BC bulb Icemaker starts at 1 1 Minute Fill Cycle BC closed BC open All components de energized To 1 1 Minute Fill Cycle NOTE Green BC CLOSED LED on continuously when K4 jumper is in place Shutdown Flow Chart Legend BC bin control ...

Page 14: ...ry freeze cycle time after the third freeze cycle time is added to the minimum maximum calculation Example After 8 cycles if the differential between the shortest cycle minimum and the longest cycle maximum is equal to or greater than 427 sec a freeze time correction cycle is initiated Number of Freeze Cycles Differential Value in Sec 3 254 4 309 5 349 6 380 7 406 8 427 9 446 10 462 Note When 1st ...

Page 15: ...sure 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 Switch Settings Note When checking high voltage 115VAC always choose a white W neutral wire to establish a good neutral connection On models with a main transformer th...

Page 16: ...sis 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 FMR TXV HM LLV str...

Page 17: ...5b Harvest Pump Time Harvest Assist LEDs 1 3 and 2 are on When the thermistor reaches 48 F 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 FMR HGV X10 and X12 relays continue Diagnosis Place a thermometer on the sucti...

Page 18: ...freeze confirm evaporator is cooling If not confirm WV de energized not leaking by HGV de energized not bypassing LLV energizes TXV and HM operate correctly Comp is efficient and refrigerant charge is correct See VIII A Specification and Performance Data b Comp and FMR Diagnosis If Comp and FMR de energize once freeze begins check that appliance has not shut off on HPS POWER OK LED off If so check...

Page 19: ...is not present replace TXV g WRV Diagnosis WRV is factory set and generally no adjustment is required If WRV fails to open in freeze check for proper refrigerant pressures See VIII A Specification and Performance Data If refrigerant pressures are correct and WRV does not open adjust or replace as needed See IV C Water Regulating Valve Adjustment water cooled models h Freeze Termination Diagnosis F...

Page 20: ...y 10 cycles or every cycle For details see III C 4 Pump Out Frequency Control S4 dip switch 5 Pump Out Diagnosis In the freeze cycle before pump out see table above after 5 min of freeze disconnect CB black K5 connector FS connector Check that PM stops and re starts Next check that PM rotation is correct water flowing down the drain through CV If PM does not stop and re start check that CB LEDs 1 ...

Page 21: ...2 Shutdown Diagnosis 1 See II E Bin Control Check 3 Freeze Time Correction Cycle Diagnosis 1 See II C Freeze Time Correction Cycle Legend BC bin control CB control board Comp compressor CT control transformer CV check valve FMR fan motor remote FS float switch HGV hot gas valve HM headmaster C P R HPS high pressure switch LLV liquid line valve MC magnetic contactor PM pump motor TXV thermostatic e...

Page 22: ... POWER OK LED Appliance starts in freeze cycle after a freeze time correction cycle To reset CB LEDs press ALARM RESET button on CB with power on CB resets LEDs and appliance continues cycle without interruption 1 Freeze Time Differential Initiation CB starts monitoring freeze times on the second freeze time After 3 freeze cycles 4th total CB begins to compare minimum and maximum freeze time cycle...

Page 23: ... FMR HGV and PM de energize WV continues 2b 10 Min Fill CB LED 4 on and WV energized 10 min timer starts 2c Final 10 Min Harvest Pump Time Harvest Assist with WV CB POWER OK LED blinking Once 10 min timer terminates CB LEDs 1 4 3 and 2 are on and Comp FMR HGV and PM energizes WV continues 10 min timer starts Once 10 min timer terminates normal freeze cycle begins CB LED 1 on and Comp FMR and PM co...

Page 24: ...k CT primary circuit Check for 115VAC at CB K1 connector pin 10 BR 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 I 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 25: ...higher altitude locations Note On thermostatic bin control models a jumper 4A4883G01 must be placed on CB red K4 connector Otherwise CB yellow BC OPEN LED is on and appliance will not start To check BC follow the steps below 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 3 Remove the control box cover and base cover then clear any ice away fro...

Page 26: ...Control Layout Z Bracket Used for Hoshizaki B 1300 B 1500 B 1650 and Non Hoshizaki Ice Stoarage Bin Bin Control Bulb Holder C Bin Control Extension Bracket Silicone Hose Upper Bin Control Bulb Holder Lower Bin Control Bulb Holder Lower Bin Control Bulb Holder Upper Bin Control Bulb Holder Bin Control Bulb Holder G Bin Control Bulb Holder E Bin Control Bulb Holder F Spacer Bin Control Bulb Holder G...

Page 27: ...connect 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 28: ...ssembly 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 29: ...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 30: ...d contacts e Refrigerant lines or components plugged 7 Control Transformer 115VAC 10 5VAC a Coil winding open or shorted 8 Control Board See II D Control Board Check a In alarm b Yellow BC OPEN LED on bin full 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 o...

Page 31: ...vaporator a Scaled up 2 Spray Tubes Spray Guides Cube Guides Splash Guard or Separator A a Dirty b Out of position 3 Refrigerant Charge a Low 4 Water Supply a Low water pressure b External water 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 D Control Board Check a Thermistor connection l...

Page 32: ...RPM too slow 11 Liquid Line Valve a Erratic or restricted 12 Headmaster C P R remote models a Not bypassing 3 Freeze Up Defrost and clean the icemaker prior to diagnosing freeze up Fill out a freeze up checklist See II J 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...

Page 33: ...ective 11 Thermostatic 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 Spray Guides Cube Guides Splash Guard or Separator A a Dirty b Out of position 3 Refrigerant Charge a Low 4 Control Board See II D Control Board Check a Freeze timer S4 dip switch 9 10 set incorrectly b Defective 5 Inle...

Page 34: ...7664 02 13 Is the cube guide positioned correctly 14 Are the evaporator separators positioned properly 15 Is the thermistor properly mounted tight and insulated 16 Is the TXV bulb properly mounted tight and insulated 17 Are splash guards in place Appliance Operation Fill YES NO 18 Does the water tank fill and overflow 60 90 sec Note Larger models may take up to 120 seconds to overflow when empty 1...

Page 35: ...re 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 thermostatic bin control jumper 4...

Page 36: ...in 2 LED 2 off K1 Connector Pin 3 LED 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 board K3 white Connector Thermistor harvest control anti slush con...

Page 37: ...g 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 or WRV leaking by 3 Beep Freeze Timer freeze freeze timer setting for two cycles in a row Check FS stuck closed up WV leaking by HGV leaking by PM not pumping TXV defective LLV not opening low charge HM not ...

Page 38: ...100SWJ3 KMH 2100SRJ3 OFF OFF OFF OFF OFF OFF ON OFF ON OFF KMH 2100SRJ OFF OFF OFF OFF ON OFF ON OFF OFF OFF S5 Dip Switch Do Not Adjust S5 Dip Switch No 1 2 3 4 5 All OFF OFF OFF OFF ON Freeze Timer 9 10 Pump Out Frequency Control 5 Pump Out Time 3 4 Harvest Timer 1 2 Factory Use 8 Harvest Pump Time Harvest Assist and Freeze Time Correction 7 Do Not Adjust 1 2 3 4 5 6 7 8 9 10 ON S4 Dip Switch 1 ...

Page 39: ...in 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 dr...

Page 40: ... cycle After 2nd freeze cycle 5 Harvest Pump Time Duration 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 w...

Page 41: ...ing 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 DBU wire energizes energizing the pump motor for the last s...

Page 42: ...ort at 1 800 233 1940 for recommendations S4 Dip Switch Setting Time min No 9 No 10 OFF OFF 60 OFF ON 50 ON OFF 70 ON ON 75 9 Float Switch Selector S5 dip switch 1 This dip switch setting allows use of this control board in single and dual float switch models This model uses a single float switch style NOTICE Do not adjust This must be left in the factory default position or the icemaker will not ...

Page 43: ...ides anti slush control during the freeze cycle When the evaporator temperature reaches 36 F 2 2 C the control board reads a 5 8kΩ signal from the thermistor and de energizes the water pump for 10 sec to melt ice slush and prevent ice slush from blocking the water supply tubing causing irregular freeze patterns NOTICE Factory set for proper operation Do not adjust Adjustment outside the factory de...

Page 44: ...tem 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 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 PO...

Page 45: ... 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 250 F 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 140 PSIG D...

Page 46: ...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 throttling valve or liquid dispensing device to ...

Page 47: ...uid 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 Smoothly fill the recessed area of ...

Page 48: ...e 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 rotate counterclockwise to raise temperature or clockwise to lower temperature See Fig 6 Next check that the reference pressure is in the range indicated in VIII A Specification and Performance Data I...

Page 49: ...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 ...

Page 50: ... line 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 ...

Page 51: ...ine drain valve If connected to a closed loop system also open the condenser return line drain valve 4 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 5 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 di...

Page 52: ...posal 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 53: ... 38 70 21 1536 5 81 1710 6 47 2236 8 46 80 27 1669 6 32 1939 7 34 2625 9 94 90 32 1710 6 47 2130 8 06 2759 10 45 gal day m3 day 100 38 2095 7 93 2278 8 62 3338 12 63 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 247 17 4 250 17 6 260 18 3 80 27 249 17 5 254 17 8 267 18 8 90 32 250 17 6 257 18 1 269 18 9 PSIG kg cm2 G 100 38 254 17 9 260 18 3 280 19 7 70 21 50 3 5 50 3 5 52 3 7 80...

Page 54: ...00 38 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 208 14 6 223 15 7 244 17 1 80 27 220 15 4 243 17 1 264 18 5 90 32 223 15 7 260 18 3 281 19 7 PSIG kg cm2 G 100 38 227 16 0 265 18 6 300 21 1 70 21 48 3 4 49 3 4 50 3 5 80 27 48 3 4 49 3 5 52 3 6 90 32 49 3 4 50 3 5 52 3 7 PSIG kg cm 2 G 100 38 49 3 5 50 3 5 54 3 8 22 600 BTU h AT 90ºF 32ºC WT 70ºF 21ºC TOTAL HEAT OF REJECTION FR...

Page 55: ...9 263 1 00 gal day m3 day 100 38 394 1 49 283 1 07 239 0 91 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 222 15 6 234 16 4 248 17 5 80 27 231 16 2 249 17 5 263 18 5 90 32 234 16 4 262 18 4 277 19 4 PSIG kg cm 2 G 100 38 236 16 6 265 18 7 290 20 4 70 21 50 3 5 51 3 6 52 3 7 80 27 50 3 5 51 3 6 53 3 7 90 32 51 3 6 52 3 7 54 3 8 PSIG kg cm2 G 100 38 51 3 6 52 3 7 55 3 9 22 900 BTU ...

Page 56: ...56 B Wiring Diagrams 1 Single Phase Models High Pressure Switch Water Cooled Model Air and Remote Model Cut out 384 22 PSIG 412 22 PSIG Cut in 284 22 PSIG 327 22 PSIG 0 0 ...

Page 57: ...57 2 Three Phase Models High Pressure Switch Water Cooled Model Remote Model Cut out 384 22 PSIG 412 22 PSIG Cut in 284 22 PSIG 327 22 PSIG 0 0 ...

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