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3. Low Ice Production

Problem

Possible Cause

Remedy

[1] Freeze cycle time is

long.

a) See chart 2.[1] and check float switch, inlet water valve, control board, water

pump, spray tubes, evaporator, and expansion valve.

b) See chart 1.[1] and check dirty air filter or condenser, ambient or water

temperature, refrigerant charge, water pressure, and condenser water
regulating valve (water-cooled model only).

c) Check pump, hot gas valve, headmaster (C.P.R.) (remote air-cooled model

only), expansion valve, refrigeration check valve, and compressor.

[2] Harvest cycle time is

long.

a) See chart 2.[2] and check evaporator, water supply line, inlet water valve,

ambient and/or water temperature, line valve (if applicable), thermistor, control
board, and hot gas valve.

4. Abnormal Ice

Problem

Possible Cause

Remedy

[1] Small cubes.

a) Ice Cube Guide

1. Out of position.

Circulated water falls
into bin.

1. Place in position.

b) See chart 1.[5] and check water supply line, inlet water valve, water system,

pump motor, and control board.

c) Pump Out Check Valve 1. Dirty or worn.

1. Clean or replace.

[2] Cloudy or irregular

cubes.

a) See chart 2.[1] and 2.[3], and check float switch, inlet water valve, control

board, spray tubes, water system, refrigerant charge, and expansion valve.

b) Spray Guide

1. Dirty.

1. Clean.

c) Water Quality

1. High hardness or

contains impurities.

1. Install a water softener or

filter.

Содержание KM-515MAH

Страница 1: ...1 Hoshizaki A Superior Degree of Reliability www hoshizaki com Models KM 515MAH KM 515MWH KM 515MRH Modular Crescent Cuber Hoshizaki America Inc SERVICE MANUAL Number 73157 Issued 2 1 2008 ...

Страница 2: ...r Should the reader have any questions or concerns which have not been satisfactorily addressed please call write or send an e mail message to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 1 800 843 1056 770 487 3360 E ma...

Страница 3: ...Voltage and Low Voltage Cut outs 18 f LED Lights and Audible Alarm Safeties 19 3 Controls and Adjustments 20 a Default S4 Dip Switch Settings 20 b Harvest Timer S4 dip switch 1 2 20 c Pump Out Timer S4 dip switch 3 4 21 d Pump Out Frequency Control S4 dip switch 5 6 22 e Factory Use S4 Dip Switch 7 8 22 f Freeze Timer S4 dip switch 9 10 22 4 Control Board Check Procedure 23 5 Control Board Replace...

Страница 4: ...ing 42 3 Evacuation and Recharge R 404A 43 B Removal and Replacement of Compressor 44 C Removal and Replacement of Expansion Valve 45 D Removal and Replacement of Hot Gas Valve or Line Valve 46 E Removal and Replacement of Evaporator 47 F Removal and Replacement of Water Regulating Valve Water Cooled Model Only 47 G Adjustment of Water Regulating Valve Water Cooled Model Only 48 H Removal and Repl...

Страница 5: ...ar WEIGHT Net 151 lbs 68 kg Shipping 175 lbs 79 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT 3 8 OD Tube 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 Thermostat COMPRESSOR Hermetic Model RST55C1E CA...

Страница 6: ...t 151 lbs 68 kg Shipping 175 lbs 79 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond Outlet 3 8 FPT 3 8 OD Tube 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 Thermo...

Страница 7: ...C Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT 3 8 OD Tube 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 Thermostat COMPRESSOR Hermetic Model RST55C1E CAA 202 CONDENSER Air Cooled Remote Condenser Unit URC 5F EVAPORATOR Ver...

Страница 8: ... 8 460 mm 20 15 32 520 mm 21 15 16 557 mm 7 8 DIA HOLE 23 mm DIA 6 5 16 160 mm 2 15 16 75 mm 18 1 8 460 mm 6 16 3 4 10 20 mm 4 2 SLOTTED HOLES 17 1 8 435 mm 14 9 16 370 mm 14 1 8 358 mm 14 15 16 380 mm 15 11 16 398 mm 17 7 8 454 mm 2 1 2 63 mm 14 15 16 380 mm Unit inches mm ...

Страница 9: ... x 460 x 834 mm EXTERIOR FINISH Galvanized Steel WEIGHT Net 61 lbs 28 kg Shipping 68 lbs 31 kg CONNECTIONS ELECTRIC Permanent Connection REFRIGERANT Discharge Line 1 1 16 12 UNF Fitting 10 AEROQUIP Liquid Line 5 8 18 UNF Fitting 6 AEROQUIP CONDENSER Air cooled Fin and tube type FAN MOTOR PROTECTION Thermal Protection REFRIGERANT CONTROL Condensing Pressure Regulator REFRIGERANT CHARGE R 404A 1 lb ...

Страница 10: ...nstruction 1 KM 515MAH air cooled Bin Control Thermostat Control Switch Expansion Valve Compressor Float Switch Water Pump Control Box Drier Fan Motor Condenser Hot Gas Valve Condenser Water Supply Pipe Liquid Line Valve Spray Tubes ...

Страница 11: ...5MWH water cooled Water Supply Pipe Water Regulator Hot Gas Valve Drier Control Box Water Pump Float Switch Compressor Expansion Valve Control Switch Bin Control Thermostat Spray Tubes Liquid Line Valve Condenser ...

Страница 12: ...H remote air cooled Water Supply Pipe Junction Box Hot Gas Valve Drier Control Box Water Pump Float Switch Compressor Expansion Valve Control Switch Bin Control Thermostat Spray Tubes Liquid Line Valve Reciever Tank ...

Страница 13: ...s The minimum total time allowed by the control board for a complete harvest cycle is 2 minutes WV is energized during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter 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 3 Freeze Cycle LED 1 is on Comp and FMR c...

Страница 14: ...p Out Timer When the pump out timer s harvest timer completes its countdown the harvest cycle is complete and the freeze cycle starts The minimum total time allowed by the control board for a complete harvest cycle is 2 minutes WV is energized during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter At the end of harvest the control board checks the position of F S a...

Страница 15: ... KM 515MWH KM 515MRH Sequence Flow Chart and Component Operation 1 One Minute Fill Cycle 2 Harvest Cycle 3 Freeze Cycle 4 Pump Out Cycle Cycle Steps WV Energized F S open F S closed Comp energized HGV energized FMR energized WV continues Thermistor temp reaches 48 F 9 C 3 9 kΩ or less Harvest timer starts F S open Comp continues FMR continues HGV de energized WV de energized PM energized FMS energ...

Страница 16: ... due to static discharge It is especially important to touch the metal part of the unit before 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 Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor and float switch K4 is not connected 5 Alw...

Страница 17: ...tic Contactor 2 Hot Gas Valve 3 Line Valve Self Contained Fan Motor FMS 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line bin control 8 Open Switch for C board and ALPINE board service boards only Alarm Reset Switch Backup Freeze Timer LED S4 Dip Switch Backup Harvest Timer LED Alarm Buzzer Power LED lights when power is supplied to the board Relay LEDs 4 indicate which relay...

Страница 18: ...o reset the safety d Low Water Safety The control board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle If the float switch is in the up position electrical circuit closed the control board changes to the ice making cycle If the float switch is in the down position electrical circuit open the control board changes t...

Страница 19: ...ery 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 in a row Orange LED marked H TIMER lights up Check for open thermistor HGV not opening TXV leaking by low charge or inefficient comp 3 Freeze Timer freeze specified settin...

Страница 20: ...F KM 515MWH OFF OFF OFF OFF OFF OFF OFF OFF ON OFF KM 515MRH OFF OFF OFF OFF OFF OFF OFF OFF ON OFF Freeze Timer 9 10 Pump Out Frequency Control 5 6 Do Not Adjust Pump Out Timer 3 4 Harvest Timer 1 2 Normally off 7 8 b Harvest Timer S4 dip switch 1 2 The harvest timer is only active during the initial harvest cycle Every cycle thereafter the pump out timer s harvest timer S4 dip switch 3 4 T2 acts...

Страница 21: ... 10 20 second pump out timer T1 is complete the pump motor stops and the inlet water valve energizes The harvest cycle continues until the pump out timer s harvest timer T2 terminates No adjustment is required under normal use as the pump out timer s harvest timer T2 is adjusted to the suitable setting However a setting longer than the factory setting may be advised in cases where the flush provid...

Страница 22: ... e Factory Use S4 Dip Switch 7 8 Factory set for optimum performance Do not adjust f Freeze Timer S4 dip switch 9 10 CAUTION Adjust to proper specification or the unit may not operate correctly The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze up issues Upon termination of freeze timer the control board initiates the harvest cycle After 2 consecutive ti...

Страница 23: ...y circuit does not have proper voltage check the control transformer primary circuit Check for 115V at the 10 pin connector Check the brown wire at pin 10 to a white neutral wire for 115V Always choose a white neutral wire to establish a good neutral connection when checking voltages For additional checks see IV B 1 1 The icemaker will not start 3 The OUTPUT TEST button provides a relay sequence t...

Страница 24: ...ee V I Removal 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 E Bin Control CAUTION When the ambient temperature is below 45 F 7 C the bin control thermostat operates to stop the ...

Страница 25: ...25 III Technical Information A Water Circuit and Refrigeration Circuit 1 KM 515MAH air cooled ...

Страница 26: ...26 2 KM 515MWH water cooled ...

Страница 27: ...27 3 KM 515MRH remote air cooled ...

Страница 28: ...rmer Output 10 5V at 115V B Wiring Diagrams 1 KM 515MAH air cooled and KM 515MWH water cooled Pressure Switch Air Cooled Model Water Cooled Model Cut out 412 21 PSIG 384 21 PSIG Cut in 327 21 PSIG 284 21 PSIG 0 0 ...

Страница 29: ...29 2 KM 515MRH remote air cooled Pressure Switch Cut out 412 21 PSIG Cut in 327 21 PSIG 0 Transformer Output 10 5V at 115V ...

Страница 30: ...0 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 226 15 9 250 17 6 278 19 5 80 27 244 17 2 282 19 8 306 21 5 90 32 250 17 6 308 21 7 335 23 5 PSIG kg cm 2 G 100 38 254 17 8 314 22 1 359 25 2 70 21 45 3 2 49 3 5 54 3 8 80 27 48 3 4 55 3 8 60 4 2 90 32 49 3 5 59 4 1 64 4 5 PSIG kg cm2 G 100 38 50 3 5 60 4 2 69 4 9 9 600 BTU h AT 90ºF 32ºC WT 70ºF 21ºC 27 33 27 28 32 27 30 2 7 4 4 3 4 3 9 3 2...

Страница 31: ... 0 272 19 1 276 19 4 90 32 271 19 0 273 19 2 277 19 5 PSIG kg cm2 G 100 38 272 19 1 274 19 3 280 19 7 70 21 50 3 5 52 3 6 56 3 9 80 27 51 3 6 54 3 8 59 4 2 90 32 52 3 6 56 3 9 61 4 3 PSIG kg cm2 G 100 38 53 3 7 57 4 0 65 4 6 8 300 BTU h AT 90ºF 32ºC WT 70ºF 21ºC TOTAL HEAT OF REJECTION FROM COMPRESSOR 1 300 BTU h AT 90ºF 32ºC WT 70ºF 21ºC WATER FLOW FOR CONDENSER 49 gal h AT 100ºF 38ºC WT 90ºF 32º...

Страница 32: ...5 2 234 16 4 252 17 7 80 27 230 16 1 257 18 1 272 19 1 90 32 234 16 4 277 19 5 294 20 6 PSIG kg cm 2 G 100 38 235 16 6 281 19 8 309 21 7 70 21 47 3 3 50 3 5 52 3 6 80 27 49 3 5 54 3 8 54 3 8 90 32 50 3 5 57 4 0 58 4 1 PSIG kg cm 2 G 100 38 50 3 5 57 4 0 59 4 1 8 500 BTU h AT 90ºF 32ºC WT 70ºF 21ºC 1 400 BTU h AT 90ºF 32ºC WT 70ºF 21ºC CONDENSER VOLUME 43 CU IN URC 5F TOTAL HEAT OF REJECTION FROM C...

Страница 33: ...ntil water enters and the float switch closes low water safety protection during initial start up and at the end of each harvest Diagnosis If the inlet water valve does not open check for no supply voltage at water valve terminals bad coil or plugged screen or external filter no water flow If unit fails to start harvest check for open float switch or bad 1 minute timer in control board 4 Initial H...

Страница 34: ... energizes self contained air cooled unit only the pump motor stops for 2 seconds and starts in reverse rotation for 10 20 seconds This removes contaminants from the water reservoir Diagnosis If the pump motor does not reverse check the circuit and pump capacitor If water does not pump out check for clear tubing at the check valve housing and check the unit drain for water flow Remove the pump out...

Страница 35: ... 2 Check for continuity and replace e Bin Control Thermostat 1 Tripped with bin filled with ice 1 Remove ice 2 Ambient temperature too cool 2 Increase ambient temperature 3 Set too warm 3 See II E Bin Control 4 Bulb out of position 4 Place in position 5 Bad contacts 5 Check for continuity and replace f High Pressure Control 1 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or co...

Страница 36: ...logged and water supply cycle does not finish 1 Clean 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace m Control Board 1 Defective or in alarm 1 See II C 4 Control Board Check Procedure 2 Water continues to be supplied and the icemaker will not start a Float Switch 1 Connector disconnected 1 Reconnect 2 Defective switch 2 Check and replace 3 ...

Страница 37: ...r 1 Motor winding opened 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 6 Mechanical seal worn out 6 Check and replace b Control Board 1 Defective 1 See II C 4 Control Board Check Procedure c Control Switch 1 Bad contacts 1 Replace 6 Freeze cycle time is...

Страница 38: ...ace headmaster h Water Supply Line water cooled model only 1 Condenser water pressure too low or off and high pressure control opens and closes frequently 1 Check and get recommended pressure i Water Regulating Valve water cooled model only 1 Set too high 1 Adjust or replace See V G Adjustment of Water Regulating Valve 2 Evaporator is Frozen Up Problem Possible Cause Remedy 1 Freeze cycle time is ...

Страница 39: ... set too short 1 Adjust longer referring to II C 3 Controls and Adjustments b Harvest Timer 2 Defective 2 See II C 4 Control Board Check Procedure i Water Regulating Valve water cooled model only 1 Leaking by in harvest 1 Check and replace 3 Other a Spray Tubes 1 Clogged 1 Clean 2 Out of position 2 Place in position b Water System 1 Dirty 1 Clean 2 Water supply line too small requires 3 8 OD line ...

Страница 40: ... 2 and check evaporator water supply line inlet water valve ambient and or water temperature line valve if applicable thermistor control board and hot gas valve 4 Abnormal Ice Problem Possible Cause Remedy 1 Small cubes a Ice Cube Guide 1 Out of position Circulated water falls into bin 1 Place in position b See chart 1 5 and check water supply line inlet water valve water system pump motor and con...

Страница 41: ...ut 1 Replace 2 Fan blade deformed 2 Replace 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 2 Reinstall d Refrigerant Lines 1 Rub or touch other lines or surfaces 1 Reposition 3 Ice in storage bin often melts a Drain Line s 1 Plugged 1 Clean b Icemaker and Bin 1 Drains not run separately 1 Separate the dr...

Страница 42: ...ure with pressurized air for leak testing 1 Refrigerant Recovery The icemaker unit is provided with refrigerant access valves 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 Brazing WARNING 1 R 404A itself is not flammable at atmospheric pressure and temperatures up to 176...

Страница 43: ...uge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 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 29 9 Hg vacuum Evacuating period depends on pump capacity 4 Close the low side valve and high side valve on the service manifold 5 Disconnect the...

Страница 44: ...bber grommets 6 Remove the discharge and suction pipes 7 Remove the compressor Unpack the new compressor package 8 Attach the rubber grommets of the prior compressor 9 Place the compressor in position and secure it using the bolts and washers 10 Remove the drier then place the new drier in position 11 Remove the plugs from the suction discharge and process pipes 12 Braze all fittings while purging...

Страница 45: ...N Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 121 C 8 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 ai...

Страница 46: ...s while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG CAUTION Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 121 C 9 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 u...

Страница 47: ...p 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 11 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the nameplate for the required refrigerant charge For remote air cooled...

Страница 48: ...d charge it with refrigerant See the nameplate for the required refrigerant charge 15 Connect the flare connections 16 Close the condenser water supply line drain valve then open the condenser water supply line shut off valve 17 Check for water leaks 18 Replace the panels in their correct positions 19 Turn on the power supply G Adjustment of Water Regulating Valve Water Cooled Model Only The water...

Страница 49: ...7 Remove the drier then place the new drier in position 8 Braze all fittings with nitrogen gas flowing at a pressure of 3 to 4 PSIG CAUTION Always protect the headmaster body by using a damp cloth to prevent it from overheating Do not braze with the headmaster body exceeding 250 F 121 C 9 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if...

Страница 50: ...ape 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 in the same position as the previous thermistor Be very careful to prevent damage to the leads Secure it using t...

Страница 51: ...ote air cooled model 9 Turn on the power supply K Removal and Replacement of Inlet Water Valve 1 Turn off the power supply 2 Close the icemaker water supply line shut off valve Open the icemaker water supply line drain valve 3 Remove the front panel 4 Disconnect the valve outlet tubing by releasing the clamp 5 Loosen the fitting nut Be careful not to lose the washer 6 Disconnect the terminals from...

Страница 52: ...sembly 8 Remove the screw attaching the pump motor to the pump motor bracket 9 Remove the screws attaching the pump housing to the pump motor Remove the housing and check the impeller 10 If the impeller is defective install a new impeller 11 Install the new motor or new parts and replace the removed parts in the reverse order of which they were removed Be sure to reattach the green ground wire 12 ...

Страница 53: ...quid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 3 Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution 4 Never run the icemaker when the water tank is empty IMPORTANT 1 The cleaning valve is used to allow solution flow to the inside of the evaporator during the cleaning and sanitizing operation It shou...

Страница 54: ...e down the float switch assembly s housing shaft float and retainer rod with cleaning solution Clean the inside of the rubber boot and hose with cleaning solution Rinse the parts thoroughly with clean water d Reassemble the float switch assembly and replace it and the rubber boot in their correct positions Reconnect the vent tube and the flush tube 7 Pour the cleaning solution into the water tank ...

Страница 55: ...f sanitizer to 3 gal 11 l of water 2 Remove the insulation panel 3 Pour the sanitizing solution into the water tank 4 Replace the insulation panel and the front panel in their correct positions Note Make sure that the control switch is in the WASH position and the cleaning valve is open 5 Turn on the power supply to start the sanitizing process 6 Turn off the power supply after 15 minutes 7 Remove...

Страница 56: ...r cooled and remote air cooled models only Check the condenser once a year and clean the coil if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on location C Preparing the Icemaker for Long Storage CAUTION 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 ...

Страница 57: ...upply to the icemaker water supply line drain valve 5 Make sure at least 3 minutes have elapsed since you turned off the power supply Make sure the control switch is in the ICE position Replace the front panel in its correct position and turn on the power supply 6 Blow the icemaker water supply line out using the compressed air or carbon dioxide supply 7 Close the icemaker water supply line drain ...

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