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Service Manual - Whaley Food Service
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1. 6 Remove the screws securing the mounting brackets lift the evaporator up slightly and disconnect the evaporator inlet tubing 7 Lift up the evaporator and disconnect the evaporator outlet tubing Remove the evaporator 8 Remove the drier located behind the upper rear panel then place the new drier in position 9 Install the new evaporator Braze all fittings including drier while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 12 Replace the removed parts in the reverse order of which they were removed 13 Open the water supply line shut off valve 14 Plug the unit back in 15 Check for leaks 16 Replace the panels in their correct positions H Removal and Replacement of Air Cooled Condenser 1 Unplug the unit from the electrical outlet 2 3 4 Remove the screws securing the electrical box located over the compressor then slide out the box Remove the panels Recover the refrigerant and store it in an approved container 5 Remove the screws securing the compressor base and the condenser Carefully slide the refrigeration assembly forward 6 Disconnect the condenser inlet and outlet piping 7 Remove the fan motor and shroud assembly from the old condenser and attach it to the new cond
2. 3 Other continued g Water Supply Line 1 Too small requires 1 Increase water line size 3 8 OD line dedicated per machine h Water Filter 1 Flow rate too small 1 Replace with filter that has larger flow rate 3 Low Ice Production Possible Cause 1 Freeze cycle time is a See chart 1 3 and check dirty air filter or condenser ambient or water long temperature water pressure condenser water regulating valve water cooled model and refrigerant charge b See chart 2 1 and check float switch water valves and control board c Check pump hot gas valve expansion valve refrigerant charge and compressor 2 Harvest cycle time is a See chart 2 2 and check control board thermistor evaporator ambient and or long water temperature water supply line water valves and hot gas valve 4 Abnormal Ice Possible Cause 1 Small cubes a Ice Cube Guides 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 5 and check water supply line water valves water system pump motor and control board 2 Cloudy or irregular a See chart 2 1 and 2 3 and check float switch water valves control board cubes spray tubes water system refrigerant charge and expansion valve D Spray Guide c Water Quality 1 High hardness or 1 Install a water softener or contains impurities filter 5 Other Possible Cause 1 Icemaker will not stop a Bin Control
3. 2 Remove the thermistor See V L Removal and Replacement of Thermistor 16 3 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 4 Verify the temperature of the glass then check for resistance between thermistor leads See the table above for temperature and resistance values Normal reading is within 3 5 to 7 kO Replace the thermistor if it exceeds the normal reading c Harvest Timer S4 dip switch 1 amp 2 The harvest timer starts counting when the thermistor reads 48 F 9 C at the evaporator outlet No adjustment is required under normal use as the harvest timer is adjusted to the suitable position Before changing this setting call the HOSHIZAKI Technical Support Department at 1 800 233 1940 for recommendations Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production Time se Corr o s ON OFF 90 d S4 dip switch 3 4 5 6 7 amp 8 Factory set for optimum performance Do not adjust e Freeze Timer S4 dip switch 9 amp 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 timer terminations the control board shuts the machine down In this case see IV B 3 Low Ice Production f
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5. 1 See II C 4 Bin Control Troubleshooting when bin is filled with ice 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 2 Mounting pad out of 12 Reinstall position d Refrigerant Lines 1 Rub or touch other 1 Replace lines or surfaces 33 Possible Cause Dies in storage bin 1 Plugged often melts b Ice Cube Guides 1 Out of position 1 Place in position Circulated water falls into bin 34 V Removal and Replacement of Components IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced IMPORTANT 1 The Polyol Ester POE oils used in R 404A units can absorb moisture quickly Therefore it is important to prevent moisture from entering the system when replacing or servicing parts 2 Always install a new drier every time the sealed refrigeration system is opened 3 Do not leave the system open for longer than 15 minutes when replacing or servicing parts A Servicing the Refrigeration Circuit 1 Refrigerant Recovery The icemaker unit is provided with two refrigerant access valves one on the low side and one on the high side line Using proper refrigerant practices recover the refrigerant from the a
6. 12 Remove the drier located behind the upper rear panel then place the new drier in position 13 14 Remove plugs from the suction discharge and process pipes Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Check for leaks using nitrogen gas 140 PSIG and soap bubbles wa ase Ta af 15 16 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 17 Connect the terminals and replace the terminal cover in its correct position 18 Replace the removed parts in the reverse order of which they were removed On water cooled models open the water supply line shut off valve and check for leaks Replace the panels in their correct positions 19 Plug the unit back in D Removal and Replacement of Drier IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the drier located behind the upper rear panel 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 when brazing the tubings 6 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 7 Evacuate
7. Jo ui amp ue eu 40 sejnuiuJ 9 s eui AMH 19A9 111 pue ezooJj 1 SO NUIW 9 ALUI SEA Jon JSEAIEU WNWIXEN e lnulin euo L js jo pug 7 l ezooJ4 l 42 1soAJeH Z sdais ajoA9 uones do u uodulo pue yeyo u nb s HM amp aSSC INX pue 8992 11 C Control Board A HOSHIZAKI exclusive solid state control is employed in KM 255BAH and KM 255BWH Self Contained Crescent Cubers All models are pretested and factory adjusted CAUTION Fragile handle very carefully A control board contains integrated 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 Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor float switch and mechanical bin control Always replace the whole board assembly if it goes bad Do not short out power supply to test for voltage 1 Control Board Layout Control Products G Control Board Connector K2 Transformer Switch for C board and ALPINE board service boards only Connector K1 Pins 1 through 10 1 9 Magnetic Contactor 2 Hot Gas Valve HGV Water Valve Relay for harvest water valve operation 3 Self
8. Switch Control and Refill Counter S5 dip switch 1 through 5 17 0 Bin Conu a 18 4 Bin Control tee ue DE 18 a Machine Wil Not SPAN MERO 18 b Machine Will Not Shut Off Eba ia hien 18 5 Float Switch Teo bleshoe 18 6 Control Board Check PTOC UTE usine a ala AD aaa b rda ua 19 7 Control Board Replacement MM 20 mE 21 A Water Circuit and Refrigeration Coup 21 UM KM 255BAH Ree E 21 2 KM 255BWH RENE Ee MM 22 ET laten MM TR 23 1 KM 255BAH air cooled deg gu 23 2 KM 255BWH water cooled erra pna naa ran ia ni nennen tb ka abb aaa aa kk Rake pan eneee 24 C Performance Dele cue Fi memk ben kxkx ex cuba examen Ra a Fas usi eeu SEX UTR 25 1 KM 255BAH air ceel d EE 25 2 KM 255BWH water coole 26 15 00 ee EE s 27 A 10 Minute Diagnostic Procedure eeeeeesessessessesseeeeen nennen nennen nnne 27 SE eeng 28 1 No lce FACTO Mil NER D UU 28 2 Evaporator is Frozen 32 3 Low do2lpos M s 33 Hh SPANO dun EE 33 SOME a 33 V Removal and Replacement of Components 35 A Servicing the Refrigeration Circuit EEN 35 1 Refrigerant e E 35 2 Evacuation and Recharge DH A0O4A
9. a maximum of 6 minutes or the length of harvest minus 50 seconds whichever is shorter The pump motor energizes and runs for the last 50 seconds of harvest Diagnosis Check if compressor is running hot gas valve is open harvest water valve open If these are okay next check for at least 48 F 9 C on the suction line If cooler check for inlet water too cold expansion valve stuck open or water regulating valve water cooled model stuck open If the suction line is at least 48 F 9 C disconnect the thermistor at the board K3 and check for resistance of 3 9 kQ or less If different check and replace if necessary See II C 3 b Harvest Control Thermistor for check procedure If resistance is 3 9 kQ or less reconnect the thermistor to the board If harvest does not terminate within 3 minutes replace the board 5 Freeze Cycle LED 1 is on The compressor and pump motor remain energized and the fan motor energizes The hot gas valve de energizes also de energizing the water valve relay and the harvest water valve de energizes The unit is held in freeze by a 5 minute short cycle protection timer After 5 minutes the freeze cycle operation is transferred to the lower float switch for freeze termination During the first 5 minutes 27 of freeze confirm that the evaporator temperature drops After 7 minutes in freeze disconnect the float switch by unplugging the harness from the K5 connector The unit should switch out of t
10. brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker C Preparing the Icemaker for Long Storage IMPORTANT When shutting off the icemaker for an extended time drain out all water from the water lines and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker and water cooled condenser if applicable using air or carbon dioxide to prevent damage to the water supply lines at sub freezing temperatures Shut off the icemaker until the proper ambient temperature is resumed When the icemaker is not used for two or three days it is sufficient to only move the control switch to the OFF position unless the icemaker will be at sub freezing temperatures To drain all water from the icemaker follow the steps below 1 Remove the front panel top panel and insulation panel 2 3 4 Allow the icemaker to complete the one minute fill cycle LED 4 is on then move the switch back to the OFF position Move the control switch on the control box to the OFF position Wait 3 minutes then move the control switch to the ICE position 5 Close the potable water supply line shut off valve and open the potable water supply line drain valve 6 Allow the line to drain by gravity 7 Move the control switch to the ICE position 8 Blow the potable water supply line out using compressed air or carbon dioxide This will clear water from t
11. dispensing device to add the remaining liquid charge through the low side access port with the unit running 9 Close the two refrigerant access valves and disconnect the service manifold hoses 10 Cap the access valves to prevent a possible leak B Brazing DANGER Refrigerant R 4044 itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C 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 hazardous Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Do not use silver alloy or copper alloy containing arsenic Do not use R 404A as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector Note Because the pipes in the evaporator case are specially coated to resist corrosion it is important to make connections outside the evaporator case when possible If it is necessary to braze inside the evaporator case use sandpaper to remove the coating from the brazing connections before unbrazing the components C Removal and Replacement of Compressor IMPORTANT Always install a new drier every time the sealed refrigeration system
12. gallon 3 8 1 of warm water 2 Remove the top panel and the insulation panel 3 Remove all ice from the evaporator and the storage bin Note To remove cubes on the evaporator move the control switch on the control box to the OFF position and move it back to the ICE position after 3 minutes The defrost cycle starts and the cubes will be removed from the evaporator 4 Move the control switch to the OFF position Open the door 5 Disconnect the suction hose to drain the water See Fig 1 6 Reconnect the suction hose back in its correct position after all of the water has drained 7 Pour the cleaning solution into the water tank 8 Move the control switch to the WASH position 9 Close the door 10 After 30 minutes move the control switch to the OFF position 11 Disconnect the suction hose to drain the water Reconnect the suction hose back in its correct position after all of the water has drained 12 Move the control switch to the ICE position to fill the water tank with water 13 After 3 minutes move the control switch to the WASH position 14 After 5 minutes move the control switch to the OFF position 15 Disconnect the suction hose to drain the water Reconnect the suction hose back in its correct position after all of the water has drained 16 Repeat steps 12 through 15 three more times to rinse thoroughly 47 17 Remove the bin control switch housing at the back of the water tank It is snapped in plac
13. gravity 5 Blow the water supply line out using compressed air or carbon dioxide until water stops coming out 6 Disconnect the water inlet and outlet at the condenser 7 Remove the screws securing the compressor base and the condenser Carefully slide the refrigeration assembly forward 8 Attach compressed air or carbon dioxide supply to the condenser and blow out the condenser 9 Close the condenser water supply line drain valve 10 Place all removed parts back in their correct positions and then place the panels back in their correct positions 51
14. is opened Do not replace the drier until after all other repair or replacement has been made Note When replacing a compressor with a defective winding be sure to install the new start capacitor and start relay supplied with the replacement compressor Due to the ability of the POE oil in the compressor to absorb moisture quickly the compressor must not be opened more than 15 minutes for replacement or service Do not mix lubricants of different compressors even if both are charged with R 404A except when they use the same lubricant 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 4 Remove the screws securing the electrical box located over the compressor then slide out the box 36 Recover the refrigerant and store it in an approved container 5 Remove the screws securing the compressor base and the condenser On water cooled models close the water supply line shut off valve drain the condenser and then disconnect the water inlet and outlet at the condenser Carefully slide the refrigeration assembly forward 6 Remove the terminal cover on the compressor and disconnect the compressor wiring 7 Remove the discharge and suction pipes 8 Remove the hold down bolts washers and rubber grommets 9 Remove the compressor Unpack the new compressor package 10 Attach the rubber grommets of the prior compressor 11 Place the compressor in position and secure it using the bolts and washers
15. shutting down the machine 4 Bin Control Troubleshooting a Machine Will Not Start 1 Confirm that the bin is not full On the control board if the yellow LED BC OPEN is on the bin control is the likely problem If the green LED BC CLOSED is on the bin control is properly calling for ice In this case refer to section IV Service Diagnosis to verify that non bin control related issues are resolved 2 Check to make sure shipping tape has been removed and the wires are connected properly 3 Check to make sure no obstruction prevents the lever from moving to the bin empty position 4 Check proximity switch continuity to make sure it is not stuck open b Machine Will Not Shut Off 1 Confirm that the bin is full and the actuator is in the bin full position On the control board if the green LED BC CLOSED is on the bin control is the likely problem If the yellow LED BC OPEN is on the bin control is properly showing that the bin is full In this case refer to section IV Service Diagnosis to verify that non bin control related issues are resolved 2 Check to make sure no obstruction prevents the lever from moving to the bin full position 5 Float Switch Troubleshooting Depending on local water conditions scale may build up on the float switch Scale on the switch can cause the floats to stick In this case the float switch should be cleaned and checked First remove the switch from the water tank Soak the sw
16. thermistor reaches 48 F 9 C The control board then receives the thermistor s 3 9 kQ signal and starts the harvest timer When the harvest timer completes its count down the harvest cycle is complete and the next freeze cycle starts The minimum total time allowed by the board for a complete harvest cycle is 2 minutes HWV is open during harvest for a maximum of 6 minutes or 9 the length of harvest minus 50 seconds whichever is shorter PM energizes and runs for the last 50 seconds of harvest 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 The unit continues to cycle through freeze and harvest cycles until the bin control activates and shuts the unit down Legend Comp compressor FMS self contained fan motor FWV freeze water valve HGV hot gas valve HWV harvest water valve LF S lower float switch PM pump motor UF S upper float switch 10 Alqwasse eje d 1ojeJode e y Jo pisino pue episul eui u1oq MO 0 Jezniues pue SMOJE SIU GA E A USEM v pue JO OW dund eui o perjddns s uonisod HSVM eui Ul eurugoeu y Buizniues pue Buiueejo ueuw pesn 51 yms 041009 v uo uornisod HSVM eur uoHsod HSVM y U 51 YOUMS O 3u02 ay ueuw pezibjeu3 sjueuoduio youms yeol 1eddn s 4n 100w duund Vid YOUMS EO S 311 1S AHEU
17. to ICE position 2 Bad contacts 2 Check for continuity and replace c Fuse internal 1 Blown 1 Check for short circuit and replace d Bin Control 1 Tripped with bin filled 1 Remove ice with ice 2 Improperly activated 2 Check for proper position and movement e High Pressure Control 1 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or 2 Clean condenser 3 Ambient or condenser 3 Reduce temperature water temperature too warm 4 Refrigerant 4 Recharge overcharged Possible Cause 1 The icemaker will not start continued 5 Fan not operating 5 See chart 1 6 except water cooled model 6 Refrigerant line or 6 Clean and replace drier components plugged 7 Condenser water 7 Check and get pressure too low or offf recommended pressure water cooled model only Transformer 1 Coil winding opened 11 Replace or shorted 9 Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace h Thermistor 1 Leads shorted or 1 See II C 3 Controls and opened and high Adjustments b Harvest temperature or harvest Control backup timer safety operates 1 beep or 2 beep alarm i Hot Gas Valve 1 Continues to open 1 Check for hot gas valve in freeze cycle and stuck open and replace freeze timer safety operates 3 beep alarm j Water Supply Line 1 Water supply off and 1 Check and get water supply cycle recommend
18. 4A 116 1 oz 475 g High 467 PSIG Low 240 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Svvitch Float Svvitch ce Scoop 6 Leg 4 pcs N A VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2 KM 255BWH water cooled Intentionally Left Blank Note We reserve the right to make changes in specifications and design without prior notice II General Information A Construction 1 KM 255BAH air cooled Rear View of Icemaker Harvest Water Expansion Evaporator S Tub pray tube Water Tank Bin Control amp Pump Motor Bin Control Switch Bin Control back side of tank Detector Water Tank Condenser Float Switch Fuse Electrical Control Switch Box Compressor 2 KM 255BWH water cooled Evaporator Electrical Control Switch Box Rear View of Icemaker Harvest Expansion in Wash Valve Drier Water Tank Bin Control amp Pump Motor Bin Control Switch Bin Control back side of tank Detector i Ces DO icc Hernan ex AE yd VVater Tank 3 Float Pump Switch Motor Rear View of Compressor amp Condenser Water Regulator VW B Sequ
19. 6 Control Board l Check Procedure 6 Fan motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is not operating 2 Bearing worn out 2 Replace 3 Wiring to fan motor 13 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace b Control Board 1 Defective 1 See II C 6 Control Board Check Procedure 7 All components a Refrigerant 1 Undercharged 1 Check for leaks and run but no ice is recharge produced 2 Air or moisture 2 Replace drier and trapped recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Valve 1 Continues to open in 1 Check and replace freeze cycle d Harvest Water Valve 1 Water valve is wide 1 Check for water leaks with open during freeze icemaker off e Water Valve Relay 1 Contacts stuck 1 Replace f Water Supply Line 1 Condenser water 1 Check and get water cooled model pressure too low or offf recommended pressure only and pressure control opens and closes frequently g Water Regulator 1 Set too high or faulty 11 Adjust or replace See water cooled model V K Adjustment of Water only Regulating Valve 31 2 Evaporator is Frozen Up Possible Cause 1 Freeze cycle time is a Float Switch 1 Leads shorted or 1 Check and replace too long defective switch 2 Float does not move 2 Clean or replace freely b Water Valves 1 Diaphragm doe
20. 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg em G 100 38 Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 25 2 KM 255BWH water cooled Intentionally Left Blank Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 26 IV Service Diagnosis A 10 Minute Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start up or for system diagnosis Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70 F or warmer air and 50 F or warmer water temperatures Before conducting a 10 minute checkout check for correct installation proper voltage per unit nameplate and adequate water supply As you go through the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect Check for voltage at the 10 pin connector 1 Unplug the unit from the electrical outlet and access the control box and the electrical box 2 Plug the unit back in and place the co
21. A 35 BUL 36 C Removal and Replacement of Compressor eese 36 D Removal and Replacement of Der 37 E Removal and Replacement of Expansion Valve 38 F Removal and Replacement of Hot Gas Valve 39 G Removal and Replacement of 40 H Removal and Replacement of Air Cooled Condenser 40 Removal and Replacement of Water Cooled Condenser 41 J Removal and Replacement of Water Regulating Valve Water Cooled Model Only 42 K Adjustment of Water Regulating Valve Water Cooled Model Only 42 L Removal and Replacement of 2840 43 M Removal and Replacement of Fan Motor 44 N Removal and Replacement of Freeze or Harvest Water Valve 44 O Removal and Replacement of Wash Vahye 2 45 P Removal and Replacement of Pump ek 45 Q Removal and Replacement of Spray Tube 46 VI Cleaning and Maintenance Instructions ee 47 Ar Cleaning NEU ET e 47 1 Cleaning POC SES ca 11 47 2 Sanitizing Procedure Following Cleaning Procedure 49 CL DEI ou I M esd t UI 49 C Preparing the Icemaker for Long Storage e 50 I Specifications A Icemaker 1 KM 255BAH air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTI
22. Contained Fan Motor FMS R 114 Pump Motor icemaking 115 Pump Motor harvest 6 Freeze Water Valve FVVV 7 10 Supply Voltage 8 Open Label board revision level indicated on label on side of relay Connector K5 Float Switch S5 Dip Switch factory set do not adjust zum NE EH Connector K4 Mechanical Bin Control IHM gay 23 224 HE EH EH 4 EE 2 Ir Connector K3 Harvest Control thermistor 6078A000 un e eech el R21 Output Test Switch used to test relays on board Control Board S4 Dip Switch 2A3792 01 factory 2A3792 02 service Part Number 13 Relay LEDs 4 indicate which relays are energized as listed below LED 1 green Compressor Comp LED 4 green Freeze Water Valve FWV when LED 2 is off Harvest Water Valve HWV when LED 2 is on LED 3 green Pump Motor PM PM on but LED off at freeze cycle LED 2 green Hot Gas Valve HGV Harvest Water Valve HWV when LED 4 is on Self Contained Fan Motor FMS FMS off when LED on Power LED red lights when power is supplied to the board Alarm Buzzer Part Number Bin Control Switch Open LED yellow Bin Control Switch Closed LED green Alarm Reset Switch 2 Features a Maximum Water Supply Period 6 minutes The harvest water valve will be open during harvest for 6 minutes or the l
23. Hoshizaki America Inc Self Contained Crescent Cuber Models KM 255BAH KM 255BWH A Superior m S E RVI C E M A N UA L of Reliability vvvvvv hoshizaki com Na 1 E Number 73146 Issued 2 2007 IMPORTANT Only qualified service technicians should attempt to install service or maintain this icemaker No installation service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker 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 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 mail techsupport hoshizaki com Web Site www hoshizaki com NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem Please review this manual It should be read carefully before the icemaker is serviced or maintenance operations are performed Only qualified service technicians should service and maintain the icemaker This manual should be
24. O 3113ND JLIHM Y Y 18 M 8 JLIHM NMOY9 M 8 DDT QAQ O EH o4 0000 Mes za ra Nu V E G ason E welt 1 X 1 5 N BA fo 19M NWA HI a 20 Ratt vav S Vo a vn M Zo HOLINS Eo Py Py WND WLIS Yo Sop I ng m bi go S 1 D L nad e SE E MR y ss 1 H Lo m oli to i 2 E nad t ik RE SOLON n mo gsl EL 69 O 0 m snd ETT TE na JH d ON mmm TOT wm SA DV N UM Na nu YSTIOULNOD ol YOLSIMYSHL nn III MOTISA A 10A A 3mg xuva nad AN d AVAD AD DN dat d WWI 28 31HM M NMOUG Ud 300 4010 N 09 4 H 5 o o 5 a o o D 41232 PSIG 327221 PSIG 23 2 KM 255BWH water cooled Intentionally Left Blank Pressure Switch 38432 PSIG 284421 PSIG 24 C Performance Data 1 KM 255BAH air cooled APPROXIMATE ICE AENT FEB WATER TEMP F C F C PRODUCTION PER 24 HR 70 24 70 21 227 80 27 216 90 32 207 Ibs day kg day 100 38 202 APPROXIMATE ELECTRIC 70 24 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27
25. ON PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 60 1 9A 5Min Freeze AT 104 F WT 80 F N A Ambient WATER TEMP F Temp F 50 70 90 235 107 227 103 207 94 Crescent Cube 4 Ibs 1 8 kg 204 pcs 120 Ibs 90 70 F 70 50 F 828 9 6 744 7 6 51 24 7 82 35 0 30 x 28 x 39 762 x 711 x 990 mm Includes 6 leg Stainless steel Galvanized steel rear Net 203 Ibs 92 kg Shipping 220 Ibs 100 kg Cord Connection Inlet 1 2 FPT Outlet 3 4 FPT N A Internal programming Hot Gas and Water Thermistor and Timer Timer Controlled Overflovv Pipe N A Mechanical Level Svvitch and Timer Hermetic Model SC12MLX Air cooled Fin and Tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 40
26. all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 11 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 12 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 13 Replace the removed parts in the reverse order of which they were removed Open the water supply line shut off valve and check for leaks Replace the panels in their correct positions 14 Plug the unit back in 41 J Removal and Replacement of Water Regulating Valve Water Cooled Model Only IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the unit from the electrical outlet 2 Close the condenser water supply line shut off valve and then drain the condenser 3 Remove the panels 4 Recover the refrigerant and store it in an approved container 5 Disconnect the capillary tube at the condenser outlet 6 Disconnect the flare connections of the valve 7 Remove the screws and the valve from the bracket 8 Install the new valve and braze the capillary tube 9 Install the new drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge Connect the flare connections Open the water supply line s
27. ccess valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 Evacuation and Recharge R 404A 1 Attach service manifold hoses and a vacuum pump to the system Be sure to connect charging hoses to both high and low side access valves IMPORTANT The vacuum level and vacuum pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the vacuum pump Never allow the oil in the vacuum pump to flow backward 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 vacuum pump and attach a refrigerant service cylinder to the high side line Remember to loosen the connection and purge the air from the hose See the nameplate for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cylinder and place it on scales Open the high side service manifold valve 7 Allow the system to charge with liquid until the nameplate weight is met 35 8 If necessary add any remaining charge to the system through the low side Use a throttling valve or liquid
28. ction line in the same location as the previous bulb The bulb should be at the 12 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the expansion valve cover in position 12 Replace the panels in their correct positions 13 Plug the unit back in 38 F Removal and Replacement of Hot Gas Valve IMPORTANT 1 Always use a copper tube of the same diameter and length when replacing the hot gas lines otherwise the performance may be reduced 2 Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 3 Always replace the strainer when replacing the hot gas valve 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 4 Remove the screws securing the electrical box located over the compressor then slide out the box Recover the refrigerant and store it in an approved container 5 Remove the screws securing the compressor base and the condenser On water cooled models close the water supply line shut off valve drain the condenser and then disconnect the water inlet and outlet at the condenser Carefully slide the refrigeration assembly forward 6 Remove the screw and the solenoid 8 9 Remove the drier located behind the upper rear panel then place the new drier in position 7 Disconnect the hot gas valve and
29. d 9 Plug the unit back in and check for leaks 10 Replace the panels in their correct positions 45 Q Removal and Replacement of Spray Tube 1 2 3 4 5 6 Unplug the unit from the electrical outlet Remove the top panel and the insulation panel Remove the rubber hoses from the spray tube water supply pipe Release the clamps and disconnect the rubber hoses Remove the spray tube Install the new spray tube and replace the removed parts in the reverse order of which they were removed wa a 7 Replace the panels in their correct positions 8 Plug the unit back in 46 VI Cleaning and Maintenance Instructions IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment A Cleaning WARNING 1 Hoshizaki recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 4 For safety and maximum effectiveness use cleaning and sanitizing solutions immediately after dilution 1 Cleaning Procedure 1 Dilute 5 fl oz 148 ml of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 1
30. e Pinch it and then pull down See Fig 2 18 Disconnect the suction hose Next remove the water tank by pressing down on the snaps on Bracket L and Bracket R and pulling the tank towards you See Fig 3 19 Remove the float switch from the water tank by pulling out on the right side wall of the water tank slightly and sliding the float switch upward Be careful to avoid breakage when handling the parts See Fig 4 20 Remove the detector from the water tank It is snapped in place Slide it up and then out See Fig 4 21 Pull Cube Guide A and Cube Guide B qty varies depending on model upward to remove them from the water tank They are snapped in place See Fig 4 22 Remove the suction hose from the water tank 23 Remove the drain pan from Bracket R by pulling it towards you It is snapped in place Remove the drain tube and the frame pipe from the drain pan See Fig 5 24 Dilute 5 fl oz 148 ml of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Drain Pan Inc with 1 gallon 3 8 of warm water 25 Wash the bin control switch housing water tank float Drain Tube switch detector Cube Guide A Cube Guide B suction hose drain pan drain tube and frame pipe by using a Frame Pipe nylon scouring pad brushes and the cleaning solution In addition to the removed parts also wash the bin liner Bracket L and Bracket R with the solution 26 Di
31. ed pressure does not finish 2 Condenser water 2 Check and get pressure too low recommended pressure or off and pressure control opens and closes frequently to finally operate high temperature safety 1 beep alarm k Water Valves 1 Mesh filter or orifice 1 Clean gets clogged and water supply cycle does not finish 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace Control Board 1 Defective or in alarm 1 See II C 6 Control Board Check Procedure m Control Switch 1 WASH position 1 Move to ICE position 2 Bad contacts 2 Check and replace 29 Possible Cause 2 Water continues to a Float Switch 1 Connector 1 Place in position be supplied and the disconnected icemaker will not 2 Leads opened or 2 Check and replace start defective switch 3 Float does not move 3 Clean or replace freely b Control Board 1 Defective 1 Replace C Low Water Safety 1 Check and reattach 3 Compressor will a Magnetic Contactor 1 Bad contacts 1 Check for continuity and not start or stops replace operating 2 Coil winding opened 2 Replace b Start Capacitor 1 Defective 1 Replace C Internal Overload 1 Loose terminal 1 Tighten or replace Protector Open check 1 through 3 to the right 2 Voltage 2 Check and correct and d through f below 3 Dirty condenser d Starter 1 Check and replace 2 Coil wi
32. ence of Operation The steps in the sequence are as outlined below When power is supplied the red LED on the control board comes on A 5 second delay occurs at startup Note that the order of the green LEDs from the outer edge of the board is 1 4 3 2 1 One Minute Fill Cycle LED 4 is on FWV opens and the fill period begins After 1 minute the board checks for a closed LF S If LF S is closed the harvest cycle begins If not FWV will remain energized through additional 1 minute cycles until water enters the sump and LF S closes This serves as a low water safety to protect the water pump 2 Initial Harvest Cycle LEDs 1 4 and 2 are on FWV closes HGV opens water valve relay energizes and HWV opens Comp energizes and harvest begins The control board monitors the warming of the evaporator via the thermistor located on the suction line When the thermistor reaches 48 F 9 C the control board reads a 3 9 kQ signal from the thermistor and turns harvest termination over to the adjustable harvest timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds S4 dip switch 1 amp 2 When the harvest timer completes its count down the harvest cycle is complete and the freeze cycle starts The minimum total time allowed by the board for a complete harvest cycle is 2 minutes HWV is open during harvest for a maximum of 6 minutes or the length of harvest minus 50 seconds whichever is shorter PM energ
33. ength of harvest minus 50 seconds whichever is shorter b Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if for two cycles in a row the harvest cycle takes more than 20 minutes to complete The control board will signal this problem using 2 beeps every 3 seconds The freeze timer shuts down the icemaker if for two cycles in a row the freeze cycle takes longer than the time specified to complete The control board will signal this problem using 3 beeps every 3 seconds The time is factory set using S4 dip switch 9 amp 10 The reset button on the control board must be pressed with power on to reset either of these safeties c High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety This protects the unit from excessively high temperatures If the evaporator temperature rises above 127 7 F 53 4 C the control board reads a 804 kQ signal from the thermistor and operates the safety This shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 1 beep every 3 seconds The reset button on the control board must be pressed with power on 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 closed the co
34. enser 40 8 Place the new condenser in position 9 Remove the drier located behind the upper rear panel then place the new drier in position 10 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 11 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 12 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 13 Replace the removed parts in the reverse order of which they were removed then replace the panels in their correct positions 14 Plug the unit back in I Removal and Replacement of Water Cooled Condenser 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the screws securing the electrical box located over the compressor then slide out the box 5 Remove the screws securing the compressor base and the condenser Close the water supply line shut off valve drain the condenser and then disconnect the water inlet and outlet at the condenser Carefully slide the refrigeration assembly forward 6 Disconnect the condenser inlet and outlet piping from the refrigeration circuit 7 Remove the mounting bracket from the old condenser and attach it to the new condenser 8 Place the new condenser in position 9 Remove the drier located behind the upper rear panel then place the new drier in position 10 Braze
35. he freeze cycle Note At this point after the initial freeze cycle and every 10th cycle thereafter LEDs 1 3 and 2 come on the compressor continues to run the hot gas valve opens and the fan motor de energizes The pump motor stops for 2 seconds The pump motor restarts and runs for 10 seconds Diagnosis If the evaporator is not cold check to see if the hot gas valve is still open or if the expansion valve is not opening properly if the harvest water valve or harvest valves relay is stuck open the freeze water valve will cycle on and off during freeze if there are improper unit pressures or an inoperative compressor If the unit remains in freeze with the float switch removed replace the board Note Normal freeze cycle will last 20 to 40 minutes depending on model and conditions Cycle times and pressures should follow performance data provided in this manual 6 Normal Harvest Cycle same as the initial harvest cycle Return to step 4 Note Unit continues to cycle until bin control is satisfied or power is switched OFF The unit always restarts at the 1 minute fill cycle B Diagnostic Charts 1 No Ice Production Possible Cause 1 The icemaker will not a Power Supply 1 Off breaker tripped or 1 Reset breaker or replace fuse blown fuse 3 Bad contacts 3 Check for continuity and replace 4 Voltage too high or too 4 Check and get low recommended voltage b Control Switch 1 OFF position 1 Move
36. he freeze water valve 9 Allow the machine to cycle from the one minute fill cycle to the initial harvest cycle LEDs 1 4 and 2 are on Blow the potable water supply line out using compressed air or carbon dioxide This will clear water from the harvest water valve 10 Move the control switch to the OFF position 11 Disconnect the suction hose to drain the water See Fig 1 12 Disconnect the upper hose from the harvest water valve Move the control switch to the WASH position and quickly blow out the hose line using compressed air or carbon dioxide This will clear water from the wash valve 50 13 14 15 16 17 18 Move the control svvitch to the OFF position Reconnect the suction hose and harvest vvater valve hose Close the potable water supply line drain valve Remove all ice from the storage bin and clean the bin Unplug the unit from the electrical outlet e Fee Fe o If the icemaker is water cooled proceed to the next section to drain the condenser If the icemaker is air cooled place the panels back in their correct positions The procedure is complete To drain all water from the water cooled condenser follow the steps below 1 Close the water cooled condenser water supply line shut off valve 2 3 4 Attach compressed air or carbon dioxide supply to the condenser water supply line drain valve Open the drain valve for the water cooled condenser water supply line Allow the line to drain by
37. hut off valve 12 13 14 Check for water leaks 15 Replace the panels in their correct positions 16 Plug the unit back in K Adjustment of Water Regulating Valve Water Cooled Model Only The water regulating valve also called water regulator is factory adjusted No adjustment is required under normal use Adjust the water regulator if necessary using the following procedures 1 Prepare a thermometer to check the condenser drain temperature Attach a pressure gauge to the high side line of the system 2 Five minutes after a freeze 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 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 42 3 Check that the condenser drain temperature is stable Adjustment Screw CW Higher CCW Lower Top View L Removal and Replacement of Thermistor IMPORTANT 1 Fragile handle very carefully 2 Always use a recommended sealant High Thermal Conductive Type Model KE4560RTV manufactured by SHINETSU SILICONE Part Code 60Y000 11 or Part Code 4A0683 01 equivalent 3 Always use a recommended foam insulation non absorbent type or equivalent 4 Do not shorte
38. itch assembly in ice machine cleaner While not necessary the floats can be removed from the shaft during cleaning If you remove them note that the blue float is on top The floats must be installed with the magnets inside them towards the top of the switch Installing the floats upside down will affect the timing of the float switch operation Once clean rinse and wipe the cleaner off Next check the switch with an ohm meter This float switch has three wires the black 18 wire is common and two separate switches Check the upper switch by ohming out the black and red wires When the float is up the switch should be closed Check the lower switch by ohming out the black and blue wires in the same manner If either switch fails the assembly should be replaced Red upper Black common Blue lower Magnet towards top Lower Float white Plastic Retainer Clip 6 Control Board Check Procedure Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis 1 Check the S4 dip switch settings to assure that they are in the factory default positions 2 Turn the control switch to ICE and check for proper control voltage If the red LED is on the control voltage is good If the red LED is off check the control transformer circuit 3 Check the 115 volt input at the 10 pin c
39. izes and runs for the last 50 seconds of harvest 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 3 Freeze Cycle LED 1 is on Comp and PM continue to run FMS energizes HGV closes water valve relay de energizes and HWV closes and the freeze cycle starts For the first 5 minutes the control board will not accept a signal from LF S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes LF S assumes control As ice builds on the evaporator the water level in the sump lowers and UF S opens 15 seconds after UF S opens FWV opens LED 4 is on when FWV is open and allows water in After UF S closes again FWV closes 3 seconds later This continues until the tank has refilled the number of times determined by the refill counter S5 dip switch is factory set do not adjust The KM 255BAH and KM 255BWH refill 10 times After the final refill the freeze continues until LF S opens and terminates the freeze cycle Note After the first freeze following startup and every 10th cycle thereafter LEDs 1 3 and 2 come on between freeze and harvest Comp continues to run HGV opens and FMS de energizes PM stops for 2 seconds PM restarts and runs for 10 seconds 4 Normal Harvest Cycle LEDs 1 4 and 2 are on Comp continues to run HGV opens water valve relay energizes and HWV opens As the evaporator warms the
40. leaking by for two cycles in a row TXV not feeding properly low charge or Low Voltage Red LED will turn off if voltage protection 92Vac 5 or less operates High Voltage The control voltage safeties automatically 147Vac 5 or more reset when voltage is corrected Legend Comp compressor FMS self contained fan motor FWV freeze water valve HGV hot gas valve HWV harvest water valve PM pump motor TXV thermostatic expansion valve WRV water regulating valve 15 3 Controls and Adjustments a Default Dip Switch Settings The dip switches are factory adjusted to the following positions Bip SwichNo 4 BpSwenve 23 a Ps S5 do not adjust Float switch control and refill counter Do not adjust b Harvest Control Thermistor A thermistor semiconductor is used for a harvest control sensor The resistance varies depending on the suction line temperatures The thermistor detects the temperature of the evaporator outlet to start the harvest timer No adjustment is required If necessary check for resistance between thermistor leads and visually check the thermistor mounting located on the suction line next to the evaporator outlet Temperature F Temperature C Resistance kO 14 401 10 613 6 000 2 474 1 633 Check a thermistor for resistance by using the following procedure 1 3 871 1 Disconnect the connector K3 on the board
41. made available to the technician prior to service or maintenance CONTENTS Bet e 5 A leemaker a a 5 UM KM 255BAH 2 2 AM 2506 V Waller COGIOG PME 6 IL General Inforti amp llODi cca ccsecux ecran iran Ra qua a q ege aha ai 7 A A OMS UIC HOM fM IN aa a 7 UM KM 255BA Tee MC b ay d aaz ad 7 2 KM 255BWH Wale r COGIOO Mm 8 B Sequence of Operation MENOS 9 1 6811 Minute Fill ee aa aa 9 2 lnitial Harvest Eegenen eegene 9 5 0 OOM TO m 9 4 Normal Harvest Cycle P 9 12 TOME OA Ay GUN PME CC Ec 13 2 Feats TT bad a 14 a Maximum Water Supply Period 6 minutes ll 14 b Harvest Backup Timer and Freezefmer nnna 14 c High Temperature Safety euntes R ne Urn 14 da Low Water E 14 e High Voltage and Low Voltage Cut outs 14 f LED Lights and Audible Alarm Gatetes AEN 15 3 Controls and Adjustments oe reacted a Yayma anladan 16 a Default Dip Switch Settings scs daaa aaa aynada m dada 16 b Harvest Control Thermistor R R R R sir 16 c Harvest Timer S4 dip switch 1 d d 17 d S4 dip switch 3 4 5 6 tuae pasara RU SUE Ud 17 e Freeze Timer S4 dip switch 9 amp 10 17 f Float
42. n 5 Plug the unit back in then place the control switch in the ICE position The red LED should come on 20 Ill Technical Information A Water Circuit and Refrigeration Circuit 1 KM 255BAH air cooled Harvest ge Water ater Valve S pray Tube Supply Wash Valve Condenser Access m GER igh Pressure je 271 Switch Ip E e j d j Freeze Evaporator Water Drier Valve Thermistor Insulation Tube 8 2 Strainer j Hot Gas Pump Valve Motor Float Switch Refrigerant Circuit r Expansion Valve VVater Circuit 21 2 KM 255BWH water cooled Water Regulating Valve Harvest Condenser Access Valve Water Drain 7 Valve Spray Tube Ki upp y Wash Valve Water de Supply iP d IH mM e 11 S sini Freeze Evaporator High Pressure J D Water j ner Switch Valve j Thermistor Insulation Tube j 7 Strainer j J Hot Gas Pump Valve Motor Float Switch Refrigerant Circuit MM Expansion Valve Vater Circuit 22 iagram D iring B W 1 KM 255BAH air cooled 1300 Q31002 Buuiw y Ul AOQE UMOUS SI l 1S Mau pue eJeu UMOUS SI l 1S Jop 9002 Buunp peBueuo oouejeedde 101061400 515 OLIVIN
43. n or cut the thermistor leads when installing it 1 Unplug the unit from the electrical outlet 3 4 Remove the plastic cable ties foam insulation thermistor holder and thermistor Disconnect the thermistor leads from the K3 connector on the control board 2 Remove the panels Thermistor Lead Cable Tie 2 El 5 Scrape avvay the old sealant on the A ZZ ZZ 5 thermistor holder and the suction pipe El g z x fes m dz zz ea SS 6 Wipe off moisture or condensation on the suction pipe NY 7 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder Foam Insulation Thermistor Holder concave 8 Attach the new thermistor to the suction pipe very carefully to prevent damage to the leads Secure it using the thermistor holder and recommended foam insulation 9 Secure the insulation using plastic cable ties 43 10 Connect the thermistor leads to the K3 connector on the control board Note Do not cut the leads of the thermistor while installing it 11 Replace the panels in their correct positions 12 Plug the unit back in M Removal and Replacement of Fan Motor Note When replacing a fan motor with defective winding it is recommended that a new capacitor be installed 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 Remove the screws securing the electrical box located over the compressor then
44. nding opened 2 Replace e Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature f Control Board 1 No power to contactor 1 See II C 6 Control Board Check Procedure 4 Water continues to be a Harvest Water Valve 1 Diaphragm does not 1 Check for water leaks with supplied by harvest close icemaker off water valve in freeze b water Valve Relay 1 Contacts stuck 1 Replace le 57 c Control Board 1 Defective 1 See 1 6 Control Board Check Procedure 5 No water comes from a Water Supply Line 1 Water pressure too 1 Check and get spray tubes Water low and water level in recommended pressure pump will not start or water tank too low freeze cycle time is p Water Valves 1 Dirty mesh filter or 1 Clean too short orifice and water level in water tank too low c Water System 1 Water leaks 1 Check connections for water leaks and replace 2 Clogged d Pump Motor 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 30 Possible Cause 5 No water comes from 4 Defective capacitor 14 Replace spray tubes Water 5 Defective or bound 5 Replace and clean pump will not start or impeller freeze cycle time is too RA continued e Control Board 1 Defective 1 See II C
45. nt of Wash Valve 1 Unplug the unit from the electrical outlet 2 Close the water supply line shut off valve 3 4 5 Disconnect the hoses and the terminals Remove the top panel and the insulation panel Remove the screws securing the valve to the bracket 6 Note the orientation of the rubber grommet then remove the rubber grommet and the valve 7 Put the rubber grommet on the new valve and then install the valve 8 9 Replace the removed parts in the reverse order of which they were removed Open the water supply line shut off valve 10 Plug the unit back in 11 Check for leaks 12 Replace the panels in their correct positions P Removal and Replacement of Pump Motor 1 Unplug the unit from the electrical outlet 2 3 4 Remove the water tank by pressing down on the snaps on Bracket L and Bracket R and pulling the tank towards you Remove the top panel and the insulation panel Disconnect the pump suction and discharge hoses 5 Remove the drain pan assembly from Bracket R by pulling it towards you It is snapped in place 6 Disconnect the ground wire from the frame and disconnect the pump viring at the connector Drain Pan 7 Push up on the plastic tab securing the vvater pump and slide the pump forvvard to Drain Tube remove it Frame Pipe 8 Install the new pump then replace the removed parts in the reverse order of which they were remove
46. ntrol board proceeds to the next cycle If the lower float switch is open the control board calls for a one minute water fill cycle After one minute the control board checks the position of the float and either proceeds to the next cycle if the lower float switch is closed or calls for an additional one minute fill if the switch is open This serves as a low water safety to protect the water pump For water cooled model if the water is shut off the unit is also protected by the high pressure switch e High Voltage and Low Voltage Cut outs High voltage and low voltage cut outs help protect the icemaker from supply voltages outside of the accepted range If miswiring causes excessive voltage 147Vac 5 or more for 3 seconds on the control board the high voltage cut out shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 7 beeps every 3 seconds The icemaker also automatically stops in cases of insufficient voltage 92Vac 5 or less The control board will signal this problem using 6 beeps every 3 seconds When the proper supply voltage is resumed the icemaker automatically starts running again 14 f LED Lights and Audible Alarm Safeties The red LED indicates control voltage 10 to 12V at K2 and will remain on unless a control voltage problem occurs At startup a 5 second delay occurs while the board conducts an internal timer check A beep occurs when the control switch is moved
47. ntrol switch in the ICE position The red LED on the control board comes on A 5 second delay occurs 3 One Minute Fill Cycle LED 4 is on The freeze water valve is energized After 1 minute the control board checks for a closed lower float switch If the lower float switch is closed the harvest cycle begins If closed continue to step 4 If the lower float switch is open the freeze water valve will remain energized through additional 1 minute fill cycles until water enters the sump and the lower float switch closes low water safety protection during initial start up and at the end of each harvest Diagnosis If the freeze 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 lower float switch or bad 1 minute timer in board 4 Initial Harvest Cycle LEDs 1 4 and 2 are on The freeze water valve de energizes and the hot gas valve energizes also energizing the water valve relay the harvest water valve energizes and the contactor coil energizes to start the compressor The evaporator warms and the thermistor senses 48 F 9 C The control board then receives the thermistor s 3 9 kO signal and turns operation of harvest over to the harvest timer The timer completes counting 1 to 3 minutes S4 dip switch 1 amp 2 The unit then cycles to freeze The harvest water valve is open during harvest for
48. onnector Check the brown and white wire at pin 410 to a white neutral wire for 115 volts Always choose a white neutral wire to establish a good neutral connection when checking voltages A jumper also feeds 115 volts into pin 7 If no voltage is present check the 115 volt supply circuit 4 The output test switch provides a relay sequence test Make sure the control switch is in the ICE position then press the output test switch The correct lighting sequence should be none 2 3 4 1 and 4 normal sequence every 5 seconds Components e g the compressor will cycle during the test Note that the order of the relays from the outer edge of the board is 1 4 3 2 Note If the LEDs light in a different sequence or the 5 second interval does not occur the control board is bad and should be replaced 5 After checking the sequence the unit automatically resumes normal operation after the test The unit begins normal operation with the 1 minute fill cycle 19 7 Control Board Replacement 1 Unplug the unit from the electrical outlet and disconnect the wiring to the board 2 Install the new board and make the wiring connections 3 Set the application switch located between relays X3 amp X4 to the ALP position If this switch is placed in the wrong position the unit will not start 4 Adjust the dip switches to the factory default settings See II C 3 a Default Dip Switch Settings S4 dip switch 8 must remain in the OFF positio
49. or possible solutions The freeze timer is factory adjusted and no adjustment is required Time minutes Lor or em ON ON 60 f Float Switch Control and Refill Counter S5 dip switch 1 through 5 These must be left in the factory default position or the unit will not operate properly Do not adjust The KM 255BAH and KM 255BWH refill 10 times Note There are no refills during the first 5 minutes of the freeze cycle The first refill generally lasts about 10 seconds and subsequent refills generally last about 5 seconds 17 g Bin Control This machine uses a lever actuated proximity switch mechanical bin control to control the ice level in the storage bin No adjustment is required 1 Explanation of Operation The bin control is connected to the K4 connector on the control board When the bin control is calling for ice proximity switch closed green LED BC CLOSED on the control board continues icemaking operations When the bin control is activated in the bin full position proximity switch open yellow LED BC OPEN on the control board shuts down the unit However to prevent incomplete batches of ice from forming on the evaporator the control board will only shut down the machine within the first 5 minutes of the freeze cycle If ice pushes the lever in after the first five minutes of the freeze cycle the control board will allow the machine to complete the freeze cycle and the following harvest cycle before
50. s not 1 Check for water leaks with close icemaker off c Control Board 1 Defective 1 See CG Control Board Check Procedure Dal ice formed on 1 Scaled up evaporator does not p water Supply Line 1 Water pressure too 1 Check and get fall into bin in harvest low recommended pressure cycle Water Filter System 1 Dirty Restricted 1 Replace filter d Water Valves 1 Dirty mesh filter or 1 Clean orifice 2 Diaphragm does not 2 Check for water leaks with close icemaker off e Ambient and or water 11 Too cool 1 Increase temperature temperature f Thermistor 1 Out of position or 1 See V L Removal loose attachment and Replacement of Thermistor g Control Board 1 Harvest timer is set 1 Adjust longer referring too short to II C 3 Controls and Adjustments c Harvest Timer 2 Defective 2 See II C 6 Control Board Check Procedure 3 Other a Spray Tubes 1 Clogged 2 Out of position 2 Place in position b Water System 1 Dirty c Refrigerant 1 Undercharged 1 Check for leaks and recharge d Expansion Valve 1 Bulb out of position or 1 Place in position loose attachment 2 Replace e Hot Gas Valve 1 Coil winding opened 11 Replace 2 Plunger does not 2 Replace move 3 Wiring to hot gas 3 Check for loose valve connection or open and replace f Ice Cube Guides 1 Out of position and ice 1 Place in position trapped 32 Possible Cause
51. scard the cleaning solution and rinse the parts thoroughly with water 48 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute approximately 0 5 fl oz 15 ml or 1 tbs of a 5 25 sodium hypochlorite solution chlorine bleach with 1 gallon 3 8 1 of warm water Using a chlorine test strip or other method confirm that you have a concentration of about 200 ppm 2 Soak the removed parts from step 25 above in a clean container containing the sanitizing solution After allowing the parts to soak for 10 minutes wash them with the solution Also wash the bin liner Bracket L and Bracket R with the solution 3 Discard the sanitizing solution and rinse the parts thoroughly with water 4 Replace the removed parts in their correct positions in the reverse order of which they were removed Put the float switch wiring tubing in the slot to the right of the water tank latch before putting the water tank in place 5 Dilute approximately 0 5 fl oz 15 ml or 1 tbs of a 5 25 sodium hypochlorite solution chlorine bleach with 1 gallon 3 8 1 of warm water Using a chlorine test strip or other method confirm that you have a concentration of about 200 ppm 6 Pour the sanitizing solution into the water tank and allow the sanitizer to sit for 10 minutes 7 Move the control switch to the WASH position 8 Close the door 9 After 15 minutes move the control switch to the OFF position 10 Open the door 11 Disconnec
52. slide out the box 4 Remove the screws securing the compressor base and the condenser Carefully slide the refrigeration assembly forward 5 Remove the closed end connectors from the fan motor leads 7 8 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 6 Remove the fan motor bracket and fan motor Remove the fan blade from the old fan motor and attach it to the new fan motor 9 Replace the panels in their correct positions 10 Plug the unit back in N Removal and Replacement of Freeze or Harvest Water Valve 1 Unplug the unit from the electrical outlet 2 Close the water supply line shut off valve 7 3 Remove the top panel and the insulation Valve panel 4 Remove the thumbscrevvs and bracket securing the valve mounting bracket and the plastic water pan 5 Loosen the fitting nuts Be careful not to lose the washers Freeze 6 Disconnect the hoses and the terminals Water then remove the valve mounting bracket Valve from the unit 7 Install the new water valve and replace the removed parts in the reverse order of which they were removed Make sure the washers are in place in the fitting nuts 8 9 0 1 Open the water supply line shut off valve Plug the unit back in Check for leaks 1 11 Replace the panels in their correct positions 44 O Removal and Replaceme
53. t the suction hose to drain the water Reconnect the suction hose back in its correct position after all of the water has drained Repeat steps 5 through 11 one time Repeat steps 12 through 15 in the Cleaning Procedure three times to rinse thoroughly Flush the storage bin with water 12 13 14 15 Move the control switch to the ICE position and start the automatic icemaking process 16 Close the door 17 Replace the front panel in its correct position B Maintenance 1 Exterior Panels To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before removing ice Use the plastic scoop provided Accessory The storage bin is for ice use only Do not 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 49 3 Air Filter air cooled model only The plastic mesh air filter removes dirt and dust from the air and keeps the condenser from getting clogged As the filter gets clogged the icemaker s performance will be reduced Check the filter at least twice a month When it is clogged use warm water and a neutral cleaner to wash the filter 4 Condenser air cooled model only Check the condenser once a year and clean if required by using a
54. the strainer Place the new valve and new strainer in position 10 Braze all fittings 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 11 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 12 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 13 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 14 Connect the new solenoid leads 15 Attach the solenoid to the valve body and secure it with a screw 16 Replace the removed parts in the reverse order of which they were removed On water cooled models open the water supply line shut off valve and check for leaks Replace the panels in their correct positions 17 Plug the unit back in 39 G Removal and Replacement of Evaporator IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repairs or replacement have been made 1 Unplug the unit from the electrical outlet 2 Close the water supply line shut off valve 3 4 5 Disconnect all affected water hoses and remove the spray tube Remove the panels Recover the refrigerant and store it in an approved container
55. the system and charge it with refrigerant See the nameplate for the required refrigerant charge 8 Replace the panels in their correct positions Plug th it back in 9 Plug the unit back in 37 E Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration circuit exceeds the drier capacity and freezes up at the expansion valve Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the unit from the electrical outlet 2 Remove the panels 3 Recover the refrigerant 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 then remove the expansion valve Place the new expansion valve in position 6 Remove the drier located below the expansion valve then place the new drier in position 7 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 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 250 F 121 C 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 10 Attach the expansion valve bulb to the su
56. to the ICE position The green LEDs 1 through 4 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 1 4 3 2 For more information see II B Sequence of Operation Sequence Ste LED 277 17 i Components 1 Minute Fill Cycle 4 FWV 60 Seconds Harvest Cycle 1 4and2 HWV HGV 2 minutes 20 minutes 13 to 5 minutes Last 50 seconds of harvest HWV de energizes and PM energizes LEDs 1 3 and 2 are on Freeze Cycle 1 and 4 at After the first freeze following startup and every 10th cycle thereafter Comp HGV and PM are energized for 10 seconds between freeze and harvest LEDs 1 3 and 2 are on The built in safeties shut down the unit and have alarms as listed below No of Beeps High Evaporator Temp Check for harvest problem stuck HGV or temperature gt 127 F relay hot water entering unit or shorted 53 C thermistor 2 Harvest Backup Timer Check for open thermistor HGV not harvest gt 20 min for two opening TXV leaking by low charge cycles in a row inefficient Comp or WRV leaking by water cooled model only Timer is factory set using linefficient compressor S4 dip switch 9 amp 10 To manually reset the above safeties press the alarm reset button with the power supply on 1 3 Freeze Timer Check for a float switch stuck closed up freeze gt specified setting HWV or FWV leaking by HGV
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