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Hoshizaki KM-501MWH User's Manual

1. 30 2 KM 501MWH water cooled APPROXIMATE ICE PRODUCTION PER 24 HR WATER TEMP F C 115 120 60 1 50 10 70 21 90 32 70 21 80 27 90 32 bs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 vvatts 100 38 APPROXIMATE VVATER 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 90 32 PSIG kg em G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg em G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 6 800 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 1 400 BTU h AT 90 F 32 C WT 70 F 21 C WATER FLOW FOR CONDENSER 52 gal h AT 100 F 38 C WT 90 F 32 C PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG 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 31 3 KM 501MRH remote air cooled APPROXIMATE ICE AMBIENT TEMP PR d CFPC 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m lday 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 1
2. b Spray Guide c Water Quality 1 High hardness or 1 Install a water softener or contains impurities filter 5 Other Possible Cause 1 lcemaker will not stop a Bin Control Thermostat 1 Set too cold 1 Adjust warmer when bin is filled with E ice 2 Defective 2 Replace 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 12 Replace fan blade 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 39 Possible Cause 2 Mounting pad out of 12 Reinstall position d Refrigerant Lines i i 1 Rub or touch other 1 Replace lines or surfaces 3 Ice in storage bin a Drain Line s 1 Plugged often melts b Icemaker and Bin 1 Drains not run 1 Separate the drain lines separately c Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin 40 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 filter drier every time the sealed refrigeration system is opened 3 Do not leav
3. c Harvest Timer 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 However a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning 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 Tine seconds Lor or e ow or o d Pump Out Timer dip switch 3 amp 4 When a freeze cycle is completed the pump motor stops and the icemaker resumes operation in 2 seconds Then during cycles when a pump out is called for the pump motor drains the water tank for the time determined by the pump out timer The pump out timer also acts in place of the harvest timer during cycles with a pump out The pump out timer is factory adjusted and no adjustment is required T1 Time to drain the water tank T2 Harvest timer at pump out Pump out always occurs on the 2nd harvest after startup Then depending on the pump out frequency control setting dip switch 5 amp 6 pump out occurs every cycle or every 2nd 5th or 10th cycle 20 e Pump Out Frequency Control dip switch 5 amp 6 The pump motor drains the water tan
4. 12 Braze the process suction and discharge lines do not change this order while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 13 Install the new drier 14 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 15 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 models see the charge label in the machine compartment 16 Connect the terminals and replace the terminal cover in its correct position 17 Replace the panels in their correct positions 18 Turn on the power supply 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 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the drier 5 Install the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 3 to 4 PSIG when brazing the tubings 6 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 7 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 models see the charge label in the mach
5. B DDD E 42 C Removal and Replacement of Compressor 8888888888 8l 42 D Removal and Replacement of Der 43 E Removal and Replacement of Expansion Valve 44 F Removal and Replacement of Hot Gas Valve and Line Valve 2222 44 G Removal and Replacement of 45 H Removal and Replacement of Water Regulating Valve Water Cooled Model Only 46 Adjustment of Water Regulating Valve Water Cooled Model Only 46 J Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air Cooled Model Only rrenan 47 K Removal and Replacement of Thermistor 48 L Removal and Replacement of Fan Motor 49 M Removal and Replacement of Inlet Water Valve 49 N Removal and Replacement of Pump Motor 49 O Removal and Replacement of Spray Tubes 50 VI Cleaning and Maintenance Instructions ee 51 A Cleaning and Sanitizing Procecdures en 51 1 Cleaning Gr iere ace PR RR D 52 2 Sanitizing Procedure Following Cleaning Procedure 53 C LT mni 53 C Preparing the Icemaker for Long Storage ana 54 I Specifications A Icemaker 1 KM 501MAH air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day k
6. connection or open and replace f Ice Cube Guide 1 Out of position and icel 1 Place in position trapped Possible Cause 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 inlet water valve and control board c Check pump hot gas valve headmaster C P R remote air cooled model expansion valve refrigeration check valve and compressor 2 Harvest cycle time is a See chart 2 2 and check control board thermistor evaporator ambient and or water temperature water supply line inlet water valve line valve and gas valve 4 Abnormal Ice Possible Cause 1 Small cubes a Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board 2 Cloudy or irregular a See chart 2 1 and 2 3 and check float switch inlet water valve control cubes board spray tubes water system refrigerant charge and expansion valve
7. the control board changes to the ice making cycle The unit will not start without adequate water in the sump This serves as a low water safety to protect the pump motor from mechanical seal failure For water cooled model if the water is shut off the unit is protected by the high pressure switch e High Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut outs If miswiring especially on single phase 3 wire models causes excessive voltage 147Vac 5 or more on the control board the high voltage cut out shuts down the circuit in 3 seconds 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 17 f LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage 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 short beep occurs when the power switch is turned OFF 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 th
8. with ice 2 Ambient temperature 2 Increase ambient too cool temperature 3 Set too warm 3 See II C 3 Controls and Adjustments g Bin Control 4 Bulb out of position 14 Place in position 5 Bad contacts 5 Check for continuity and replace e High Pressure Control 11 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or 2 Clean condenser 34 3 Ambient or condenser 3 Reduce temperature water temperature too warm 4 Refrigerant 4 Recharge overcharged 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 off recommended pressure water cooled model only f Transformer 1 Coil winding opened 11 Replace or shorted g Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace h Thermistor i Hot Gas Valve j Water Supply Line k Inlet Water Valve 1 See II C 3 Controls and Adjustments b Harvest Control 1 Leads shorted or opened and high temperature or harvest backup timer safety operates 1 beep or 2 beep alarm 1 Continues to open in freeze cycle and freeze timer safety operates 3 beep alarm 1 Check for hot gas valve stuck open and replace 1 Water supply off and water supply cycle does not finish 1 Check and get recommended pressure
9. 10 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 11 Connect the new solenoid leads 12 Attach the solenoid to the valve body and secure it with a screw 13 Replace the panels in their correct positions 14 Turn on the power supply 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 2 3 4 Turn off the power supply Remove the panels and the top insulation over the evaporator Recover the refrigerant and store it in an approved container Remove the spray tubes and the insulations at the U shaped notch where the refrigeration tubings go through the molded chassis 5 Remove the insulation tube and disconnect the evaporator inlet tubing at the tee next to the expansion valve Lift up the evaporator and disconnect the evaporator outlet tubing 6 7 8 9 Install the new evaporator Install the new drier Check for leaks using nitrogen gas Ue PSIG and soap bubbles 5 10 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 models see the charge label in the machine compartment 11 Replace the removed parts in the reverse order of
10. Condenser Water Valve High Pressure ETT r Switch Water Suv vie d Evaporator AL j 11 Thermistor f j Insulation j Strainer Be ES Hot Gas Suction Valve Line 1 Access Valve ischarge Line Compressor Access Valve Expansion Valve Refrigerant Circuit Drain Valve m Water Circuit 23 2 KM 501MWH water cooled Water Regulating Condenser Valve Spray Tubes Water Valve b ali Drain o Water Water J j Suy vi AL d Evaporator 7 d Switch Thermistor Drier Cleaning Insulation z Valve j Strainer d Hot Gas Valve mm ischarge Line Compressor Freeze Pump Out 7 Drain Access Valve Expansion Valve Refrigerant Circuit Drain Valve mm Water Circuit 24 3 KM 501MRH remote air cooled Condenser Unit Condensing Pressure Regulator Spray Tubes High Pressure Switch Water Valve N ZN Water Seer f ajom B Evaporator Receiver Tank Access Valve Fusible Plu Thermistor g Drier Insulation Cleaning Valve Line Valve Strainer EE d Hot Gas Bypass Valve 1 Discharge Line Compressor Access Valve Expansion Valve
11. check for leaks 14 Replace the base cover in its correct position 15 Replace the front panel in its correct position O Removal and Replacement of Spray Tubes 1 2 3 4 5 6 Turn off the power supply Remove the front panel and the insulation panel Remove the rubber hoses from the spray tubes water supply pipe Release the clamps and disconnect the rubber hoses Remove the spray tubes by squeezing the side tabs wa Ta a Install the new spray tubes and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply 50 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 and Sanitizing Procedures WARNING HOSHIZAKI recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin IMPORTANT The cleaning valve is used to allow solution flow to the inside of the evaporator during the cleaning and sanitizing operations It should be closed for all icemaking operation The co
12. compressed air or carbon dioxide supply to the potable water line drain valve Move the control switch to the ICE position No Blow the potable water line out using compressed air or carbon dioxide 3 Drain the potable water tank 1 Turn off the power supply 2 Move the control switch to the OFF position 3 Drain the water tank by removing the base cover and one end of the pump tubing See Fig 5 4 Replace the pump tubing and the base cover in their correct positions Do not pull out this side Pump Tubing 5 Remove all ice from the storage bin and clean the storage bin Fig 5 6 Replace the front panel in its correct position 7 Close the drain valve 55
13. damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed 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 1 On water cooled model only first remove the water from the water cooled condenser 1 Remove the front panel 2 Move the control switch on the control box to the OFF position 3 Wait 3 minutes 4 Move the control switch to the ICE position 5 Allow 5 minutes for the icemaker to fill with water and the water pump to start operating 6 Close the water cooled condenser water supply line shut off valve 7 Open the drain valve for the water cooled condenser water supply line 8 Allow the line to drain by gravity 9 Attach compressed air or carbon dioxide supply to the condenser water line drain valve 10 Quickly blow the water cooled condenser out using compressed air or carbon dioxide until water stops coming out 54 2 Remove the water from the potable water supply line 1 Remove the front panel except water cooled model 2 Move the control switch on the control box to the OFF position 3 Wait 3 minutes 4 Close the potable water supply line shut off valve and open the potable water supply line drain valve 5 6 7 8 Allow the line to drain by gravity Attach
14. hot gas valve energizes the fan motor de energizes the pump motor stops for 2 seconds and starts in reverse rotation for 10 20 seconds This removes contaminants from the water reservoir through the check valve drain valve and down the drain and allows for a power flush of the float switch Check for clear tubing at the check valve housing and check the unit drain for water flow Diagnosis If the pump motor does not reverse check the circuit and capacitor If water does not pump out remove the check valve drain valve housing and check clean the valve assembly 7 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 pump out cycle can be adjusted to occur every cycle or every 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle B Diagnostic Charts 1 No Ice Production 1 The icemaker will not a Power Supply 1 OFF position 1 Move to ON position 3 Bad contacts 3 Check for continuity and replace 4 Voltage too high or too 4 Check and get low recommended voltage b Fuse Inside fused 1 Blown 1 Check for short circuit and disconnect if any replace c Control Switch 1 OFF position 1 Move to ICE position 2 Bad contacts 2 Check for continuity and replace d Bin Control Thermostat 1 Tripped with bin filled 1 Remove ice
15. it hot If it is hot and the freeze cycle is not starting check the harvest timer adjustment the thermistor for open circuit the discharge line temperature compressor efficiency and if the hot gas valve is fully open 5 Freeze Cycle compressor remains energized pump motor line valve on remote condenser unit and fan motor energize The inlet water valve and hot gas valve de energize 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 float switch for freeze termination During the first 5 minutes of freeze confirm that the evaporator temperature drops After 7 minutes in freeze remove the black float switch lead from the K5 connector The unit should immediately switch to the pump out cycle 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 water valve is continuing to fill the reservoir if there are improper unit pressures an inoperative compressor or an inoperative headmaster C P R remote condenser unit only If the unit remains in 33 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 Pump Out Cycle 10 20 second pump out the compressor remains energized the
16. kg 480 pcs N A 90 70 F 70 50 F 1080 5 3 1070 5 2 101 20 8 177 35 6 670 137 390 78 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe Pressure Regulator Thermostat Hermetic Model AKA9455ZXA Water cooled Tube in tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 15 oz 4259 High 427PSIG Lovv 210PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin 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 3 KM 501MRH remote air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION 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 Ibs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE
17. 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 4 Control Board Check Procedure 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 11 Check and replace freeze cycle d Line Valve 1 Continues to close in 1 Check and replace freeze cycle e Inlet Water Valve 1 Water valve is wide 1 Check for water leaks with open during freeze icemaker off f Headmaster C P R 11 Not operating properly 1 Replace headmaster Remote Unit and liquid line temperature too warm 7 All components a Refrigerant 1 Undercharged 1 Check for leaks and run but no ice is recharge g 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 h Water Regulator 1 Set too high 1 Adjust or replace See water cooled model V I Adjustment of Water only Regulating Valve 37 2 Evaporator is Frozen Up Possible Cause 1 Freeze cycle time is a Float Switch 1 Leads short circuit or 1 Check and replace too long defective switch 2 Float does not move 2 Clean or replace freely b Inlet Wat
18. water valve is energized After 1 minute the control board checks the float switch If the float switch is closed the unit cycles to harvest If closed continue to step 4 If the float switch is open the unit repeats the 1 minute fill cycle until 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 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 board 4 Initial Harvest Cycle Inlet water valve remains energized contactor coil energizes to start the compressor and fan motor on a remote condenser unit and the hot gas valve energizes The evaporator warms and the thermistor senses 48 F 9 C The control board then receives the thermistor s 3 9 kQ signal and turns operation of harvest over to the harvest timer The timer completes counting 1 to 3 minutes The unit then cycles to freeze Diagnosis Check if compressor is running hot gas valve is open water valve still open Average harvest cycle at factory setting is 2 to 3 minutes How long does initial harvest last 1 5 minutes after initial harvest begins touch the compressor discharge line Is it hot If not check refrigerant pressures and compressor operation If it is hot touch the inlet line to the evaporator Is
19. which they were removed 12 Replace the top insulation and the panels in their correct positions 13 Turn on the power supply H 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 Turn off the power supply 2 Close the water supply line shut off valve 3 Remove the panels 4 Recover the refrigerant and store it in an approved container 5 Disconnect the capillary tube at the condenser outlet using brazing equipment 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 shut off valve 12 13 14 Check for water leaks 15 Replace the panels in their correct positions 16 Turn on the power supply 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 follo
20. 0 oz 735g High 467PSIG Lovv 210PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin 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 501MWH water cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION 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 KVVH 100 lbs WATER gal 24HR gal 100 Ibs WATER COOLED CONDENSER 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 10 A 5 Min Freeze AT 104 F WT 80 F 20A WATER TEMP F Ey 50 70 o 498 226 495 224 465 211 Crescent Cube 9 5 Ibs 4 3
21. 00 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg em G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 8000 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 1500 BTU h AT 90 F 32 C WT 70 F 21 C CONDENSER VOLUME 74 5 CU IN URC 6F 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 32 IV Service Diagnosis A 10 Minute KM 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 Turn power OFF and access the control box 2 Turn power ON and place the control switch in ICE position A 5 second delay occurs 3 One Minute Fill Cycle The inlet
22. 2 Condenser water pressure too low or off and pressure control opens and closes frequently to finally operate high temperature safety 1 beep alarm 2 Check and get recommended pressure 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 11 See II C 4 Control Board Check Procedure 2 Water continues to be supplied and the icemaker will not start 3 Compressor will not start or stops operating 4 Water continues to be supplied in freeze cycle 5 No water comes from spray tubes Water pump will not start or freeze cycle time is too short Cleaning Valve 2 Bad contacts 2 Check for continuity and replace n Wash Switch 1 WASH position 1 Move to ICE position 2 Check and replace a Float Switch 1 Connector 1 Place in position disconnected 2 Leads opened or 2 Check and replace defective switch 3 Float does not move 13 Clean or replace freely b Control Board 1 Replace a Magnetic Contactor 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 12 Replace b Start Capacitor or Run 1 Defective 1 Replace Capacitor c Internal Overload 1 Loose terminal 1 Tighten or replace Protector Open check 1 through 3 to the right 2 Vo
23. 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 15 A 5 Min Freeze AT 104 F WT 80 F LB 100 Crescent Cube 9 5 lbs 4 3 kg 480 pcs N A 90 70 F 70 50 F 1260 6 6 1220 6 1 90 19 6 182 37 8 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model AKA9455ZXA Air cooled Remote Condenser Unit URC 6F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on URC 6F R 404A 4 165 oz 18009 Icemaker 2 Ibs 1 5 oz Cond Unit 1 Ib 14 oz High 467 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin Remote Condenser Unit VOLTAGE RANGE 104 127V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserv
24. Control Box 2 KM 501MWH water cooled Water Supply Inlet Spray Tubes Water Regulator Hot Gas Valve Drier Control Box Control Switch Expansion Valve Compressor Float Switch Water Pump 11 3 KM 501MRH remote air cooled Spray Tubes Water Supply Inlet Control Switch Junction Box Bin Control Thermostat Expansion Valve Receiver Tank Compressor Float Switch Drier Water Pump Hot Gas Valve Line Valve Control Box B Sequence of Operation The steps in the sequence are as outlined below When power is supplied a 5 second delay occurs at startup Note that the order of the LEDs from the outer edge of the board is 1 4 3 2 1 One Minute Fill Cycle LED 4 is on WV opens and the fill period begins After 1 minute the board checks for a closed F S If F S is closed the harvest cycle begins If not WV will remain energized through additional 1 minute cycles until water enters the sump and F 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 WV remains open Comp and FMR energize HGV opens and harvest begins As the evaporator warms the thermistor located on the suction line checks for a 48 F 9 C temperature When 48 F 9 C is reached a 3 9 kQ signal turns the harvest over to the adjustable har
25. Hoshizaki America Inc Modular Crescent Cuber Models KM 501MAH KM 50 MWH KM 50 IMRH SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com nne evercheck Number 73137 Issued 10 16 2006 Revised 3 27 2007 IMPORTANT Only qualified service technicians should attempt to service or maintain this icemaker No such 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 or write 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 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 made available to the tech
26. Refrigerant Circuit Drain Valve n n Water Circuit 25 B Wiring Diagrams 1 KM 501 MAH air cooled and KM 501MWH water cooled BIN CONTROL THERMISTOR E 1 B 115 120 60 1 Ls WIRE COLOR CODE BROWN STARTER START CAP 72 86MFD ONLY AIR COOLED MODEL AirCooled Model Water Cooled Model 26 2 KM 501MRH remote air cooled ilir R ES P HOTGAS VALVE R REMOTE CONDENSER UNIT Pressure Switch 4122 PSIG 327421 PSIG 27 C Timing Chart When control switch is turned OFF pressure switch is OFF or thermistor temperature exceeds t1 porem Q Float Switch o a Congresso DE orrL Crankcase Heater Remote Only OF Icemakin Pump Motor Thermistor Temperature N N da a Fan Motor ON amp Line Valve a N N Fan Motor m Condenser o Water Valve 4 ON Hot Gas Valve Initial Stand by Water Supply Control Switch in ICE Bin Thermostat ON Pressure Switch ON Overheat Protect Reset If float switch is OFF E From harvest cycle To harvest cycle Too Low Temp Too Hi Temp Harvest Freeze N 7 uni passer freeze timer setting Led 1 The icemaker does not complete a harvest cycle in the first 2 or 3 minutes See II C 3 Controls and Adjustments 28 To stand by cycle When control sw
27. Z JO Daum uones do s nunuo YIN 9 6 4 87 seuoeoi 2 ASH sdo1s 1010uJ duing z z i s nunuo duos duer Jojsiu49U 2 duos pezibisu3 AM S d Aejap puooes g NEY II pJeog 3 paso 4 n solo Si a o11uoo Ul L 101 U09 JOW ejnulul e 01 Ul JO SIUJ9U 14 4 suifeq skemje dnieis eniu joguoo 041009 ul 1 ul 9 4 Jeun g r l Bumes sown z i oun 92961 WNWIXeW sejnuiui OZ 1Se Jeu WNWIXEN r o 113 1no duing vl Sojnului G eut 2 WNWIUIN e 9 WI A PA 9 UI UJnUJIXe N e inuliy suo L wb ezooJ4 9 9249 1soAJeH Z sdeis 9 2949 uonejedo 3ueuoduio pue eyg Mo 4 eouenbes HHINLOS INX HAAN LOS INM HYN LOS INX C Control Board A HOSHIZAKI exclusive solid state control is employed in KM 501MAH KM 501MWH and KM 501MRH Modular Crescent Cubers All models are pretested and factory adjusted CAUTION Fragile handle very carefully Acontrol 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 chan
28. a Ax aya pub axsa 20 e Pump Out Frequency Control dip switch 5 amp 6 oot eontra iaa 21 f Freeze Timer dip switch 9 amp T0 E 21 sspe M 21 4 Control Board Check UNG ai aa nca pav ot La NS 22 5 Control Board KEE TN 22 Ili Technical Information sina ess aaa sanada Fen bez ntu 23 A Water Circuit and Refrigeration Coup 23 1 KM 501MAH BET E 23 2 KM 501 MWH water coole 24 3 KM 501MRH remote air cooled AAA 25 B Wiring RE lee rcs a deni geo Sd aca ea cqui 26 1 KM 501MAH air cooled and KM 501MWH water cooled 2222 26 2 KM 501MRH remote air cooled 27 iH H r NPR UNR PRN IE LM E 28 D Performance Data EE 30 1 KM 501MAH TalF COolod EE 30 2 KM 501MVVH water coole 31 3 KM 501MRH remote air cooled AAA 32 IV Service Diagnosis m N 33 A 10 Minute KM Diagnostic Procedure AAA 33 EE ee e EE 34 ha ee Te e RR ES 34 2 Evaporator is Frozen Up aaa ere A Used 38 3 Low lce Production E 39 KEESSIER 39 39 V Removal and Replacement of 45 41 A Service for Refrigerant Lines un 41 1 Refrigerant e E nn e eee eeeeeeeeeeeee sea saeeceeceeeeeeeeeeeaeeeeeeeeeeeenenenes 41 2 Evacuation and Recharge 404 22 41
29. ck 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 Turn on the power supply F Removal and Replacement of Hot Gas Valve and Line 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 44 1 2 3 4 5 6 Turn off the power supply Remove the panels Recover the refrigerant and store it in an approved container Remove the screw and the solenoid Disconnect the hot gas valve or line valve using brazing equipment wae 5 N nstall ihe nevv valve 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 7 Install the new drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 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 models see the charge label in the machine compartment
30. e board is 1 4 3 2 For more information see II B Sequence of Operation Energized Time LEDs are On Sequence Step LED C 9 omponenis 1 Minute Fill Cycle 4 ET EE Harvest posse A minutes to 5 minutes Comp FMR Freeze Comp PM 5 minutes timer to 35 minutes FMR FMS setting LLV PM FMR The built in safeties shut down the unit and have alarms as follows Ss 3 sec High Evaporator Temp temperature gt 127 F 53 C Harvest Backup Timer harvest gt 20 min for two cycles in a row Freeze Timer freeze gt specified setting for two cycles in a row Timer is factory set using dip switches 9 amp 10 Check for harvest problem stuck HGV or relay hot water entering unit stuck HM or shorted thermistor Orange LED marked H TIMER lights up Check for open thermistor HGV not opening TXV leaking by low charge or inefficient compressor Yellow LED marked F TIMER lights up Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge HM not bypassing or inefficient compressor To manually reset the above safeties press the alarm reset button with the power supply on Low Voltage 92Vac 5 or less High Voltage 147Vac 5 or more Red LED will turn off if voltage protection operates The control voltage safeties automatically reset when voltage is corrected Legend Comp compressor FMR remote fan motor FMS self contained
31. e the right to make changes in specifications and design without prior notice B Condensing Unit 1 URC 6F 24 610 mm 23 1 32 585 mm 19 11 16 6 16 x 3 4 10 mm x 20 mm 4 x 2 SLOTTED HOLES 500 mm m z E F o A o E BE BE E RE BE S as ue il 38 22 95 e m de Te y y 18 1 8 460 mm 20 15 32 520 mm 21 15 16 557 mm i co T N 7 8 DIA HOLE 23 mm DIA 1 H m gE i o 2 15 16 B og 20 75 mm 53 b 1 1 SPECIFICATIONS MODEL URC 6F EXTERIOR DIMENSIONS W x D x H REFRIGERANT CHARGE WEIGHT CONNECTIONS REFRIGERANT ELECTRICAL CONDENSER HEAD PRESSURE CONTROL AMBIENT CONDITION Galvanized Steel 21 15 16 x 15 11 16 x 17 7 8 557 x 398 x 453 8 mm R404A 1 Ib 2 oz 505 g Net 61 Ibs 28 kg Shipping 68 Ibs 31 kg One Shot Couplings Parker Permanent Connection Air cooled Condensing Pressure Regulator Min 20 F Max 122 F 29 C to 50 C Outdoor use Il General Information A Construction 1 KM 501MAH air cooled Spray Tubes Control Switch Bin Control Thermostat Expansion Valve Compressor Float Switch Water Pump Water Supply Inlet Condenser Hot Gas Valve Fan Motor Condenser Drier
32. e the system open for longer than 15 minutes when replacing or servicing paris A Service for Refrigerant Lines 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 access valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 Evacuation and Recharge R 404A 1 Attach charging hoses a service manifold and a vacuum pump to the system Be sure to connect charging hoses to both high and low side access valves IMPORTANT The 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 cha
33. er Valve 1 Diaphragm does not 1 Check for water leaks with close icemaker off Control Board 1 Defective 1 See II C 4 Control Board Check Procedure 2 All ice formed on a Evaporator 1 Scaled up evaporator does not 16 water Supply Line 1 Water pressure too 11 Check and get fall 7 bin in harvest low recommended pressure cycle Water Filter System 1 Dirty Restricted 1 Replace filter d Inlet Water Valve 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 Line Valve 1 Continues to open in 11 Check operation in harvest harvest cycle cycle and replace g Thermistor 1 Out of position or See V I Removal loose attachment and Replacement of Thermistor h Control Board 1 Harvest timer is set Adjust longer referring too short to II C 3 Controls and Adjustments c Harvest Timer 2 Defective 2 See II C 4 Control Board Check Procedure 3 Other Spray Tubes 1 Clogged a 2 Out of position 2 Place in position b Water System c d Refrigerant 1 Undercharged 1 Check for leaks and recharge 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 VViring to hot gas 3 Check for loose valve
34. f 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 dip switches 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 thermistor 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 If the pump motor is operated without water the mechanical seal can fail To prevent this type of failure 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 to additional one minute water fill cycles until water enters the sump and the float switch closes When the float switch closes
35. fan motor F S float switch HGV hot gas valve HM headmaster C P R LLV Liquid Line Valve PM pump motor TXV thermostatic expansion valve WV inlet water valve 18 3 Controls and Adjustments a Default Dip Switch Settings The dip switch is factory adjusted to the following positions Dp Swen rl lslalsl lzrisl lm Pump Out Frequency Control 5 amp 6 Pump Out Timer 3 amp 4 Harvest Timer 1 amp 2 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 0080107 8 14401 10 613 832 600 900 32 1633 Check a thermistor for resistance by using the following procedure 1 Disconnect the connector K3 on the board 2 Remove the thermistor See V K 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 kO Replace the thermistor if it exceeds the normal reading 19
36. g day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 Ibs 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 13 A 5 Min Freeze AT 104 F WT 80 F 20A 59080 498 226 474 215 433 197 480 218 442 201 397 180 90 474 215 416 189 372 169 100 463 210 406 184 332 150 Crescent Cube 9 5 Ibs 4 3 kg 480 pcs N A 90 70 F 70 50 F 1210 7 0 1140 5 5 89 21 3 245 49 1 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Svvitch Hot Gas and VVater Thermistor and Timer Timer Controlled Overflovv Pipe N A Thermostat Hermetic Model AKA9455ZXA Air Cooled Fin and tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 116 1
37. ge 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 Always replace the whole board assembly if it goes bad Do not short out power supply to test for voltage 15 1 Control Board Layout Control Products E Control Board Output Test Switch used to test relays on board Alarm Reset Switch Dip Switch ALARH RESET 0008810 OUTPUT TEST mu Backup Freeze Q O ER AO mici Q Timer LED uoo 000000000 5 1 m 2 2 SECH Connector K3 I 2 1 RT o as PS as oq 7 z 60 og 60 0 50 SE z Harvest Control Re q ku thermistor hs I e 5 us AN In 2 Connector K4 AT Open not connected m Lu a R16 Backup Harvest 2 E Timer LED m Alarm Buzzer Microprocessor board revision level indicated by last 2 digits on label Povver LED lights when power is supplied to the board BLACK Relay LEDs 4 P N 2A1410 01 Connector K5 indicate w
38. h 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 place the output test switch back in the OFF position on units with a slide type switch The output test switch must remain in the OFF position during normal operation On units with a push type output test switch the unit automatically resumes normal operation after the test The unit begins normal operation with the 1 minute fill cycle 5 Control Board Replacement The application switch located between relay X3 amp X4 must be set to match the original board application Place this switch in the ALP position if there is no white wire supplied to the K1 connector If there is a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch OFF or the unit will not start The dip switches should be adjusted to the factory default settings as outlined in this manual Dip switch 8 must remain in the OFF position 22 Ill Technical Information A Water Circuit and Refrigeration Circuit 1 KM 501MAH air cooled Spray Tubes
39. he front panel Remove the valve outlet tubing by releasing the clamp Wu Remove the bracket from the unit 6 Remove the fitting nut and water valve N Disconnect the terminals from the water valve 8 Install the new water valve and replace the removed parts in the reverse order of which they were removed 9 Open the water supply line shut off valve Turn on the power supply Check for leaks 10 11 12 Replace the front panel in its correct position N Removal and Replacement of Pump Motor 1 2 d 4 5 6 Turn off the power supply Remove the front panel Remove the base cover Pump Tubing Drain the water tank by removing one end of the pump tubing Replace the removed parts in their correct positions Do not pull out this side wae a 5 Disconnect the pump suction and discharge hoses Fig 3 49 7 Remove the closed end connectors from the pump motor leads 8 Remove the screw attaching the pump motor assembly to the base then remove the pump motor assembly 9 Remove the screw attaching the pump motor to the pump motor bracket 10 Remove the screws attaching the pump housing to the pump motor Remove the housing and check the impeller 11 If the impeller is defective install a new impeller 12 Install the new motor or new parts and replace the removed parts in the reverse order of which they were removed 13 Turn on the power supply and
40. hich Float Svvitch relays are energized Hd as listed below X me a LM Part Number 19 LED 2 R3 S Connector K1 Hot Gas Valve HGV 15 TT Pins 1 through 10 Self Contained Fan y S M Ste iH 9 Magnetic Contactor Motor FMS FMS n OR sts 2 Hot Gas Valve off when LED on wr 3 Line Valve LED 3 Re R2 Self Contained Fan Motor FMS Pump Motor PM pp Re 8 ete 4 Pump Motor icemaking on at pump out only 710 5 1 5 Pump Motor drain ip 6 Water Valve LED 4 lo 7 10 Power line bin control Water Valve WV SR Em M 8 Open LED 1 Die R46 Switch for C board Compressor Comp s and ALPINE board Remote Fan Motor Cal dm o o service boards only FMR hi 428 pg IX Transformer Connector Control Board 2A1410 01 factory 2A1410 02 service HOS 001A Control Products 10 Pin 16 2 Features a Maximum Water Supply Period 6 minutes Inlet water valve opening in the harvest cycle is limited by the harvest timer The water valve cannot remain open longer than the maximum period The water valve can close in less than six minutes if the harvest cycle is completed 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 i
41. ine compartment 8 Replace the panels in their correct positions 9 Turn on the power supply 43 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 Turn off the power 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 disconnect the expansion valve using brazing equipment 6 Braze the new expansion valve with nitrogen gas flowing at the 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 7 Install the new drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 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 models see the charge label in the machine compartment 10 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be at the 12 o clo
42. ing shaft float and retainer rod with cleaning solution Wipe the inside of the rubber boot with cleaning solution d Reassemble the float switch assembly and replace it and the rubber boot in their correct positions 7 Pour the cleaning solution into the water tank 8 Fully open the cleaning valve on the left side wall of the machine compartment 9 Move the control switch on the control box to the WASH position 10 Replace the insulation panel and the front panel in their correct positions 11 Turn on the power supply and start the washing process 13 Remove the front panel 14 Remove one end of the pump tubing Drain the water tank Replace the pump tubing in its correct position 12 Turn off the power supply after 30 minutes 15 Move the control switch to the ICE position 16 Close the cleaning valve Note The icemaker will not operate unless the cleaning valve is completely closed 17 Replace the front panel in its correct position 18 Turn on the power supply to fill the water tank with water 19 Turn off the power supply after 3 minutes 52 20 Remove the front panel and fully open the cleaning valve 21 Move the control switch to the WASH position 22 Replace the front panel in its correct position 23 Turn on the power supply to rinse off the cleaning solution 24 Turn off the power supply after 5 minutes 25 Remove the front panel 26 Remove one end of the pump tubi
43. itch is turned OFF pressure switch is OFF or thermistor temperature exceeds t1 To freeze cycle From freeze cycle Too Low Temp do F 4 Thermistor Temperature 3 ON 2 Float Switch OFF ON i OFF 4 Crankcase Heater Remote Only oFF Control n Switch in Icemaki WASH 5 Pump Motor or N E 1 m N 1 The pump motor waits for 2 seconds before starting a pump out drain cycle See II C 3 Controls and Adjustments 2 The icemaker does not complete a harvest cycle in the first 2 or 3 minutes See II C 3 Controls and Adjustments 29 D Performance Data 1 KM 501MAH air cooled APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR CF C 50 10 70 21 90 32 lbs day kg day APPROXIMATE ELECTRIC 70 21 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 90 32 PSIG kg em G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg em G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 9 200 BTU h AT 90 F 32 C WT 70 F 21 C 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
44. k at the frequency set by the pump out frequency control The pump out frequency control is factory adjusted to drain the water tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a pump drain more often the pump out frequency can be adjusted as shown in the table below 5 Switch E Frequency No 5 5 No 6 6 f Freeze Timer 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 machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem The freeze timer is factory adjusted and no adjustment is required Tine minute Lor or eo ON ON 60 9 Bin Control CAUTION When the ambient temperature is below 45 F 7 C the bin control thermostat operates to stop the icemaker even if the ice storage bin is empty When the thermostat is set in the prohibited range the icemaker operates continuously even if the ice storage bin is filled with ice Setting in the prohibited range might cause severe damage to the icemaker resulting in failure No adjustment is required under normal use as the bin control is factory adjusted Adjust it if necessary so that the icemaker stops automatically within 10
45. l and labels provided with the icemaker 1 Stainless Steel Exterior 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 53 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 3 Air Filters air cooled models only The plastic mesh air filters located behind the louvers remove dirt or dust from the air and keep the condenser from getting clogged As the filters get clogged the icemaker s performance will be reduced Check the filters at least twice a month When they are clogged use warm water and a neutral cleaner to wash the filters 4 Condenser air cooled and remote air cooled models only Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker or condenser unit C Preparing the Icemaker for Long Storage WARNING When shutting off the icemaker for an extended time drain out all water from the water tank and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker to prevent
46. ltage 2 Check and correct and d through f below 3 Dirty condenser 3 Clean d Starter 1 Check and replace 2 Coil winding opened 12 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 4 Control Board Check Procedure a Inlet Water Valve 1 Diaphragm does not 11 Check for water leaks with close icemaker off b Control Board 1 Defective 1 See II C 4 Control Board Check Procedure a VVater Supply Line 1 VVater pressure too 1 Check and get lovv and vvater level in recommended pressure vvater tank too lovv b Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice and water level in water tank too low c Water System 1 Water leaks 1 Check connections for water leaks and replace 36 2 Clogged 3 Pump out check valve 3 Check assembly and leaking by clean d Pump Motor 1 Motor winding opened 1 Replace 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 5 Replace and clean impeller 6 Mechanical seal worn 6 Check and replace out e Control Board 1 Defective 1 See II C 4 Control Board Check Procedure 6 Fan motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is
47. mpressor will not operate unless this valve is completely closed To open the cleaning valve the valve handle should be parallel to the valve body To close the valve the valve handle should be at a right angle to the valve body Closed Position Open Position 51 1 Cleaning Procedure 1 Dilute approximately 16 fl oz of the recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 3 gal of water 2 Remove all ice from the evaporator and the storage bin Note To remove cubes on the evaporator turn off the power supply and turn it on after 3 minutes The defrost cycle starts and the cubes will be removed from the evaporator 3 Turn off the power supply 4 Remove the front panel and the base cover and then remove the insulation panel by lifting up the panel slightly and pulling it towards you 5 Remove one end of the pump tubing see Est Fig 4 Drain the water tank Replace the pump tubing in its correct position Fig 4 6 In bad or severe water conditions clean the float switch assembly as described below Otherwise continue to step 7 a Remove the float switch assembly from the mounting bracket and remove the rubber boot from the bottom of the assembly b Remove the retainer rod from the bottom of the float switch assembly then remove the float Be careful not to bend the retainer rod excessively when removing it c Wipe down the float switch assembly s hous
48. ng Drain the water tank Replace the pump tubing in its correct position 27 Repeat steps 15 through 26 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to step 10 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute a 5 25 sodium hypochlorite solution chlorine bleach with water add 1 5 fl oz of sanitizer to 3 gal 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 6 7 8 Turn on the power supply and start the sanitizing process Turn off the power supply after 15 minutes Remove the front panel See Remove one end of the pump tubing Drain the water tank Replace the pump tubing in its correct position 9 0 1 Repeat steps 15 through 26 in 1 Cleaning Procedure two times to rinse thoroughly 10 Close the cleaning valve 11 Move the control switch to the ICE position 12 13 14 Replace the front panel and the base cover in their correct positions Clean the storage bin with water wars i Turn on the power supply and start the automatic icemaking process B Maintenance IMPORTANT This icemaker must be maintained individually referring to the instruction manua
49. nician prior to service or maintenance CONTENTS RE EN 5 PCS Ate 5 1 KM 501MAH RE ee ME 5 2 KM 501MWH water cooled saia LS yab baa aman 6 3 KM 501MRH Re E R aaa baga dead ao 7 OMG SII L L ya aaa RR A ab n nda b baa 8 L B C EN 8 Il General Informatio anas yla a yaaa sadalayan palan 10 A DSO DIO aaa ula uyu HEN a asasasasab EN EEE SE AEE 10 1 EAR Ree M 10 2 KM 501MWH water cooled E 11 3 KM 501MRH remote air cooled WE 12 B Seguente L aa 13 One Minute Fill e gt eee ene ala en a m RR 13 2 Initial el 13 1 e 13 4 PUT SO e EE 13 5 Normal Harvest Cycle asirian naa sk des aaaea n EESE E aAA AEA 13 C Control Board EE 15 im een dee Board Layout serinus RAT RV 16 SEENEN AR RR OEE E EEEE 17 a Maximum Water Supply Period 6 minutes 17 b Harvest Backup Timer and Freeze 14 El High Temperature EE 17 d Low Water Safety ay b tua aeuemiktsmae annaia paa Re SEHE anaidi 17 e High Voltage and Low Voltage Cut outs 17 f LED Lights and Audible Alarm Safelles e crainte tont ti ta 18 s Controls and PCS UI AS eenegen 19 a Default Dip Switch Settings E 19 b Harvest Control s Thermistor EE 19 c Harvest Timer dip switch 1 amp 2 EN 20 d Pump Out Timer dip switch 3 amp A aa R
50. ommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 9 Attach the new thermistor to the suction pipe very carefully to prevent damage to the leads Secure it using the thermistor holder and recommended foam insulation 10 Secure the insulation using the plastic cable ties 11 Connect the thermistor leads through the bushing of the control box to the K3 connector on the control board Note Do not cut the leads of the thermistor while installing it 12 Replace the control box cover and the panels in their correct positions 13 Turn on the power supply 48 L 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 Turn off the power supply 2 Remove the panels 3 Remove the junction box cover from the remote condenser unit remote air cooled model 4 Remove the closed end connectors from the fan motor leads 5 Remove the fan motor bracket and fan motor 6 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Replace the junction box cover in its correct position remote air cooled model 9 Turn on the power supply M Removal and Replacement of Inlet Water Valve 1 Turn off the power supply N 50 I 5 Aes ah Close the water supply line shut off valve 3 Remove t
51. otect 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 7 Install the new drier in the icemaker 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the charge label in the machine compartment in the icemaker 47 10 Replace the panels in their correct positions 11 Turn on the power supply K 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 shorten or cut the thermistor leads when installing it 1 Turn off the power supply 2 d 4 Disconnect the thermistor leads from the K3 connector on the control board Remove the panels Thermistor Lead Cable Tie Remove the control box cover 202 a 5 Remove the plastic cable ties foam insulation thermistor holder and thermistor See Fig 2 6 Scrape away the old sealant on the thermistor holder and the suction pipe E A 222 2222 222 ZG NY Foam Insulation Thermistor Holder 7 Wipe off moisture or condensation on the suction pipe Fig 2 8 Smoothly apply rec
52. razing the components Use a good abrasive cloth to remove the coating C Removal and Replacement of Compressor 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 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 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 42 4 5 6 7 Remove the terminal cover on the compressor and disconnect the compressor wiring Remove the discharge and suction pipes using brazing equipment Remove the hold down bolts washers and rubber grommets Slide and remove the compressor Unpack the new compressor package Install the new compressor 8 Attach the rubber grommets of the prior compressor 9 Sandpaper the suction discharge and process pipes Remove plugs from the suction discharge and process pipes 10 Place the compressor in position and secure it using the bolts and washers 11
53. rge is recommended for charging an R 404A system Invert the service cylinder Open the high side service manifold valve 7 Allow the system to charge with liquid until the pressures balance 41 8 If necessary add any remaining charge to the system through the low side Use a throttling valve or liquid 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 hoses and service manifold 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 3 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 All brazing connections inside the evaporator case are clear paint coated Sandpaper the brazing connections before unb
54. seconds after ice contacts the bin control thermostat bulb 21 4 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 dip switch settings to assure that 3 4 7 8 9 amp 10 are in the factory default position On units with a slide type output test switch the output test switch S3 should be OFF Switches 1 2 5 amp 6 are cleaning adjustments and the settings are flexible 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 connector Check the brown wire at pin 10 toa 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 On units with a slide type output test switch move the control switch to the OFF position move the output test switch to the ON position then move the control switch to the ICE position On units with a push type output test switch make sure the control switch is in the ICE position then press the output test switc
55. vest timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds dip switch 1 amp 2 The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter 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 3 Freeze Cycle LED 1 is on Comp and FMR continue to run PM and FMS energize LLV opens HGV and WV close and the freeze cycle starts For the first 5 minutes the control board will not accept a signal from F S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes F S assumes control As ice builds on the evaporator the water level in the sump lowers The freeze continues until F S opens and terminates ice production 4 Pump Out Cycle LEDs 1 3 and 2 are on Comp and FMR continue to run HGV opens LLV closes and FMS deenergizes PM stops for 2 seconds and reverses taking water from the bottom of the sump and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain At the same time water flows through the small tube to power flush the F S When the pump out timer stops counting the pump out is complete Pump out always occurs on the 2nd harvest after startup Then depending on the control board setting pump out occurs ever
56. wing procedures 1 Prepare a thermometer to check the condenser drain temperature Attach a pressure gauge to the high side line of the system 46 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 See Fig 1 Next check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section If it is not in the proper range verify the refrigerant charge 3 Check that the condenser drain temperature is stable Adjustment Screw CW Higher CCW Lower Top View Fig 1 J Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air 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 2 3 4 5 6 Turn off the power supply Remove the panels from the remote condenser unit Recover the refrigerant and store it in an approved container Before heating break off the stub on the dome to release the dome charge Disconnect the headmaster using brazing equipment Install the new headmaster Use nitrogen gas at a pressure of 3 to 4 PSIG when brazing the headmaster wae a CAUTION Always pr
57. y cycle or every 2nd 5th or 10th cycle dip switch 5 amp 6 5 Normal Harvest Cycle LEDs 1 4 and 2 are on Comp and FMR continue to run HGV remains open and WV opens As the evaporator warms the thermistor reaches 48 F 9 C The control board then receives the thermistor s 3 9 kO signal and starts the harvest timer The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the next freeze cycle starts The unit continues to cycle through 3 4 and 5 sequence until the bin control senses ice and shuts the unit down Legend Comp compressor FMR remote fan motor FMS self contained fan motor F S float switch HGV hot gas valve LLV Liquid Line Valve PM pump motor WV inlet water valve 13 J0jou duund Nd YOUMS 1801 S 4 1010 UEL YNA OA EA Jejui AM anyen 586 104 ASH JO OW UP poulejuoo os SINA Josseidwod duoS puoba7 pezibieue ep SINA 11 auu 0 su4mei 9 9249 pue sdojs JosseJduioo usado si S 4 1I pezibieus ASH senunuoo YIN 2 sy 979 5 3 s nunuo duos pezibjeue Wd S l OL 10 G Z 1 21 AM SUIS JWI 15 s nunuo AM 0 S 02 0 10 S 4 01 21 ASH sse 10 Ox 6 2 YWA uedo S 4 uau pue 99S

Hoshizaki KM-501MWH User's Manual

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