NO. F015-774 ISSUED: MAR. 18, 2009 REVISED: JUN.
IMPORTANT Only qualified service technicians should install, service or maintain the product. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the equipment in accordance with this manual may adversely affect safety, performance, and warranty coverage. Hoshizaki provides this manual primarily to assist qualified service technicians in the maintenance and service of the product.
IMPORTANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety. Please retain this booklet for any further reference that may be necessary. CONTENTS PAGE I.
[a] KM-201BAH, KM-260BAH ----------------------------------------------------------------- 26 [b] KM-201BWH, KM-260BWH --------------------------------------------------------------- 27 2. WIRING DIAGRAM ------------------------------------------------------------------------------ 28 3.
[c] FUSE HOLDER ------------------------------------------------------------------------------- 66 [d] CONTROL BOARD -------------------------------------------------------------------------- 66 [e] POWER RELAY ------------------------------------------------------------------------------ 66 [f] CONTROL BOARD TRANSFORMER -------------------------------------------------- 67 19. WATER TANK ------------------------------------------------------------------------------------- 67 20.
I. SPECIFICATIONS 1. SPECIFICATIONS [a] KM-201BAH AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
[b] KM-260BAH AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
[c] KM-201BWH AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) COND.WATER gal./24HR (gal.
[d] KM-260BWH AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) COND.WATER gal./24HR (gal.
II. GENERAL INFORMATION 1.
[b] KM-201BWH Top Panel Side Panel (L) Front Cover Rear Panel Door Side Panel (R) Louver Power Supply Cord Leg Top Cover Drain Valve Hot Gas Valve Cleaning Valve Water Regulator Thermistor Evaporator Condenser Separator Compressor Water Tank Water Valve Expansion Valve Float Switch Overflow Pipe Drier Control Switch Service Switch Control Box Front View Rear View Bin Control Switch With Tank Removed 6
[c] KM-260BWH Top Panel Front Cover Side Panel (L) Rear Panel Door Side Panel (R) Louver Power Supply Cord Leg Top Cover Drain Valve Hot Gas Valve Thermistor Cleaning Valve Water Regulator Evaporator Condenser Separator Water Tank Compressor Expansion Valve Water Valve Overflow Pipe Drier Control Switch Service Switch Float Switch Control Box Front View Rear View Bin Control Switch With Tank Removed 7
[d] ICEMAKING COMPARTMENT Spray Tube Evaporator Water Supply Pipe Separator Cube Guide Water Tank Overflow Pipe Drain Valve Cleaning Valve Separator Water Valve Pump Motor Float Switch 8
2. 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 5, 6, 8, 9, 4, 7. [a] ONE MINUTE FILL CYCLE LED 8 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.
the control board setting, pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle (S1 dip switch 5 & 6). [e] NORMAL HARVEST CYCLE LEDs 5, 6, and 8 are on. Comp continues 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 kΩ signal and starts the harvest timer.
11 When in the “SERVICE” position, the control switch supplies power to the service switch and the machine is in service mode. The service switch has three positions: “DRAIN”, “CIRCULATE”, and “WASH”. See the information below for details of each function. DRAIN Power is supplied to the pump and drain valve. This drains the water tank. CIRCULATE Power is supplied to the pump only. This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator.
3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in crescent cubers. * All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. 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 before handling or replacing the board. 3. Do not touch the electronic devices on the board or the back of the board to prevent damage to the board. 4.
[a] CONTROL BOARD LAYOUT ) $POUSPM #PBSE r 3FMBZ -&%T JOEJDBUF XIJDI SFMBZT BSF FOFSHJ[FE BT MJTUFE CFMPX r , $POOFDUPS 5SBOTGPSNFS r -&% 9 3FMBZ $PNQSFTTPS $PNQ 'BO .PUPS 3FNPUF '.3 r -&% 9 3FMBZ )PU (BT 7BMWF )(7 'BO .PUPS '. (FM off when LED --7 on) -JRVJE -JOF 7BMWF '. BOE --7 PGG XIFO -&% PO r , $POOFDUPS Power Relay .
[b] FEATURES a) Maximum Water Supply Period - 6 minutes The inlet water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), 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.
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.
“POWER OK” LED will turn off if voltage Low Voltage protection operates. (92Vac ± 5% or less) The control voltage safeties automaticlly High Voltage 7 reset when voltage is corrected. (147Vac ± 5% or more) Legend: Comp–compressor; DV–drain valve; FMS–self-contained fan motor; HGV–hot gas valve; PM–pump motor; TXV–thermostatic expansion valve; WRV–water regulating valve; WV–inlet water valve 6 [c] CONTROLS AND ADJUSTMENTS CAUTION Dip switches are factory set.
S1 Dip Switch S2 Dip Switch Freeze Timer (9 & 10) Anti-Slush Control (5 & 6) Water Saver Timer (7 & 8) Pump-Out Frequency Control (5 & 6) Pump-Out Timer (3 & 4) Refill Counter (3 & 4) Float Switch Selector (2) Pump-Out/Drain Selector (1) * Functions of S2 dip switch nos. 2 through 6 depend on program version. Harvest Timer (1 & 2) Fig. 1 Fig. 2 b) Harvest Timer (S1 dip switch 1 & 2) Used for adjustment of the harvest timer.
Pump-out cycle always occurs on the 2nd harvest after startup. Then, depending on the pump-out frequency control setting (S1 dip switch 5 & 6), pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle. d) Pump-Out Frequency Control (S1 dip switch 5 & 6) The water tank drains 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.
The freeze timer is factory adjusted, and no adjustment is required. Dip Switch Setting No. 9 No. 10 ON OFF OFF OFF OFF ON ON ON Time (minutes) 50 60 70 100 g) Pump-Out Pump Motor Delay (S2 dip switch 1) The pump-out pump motor delay determines whether or not the pump motor deenergizes for 2 seconds before restarting at the beginning of a drain cycle. The pump-out pump motor delay is factory adjusted, and no adjustment is required. S2 Dip Switch Setting No.
S2 Dip Switch Setting No. 5 No. 6 OFF OFF ON OFF OFF ON ON ON Anti-Slush Control Activated (Ver. 1.0) Activated (Ver. 2.0) Deactivated Deactivated Control Board P01771-02 j) Harvest Promotion Control (S2 dip switch 2) [Program Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly. When activated, this control promotes harvest of ice on the evaporator that is hard to remove.
m) Overfreeze Detection Control (S2 dip switch 5) [Program Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KM-201BAH/BWH and KM-260BAH/BWH. When activated, the thermistor detects the temperature of the evaporator outlet to find overfreeze in a harvest cycle and at the beginning of a freeze cycle.
1) Check the dip switch settings to assure that S1 dip switch 3, 4, 7, 8, 9 & 10 and S2 dip switch 1 through 6 are in the factory default position. S1 dip switch 1, 2, 5, & 6 are cleaning adjustments and the settings are flexible. 2) Move the control switch to the “ICE” position and check for proper control voltage. If the “POWER OK” LED is on, the control voltage is good. If the “POWER OK” LED is off, check the control transformer circuit. If no voltage is present, check the power supply circuit.
4) Check for resistance between the thermistor leads. Normal reading is within 4.7 to 6.2 kΩ. Replace the thermistor if it exceeds the normal reading. 5. 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. [a] EXPLANATION OF OPERATION The bin control is connected to the K1 connector (pins 4 & 5) on the control board.
5) Disconnect the bin control at the 2-pin connector attached to the black wires coming from the K1 connector (pins 4 & 5) on the control board. 6) Check for continuity across the bin control leads. When calling for ice, the bin control proximity switch should be closed. If open, replace the bin control. Activate the bin control actuator (press the actuator in), check for continuity across the bin control leads. The bin control proximity switch should be open. If closed, replace the bin control.
b) CIRCULATE When the service switch is active and placed in the “CIRCULATE” position, power is supplied to the pump only. This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator. c) WASH This machine utilizes a solenoid operated wash (bypass) valve. When the service switch is active and placed in the “WASH” position, power is supplied to the pump and cleaning valve.
26 Pump Motor Water Tank Water Circuit Refrigerant Circuit Float Switch Drain Thermistor Drain Valve Cleaning Valve Water Supply Expansion Valve Suction Line Discharge Line Compressor Drier Access Valve Insulation Tube Fan Hot Gas Valve Strainer High Pressure Switch [a] KM-201BAH, KM-260BAH Cube Guide Evaporator Spray Tube Water Valve Condenser III. TECHNICAL INFORMATION 1.
Cube Guide Evaporator Spray Tube 27 Pump Motor Float Switch Water Circuit Refrigerant Circuit Water Tank Water Valve Drain Thermistor Drain Valve Cleaning Valve Water Supply Water Supply Expansion Valve Suction Line Discharge Line Compressor Drier Drain Access Valve Insulation Tube Water Condenser Water Regulator Hot Gas Valve Strainer High Pressure Switch [b] KM-201BWH, KM-260BWH
2.
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF HOT GAS VALVE WATER VALVE DRAIN VALVE CLEANING VALVE FLOAT SWITCH BIN CONTROL SWITCH RELAY: X1 (COMP) RELAY: X2 (HV/FM) RELAY: X3 (PM) RELAY: X4 (WV) RELAY: X6 (DV) ON OFF ON OFF ON OFF FAN MOTOR Program Ver 2.5 or earlier (Auxiliary Code: V-0 or earlier) Program Ver 3.
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF DRAIN VALVE CLEANING VALVE FLOAT SWITCH BIN CONTROL SWITCH RELAY: X1 (COMP) RELAY: X2 (HV/FM) RELAY: X3 (PM) RELAY: X4 (WV) RELAY: X6 (DV) ON OFF WATER VALVE HOT GAS VALVE ON OFF ON OFF ON OFF FAN MOTOR Program Ver 2.5 or earlier (Auxiliary Code: V-0 or earlier) Program Ver 3.
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF DRAIN VALVE CLEANING VALVE FLOAT SWITCH BIN CONTROL SWITCH RELAY: X1 (COMP) RELAY: X2 (HV/FM) RELAY: X3 (PM) RELAY: X4 (WV) RELAY: X6 (DV) ON OFF WATER VALVE HOT GAS VALVE ON OFF ON OFF ON OFF FAN MOTOR Program Ver 2.5 or earlier (Auxiliary Code: V-0 or earlier) Program Ver 3.
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF DRAIN VALVE CLEANING VALVE FLOAT SWITCH BIN CONTROL SWITCH RELAY: X1 (COMP) RELAY: X2 (HV/FM) RELAY: X3 (PM) RELAY: X4 (WV) RELAY: X6 (DV) ON OFF WATER VALVE HOT GAS VALVE ON OFF ON OFF ON OFF FAN MOTOR Program Ver 2.5 or earlier (Auxiliary Code: V-0 or earlier) Program Ver 3.
4. PERFORMANCE DATA [a] KM-201BAH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 201 193 91 88 190 177 86 80 176 162 80 73 90/32 100/38 70/21 80/27 190 187 86 85 165 161 75 73 150 136 68 62 90/32 490 494 496 504 509 520 496 510 526 514 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 72 64 61 0.27 0.24 0.23 61 48 36 0.23 0.18 0.
[b] KM-260BAH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 263 249 119 113 245 220 111 100 227 207 103 94 90/32 100/38 70/21 80/27 245 244 111 111 200 196 91 89 185 171 84 78 590 599 602 617 606 614 630 90/32 602 630 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 598 630 78 70 67 gal./day m3/day FREEZING CYCLE TIME 100/38 54 0.30 0.
[c] KM-201BWH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 215 207 98 94 205 192 93 87 192 180 87 82 90/32 100/38 70/21 80/27 205 203 93 92 181 178 82 81 168 157 76 71 460 462 463 467 464 466 470 90/32 463 470 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 462 470 55 52 52 gal./day m3/day FREEZING CYCLE TIME 100/38 46 0.21 0.20 0.
[d] KM-260BWH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 268 261 122 118 259 247 117 112 242 228 110 103 90/32 100/38 70/21 80/27 259 254 117 115 237 233 108 106 218 201 99 91 620 622 623 627 624 626 630 90/32 623 630 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 622 630 77 74 73 gal./day m3/day FREEZING CYCLE TIME 100/38 65 0.
IV. SERVICE DIAGNOSIS 1. DIAGNOSTIC PROCEDURE The diagnostic procedure is basically a sequence check which can be used at unit startup 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 (21°C) or warmer air and 50°F (10°C) or warmer water temperatures.
starts after the thermistor temperature reaches 36°F (2°C). After this period, 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 the minimum freeze period, disconnect the float switch at the 2-pin connector attached to the red wires. The unit should immediately switch to the pump-out cycle.
2. NO ICE PRODUCTION PROBLEM [1] The icemaker will not start. POSSIBLE CAUSE a) Power Supply 1. OFF position. 2. Loose connections. 3. Bad contacts. 4. Voltage too high. 5. Unplugged. b) Fuse (inside fused 1. Blown out. disconnect, if any) c) Control Switch 1. OFF or SERVICE position. 2. Bad contacts. d) Bin Control Switch 1. Tripped with bin filled with ice. 2. Defective reed switch.
PROBLEM [1] (Continued) POSSIBLE CAUSE l) Control Board 1. Defective. [2] Water continues to be supplied, and the icemaker will not start. a) Float Switch [3] Compressor will not start or operates intermittently. b) Control Board a) Control Switch b) High Pressure Control c) Overload Protector d) Starter e) Start Capacitor f) Power Relay g) Compressor h) Control Board i) Condenser, Air Filter j) Water regulator (water-cooled model) 1. Connector disconnected. 2. Leads opened or defective switch.
PROBLEM [4] Water continues to be supplied in freeze cycle. POSSIBLE CAUSE a) Inlet Water Valve 1. Diaphragm does not close. b) Control Board 1. Defective. [5] No water a) Water Supply Line 1. Water pressure too low comes from and water level in water Spray Tubes. tank too low. Water Pump b) Inlet Water Valve 1. Dirty mesh filter or will not start, or orifice and water level in freeze cycle water tank too low. time is too c) Water System 1. Water leaks. short. 2. Clogged. d) Pump Motor 1.
3. EVAPORATOR IS FROZEN UP PROBLEM [1] Freeze cycle time is too long. POSSIBLE CAUSE 1. Leads shorted or defective switch. 2. Float does not move freely. b) Inlet Water Valve 1. Diaphragm does not close. a) Float Switch c) Control Board [2] All ice formed on Evaporator does not fall into bin in harvest cycle. a) Evaporator 1. Scaled up. b) Water Supply Line 1. Water pressure too low. c) Inlet Water Valve d) Ambient and/or water temperature e) Thermistor f) Control Board [3] Others 1. Defective.
4. LOW ICE PRODUCTION PROBLEM [1] Freeze cycle time is long. [2] Harvest cycle time is long. POSSIBLE CAUSE REMEDY a) See chart 2 - [3] and check dirty air filter or condenser, ambient or water temperature, water pressure, and refrigerant charge. b) See chart 3 - [1] and check float switch, inlet water valve, and control board. a) See chart 3 - [2] and check control board, thermistor, evaporator, ambient and/or water temperature, water supply line, and inlet water valve. 5.
6. OTHER PROBLEM POSSIBLE CAUSE [1] Icemaker will a) Bin Control Switch 1. Completely not stop when disconnected and bin is filled with dropped inside bin. ice. 2. Detector broken. 3. Detector out of position. 4. Defective reed switch. b) Control Board [2] Abnormal noise a) Pump Motor b) Fan Motor c) Compressor d) Refrigerant Lines [3] Ice in Storage Bin often melts. a) Bin Drain 5. Reed switch out of position. 6. Magnet disconnected from detector. 1. Defective. 1. Bearings worn out. 1.
V. REMOVAL AND REPLACEMENT WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the control switch to the “OFF” position and turn off the power supply before servicing. 3. C H O K I N G H A Z A R D : E n s u r e a l l c o m p o n e n t s , f a s t e n e r s , a n d thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the storage bin. 4.
3. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow. 4. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 250°F (121°C). [b] REFRIGERANT RECOVERY The icemaker unit is provided with refrigerant access valves.
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 valve with the unit running. 9) Close the gauge manifold valves and disconnect the gauge manifold hoses. 10) Cap the access valves to prevent a possible leak. 2. BRAZING WARNING 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). 2.
3. COMPRESSOR WARNING The compressor terminal cover must be refitted in its correct position. Otherwise, operation under high temperature and high humidity conditions may cause electric shock, fire, or corrosion to shorten the service life. CAUTION 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow.
13) Install the new drier (see “4. DRIER”). 14) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 15) Evacuate the system and charge it with refrigerant (see “1. [c] EVACUATION AND RECHARGE”). 16) Connect the solderless terminals and replace the terminal cover in its correct position. 17) Refit the panels in their correct positions. 18) Plug in the icemaker or connect the power source.
7) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 8) Evacuate the system and charge it with refrigerant (see “1. [c] EVACUATION AND RECHARGE”). 9) Refit the panels in their correct positions. 10) Plug in the icemaker or connect the power source. Note: Always use a drier of the correct capacity and refrigerant type. 5. HOT GAS VALVE CAUTION 1. To ensure optimum performance, use a copper tube of the same diameter and length for replacement of the hot gas circuit. 2.
Hot Gas Valve Fig. 4 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 275°F (135° C). 8) Install the new drier (see “4. DRIER”). 9) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 10) Evacuate the system and charge it with refrigerant (see “1. [c] EVACUATION AND RECHARGE”). 11) Attach the solenoid coil to the valve body, and secure it with the screw. 12) Connect the lead wires.
6. EXPANSION VALVE IMPORTANT The water in the refrigeration circuit may exceed the capacity of the drier and freeze in 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 icemaker or disconnect the power source. 2) Remove the top panel, rear panel and side panel (R).
Cut ties to make Bulb removable Bulb Bulb Insulation Hose Remove Expansion Valve Cover first Expansion Valve Fig. 5 7. AIR-COOLED CONDENSER CAUTION 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow. 3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating.
7) Install the new condenser, then attach the fan motor bracket. 8) Remove the drier, then place the new drier in position. 9) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 10) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.
6) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out. 7) Recover the refrigerant and store it in an approved container. 8) Disconnect the condenser water inlet and outlet piping and the refrigeration inlet and outlet piping at the condenser. 9) Remove the old condenser and install the new condenser.
5) Install the new fan motor in the reverse order of the removal procedure. 6) Refit the panels in their correct positions. 7) Plug in the icemaker or connect the power source. Screw Fan Motor Fan Motor Bracket Fig. 6 10. WATER REGULATING VALVE (WATER-COOLED MODEL) CAUTION 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made.
4) Open the condenser water supply line drain valve. If connected to a closed loop water supply, also open the condenser return outlet drain valve. 5) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve. 6) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out.
11. ADJUSTMENT OF WATER REGULATING VALVE (WATER-COOLED MODEL) 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).
12. PUMP MOTOR 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel, rear panel and side panel (R). 3) Disconnect the connector of the pump motor lead. 4) Remove the water tank (see “19. WATER TANK”). 5) Remove the hose band connecting the pump motor discharge outlet and pull off the rubber hose. Rubber Hose Pull off Hose Band Fig. 8 6) Remove the screws securing the pump motor, and lift it off. Lift off Screw Fig.
13. WATER VALVE 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the top panel, rear panel and side panel (R). 4) Disconnect the tab terminals. 5) Pinch and lower the hose clamp. 6) Disconnect the rubber hose from the water valve. Put a towel under the water valve to receive water coming out. 7) Turn the inlet nut in the arrow direction to remove it from the water valve. Do not lose the gasket inside. 8) Remove the two mounting screws.
14. DRAIN VALVE, CLEANING VALVE 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the top panel, rear panel and side panel (R). 4) Disconnect the tab terminals. 5) Remove the hose clamps at the inlet and outlet sides. 6) Remove the rubber hoses at the inlet and outlet sides. 7) Remove the two mounting screws. 8) Install the new valve in the reverse order of the removal procedure. 9) Open the water supply tap. 10) Plug in the icemaker or connect the power source.
15. FLOAT SWITCH 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel, rear panel and side panel (R). 3) Disconnect the connector of the float switch lead. 4) Remove the two mounting screws. 5) Install the new float switch in the reverse order of the removal procedure. 6) Refit the panels in their correct positions. 7) Plug in the icemaker or connect the power source. Lift off Fig.
16. BIN CONTROL SWITCH 1) Remove the water tank (see “19. WATER TANK”). The bin control switch is located as shown below when viewed from the front. Bin Control Switch Fig. 13 2) Remove the top panel and the rear panel. 3) Disconnect the connector of the bin control switch lead (black) covered with a silicone hose and remove the lead wire from the grommet. 4) Loosen the thumbscrew on the right side. 5) Remove the thumbscrew on the left side. Shift the bin control switch to the left to remove.
17. THERMISTOR 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel and unscrew the rear panel. 3) Disconnect the connector of the thermistor lead (orange). 4) Remove the ties, insulation, thermistor holder, and thermistor in this order. 5) Remove the old sealant from the thermistor holder and suction pipe. 6) Wipe off any moisture or condensation from the suction pipe surfaces.
18. CONTROL BOX 1) Unplug the icemaker or disconnect the power source. 2) Remove the louver. 3) Remove the two mounting screws, and pull the control box toward you. 4) Refit the removed parts in the reverse order of the removal procedure. Note: After replacing the components inside the control box, connect and tie the wires properly in their correct position. Especially make sure that the harness does not press the push buttons on the control board.
[a] POWER SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [b] FUSE 1) Use a phillips head screwdriver to remove the fuse holder cap and take out the fuse. 2) Install the new fuse in the reverse order of the removal procedure.
3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [f] CONTROL BOARD TRANSFORMER 1) Disconnect the connectors and closed end connectors connecting the control board. (The tie securing the harness may be removed. But be careful not to break the lead wires.) 2) Remove the mounting screw and lift off the transformer from the fit at the bottom. 3) Install the new transformer in the reverse order of the removal procedure. 19.
20. CUBE GUIDE 1) Remove the water tank (see “19. WATER TANK”). 2) Lift off the cube guide out of the water tank. 3) To refit the cube guide, fit the notches on both sides to the stoppers in the water tank. 4) The unit is provided with three or four cube guides (quantity varies depending on model). Be sure to locate the vertical flanges on the outside edges. Vertical Flange Notch Cube Guide Stopper Fig. 18 21. SEPARATOR IMPORTANT 1.
3) Remove the top cover and front cover. See Fig. 19. 4) Disconnect the silicone hose from the spray tube, and remove the spray tube from the evaporator bracket. 5) Remove the front separator by pushing the pins inserted into both sides of the evaporator bracket toward the center. See Fig. 19. Note: Be careful not to break the pins. 6) The rear separator is hooked on the groove in the evaporator bracket. Remove the rear separator by lifting it up and down. See Fig. 19.
22. SPRAY TUBE, WATER SUPPLY PIPE, SPRAY GUIDE 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel. 3) Remove the top cover. 4) Remove the silicone hose and spray tube. See Fig. 20. 5) Remove the water spray pipe and spray guide from the evaporator plate. See Fig. 20. 6) Refit the removed parts in the reverse order of the removal procedure. Check for water leaks. IMPORTANT Fit the spray guide securely and tightly on the evaporator fin.
23. DOOR 1) Open the door. 2) Unscrew and remove the hinges on both sides, and remove the door. 3) Refit the removed parts in the reverse order of the removal procedure. Check that the door opens and closes smoothly. Door Hinge Fig.
VI. CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components, fasteners and screws are securely in place after any maintenance or cleaning is done to the equipment. 1. 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.
6) Pour the cleaning solution into the water tank. Move the control switch to the “SERVICE” position and the service switch to the “WASH” position. Close the door. 7) After 30 minutes, move the control switch to the “OFF” position. 8) Same as step 4. 9) Move the control switch to the “ICE” position to fill the water tank with water. 10) After 3 minutes, move the control switch to the “SERVICE” position and the service switch to the “WASH” position.
they were removed. 5) Same as step 1. 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 “SERVICE” position and the service switch to the “WASH” position. 8) After 15 minutes, move the control switch to the “OFF” position. 9) Move the control switch to the “SERVICE” position and the service switch to the “DRAIN” position. 10) After 2 minutes, move the control switch to the “OFF” position.
[c] AIR FILTER (AIR-COOLED MODEL) The plastic mesh air filter removes dirt or 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. [d] CONDENSER (AIR-COOLED MODEL) Check the condenser once a year, and clean if required by using a brush or vacuum cleaner.
“DRAIN” position. 2) After 2 minutes, move the control switch to the “OFF” position. 3) Open the door. Remove all ice from the storage bin and clean the storage bin. 4) Close the door. 5) Replace the louver in its correct position. 6) Turn off the power supply at the breaker box. Inlet Hose Washer Stop Valve Fig.
