HoshizakiHoshizaki America, Inc.
Modular Crescent Cuber
Models
KM-320MAH
KM-320MWH
“A Superior Degree
of Reliability”
www.hoshizaki.com
SERVICE MANUAL
Number: 73132
Issued: 1-24-2006
Revised: 11-30-2006
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 technician prior to service or maintenance.
CONTENTS |
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I. Specifications...................................................................................................................... |
5 |
A. KM-320MAH (air-cooled)............................................................................................... |
5 |
B. KM-320MWH (water-cooled)......................................................................................... |
6 |
II. General Information............................................................................................................ |
7 |
A. Construction.................................................................................................................. |
7 |
1. KM-320MAH (air-cooled)......................................................................................... |
7 |
2. KM-320MWH (water-cooled).................................................................................... |
8 |
B. Controller Board............................................................................................................. |
9 |
1. Solid-State Control................................................................................................... |
9 |
2. Controller Board....................................................................................................... |
9 |
3. Sequence............................................................................................................... |
13 |
4. Controls and Adjustments ..................................................................................... |
16 |
5. Checking the Controller Board............................................................................... |
19 |
III. Technical Information....................................................................................................... |
21 |
A. Water Circuit and Refrigerant Circuit........................................................................... |
21 |
1. KM-320MAH........................................................................................................... |
21 |
2. KM-320MWH.......................................................................................................... |
22 |
B. Wiring Diagram............................................................................................................ |
23 |
1. KM-320MAH, KM-320MWH................................................................................... |
23 |
C. Timing Chart ............................................................................................................... |
24 |
D. Performance Data........................................................................................................ |
26 |
1. KM-320MAH........................................................................................................... |
26 |
2. KM-320MWH.......................................................................................................... |
27 |
IV. Service Diagnosis............................................................................................................ |
28 |
A. No Ice Production........................................................................................................ |
28 |
B. Evaporator is Frozen Up.............................................................................................. |
31 |
C. Low Ice Production...................................................................................................... |
33 |
D. Abnormal Ice............................................................................................................... |
33 |
E. Other............................................................................................................................ |
33 |
V. Removal and Replacement of Components..................................................................... |
34 |
A. Service for Refrigerant Lines....................................................................................... |
34 |
1. Refrigerant Recovery............................................................................................. |
34 |
2. Evacuation and Recharge (R-404A)...................................................................... |
34 |
B. Brazing......................................................................................................................... |
35 |
C. Removal and Replacement of Compressor................................................................. |
36 |
D. Removal and Replacement of Drier............................................................................. |
37 |
E. Removal and Replacement of Expansion Valve.......................................................... |
37 |
F. Removal and Replacement of Hot Gas Valve and Line Valve...................................... |
38 |
G. Removal and Replacement of Evaporator................................................................... |
39 |
H. Removal and Replacement of Thermistor................................................................... |
40 |
I. Removal and Replacement of Fan Motor...................................................................... |
41 |
J. Removal and Replacement of Water Valve.................................................................. |
41 |
K. Removal and Replacement of Pump Motor................................................................. |
42 |
L. Removal and Replacement of Spray Tubes................................................................. |
42 |
M. Removal and Replacement of Water Regulating Valve – Water Cooled Model Only.. 43 |
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N. Adjustment Of Water Regulating Valve – Water-Cooled Model Only........................... |
44 |
VI. Cleaning and Maintenance Instructions.......................................................................... |
45 |
A. Preparing the Icemaker for Long Storage.................................................................... |
45 |
B. Cleaning and Sanitizing Instructions............................................................................ |
47 |
1. Cleaning Procedure............................................................................................... |
48 |
2. Sanitizing Procedure - Following Cleaning Procedure........................................... |
49 |
C. Maintenance................................................................................................................ |
50 |
AC SUPPLY VOLTAGE |
115/60/1 |
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AMPERAGE |
9.7 A ( 5 Min. Freeze AT 104°F / WT 80°F) |
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MINIMUM CIRCUIT AMPACITY |
20 A |
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MAXIMUM FUSE SIZE |
20 A |
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APPROXIMATE ICE PRODUCTION |
Ambient |
WATER TEMP. (°F) |
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PER 24 HR. |
Temp.(°F) |
50 |
|
70 |
|
90 |
lbs./day ( kg/day ) |
70 |
*325 (147) |
|
311 (141) |
|
287 (130) |
Reference without *marks |
80 |
315 (143) |
|
293 (133) |
|
265 (120) |
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90 |
311 (141) |
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*278 (126) |
|
251 (114) |
SHAPE OF ICE |
100 |
304 (138) |
|
272 (123) |
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226 (103) |
Crescent Cube |
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ICE PRODUCTION PER CYCLE |
7.2 lbs. (3.3 kg) 360 pcs. |
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APPROXIMATE STORAGE CAPACITY |
N/A |
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ELECTRIC & WATER CONSUMPTION |
90/70°F |
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70/50°F |
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ELECTRIC W (kWH/100 lbs.) |
800(6.9) |
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750(5.5) |
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WATER gal./24HR (gal./100 lbs.) |
51(18.4) |
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117(35.9) |
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EXTERIOR DIMENSIONS (WxDxH) |
22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm) |
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EXTERIOR FINISH |
Stainless Steel, Galvanized Steel (Rear) |
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WEIGHT |
Net 123 lbs. (56 kg), Shipping |
153 lbs. (70 kg) |
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CONNECTIONS - ELECTRIC |
Permanent - Connection |
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- WATER SUPPLY |
Inlet |
1/2" FPT |
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- DRAIN |
Outlet |
3/4" FPT |
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3/8" OD Tube |
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CUBE CONTROL SYSTEM |
Float Switch |
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HARVESTING CONTROL SYSTEM |
Hot Gas and Water, Thermistor and Timer |
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ICE MAKING WATER CONTROL |
Timer Controlled. Overflow Pipe |
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COOLING WATER CONTROL |
N/A |
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BIN CONTROL SYSTEM |
Thermostat |
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COMPRESSOR |
Hermetic, Model ASE32C3E-CAA |
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CONDENSER |
Air-Cooled , Fin and tube type |
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EVAPORATOR |
Vertical type, Stainless Steel and Copper |
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REFRIGERANT CONTROL |
Thermostatic Expansion Valve |
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REFRIGERANT CHARGE |
R-404A, 1 lb. 4.3 oz. (575g) |
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DESIGN PRESSURE |
High 467PSIG, Low 210PSIG |
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P.C. BOARD CIRCUIT PROTECTION |
High Voltage Cut-out ( Internal ) |
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COMPRESSOR PROTECTION |
Auto-reset Overload Protector ( Internal ) |
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REFRIGERANT CIRCUIT PROTECTION |
Auto-reset High Pressure Control Switch |
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LOW WATER PROTECTION |
Float Switch |
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ACCESSORIES -SUPPLIED |
N/A |
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-REQUIRED |
Ice Storage Bin |
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OPERATING CONDITIONS |
VOLTAGE RANGE |
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104 - 127 V |
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AMBIENT TEMP. |
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45 -100° F |
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WATER SUPPLY TEMP. |
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45 - 90° F |
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WATER SUPPLY PRESSURE |
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|
10 - 113 PSIG |
Note: We reserve the right to make changes in specifications and design without prior notice.
AC SUPPLY VOLTAGE |
115/60/1 |
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|
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|
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AMPERAGE |
8.2 A ( 5 Min. Freeze AT 104°F / WT 80°F) |
|
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MINIMUM CIRCUIT AMPACITY |
20 A |
|
|
|
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MAXIMUM FUSE SIZE |
20 A |
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APPROXIMATE ICE PRODUCTION |
Ambient |
WATER TEMP. (°F) |
||||
PER 24 HR. |
Temp.(°F) |
50 |
|
70 |
|
90 |
lbs./day ( kg/day ) |
70 |
*352 (160) |
|
348 (158) |
|
324 (147) |
Reference without *marks |
80 |
349 (158) |
|
342 (155) |
|
309 (140) |
|
90 |
348 (158) |
|
*337 (153) |
|
308 (140) |
SHAPE OF ICE |
100 |
337 (153) |
|
330 (150) |
|
281 (127) |
Crescent Cube |
|
|
|
|
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ICE PRODUCTION PER CYCLE |
7.2 lbs. (3.3 kg) 360 pcs. |
|
|
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APPROXIMATE STORAGE CAPACITY |
N/A |
|
|
|
|
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ELECTRIC & WATER CONSUMPTION |
90/70°F |
|
|
70/50°F |
|
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ELECTRIC W (kWH/100 lbs.) |
730(5.2) |
|
|
730(5.0) |
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WATER gal./24HR (gal./100 lbs.) |
57(16.8) |
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|
103(29.4) |
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WATER COOLED CONDENSER |
528(157) |
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|
327(93) |
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gal./24HR (gal./100 lbs.) |
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EXTERIOR DIMENSIONS (WxDxH) |
22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm) |
|
||||
EXTERIOR FINISH |
Stainless Steel, Galvanized Steel (Rear) |
|
||||
WEIGHT |
Net 123 lbs. (56 kg), Shipping |
153 lbs. (70 kg) |
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CONNECTIONS - ELECTRIC |
Permanent - Connection |
|
|
|
||
- WATER SUPPLY |
Inlet |
1/2" FPT |
|
|
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- DRAIN |
Outlet |
3/4" FPT |
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|
3/8" OD Tube |
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CUBE CONTROL SYSTEM |
Float Switch |
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HARVESTING CONTROL SYSTEM |
Hot Gas and Water, Thermistor and Timer |
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ICE MAKING WATER CONTROL |
Timer Controlled. Overflow Pipe |
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COOLING WATER CONTROL |
Pressure Regulator |
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BIN CONTROL SYSTEM |
Thermostat |
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COMPRESSOR |
Hermetic, Model ASE32C3E-CAA |
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CONDENSER |
Water-cooled, Tube in tube type |
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EVAPORATOR |
Vertical type, Stainless Steel and Copper |
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REFRIGERANT CONTROL |
Thermostatic Expansion Valve |
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REFRIGERANT CHARGE |
R-404A, 1 lb. 0.8 oz. (486g) |
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DESIGN PRESSURE |
High 427PSIG, Low 210PSIG |
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|
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P.C. BOARD CIRCUIT PROTECTION |
High Voltage Cut-out ( Internal ) |
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|
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||
COMPRESSOR PROTECTION |
Auto-reset Overload Protector ( Internal ) |
|
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REFRIGERANT CIRCUIT PROTECTION |
Auto-reset High Pressure Control Switch |
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LOW WATER PROTECTION |
Float Switch |
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ACCESSORIES -SUPPLIED |
N/A |
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|
|
|
|
-REQUIRED |
Ice Storage Bin |
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|
|
|
|
OPERATING CONDITIONS |
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.
A.Construction
1.KM-320MAH (air-cooled)
Evaporator
Cleaning Valve
Bin Control
Thermostat
Float Switch
Water Pump
Compressor
Spray Tubes |
Expansion Valve |
|
|
|
Control Switch |
Water Supply Inlet
Hot Gas Valve
Condenser
Fan Motor
Drier
Control Box
(shown transparent to allow view of other components)
Spray Tubes |
Expansion Valve |
|
Control Switch |
|
Water Supply Inlet |
|
Hot Gas Valve |
Evaporator
Water Regulator
Cleaning Valve
Condenser
Bin Control
Thermostat
Float Switch
Water Pump
Drier Compressor
Control Box
(shown transparent to allow view of other components)
1.Solid-State Control
•A HOSHIZAKI exclusive solid-state control is employed in KM-320MAH and
KM 320MWH Modular Crescent Cubers.
•A printed circuit board (hereafter called "controller board") includes a stable and high quality control system.
•All models are pretested and factory-adjusted.
2.Controller Board
CAUTION
1.Fragile, handle very carefully.
2.A controller 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.
3.Do not touch the electronic devices on the board or the back of the board to prevent damage to the board.
4.Do not change wiring and connections. Do not misconnect K3, K4 and K5, because the same connector is used for the thermistor and float switch. K4 is not connected.
5.Always replace the whole board assembly when it goes bad.
6.Do not short out power supply to test for voltage.
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Controller Board |
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Part Number |
Type |
2A1410-01 |
HOS-001A (Control Products - 10 Pin) |
Features of Control Products "E" Controller Board
a) Maximum Water Supply Period - 6 minutes
Water solenoid valve opening, in the defrost (harvest) cycle, is limited by the defrost timer. The water valve cannot remain open longer than the maximum period. The water valve can close in less than six minutes if the defrost cycle is completed.
b) Defrost Timer
The defrost cycle starts when the float switch opens and completes the freeze cycle. But the defrost timer does not start counting until the thermistor senses 48°F (9°C) at the evaporator outlet. The period from the end of the freeze cycle up to the point of the thermistor’s sensing varies depending on the ambient and water temperatures.
c) High Temperature Safety - 127 ± 7°F (53 ± 4°C)
The temperature of the suction line in the refrigerant circuit is limited by the high temperature safety.
During the defrost cycle the evaporator temperature rises. The thermistor senses 48°F (9°C) and starts the defrost timer. After the defrost timer counts down to zero, the normal freeze cycle begins. If the evaporator temperature continues to rise, the
thermistor will sense the rise in temperature and at 127 ± 7°F (53 ± 4°C) the thermistor operates the high temperature safety.
This high temperature safety shuts down the circuit and the icemaker automatically stops.
This high temperature safety protects the unit from excessive temperature. The control board will beep every 3 seconds. The white 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 controller 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 defrost cycle.
If the float switch is in the up position (electrical circuit closed), the controller board changes to the ice making cycle. If the float switch is in the down position (electrical circuit open), the controller board changes to a one minute water fill cycle before starting the ice making cycle. This method allows for a low water safety shut down to protect the water pump 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 Cut-out
The maximum allowable supply voltage of this icemaker is limited by the high voltage cut-out.
If miswiring (especially on single phase 3 wire models) causes excessive voltage on the controller board, the high voltage cut-out shuts down the circuit in 3 seconds and the icemaker automatically stops. When the proper supply voltage is resumed, the icemaker automatically starts running again. The control board will signal this problem using 7 beeps every 3 seconds.
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 ON or OFF.
10
The green LEDs 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows:
Sequence Step |
LED |
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Time LEDs are Lit |
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Min. |
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Max. |
Avg. |
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1 Minute Fill Cycle |
4 |
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|
60 seconds |
Harvest Cycle |
1, 4, and 2 |
2 minutes |
|
20 minutes |
3 to 5 minutes |
Freeze Cycle |
1 |
5 minutes |
|
60 minutes |
30 to 35 minutes |
Reverse Pump Out |
1, 3, and 2 |
10 seconds |
20 seconds |
factory setting |
|
{Led 1 – Comp; Led 2 - HGV/CFM; |
Led 3 – PM; |
Led 4 - WV} |
The built in safeties shut down the unit and have alarms as follows:
No. of Beeps |
Type of Alarm |
Notes |
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(every 3 sec.) |
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1 |
High Evaporator Temp. |
Check for defrost problem (stuck HGV |
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(temperature > 127°F) |
or relay), hot water entering unit, stuck |
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(53°C) |
headmaster, or shorted thermistor. |
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2 |
Defrost Backup Timer |
Orange LED marked H TIMER lights up. |
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(defrost > 20 min.) |
Check for open thermistor, HGV not |
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opening, TXV leaking by, low charge, or |
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inefficient compressor. |
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3 |
Freeze Backup Timer |
Yellow LED marked F TIMER lights up. |
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(freeze > 60 min.) |
Check for F/S stuck closed (up), WV |
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leaking by, HGV leaking by, TXV not |
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feeding properly, low charge, or inefficient |
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compressor. |
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To manually reset the above safeties, press the white alarm reset button with the power supply on.
6 |
Low Voltage |
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(92Vac or less) |
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7 |
High Voltage |
Red LED will turn off if voltage protection |
|
(control voltage |
operates. |
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> 147Vac ±5%) |
The voltage safety automatically resets |
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when voltage is corrected. |
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The output test switch "S3" provides a relay sequence test. With power OFF, place S3
ON and switch power to ICE. The correct lighting sequence should be none, 2, 3, 4, 1, & 4, normal sequence every 5 seconds. S3 should remain in the "OFF" position for normal operation.
11
The application switch located between relay X3 & 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 per the adjustment chart published in the Tech Specs book. 7 & 8 must remain in the OFF position.
(Control Products HOS-001A Board)
12
1st Cycle
1.Unit energized and control switch to "ICE" position. Water supply cycle starts.
2.After 1 minute, defrost cycle starts.
3.Thermistor reads 48°F (9°C). Defrost timer starts counting.
Water Valve |
Water Valve |
|
Hot Gas Valve |
Defrost
Cycle
Freeze
Cycle
Pump, Fan &
Line Valve
Timer
Defrost
IMPORTANT
Water valve opening is limited to 6 minutes.
5.After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when float switch circuit opens.
IMPORTANT
Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.
4.Defrost timer stops counting. Defrost cycle is completed and freeze cycle starts.
IMPORTANT
1.Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.
2.Defrost cycle time is limited to 20 minutes even if defrost timer does not stop counting.
13
2nd Cycle and after with pump drain
IMPORTANT
Freeze cycle time is limited by the freeze timer factory setting even if the float switch does not open.
1.Float switch opens and signals to complete freeze cycle. Drain timer starts counting.
2.Drain timer stops counting. Pump drain is completed.
Drain Pump
Hot Gas Valve
Defrost
Cycle
Freeze
Cycle
Pump, Fan &
Line Valve
Valve
Water
3.Thermistor reads 48°F (9°C). Defrost timer starts counting.
Defrost |
Timer |
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IMPORTANT |
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Water valve opening is |
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limited to 6 minutes. |
5.After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when float switch circuit opens.
4.Defrost timer stops counting. Defrost cycle is completed and freeze cycle starts.
IMPORTANT
Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.
IMPORTANT
1.Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.
2.Defrost cycle time is limited to 20 minutes even if defrost timer does not stop counting.
14
2nd Cycle and after with no pump drain
IMPORTANT
Freeze cycle time is limited by the freeze timer factory setting even if the float switch does not open.
1.Float switch opens and signals to complete freeze cycle.
2.Thermistor reads 48°F (9°C). Defrost timer starts counting.
Water Valve
Hot Gas Valve
Defrost
Cycle
Freeze
Cycle
Pump, Fan &
Line Valve
Timer
Defrost
IMPORTANT
Water valve opening is limited to 6 minutes.
4.After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when float switch circuit opens.
IMPORTANT
Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.
3.Defrost timer stops counting. Defrost cycle is completed and freeze cycle starts.
IMPORTANT
1.Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.
2.Defrost cycle time is limited to 20 minutes even if defrost timer does not stop counting.
15