Hoshizaki KM-1600SWF3, KM-1600SWF, KM-1600SRF3, KM-1600SRF User Manual

NO.:
ISSUED:
REVISED:

73079

DEC. 8, 1998

DEC. 16, 2003

HOSHIZAKI

STACKABLE CRESCENT CUBER

MODEL

KM-1600SWF
KM-1600SRF
KM-1600SWF3
KM-1600SRF3

SERVICE MANUAL

IMPORTANT

Only qualified service technicians should attempt to service or maintain this icemaker.
No 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 T echnical Support Department

Phone: [phone] T echnical Service

[phone]

Fax: [phone]

NOTE: T o expedite assistance, all correspondence/communication MUST include the following

information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem

2

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

PAGE

I. SPECIFICATIONS .............................................................................................................5

1. KM-1600SWF (Water-cooled) ......................................................................................5

2. KM-1600SRF (Remote air-cooled)...............................................................................6

3. KM-1600SWF3 (Water-cooled) ....................................................................................7

4. KM-1600SRF3 (Remote air-cooled).............................................................................8

5. CONDENSING UNIT, URC-20F ..................................................................................9

II. GENERAL INFORMATION .............................................................................................11

1. CONSTRUCTION...................................................................................................... 11

[a] KM-1600SWF, KM-1600SWF3 ............................................................................11

[b] KM-1600SRF, KM-1600SRF3..............................................................................12

2. CONTROLLER BOARD.............................................................................................13

[a] SOLID-STATE CONTROL ...................................................................................13

[b] CONTROLLER BOARD.......................................................................................1 3

[c] SEQUENCE ......................................................................................................... 18

[d] CONTROLS AND ADJUSTMENTS ....................................................................21

[e] CHECKING CONTROLLER BOARD ..................................................................24

III. TECHNICAL INFORMATION ........................................................................................26

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT...................................................26

[a] KM-1600SWF, KM-1600SWF3 ............................................................................26

[b] KM-1600SRF, KM-1600SRF3..............................................................................27

2. WIRING DIAGRAMS..................................................................................................28

[a] KM-1600SWF, KM-1600SRF ...............................................................................28

[b] KM-1600SWF3, KM-1600SRF3 ...........................................................................29

3. TIMING CHART .........................................................................................................30

4. PERFORMANCE DATA ............................................................................................32

[a] KM-1600SWF.......................................................................................................32

[b] KM-1600SRF .......................................................................................................33

[c] KM-1600SWF3.....................................................................................................34

[d] KM-1600SRF3 .....................................................................................................35

IV. SERVICE DIAGNOSIS .................................................................................................36

1. NO ICE PRODUCTION..............................................................................................36

2. EVAPORATOR IS FROZEN UP................................................................................39

3. LOW ICE PRODUCTION ...........................................................................................39

4. ABNORMAL ICE........................................................................................................40

5. OTHERS ....................................................................................................................40

3

V. REMOVAL AND REPLACEMENT OF COMPONENTS ............................................... 41

1. SERVICE FOR REFRIGERANT LINES ................................................................... 41

[a] REFRIGERANT RECOVERY ............................................................................. 41

[b] EVACUATION AND RECHARGE ...................................................................... 41

2. BRAZING .................................................................................................................. 42

3. REMOVAL AND REPLACEMENT OF COMPRESSOR........................................... 43

4. REMOVAL AND REPLACEMENT OF DRIER ......................................................... 44

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE................................... 45

6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE,...........................................

LINE VALVE AND GAS VALVE................................................................................ 46

7. REMOVAL AND REPLACEMENT OF EVAPORATOR ........................................... 47

8. REMOVAL AND REPLACEMENT OF WATER-REGULATING VALVE ......................

- WATER COOLED MODEL ONLY.......................................................................... 48

9. ADJUSTMENT OF WATER-REGULATING VALVE ....................................................

- WATER COOLED MODEL ONLY.......................................................................... 49

10. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE ...........................

REGULATOR (C.P.R.) - REMOTE AIR-COOLED MODEL ONLY ............................ 50

11. REMOVAL AND REPLACEMENT OF THERMISTOR ............................................. 51

12. REMOVAL AND REPLACEMENT OF FAN MOTOR................................................ 52

13. REMOVAL AND REPLACEMENT OF WATER VALVE ........................................... 52

14. REMOVAL AND REPLACEMENT OF PUMP MOTOR............................................. 5 3

15. REMOVAL AND REPLACEMENT OF SPRAY TUBES ........................................... 54

VI. MAINTENANCE AND CLEANING INSTRUCTIONS .................................................. 55

1. PREPARING THE ICEMAKER FOR LONG STORAGE........................................... 55

2. CLEANING PROCEDURE ....................................................................................... 57

[a] CLEANING PROCEDURE ................................................................................. 58

[b] SANITIZING PROCEDURE................................................................................ 5 9

3. MAINTENANCE........................................................................................................ 60

4

I. SPECIFICATIONS

1. KM-1600SWF

5

2. KM-1600SRF

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We reserve the right to make changes in specifications and design without prior notice.

6

3. KM-1600SWF3

AC SUP P LY VOLTAGE 208-230/60/3
AM P E RA GE 9.5 A ( 5 M in. Freeze A T 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 20 A
MAXIMUM FUSE SIZE 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PE R 24 HR. Temp.(°F) 50 70 90
lbs . /day ( k g/ day ) 70 *1500 (680) 1495 (678) 1451 (658)
Reference without *m ark s 80 1496 (679) 1489 (675) 1423 (646)

90 1495 (678) *1484 (673) 1426 (647)

100 1473 (668) 1470 (667) 1373 (623)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 30.9 lbs. ( 14 k g ) 1440 pc s.
APPROXIMATE STORAGE CAPACITY N/A
ELE CTRIC & WATER CONSUMP TION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 2597 (4.2) 2563 (4.1)
POTABLE WATER 463 (31.2) 887 (59.1)
WATER COOLED CONDENSER 1914 (129.0) 1005 (67.0)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDx H) 48" x 27-3/ 8" x 27 3/ 8" (1219 x 695 x 695 mm)
EXTERIOR FINISH St ai nless Steel, G alvanized Steel (Rear)
WEIGHT Net 310 lbs . ( 141 kg ), S hippi ng 360 lbs. ( 163 k g )
CONNECTIONS - ELECTRIC Permanent - Connec t i on

- WATER SUPPLY Inlet 1/2" FPT Cond. Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT Cond. Outlet 1/2" FPT

3/8" OD P i pe
CUBE CONTROL SYSTEM Float S wi tc h
HARVESTING CONTROL SYSTEM Hot Gas and Wat er, Thermis tor and Timer
ICE MAK ING W ATER CONTROL Timer Controlled. Overfl ow P i pe
COOLING WATER CONTROL Water Regulator
BIN CO NTROL SYSTEM Thermost a t
COMPRE SSO R Hermetic, Model CS20K 6 E-P F V
CONDENSER Water-cooled, Tube in tube t ype
EV A PORATOR Vert ical t ype, S t ai nless S teel and Copper
REFRIGERA NT CONTROL Thermostat i c Ex pansion Val ve
REFRIGERA NT CHARGE R-404A, 3 lb. 1 oz. ( 1400 g )
DESIGN PRESSURE High 427 PSIG, Low 230 PSIG
P.C. BOA RD CIRCUIT PRO TE CTION High Voltage Cu t-out ( Internal )
COMPRE S SOR PROTECTION Aut o-res et O verload Prot ector ( Internal )
REF R IGERANT CIRCUIT PROTE CTION Au to-reset Hi g h Pres sure Co ntrol Switch
LOW W ATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin
OPE RA TING CONDITIONS VOLTAGE RA NGE 187 - 253 V

AM B IENT TEM P. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

We reserve t he right to mak e c hanges in specific at i ons and design without pri or not i c e.

7

4. KM-1600SRF3

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8

5. CONDENSING UNIT

URC-20F

9

MODEL: URC-20F

SPECIFICATIONS

EXTERIOR

DIMENSIONS (W x D x H)

REFRIGERANT CHARGE

URC-20F

WEIGHT

CONNECTIONS

REFRIGERANT
ELECTRICAL

CONDENSER

HEAD PRESSURE CONTROL

AMBIENT CONDITION

Galvanized Steel

46 - 3/8" x 15 - 11/16" x 25 - 15/16"
(1178 x 398 x 659 mm)

R404A 7 lbs.11 oz. (3500 g)

Net 104 lbs. (47 kg)
Shipping 150 lbs. (52 kg)

One Shot Couplings (Aeroquip)
Permanent Connection

Air-cooled

Condensing Pressure Regulator

Min. -20°F - Max. +122°F
(-29°C to +50°C)
Outdoor use

10

II. GENERAL INFORMATION

1. CONSTRUCTION

[a] KM-1600SWF, KM-1600SWF3

Evaporator Spray Tube Water Valve

Water Supply Inlet

Expansion Valve

Hot Gas Valve
Junction Box
Water-cooled

Condenser
Check Valve
Control Box
Water Regulator

Water Pump
Float Switch Drier
Cleaning Valve Line Valve
Compressor Transformer Box

(KM-1600SWF3)

Control Switch Bin Control Thermostat Capacitor Box

(KM-1600SWF)

11

[b] KM-1600SRF, KM-1600SRF3

Evaporator Spray Tube Water Valve

Expansion Valve

Water Supply Inlet
Hot Gas Valve
Junction Box
Check Valve
Control Box
Receiver Tank

Water Pump
Float Switch Drier
Cleaning Valve Line Valve
Compressor Transformer Box

(KM-1600SRF3)

Control Switch Bin Control Thermostat Capacitor Box

(KM-1600SRF)

12

2. CONTROLLER BOARD

[a] SOLID-STATE CONTROL

1) A HOSHIZAKI exclusive solid-state control is employed in KM-2000SWF3 and
KM-2000MRF3 Stackable Crescent Cubers.

2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high
quality control system.

3) All models are pretested and factory-adjusted.

[b] 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.

PART NUMBER TYPE

2A0836-01 HOSIZAKI-001 (Control Products - 8 Pin)

or 2A1410-01 HOS-001A (Control Products - 10 Pin)

Features of Control Products “E” Controller Board

1) 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.

13

2) 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 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.

3) High Temperature Safety - 127 ± 7°F
The temperature of the suction line in the refrigerant circuit is limited by the High Tempera-

ture Safety.
During the defrost cycle the Evaporator temperature rises. The Thermistor senses 48°F
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 the Thermistor operates the High Tempera­ture Safety.
This High Temperature Safety shuts down the circuit and the icemaker automatically
stops. To reset the safety, turn the power off and back on again.
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.

4) 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.

5) 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.

6) LED Lights and Audible Alarm Safeties
The red LED indicates proper control voltage and will remain on unless a control voltage

14

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.

The green LED’s 1-4 represent the corresponding relays and energize and sequence 5
seconds from initial startup as follows:

Sequence Step LED’s on Length: Min. Max. Avg.

1 Minute Fill Cycle LED4 60 sec.
Harvest Cycle LED1, 4, & 2 2 min. 20 min. 3-5 min.
Freeze Cycle LED1 5 min. 60 min. 30-35 min.
Reverse Pump Out LED1, 3, & 2 10 sec. 20 sec. Factory set.

{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:

1 beep every 3 sec. = High Evaporator Temperature >127 ° F.
Check for defrost problem (stuck HGV or relay), hot water entering unit, stuck headmaster,

or shorted thermistor.
2 beeps every 3 sec. = Defrost Back Up Timer. Defrost >20 minutes.

Orange LED marked 20 MIN energizes.
Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient
compressor.

3 beeps every 3 sec. = Freeze Back Up Timer. Freeze > 60 minutes.
Yellow LED marked 60 MIN energizes.
Check for F/S stuck closed (up), WV leaking by, HGV leaking by, TXV not feeding prop­erly, low charge, or inefficient compressor.

To manually reset the above safeties, depress white alarm reset button with the power
supply ON.

6 beeps every 3 sec. = Low Voltage. Voltage is 92 Vac or less.
7 beeps every 3 sec. = High Voltage. Control voltage > 147Vac ±5%.

The red LED will de-energize if voltage protection operates.
The voltage safety automatically resets when voltage is corrected.

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.

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

15

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 HOSHIZAKI001 Board)

16

(Control Products HOS-001A Board)

17

[c] SEQUENCE

1st Cycle [KM-1600SWF, KM-1600SWF3, KM-1600SRF and KM-1600SRF3]

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.
Defrost Timer starts counting.

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.

IMPORTANT

Water Valve
opening is limited
to 6 minutes.

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.

18