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Hoshizaki
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KM1601SRJ3
User Manual
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Specifications
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Part List
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User Manual
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Hoshizaki KM1601SRJ3, KM1301SRJ3 User Manual

Service Manual
Modular Crescent Cuber
Models
KM-1301SAJ/3, SWJ/3, SRJ/3 KM-1601SAJ/3, SWJ/3, SRJ/3 KM-1900SAJ/3, SWJ/3, SRJ/3 KM-2200SWJ3, SRJ3 KM-2600SWJ3, SRJ3
Number: 73216 Issued: 10-27-2017 Revised: 5-30-2018
WARNING
Only qualied service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certied Service Representative, visit www.hoshizaki.com. No installation or service should be undertaken until the technician has thoroughly read this Service Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation. Failure to install, operate, and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. Proper installation is the responsibility of the installer. Product failure or property damage due to improper installation is not covered under warranty.
Hoshizaki provides this manual primarily to assist qualied service technicians in the installation, maintenance, and service of the appliance.
Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance.
Phone: 1-800-233-1940; (770) 487-2331 Fax: 1-800-843-1056; (770) 487-3360
E-mail: techsupport@hoshizaki.com
618 Highway 74 South Peachtree City, GA 30269 Attn: Hoshizaki Technical Support Department
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
• Model Number
• Serial Number
• Complete and detailed explanation of the problem.
2
IMPORTANT
This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary.
CONTENTS
Important Safety Information ................................................................................................. 6
I. Construction and Water/Refrigeration Circuit Diagram ....................................................... 8
A. KM Construction............................................................................................................ 8
1. Air-Cooled Models (SAJ/3) ....................................................................................... 8
2. Water-Cooled Models (SWJ/3) ................................................................................ 9
3. Remote Models (KM-1301SRJ/3 and KM-1601SRJ/3) .......................................... 10
4. Remote Models (KM-1900SRJ/3, KM-2200SRJ3, KM-2600SRJ3) ........................11
B. Bin Control .................................................................................................................. 12
1. Single Bin Control .................................................................................................. 12
2. Stacked Bin Control ............................................................................................... 12
C. Water/Refrigeration Circuit Diagram ............................................................................ 13
1. Air-Cooled Models (SAJ/3) ..................................................................................... 13
2. Water-Cooled Models (SWJ/3) .............................................................................. 14
3. Remote Models (SRJ/3) ........................................................................................ 15
II. Sequence of Operation and Service Diagnosis ............................................................... 16
A. Sequence of Operation Flow Chart ............................................................................. 16
1. Operation Flow Chart ............................................................................................ 16
2. Shutdown Flow Chart ............................................................................................ 17
3. Freeze-Time Correction Chart ............................................................................... 18
B. Service Diagnosis ....................................................................................................... 19
C. Freeze-Time Correction Cycle (90 min.) ..................................................................... 26
D. Control Board Check ................................................................................................... 28
E. Bin Control Check ....................................................................................................... 29
1. Bin Control Check .................................................................................................. 29
2. Bin Control Cleaning .............................................................................................. 30
F. Float Switch Check and Cleaning ................................................................................ 31
1. Float Switch Check ................................................................................................ 31
2. Float Switch Cleaning ............................................................................................ 32
G. Thermistor Check ........................................................................................................ 33
H. Control Switch ............................................................................................................. 33
I. Diagnostic Tables .......................................................................................................... 34
J. Freeze-Up Check List .................................................................................................. 38
3
III. Controls and Adjustments ............................................................................................... 39
A. Control Board Layout .................................................................................................. 40
B. LED Lights and Audible Alarm Safeties ....................................................................... 41
C. Settings and Adjustments ............................................................................................ 42
1. Default Dip Switch Settings .................................................................................... 42
2. Harvest Time (S4 dip switch 1 & 2)........................................................................ 43
3. Pump-Out Time/Harvest Time During Pump-Out (S4 dip switch 3 & 4) ................. 43
4. Pump-Out Frequency Control (S4 dip switch 5) ..................................................... 44
5. Harvest Pump Time (Harvest Assist) (S4 dip switch 6) ......................................... 44
6. Harvest Pump Time (Harvest Assist)/Freeze-Time Correction (S4 dip switch 7) .. 45
7. Factory Use (S4 dip switch 8)................................................................................. 45
8. Freeze Timer (S4 dip switch 9 & 10) ...................................................................... 46
9. Float Switch Selector (S5 dip switch 1) ................................................................. 46
10. Rell Counter (S5 dip switch 2 and 3) .................................................................. 46
IV. Refrigeration Circuit and Component Service Information.............................................. 48
A. Refrigeration Circuit Service Information .................................................................... 48
B. Component Service Information .................................................................................. 51
C. Water Regulating Valve Adjustment (water-cooled models) ........................................ 52
V. Maintenance .................................................................................................................... 53
VI. Preparing the Icemaker for Periods of Non-Use ............................................................. 54
VII. Disposal ......................................................................................................................... 56
VIII. Technical Information .................................................................................................... 57
A. Specication and Performance Data ........................................................................... 57
1. KM-1301SAJ .......................................................................................................... 57
2. KM-1301SAJ3 ........................................................................................................ 58
3. KM-1301SWJ ........................................................................................................ 59
4. KM-1301SWJ3 ...................................................................................................... 60
5. KM-1301SRJ with URC-14F .................................................................................. 61
6. KM-1301SRJ3 with URC-14F ................................................................................ 62
7. KM-1601SAJ .......................................................................................................... 63
8. KM-1601SAJ3 ........................................................................................................ 64
9. KM-1601SWJ ......................................................................................................... 65
10. KM-1601SWJ3 ..................................................................................................... 66
11. KM-1601SRJ with URC-22F ................................................................................. 67
12. KM-1601SRJ3 with URC-22F .............................................................................. 68
13. KM-1900SAJ ........................................................................................................ 69
14. KM-1900SAJ3 ...................................................................................................... 70
15. KM-1900SWJ ...................................................................................................... 71
16. KM-1900SWJ3 .................................................................................................... 72
17. KM-1900SRJ with URC-22F ................................................................................ 73
18. KM-1900SRJ3 with URC-22F ...............................................................................74
19. KM-2200SWJ3 .................................................................................................... 75
20. KM-2200SRJ3 with URC-22F ............................................................................. 76
21. KM-2600SWJ3 ..................................................................................................... 77
22. KM-2600SRJ3 with URC-26F ............................................................................. 78
4
B. Wiring Diagrams .......................................................................................................... 79
1. Single Phase Models ............................................................................................. 79
a) KM-1301S_J ..................................................................................................... 79
b) KM-1601S_J ..................................................................................................... 80
c) KM-1900S_J ..................................................................................................... 81
2. Three Phase Models .............................................................................................. 82
a) KM-1301S_J3 ................................................................................................... 82
b) KM-1601S_J3 ................................................................................................... 83
c) KM-1900_2200_2600S_J3 ............................................................................... 84
5

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
NOTICE Indicates a situation which could result in damage to the
appliance or property.
IMPORTANT Indicates important information about the use and care of the
appliance.
WARNING
The appliance should be destined only to the use for which it has been expressly conceived. Any other use should be considered improper and therefore dangerous. The manufacturer cannot be held responsible for injury or damage resulting from improper, incorrect, and unreasonable use. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
To reduce the risk of death, electric shock, serious injury, or re, follow basic precautions including the following:
• Only qualied service technicians should install and service this appliance.
• The appliance must be installed in accordance with applicable national, state, and local codes and regulations. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage to the appliance.
• Electrical connection must be hard-wired and must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage.
• The icemaker requires an independent power supply of proper capacity. See the nameplate for electrical specications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuse, damage to existing wiring, or component failure. This could lead to heat generation or re.
• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker could result in death or serious injury.
• To reduce the risk of electric shock, do not touch the control switch with damp hands.
• Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
• Do not make any alterations to the appliance. Alterations could result in electric shock, serious injury, re, or damage.
6
WARNING, continued
• The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
• Children should be properly supervised around the appliance.
• Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged.
• Do not use combustible spray or place volatile or ammable substances near the appliance. They might catch re.
• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance.
Additional Warning for Remote Models
• THE REMOTE CONDENSER UNIT MUST BE GROUNDED. The power supply and ground connection to the remote condenser unit are supplied from the icemaker. Failure to properly ground the remote condenser unit could result in death or serious injury.
• Wire routing (conduit) and disconnect (if required) must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage.
• Move the icemaker control switch to the "OFF" position and turn off the power supply to the icemaker before servicing the remote condenser unit. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
NOTICE
• Follow the instructions in this manual carefully to reduce the risk of costly water damage.
• In areas where water damage is a concern, install in a contained area with a oor drain.
• Install the appliance in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C).
• Do not leave the appliance on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the appliance for these occasions, follow the instructions in "VI. Preparing the Icemaker for Periods of Non-Use."
• Do not place objects on top of the appliance.
• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in the dispenser unit/ice storage bin.
7

I. Construction and Water/Refrigeration Circuit Diagram

A. KM Construction

1. Air-Cooled Models (SAJ/3)

Evaporator Assembly
Cleaning Valve
Check Valve (water)
Water Pump
Inlet Water Valve
Spray Tubes
Low-Side Service Valve
High-Side Service Valve
Thermostatic Expansion Valves
Water Supply Inlet
Junction Box
Hot Gas Valve
Check Valves (refrigeration)
Condenser
Control Box
Fan Blade
Float Switch
Compressor
Control Switch
Model Shown: KM-1301SAJ3
8
Drier
Liquid Line Valve
Transformer Box
Fan Motor
High-Pressure Switch

2. Water-Cooled Models (SWJ/3)

Evaporator Assembly
Cleaning Valve
Check Valve (water)
Water Pump
Float Switch
Inlet Water Valve
Compressor
Spray Tubes
Low-Side Service Valve
High-Side Service Valve
Thermostatic Expansion Valves
Water Supply Inlet
Junction Box
Hot Gas Valve
Check Valves (refrigeration)
Water-Cooled Condenser
Water Regulating Valve
Control Switch
Transformer Box
Model Shown: KM-1301SWJ3
9
Drier
Control Box
Liquid Line Valve

3. Remote Models (KM-1301SRJ/3 and KM-1601SRJ/3)

Evaporator Assembly
Check Valve (water)
Spray Tubes
Inlet Water Valve
Low-Side Service Valve
High-Side Service Valve
High-Side Liquid Service Valve
Water Supply Inlet
Hot Gas Valve
Junction Boxes
Check Valves (refrigeration)
Receiver
Water Pump
Float Switch
Cleaning Valve
Compressor
Model Shown: KM-1301SRJ
Thermostatic Expansion Valves
10
Control Box
Drier
Liquid Line Valve
Transformer Box

4. Remote Models (KM-1900SRJ/3, KM-2200SRJ3, KM-2600SRJ3)

Evaporator Assembly
Check Valve (water)
Inlet Water Valve
Spray Tubes
Low-Side Service Valve
High-Side Service Valve
High-Side Liquid Service Valve
Water Supply Inlet
Hot Gas Valve
Check Valves (refrigeration)
Thermostatic Expansion Valves
Control Box
High-Pressure Switch
Water Pump
Float Switch
Cleaning Valve
Compressor
Control Switch
Model Shown: KM-2200SRJ3
Note: KM-2600SRJ3 Includes Headmaster (C.P.R.)
Transformer Box
11
Receiver
Drier
Liquid Line Valve

B. Bin Control

1. Single Bin Control

Mechanical Bin Control Connection Overview
Wire Harness Connector B (for upper unit)
Thumbscrews
Bin Control Cable Connector to Wire Harness Connector A
Bin Control Bracket
Bin Control Assembly

2. Stacked Bin Control

Upper Unit Connection Overview
Lower Unit Wire Harness Connector B to
Upper Unit Wire Harness Connector A Upper Unit Wire Harness Connector B (not used)
Bin Control Cable Bracket
Wire Harness
Control Board Red K4 Connector
Wire Saddle
Bin Control Cable Bracket
Bin Control Cable
Upper Unit Wire Harness
Control Board Red K4 Connector
Lower Unit Wire Harness
Wire Saddle
Control Board Red K4 Connector
Wire Harness Connector B (for upper unit)
Bin Control Cable Connector
Upper Unit Connection Detail
Upper Unit Wire Harness Connector B (not used)
Lower Unit Wire Harness Connector B
See "II.D.1. Dispenser Unit/Ice Storage Bin and Icemaker Setup" and "II.D.2. Bin Control Installation" for the Lower Unit Connection
Connection Detail
Wire Harness Connector A
Control Board Red K4 Connector
Upper Unit Wire Harness Connector A
Control Board Red K4 Connector
12

C. Water/Refrigeration Circuit Diagram

1. Air-Cooled Models (SAJ/3)

Hot Gas
Val ve
High-Pressure
Switch
Check
Valves
Strainer
Drier
Fan Speed Control
Pressure Switch
KM-1601SAJ/3
Suction Line
Fan
Condenser
Water Supply
Inlet Water Valve
Spray Tubes
Cleaning Valve
Liquid Line
Thermistor
Val ve
Heat Exchanger
Service
Val ve
Service
Val ve
Float Switch
Check Valve
Discharge Line
Compressor
Thermostatic Expansion Valves
Drain
Water Pump
Pump-Out
Spray Tubes
Evaporator
13
Water
Tank
Freeze/Harvest
Pump Timer
Refrigeration Circuit
Water Circuit

2. Water-Cooled Models (SWJ/3)

Check
Valves
Water Regulating Valve
Drain/Return
Condenser
Water Supply
High-Pressure
Switch
Hot Gas
Val ve
Strainer
Drier
Service
Val ve
Discharge Line
Suction Line
Liquid Line
Val ve
Service
Val ve
Compressor
Thermostatic Expansion Valves
Heat Exchanger
Thermistor
Cleaning Valve
Float Switch
Drain
Water Supply
Inlet Water Valve
Spray Tubes
Check Valve
Water Pump
Pump-Out
Evaporator
Freeze/Harvest
Pump Timer
Water
Tank
Refrigeration Circuit
Water Circuit
Spray Tubes
14

3. Remote Models (SRJ/3)

Service
Val ve
Fusible Plug
High Pressure
Hot Gas
Switch
Check
Valves
Val ve
Strainer
KM-2500SRH3: Headmaster
located in icemaker
Condenser
Water
Service
Val ve
Discharge Line
Suction Line
Receiver
Drier
Headmaster
(C.P.R.)
Service
Liquid Line
Val ve
Fan
Heat Exchanger
Val ve
Compressor
Expansion Valves
Thermistor
Cleaning Valve
Supply
Inlet Water Valve
Float Switch
Check Valve
Drain
Water Pump
Spray Tubes
Spray Tubes
Evaporator
15
Water
Tank
Pump-Out
Freeze/Harvest
Pump Timer
Refrigeration Circuit
Water Circuit

II. Sequence of Operation and Service Diagnosis

A. Sequence of Operation Flow Chart

1. Operation Flow Chart

10th cycle
(S4 dip switch 5)
2 sec., then reverses
for 10/20 sec.
• Factory set for every
4. Pump-Out Cycle
• Pump motor stops for
(S4 dip switch 3 & 4)
FS in control
FS opens or freeze
timer terminates
Comp energized
FM*/FMR energized
HGV energized
PM de-energizes for 2 sec.,
then reverses for 10/20 sec.
Anti-Slush
Thermistor temperature
reaches 36°F (2.2°C)
(5.8 kΩ).
PM de-energized for
FM* de-energized
LLV de-energized
10 sec.
CB: 2A7664-02
When freeze time differential exceeded,
freeze-time correction cycle starts.
See "II.A.3. Freeze-Time Correction
Chart."
FS closed
50 sec.
Comp energized
FM energized
FMR energized
PM energized
LLV energized
HGV de-energized
FS check
FS open
3. Freeze Cycle
• Min. freeze time: 5 min.
• Max. freeze time: freeze timer setting
(S4 dip switch 9 & 10).
5-min.
minimum
freeze timer
in control
Harvest Pump
Time
Operation Flow Chart
PM energized
1 to 3-min. harvest timer in
control (S4 dip switch 1 & 2)
Thermistor
in control
HPT setting (S4 dip switch 6), whichever is
shorter.
• WV time: 6 min. or the length of harvest minus
2. Harvest Cycle
• Max. harvest time: 20 min.
WV de-energized
FS closed
Comp energized
Thermistor temperature reaches
48°F (9°C) (3.9 kΩ or less).
Harvest timer starts.
FM*/FMR energized
HGV energized
WV energized
FM* – FM energized in 2. Harvest Cycle and
4. Pump-Out Cycle when connected to CB
K1 connector pin #9.
Components Energized when the Control Switch is in the "WASH" Position
The "WASH" position on the control switch is used when cleaning and sanitizing the unit. When in the "WASH" position,
power is supplied to the pump motor. With the cleaning valve closed, the cleaner and sanitizer ow over the outside of the
evaporator plate assembly. With the cleaning valve open, the cleaner and sanitizer ow over both the outside and the inside
of the evaporator plate assembly.
Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not restart when the control
switch is placed in the "ICE" position.
WV energized
FS open
16
If FS is open, Comp stops and cycle
returns to 1-Min. ll.
Legend:
BC–bin control
CB–control board
Comp–compressor
FM*–fan motor
FMR–fan motor-remote
FS–oat switch
HGV–hot gas valve
HPT–harvest pump time
LLV –liquid line valve
PM–pump motor
WV–inlet water valve
Fill Cycle
1. 1-Minute
Cycle
Steps
FS check
Startup

2. Shutdown Flow Chart

3. Ice Level Lowered
Icemaker starts at
"1. 1-Minute Fill Cycle."
To 1. 1-Minute Fill Cycle
BC closed
(BC actuator paddle disengaged)
Green "BC CLOSED" LED on
Yellow "BC OPEN" LED off
2. Icemaker Off
All components
de-energized.
Yellow "BC OPEN" LED continues.
All components de-energized.
Shutdown Flow Chart
Control board 2A7664-02 retains freeze-time
correction count data between bin control restarts.
to 15 sec. into the freeze cycle if
activated at the end of the harvest cycle.
15 sec. before the 5-min. short cycle
protection timer terminates.
Otherwise, at the end of the next harvest
cycle.
BC open (BC actuator paddle engaged)
Green "BC CLOSED" LED off
Yellow "BC OPEN" LED on
Legend:
BC–bin control
1. Bin Full
Shutdown Delay:
• Fill Cycle–15 sec. after activation.
• Harvest Cycle–At the end of the harvest cycle, or up
• Freeze Cycle– 15 sec. after activation if activated at least
Shutdown
and Restart
BC Operation
17

3. Freeze-Time Correction Chart

2. 10-Minute Fill/Overow
WV energized
Comp de-energized
FMR de-energized
HGV de-energized
PM de-energized
After 5th 10-Minute Harvest Pump Cycle with WV
Freeze-Time Correction Cycle Complete.
Go to Step "3. Freeze Cycle" in Operation Flow Chart.
repeat step 1 for 5th and nal time.
• Do not adjust S4 dip switch 7 out of the factory position.
• After step 2 completes 4th sequence (80 min. completed),
1. 10-Minute Harvest Cycle with WV Comp energized
FMR energized
HGV energized
PM energized
WV energized
2A7664-02 Freeze-Time Correction Flow Chart
Cycle Steps
Steps 1 and 2 repeat
4 times (total 80 min.),
then step 1 repeats for
a 5th time to complete
Freeze-Time Correction
Start
Legend:
Comp–compressor
FM–fan motor
FMR–fan motor-remote
HGV–hot gas valve
PM–pump motor
WV–inlet water valve
Appliance Cycle Reset and Alarm Reset:
Cycle Reset: Power Supply or Control Switch Turned Off and On
again: Appliance turns off, then re-starts at 1.Fill Cycle.
Alarm Reset: CB "ALARM RESET" pressed during or after a
freeze-time correction cycle with power supply on:
Appliance continues cycle with no interruption or reset.
CB red "POWER OK" LED blinking:
CB red "POWER OK" LED resets to solid.
CB yellow "EXT HARVEST" LED blinking:
Cycle.
Differential
Value in Sec.
3 254
4 309
5 349
6 380
7 406
8 427
9 446
10 462
CB yellow "EXT HARVEST: LED turns off.
Freeze Time Differential Exceeded.
Minimum and Maximum Freeze times
have exceeded differential parameters.
Freeze-Time Correction function is
enabled when S4 Dip Switch 7 is in the
"ON" position. CB monitors freeze time.
After 3freeze cycles, CB compares the
minimum and maximum differential of
the 3 freeze cycle times. Every freeze
cycle time after the third freeze cycle
time is added to the minimum/maximum
calculation.
Example: After 8 cycles, if the differential
between the shortest cycle (minimum)
and the longest cycle (maximum) is equal
to or greater than 427 sec. a freeze-time
correction cycle is initiated:
Number of
Freeze Cycles
18
Note: When 1st freeze-time correction
cycle is initiated, CB "POWER OK"
LED starts blinking. On 2nd freeze-time
correction cycle, if CB "POWER OK"
LED has been reset, CB "POWER OK"
LED starts blinking. If CB "POWER OK"
had not been reset after 1st freeze-time
correction cycle CB "POWER OK" LED
continues to blink.
After 3rd freeze-time correction cycle in
36hours, CB yellow "EXT HARVEST"
LED starts blinking.
Appliance continues to operate and LEDs
continue to blink until ALARM RESET
button is pressed with power on.

B. Service Diagnosis

WARNING
• The appliance should be diagnosed and repaired only by qualied service personnel to reduce the risk of death, electric shock, serious injury, or re.
• Risk of electric shock. Control switch in "OFF" position does not de-energize all loads Use extreme caution and exercise safe electrical practices.
• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
• Before servicing the appliance, move the control switch to the "OFF" position and turn off the power supply.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the appliance is serviced. Make sure that none have fallen into the dispenser unit/ice storage bin.
• Make sure all food zones in the appliance and dispenser unit/ice storage bin are clean after service.
The diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, proper voltage per nameplate, and adequate water supply. Check CB using the steps in "II.D. Control Board Check." Check dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10 and S5 dip switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, 6 are cleaning adjustments and the settings are exible. For factory default settings, see "III.C.1. Default Dip Switch Settings."
Note: • When checking high voltage (115VAC), always choose a white (W) neutral wire to
establish a good neutral connection.
• On models with a main transformer, the neutral (W) is provided through MT. To conrm a good neutral, check for 60VAC from white (W) neutral to ground (GND). If 60VAC is present, neutral is good. If 60VAC is not present, check 208-230VAC main power supply to MT. If 208-230VAC is present, check MT continuity.
• When checking voltage from the CB K1 connector (10 pin connector), pull CB K1connector out slightly to allow room for multimeter test leads contact.
1) Turn off the power supply, then access the control box. Move the control switch to the "OFF" position. Clear any ice from BC.
2) Check that BC is closed and the 115VAC 10A fuse is good.
19
1. Operation Diagnosis
3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5-sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on. If yellow "BC OPEN" LED is on (indicating a full bin), check BC. Move ice away from BC actuator paddle. If yellow "BC OPEN" LED stays on, see "II.D. Bin Control Check.".
Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is
interrupted (K2 connector).
• Check CB using the steps in "II.C.Control Board Check."
• Conrm CB green "BC CLOSED" LED is on. If CB yellow "BC OPEN" LED is on, remove ice from BC. If no ice is around BC and yellow "BC OPEN" LED is on, see "II.D.2. Bin Control Check."
a) Power On Diagnosis: If CB red "POWER OK" LED is off, conrm 10A fuse is good.
Check for 115VAC at control switch #1 (BR) to neutral (W) then at control switch #2(P) to neutral (W). If 115VAC is present on #1 (BR) and not on #2(P), replace control switch. If 115VAC is present on control switch #2 (P), check for 115VAC at HPS (P) to neutral (W) then HPS (BK) to neutral (W). If115VAC is present at HPS (P) and not at HPS (BK), HPS is open. See HPS Diagnosis below. If115VAC is present at HPS (BK), check for 10.5VAC at CB K2#1 red wire to CB K2 #2 red wire. If10.5VAC is not present, check that the cleaning valve interlock switch is closed. Next, check CT continuity. If open, replace CT.
b) HPS Diagnosis: Conrm condenser coil is not clogged or restricted. Let refrigeration
circuit pressures equalize. If HPS does not reset and pressures are equalized, replace HPS. Ifpressures are not equalized, reclaim refrigerant and diagnose refrigeration circuit restriction. Check that there are no restrictions in the refrigeration circuit. Harvest Cycle: HGV, strainer, or check valve. Freeze Cycle: FM, FMR, TXV, HM, LLV, WRV, strainer, check valve, drier, damaged line set or tting, and fan blade for binding.
Conrm that the location meets installation requirements. See the appliance's
instruction manual for details.
4) 1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGV, FMR energized), continue to step 5a. If FS is open, WV remains energized until FS closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: Check that water enters the water tank. If not, check that the water supply line shut-off valve is open and screens or external lters are clear. Check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, and WV does not energize, check for 115VAC at WV. If 115VAC is present, check coil continuity. Ifopen, replace WV. If the water tank lls, but the appliance fails to start harvest (Comp energized), check for open FS. See "II.E. Float Switch Check and Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace CB.
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5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp,
FM* (if connected to CB K1 connector pin #9), FMR, HGV, and X10 relay energize. CBmonitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5dip switch 4). WV and X11 relay are energized during harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), whichever is shorter. See step 5b below.
a) Comp Diagnosis: Check that evaporator is warming. Ifnot, conrm that Comp
energizes. If not, check for 115VAC at CB K1 #1 (V) or #9 (V) to neutral (W). If115VAC is not present, check for 115VAC at CB K1 #7 (BR) or #10 (BR) to neutral (W). If115VAC is present at #7 (BR) or #10 (BR) and not at #1 (V) or #9 (V), replace CB. If 115VAC is present, check for 115VAC at CR or MC solenoid. If 115VAC is present, conrm contacts are closed. If not, replace CR or MC. If CR or MC contacts are closed, check Comp external overload, Comp start and run capacitors, Comp start relay, and Comp motor winding.
b) HGV Diagnosis: If Comp is energized and evaporator is not warming, check that
HGV energizes and opens. Check for 115VAC at CB K1 #2 (P) to neutral (W). If115VAC is not present and LED 2 is on, replace CB. If 115VAC is present, check for 115VAC at HGV coil and check HGV coil continuity. Replace as needed.
c) LLV Diagnosis: Conrm that LLV is de-energized and closed (not bypassing).
Ifenergized, replace CB. If de-energized and bypassing, replace LLV.
d) FM* Diagnosis (if connected to CB K1 connector pin #9):
KM-1301SAJ3: Check that FM* is energized and fan blades are turning. If not, check FM* capacitor, motor winding, and fan blade for binding. Note: FM* is energized at full speed RPMs (1600) during the harvest cycle and only capable of 1 speed. KM-1601SAJ/3: Check that FM* is energized and fan blades are turning. If not, check FM capacitor, motor winding, and fan blade for binding. Note: KM-1601SAJ/3 FM* is capable of 2speeds and is energized at slower RPMs (700) during the harvest cycle through the fan speed control pressure switch. If FM* is operating at high-speed RPMs (1600) during the harvest cycle, check condition of the fan speed control pressure switch. When open, head pressure <190 +- 10 PSIG RPMs at 700. When closed, head pressure >250 +- 10 PSIG RPMs at 1600.
e) WRV Diagnosis: Conrm WRV is not leaking by. If WRV is leaking by, conrm HGV
is open and LLV is closed. Next, check for proper refrigerant pressures. If refrigerant pressures are correct, adjust or replace WRV. See "IV.C. Water Regulating Valve Adjustment (water-cooled models)."
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5b) Harvest Pump Time (Harvest Assist) – LEDs 1, 3, and 2 are on. When the
thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch4). WhenWV de-energizes, LED 4 turns off, X11 relay de-energizes and LED 3turns on. PM energizes. Comp, FM* (if connected to CB K1 connector pin #9), FMR, HGV, and X10relay continue. Diagnosis: Place a thermometer on the suction line next to the thermistor. Has it warmed to 48°F (9°C) or warmer? Conrm thermistor status. See "II.F. Thermistor Check." If the thermistor reading is in proper range, dip switch 7 is on, and PM does not energize before harvest terminates, replace CB. If WV continues, check for 115VAC at CB K1 #6 (O). If115VAC is present, and LED 4 is off, replace CB. If LED 3is on and PM is not energized, check for 115VAC at CB K1 #5(DBU). If115VAC is not present, replace CB. If 115VAC is present and PM is not energized, check for 115VAC at X10relay terminal #7 (Y) to neutral (W). If 115VAC is not present, check for 115VAC at X10 relay terminal #3 (P) to neutral (W) and X10 relay terminal #5 (Y) to neutral (W). If 115VAC is present on terminal #3(P) and not on terminal #5 (Y), replace X10 relay. If 115VAC is present on X10 relay terminal #7 (Y) and PM is not energized, check for 115VAC at X10 relay terminal #4 (R) to neutral (W) and terminal #6 (DBU) to neutral (W). If 115VAC is present on terminal #6(DBU) and not on terminal #4 (R), replace X10relay. If 115VAC is present on X10relay terminal #4 (R), check control switch contact continuity between terminals #4(R) and #5(R). Ifcontacts are open, replace control switch. If contacts are closed and 115VAC is present between control switch terminal #5(R) and neutral (W), check PM capacitor and motor winding continuity.
5c) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 48°F
(9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.F.Thermistor Check." If 1-min. ll cycle starts after harvest timer terminates, check that FS is clean and operating properly, see "II.E. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle. Ifnot, replace CB. Note: The minimum total time allowed by CB for a complete harvest cycle is based on
S5 dip switch 4. Maximum harvest time allowed is 20min.
NOTICE! S4 dip switch 7 must remain on. Otherwise, PM will not energize during the last seconds of harvest.
6) Freeze Cycle – LED 1 is on. Comp, FM* (if connected to CB K1 connector pin #9), FMR, and PM continue. FM (if not connected to CB K1 connector pin #9) and LLV energize. HGV and X10 relay de-energize. Appliance is held in freeze by a 5-min. short cycle protection timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle terminates. Note: PM power supply switches from CBK1 #5(DBU) in harvest to K1 #4 (R) in freeze. Anti-Slush: When anti-slush is enabled (S5 dip switch 5 "ON"), PM de-energizes when thermistor reaches 36°F (2.2°C) (5.8kΩ) for 10 sec. then, energizes for the remainder of the freeze cycle.
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a) Freeze Cycle Diagnosis: Conrm Comp, FM* (if connected to CB K1 connector pin
#9), FMR, and PM continue. Conrm that FM (if not connected to CB K1 connector pin #9) and LLV energize. Conrm WRV opens. Next, conrm HGV and X10 relay de-energize. During the rst 5 min. of freeze, conrm evaporator is cooling. If not, conrm WV de-energized (not leaking by), HGV de-energized (not bypassing), LLV and FM (if not connected to CB K1 connector pin #9) energize, TXV and HM operate correctly, WRV opens, Comp is efficient, and refrigerant charge is correct. See "VIII.A. Specication and Performance Data."
b) Comp, FM*, and FMR Diagnosis: If Comp. FM* (if connected to CB K1 connector
pin #9), and FMR de-energize once freeze begins, check that appliance has not shut off on HPS ("POWER OK" LED off). If so, check "3)b) HPS Diagnosis" above. If"POWER OK" LED is on, check for 115VAC at CB K1 #1 (V) or #9 (V) to neutral (W). If 115VAC is not present and LED 1 is on, replace CB. Comp: If 115VAC is present, check for 115VAC at CR or MC coil. If 115VAC is present, check CR or MC coil and contact continuity. Replace as needed. If CR or MC is okay, check Comp start relay and start and run capacitors. Next, check Comp motor winding continuity. If Comp is energized but evaporator is not cooling, check for an inefficient Comp. See "VIII.A. Specication and Performance Data." FM*: If Comp is energized but FM* is not, check capacitor, motor winding, and fan blade for binding. FMR: If Comp is energized but FMR is not, check for 115VAC at the FMR junction box. If 115VAC is not present, check icemaker wiring connections. If 115VAC is present, check for voltage at condenser unit. If115VAC is not present, check eld wiring connections. If 115VAC is present, check FMR capacitor, motor winding, and fan blade for binding.
c) WV and HGV Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to
neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB. If115VAC is not present, replace WV (bypassing). If HGV did not close at the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC is present and LED 3 is off, replace CB. If 115VAC is not present, replace HGV (bypassing).
d) PM Diagnosis: Conrm water is owing over evaporator from PM and not WV. If PM
de-energizes once freeze begins, check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized, check for 115VAC at control switch #5 (R) to neutral (W). If 115VAC is present at CB K1 #4 (R) and not at control switch #5 (R), check control switch continuity between #5 (R) and #4 (R). Replace as needed. If 115VAC is present at control switch #5 (R) to neutral (W), check PM capacitor and motor winding continuity.
e) FM and LLV Diagnosis: If FM (if not connected to CB K1 connector pin #9) or LLV
does not energize, check for 115VAC at CB K1#3 (BK) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present: For FM, check capacitor, motor winding, and blade for binding. For LLV, check coil voltage and continuity.
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f) Refrigerant Pressures, HM, and TXV Diagnosis: If evaporator is still not cooling,
check refrigerant pressures. See "VIII.A. Specication and Performance Data." Next, check HM operation. If refrigeration pressures are above HM setpoint and HMis bypassing, replace HM. Check TXV for proper operation. Remove TXV bulb and hold it in your hand, refrigerant low-side pressure should rise, place TXV bulb in ice water, refrigerant low-side pressure should drop. A 10 to 15 pound pressure swing between warm and cold conditions indicate a good TXV. If a 10 to 15 pound swing is not present, replace TXV.
g) WRV Diagnosis: WRV is factory set and generally no adjustment is required.
IfWRV fails to open in freeze, check for proper refrigerant pressures. See "VIII.A. Specication and Performance Data." If refrigerant pressures are correct and WRV does not open, adjust or replace as needed. See "IV.C. Water Regulating Valve Adjustment (water-cooled models)."
h) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS
connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with FS removed but would previously not switch out of freeze with FS connected (long freeze - 3 beep alarm), see "II.E. Float Switch Check and Cleaning."
Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions.
Cycle times and pressures should follow performance data provided in this manual. See "VIII.A. Specication and Performance Data."
i) Short Freeze Cycle Diagnosis: Conrm water tank lls and overows during ll and
harvest cycles. If not, check water supply lters, shut-off valve, WV screen. Ifwater tank empties before 5 min. timer terminates and freeze cycle is short, check that CV is not leaking by (water owing down the potable drain). If CV is leaking by, remove and clean CV, replace rubber seat and spring if necessary. If water tank is full, see "II.E. Float Switch Check and Cleaning." for erratic FS.
7) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the rst pump-out is determined by S4 dip switch 5. See the table below.
"J" Control Board Settings
S4 Dip
Switch
Setting
No. 5
OFF Every 10 cycles After 11th freeze cycle
ON Every cycle After 2nd freeze cycle
Pump-Out Frequency
1st Pump-Out
"J" Control Board
Comp, FM* (if connected to CB K1 connector pin #9), and FMR continue, HGV energizes. If S4dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV and X11 relay energize, energizing X10relay. NOTICE!S4dip switch 3 & 4 must
not be set to 3 off and 4 on. Otherwise, PM will rotate in freeze cycle direction instead of pump-out direction. FM (if connected to CB K1 connector pin #3) and
LLVde-energize. PM stops for 2 sec., then reverses for 10/20 sec. depending on pump-out timer (S4dip switch 3 & 4) setting. When the pump-out timer terminates,
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pump-out is complete. The pump-out frequency control (S4 dip switch 5) is factory set, and generally no adjustment is required. However, the pump-out frequency control can be set to have a pump-out occur every 10 cycles or every cycle. For details, see "III.C.4. Pump-Out Frequency Control (S4 dip switch 5)."
Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5min. of freeze disconnect CB black K5 connector (FS connector). Check that PM stops and re-starts. Next, check that PM rotation is correct (water owing down the drain through CV). If PM does not stop and re-start, check that CB LEDs 1, 3, and 2are on. If not, replace CB. IfLEDs1,3, and 2 are on and PM does not energize, check for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB. If115VAC is present, check that X10 relay is de-energized. If not, check X11 relay status. If X11 relay is energized, replace CB. If X11 relay is de-energized and X10 relay is energized, replace X11 relay (contacts sticking). If X10 relay is de-energized, check for 115VAC at terminal #6 (DBU) to neutral (W) and terminal #2 (DBU) to neutral (W). If 115VAC is present on terminal #6 (DBU) and not on terminal #2 (DBU), replace X10relay. If PM is energized and rotating in pump-out rotation, make sure the drain line is not clogged and that CV is clean and operating properly.
Conrm FM (if connected to CB K1 connector pin #3) and LLV de-energize. If FM is energized, conrm where FM is connected on CB. If connected to CB K1 connector pin #9, FM should be energized. If connected to CB K1 connector pin #3 and FM is energized, replace CB. If LLV is energized with LEDs 1, 3, and 2 on, replace CB.
8) Normal Harvest Cycle – Same as the initial harvest cycle. Return to step 5a) above. Note: Appliance continues to cycle until BC is satised, power is switched off or
freeze-time correction cycle is initiated. The appliance always restarts at the 1-min. ll cycle.
2. Shutdown Diagnosis
1) See "II.E.1. Bin Control Check."
3. Freeze-Time Correction Cycle Diagnosis
1) See "II.C. Freeze-Time Correction Cycle."
Legend: BC–bin control; CB–control board; Comp–compressor; CR–compressor relay;
CT–control transformer; CV–check valve; FM–fan motor; FMR–fan motor remote; FS–oat switch; HGV–hot gas valve; HM–headmaster (C.P.R.); HPS–high-pressure switch; L LV–liquid line valve; MC–magnetic contactor; PM–pump motor; TXV–thermostatic expansion valve; WRV–water regulating valve; WV–inlet water
valve
25

C. Freeze-Time Correction Cycle (90 min.)

Freeze-Time Correction function is enabled when S4 Dip Switch 7 is in the "ON" position and initiates when the minimum and maximum freeze times have exceeded differential parameters. Freeze-time correction timer and count starts at the beginning of the 2nd freeze cycle after startup from power off condition. Freeze-time correction timer and count continues and retains its freeze-time correction timer and count during a BC off cycle and resumes its freeze-time correction timer and count on the 2nd freeze cycle after BC restart. If freeze-time differential is exceeded (see table below), freeze-time correction cycle starts and CB red "POWER OK" LED blinks. When freeze-time correction cycle occurs 3 or more times within a 36 hour period, CB yellow "EXT HARVEST" LED blinks with CB red "POWER OK" LED. Appliance starts in freeze cycle after a freeze-time correction cycle. Toreset CB LEDs, press ALARM RESET button on CB with power on. CB resets LEDs and appliance continues cycle without interruption.
1) Freeze Time Differential Initiation: CB starts monitoring freeze times on the second freeze time. After 3freeze cycles (4th total), CBbegins to compare minimum and maximum freeze time cycles. Every freeze cycle time after the rst freeze cycle time is added to the freeze time list. Minimum and maximum freeze time differential comparisons begin on the third cycle and are monitored up to 10cycles. On the 11th cycle the rst freeze cycle time is dropped to maintain the 10 maximum number of cycles. Example: After 8 cycles (excluding rst cycle), if the differential between the shortestcycle (minimum) and the longets cycle (maximum) is equal to or greater than 427 sec. a freeze-time correction cycle is initiated:
Number of Freeze Cycles
3 254 4 309 5 349 6 380 7 406 8 427 9 446
10 462
Differential Value in Sec.
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