Hoshizaki KM-2500SRH3, KM-2500SWH3 User Manual
Hoshizaki America, Inc.
Stackable Crescent Cuber
Models
KM-2500SWH3
“A Superior Degree
of Reliability”
www.hoshizaki.com
KM-2500SRH3
SERVICE MANUAL
™
Number: 73164
Issued: 6-10-2010
IMPORTANT
Only qualied service technicians should install, service, and maintain the
icemaker. No service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual. Failure to service and
maintain the equipment in accordance with this manual may adversely affect
safety, performance, component life, and warranty coverage.
Hoshizaki provides this manual primarily to assist qualied 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, write, or send an e-mail message 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 Support
(770) 487-2331
Fax: 1-800-843-1056
(770) 487-3360
E-mail: techsupport@hoshizaki.com
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.
2
IMPORTANT
This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualied service technicians
should install, service, and maintain the icemaker. Read the warnings contained
in this booklet carefully as they give important information regarding safety.
Please retain this booklet for any further reference that may be necessary.
CONTENTS
Important Safety Information ................................................................................................. 5
I. Specications ...................................................................................................................... 6
A. Icemaker ....................................................................................................................... 6
1. KM-2500SWH3 (water-cooled) ................................................................................ 6
2. KM-2500SRH3 (remote air-cooled) ......................................................................... 7
B. Condenser Unit ............................................................................................................. 8
1. URC-23F .................................................................................................................. 8
II. General Information ......................................................................................................... 10
A. Construction ................................................................................................................ 10
1. KM-2500SWH3 (water-cooled) .............................................................................. 10
2. KM-2500SRH3 (remote air-cooled) ........................................................................11
B. Sequence of Operation ............................................................................................... 12
1. Sequence Cycles and Shutdown ........................................................................... 12
a) 1-Minute Fill Cycle ........................................................................................... 12
b) Initial Harvest Cycle ........................................................................................ 12
c) Freeze Cycle ................................................................................................... 12
d) Pump-Out Cycle .............................................................................................. 12
e) Harvest Cycle .................................................................................................. 13
f) Shutdown .......................................................................................................... 13
2. Sequence Flow Chart ............................................................................................ 14
C. Control Board .............................................................................................................. 15
1. Control Board Layout ............................................................................................. 16
2. Features ................................................................................................................. 17
a) Maximum Water Supply Period – 6 minutes .................................................... 17
b) Harvest Backup Timer and Freeze Timer ......................................................... 17
c) High Temperature Safety .................................................................................. 17
d) Low Water Safety ............................................................................................. 17
e) High Voltage and Low Voltage Cut-outs ........................................................... 17
3. LED Lights and Audible Alarm Safeties ................................................................. 18
4. Controls and Adjustments ...................................................................................... 19
a) Default Dip Switch Settings .............................................................................. 19
b) Harvest Timer (S4 dip switch 1 & 2) ................................................................. 19
c) Pump-Out Timer (S4 dip switch 3 & 4) ............................................................. 20
d) Pump-Out Frequency Control (S4 dip switch 5 & 6)......................................... 20
e) Bin Control Selector (S4 dip switch 7) .............................................................. 21
f) Factory Use (S4 dip switch 8) ........................................................................... 21
g) Freeze Timer (S4 dip switch 9 & 10) ................................................................ 21
3
D. Bin Control .................................................................................................................. 22
E. Float Switch ................................................................................................................. 22
F. Thermistor .................................................................................................................... 22
G. Control Switch ............................................................................................................. 22
III. Technical Information ...................................................................................................... 23
A. Water Circuit and Refrigeration Circuit ........................................................................ 23
1. KM-2500SWH3 (water-cooled) .............................................................................. 23
2. KM-2500SRH3 (remote air-cooled) ....................................................................... 24
B. Wiring Diagrams .......................................................................................................... 25
1. KM-2500SWH3 (water-cooled), KM-2500SRH3 (remote air-cooled) ..................... 25
C. Performance Data ....................................................................................................... 26
1. KM-2500SWH3 (water-cooled) .............................................................................. 26
2. KM-2500SRH3 (remote air-cooled) ....................................................................... 27
IV. Service Diagnosis ........................................................................................................... 28
A. Diagnostic Procedure ................................................................................................. 28
B. Control Board Check ................................................................................................... 31
C. Bin Control Check ....................................................................................................... 32
D. Float Switch Check and Cleaning ............................................................................... 32
E. Thermistor Check ........................................................................................................ 34
F. Diagnostic Charts ........................................................................................................ 35
V. Removal and Replacement of Components .................................................................... 43
A. Service for Refrigerant Lines ....................................................................................... 43
1. Refrigerant Recovery ............................................................................................. 43
2. Brazing .................................................................................................................. 44
3. Evacuation and Recharge (R-404A) ...................................................................... 44
B. Removal and Replacement of Compressor ................................................................. 45
C. Removal and Replacement of Expansion Valve .......................................................... 46
D. Removal and Replacement of Hot Gas Valve or Liquid Line Valve ............................. 47
E. Removal and Replacement of Evaporator ................................................................... 48
F. Removal and Replacement of Water-Cooled Condenser ............................................. 49
G. Removal and Replacement of Remote Air-Cooled Condenser ................................... 50
H. Removal and Replacement of Water Regulating Valve (water-cooled model) ............. 51
I. Adjustment of Water Regulating Valve - Water-Cooled Model ...................................... 52
J. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.) -
Remote Air-Cooled Model ......................................................................................... 52
K. Removal and Replacement of Thermistor ................................................................... 53
L. Removal and Replacement of Fan Motor – Remote Air-Cooled Model........................ 54
M. Removal and Replacement of Inlet Water Valve ......................................................... 54
N. Removal and Replacement of Pump Motor ................................................................ 55
O. Removal and Replacement of Control Board .............................................................. 56
VI. Cleaning and Maintenance ............................................................................................. 57
A. Cleaning and Sanitizing Instructions ........................................................................... 57
1. Cleaning Procedure ................................................................................................ 58
2. Sanitizing Procedure - Following Cleaning Procedure ........................................... 59
B. Maintenance ................................................................................................................ 60
C. Preparing the Icemaker for Long Storage ................................................................... 60
4
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, or damage to the unit.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
CAUTION Indicates a situation which could result in damage to the unit.
IMPORTANT Indicates important information about the use and care of the
unit.
WARNING
This icemaker 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 eventual
damage caused by improper, incorrect, and unreasonable use.
To reduce the risk of death, electric shock, serious injury, or re, follow
basic precautions including the following:
• 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 severe damage to
equipment.
• This unit requires an independent power supply. See the nameplate for proper
voltage and breaker/fuse size. Failure to use a proper breaker or fuse can
result in a tripped breaker, blown fuse, or damage to existing wiring. This
could lead to heat generation or re.
• THIS UNIT MUST BE GROUNDED. Failure to properly ground this unit could
result in death or serious injury.
• This unit should be disassembled or repaired only by qualied service
personnel to reduce the risk of electric shock, injury, or re.
• Do not make any alterations to the unit. Alterations could result in electric
shock, injury, re, or damage to the unit.
5
I. Specications
A. Icemaker
1. KM-2500SWH3 (water-cooled)
AC SUPPLY VOLTAGE 208-230/60/3
AMPERAGE 14.2 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 30 A
MAXIMUM FUSE SIZE 30 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *2408 (1092) 2395 (1087) 2256 (1024)
Reference without *marks 80 2398 (1088) 2379 (1079) 2172 (985)
90 2395 (1087) *2365 (1073) 2184 (991)
100 2327 (1055) 2323 (1054) 2018 (915)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 46.3 lbs. (21 kg) 2160pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 3720(3.78) 3510(3.5)
WATER gal./24HR (gal./100 lbs.) 459(19.4) 744(30.9)
WATER COOLED CONDENSER 1430(101) 1430(59)
gal./24HR (gal./100 lbs.)
CEC/CEE TIER LEVEL 1
ENERGY STAR N/A
EXTERIOR DIMENSIONS (WxDxH) 48" x 27-3/8" x 36-7/16" (1219 x 695 x 925 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 390 lbs. (177 kg), Shipping 415 lbs. (188 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT Condenser Outlet 1/2" FPT
3/8" OD Tube
CUBE CONTROL SYSTEM Float Switch
HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Thermostat
COMPRESSOR Hermetic, Model CS27K6E-TF5-237
CONDENSER Water Cooled, Tube in Tube Type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 4 lb. 11.5 oz. (2140g)
DESIGN PRESSURE High 427PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )
COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A
-REQUIRED Ice Storage Bin
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 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 specications and design without prior
notice.
6
2. KM-2500SRH3 (remote air-cooled)
AC SUPPLY VOLTAGE 208-230/60/3
AMPERAGE 17.7 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 30 A
MAXIMUM FUSE SIZE 30 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *2424 (1100) 2373 (1076) 2196 (996)
Reference without *marks 80 2385 (1082) 2306 (1046) 2069 (939)
90 2373 (1076) *2250 (1021) 2035 (923)
100 2301 (1044) 2200 (998) 1837 (833)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 46.1 lbs. (20.9 kg) 2160pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 4220(4.5) 3780(3.7)
WATER gal./24HR (gal./100 lbs.) 419(18.6) 791(32.6)
CEC/CEE TIER LEVEL 2
ENERGY STAR YES
EXTERIOR DIMENSIONS (WxDxH) 48" x 27-3/8" x 36-7/16" (1219 x 695 x 925 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 390 lbs. (177 kg), Shipping 440 lbs. (200 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
3/8" OD Tube
CUBE CONTROL SYSTEM Float Switch
HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Thermostat
COMPRESSOR Hermetic, Model MTZ-57-HL3A
CONDENSER Air-Cooled Remote, Condenser Unit URC-23F
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
Condensing Pressure Regulator on Icemaker (190 PSI)
REFRIGERANT CHARGE R404A, 24 lb. 7.5 oz. (11100g)
(Icemaker 14 lbs. 12.3 oz. Cond. Unit 9 lbs. 11.2 oz.)
DESIGN PRESSURE High 467PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )
COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A
-REQUIRED Ice Storage Bin, Remote Condenser Unit
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 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 specications and design without prior
notice.
7
B. Condenser Unit
1. URC-23F
Unit: mm (inches)
Note: We reserve the right to make changes in specications and design without prior
notice.
8
SPECIFICATIONS
MODEL: URC-23F
AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker)
FAN MOTOR 115 V Total 2.6FLA 130W
EXTERIOR DIMENSIONS (WxDxH) 46-3/8" x 15-11/16" x 25-15/16" (1178 x 398 x 659 mm)
DIMENSIONS INCLUDING LEGS (WxDxH) 48-7/16" x 18-1/8" x 40-7/8" (1230 x 460 x 1039 mm)
EXTERIOR FINISH Galvanized Steel
WEIGHT Net 158 lbs. ( 72 kg ) Shipping 169 lbs. ( 77 kg )
CONNECTIONS - ELECTRIC Permanent - Connection
- REFRIGERANT Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)
Liquid Line 5/8"-18 UNF Fitting (#6 AEROQUIP)
CONDENSER Air-cooled, Fin and tube type
FAN MOTOR PROTECTION Thermal Protection
REFRIGERANT CONTROL Condensing Pressure Regulator (In Ice Machine)
REFRIGERANT CHARGE R-404A 9 lb. 11oz. (4400g)
DESIGN PRESSURE High 467 PSIG 32.2 Bar
OPERATING CONDITIONS VOLTAGE RANGE 104 ~ 127 V
AMBIENT TEMP. -20 ~ 122 °F
ACCESSORIES -SUPPLIED Leg 2 pcs
Hex. Head Bolt w/Washer 8 x 16 8 pcs
Hex. Nut 8 8 pcs
Note: We reserve the right to make changes in specications and design without prior
notice.
9
II. General Information
A. Construction
1. KM-2500SWH3 (water-cooled)
Spray Tubes
Evaporator Assembly
Check Valve
(water)
Inlet Water Valve
Expansion Valves
Water Supply Inlet
Check Valves
(Refrigeration Circuit)
Junction Box
Hot Gas Valve
Strainer
Water
Regulating
Valve
Control Box
Service Valves
Condenser
Water Pump
Float Switch
Cleaning Valve
Bin Control Bulb Holder
Bin Control "Z" Bracket
Bin Control Extension Bracket
Compressor
Drier
Liquid Line Valve
Main Transformer
Box
Bin Control Thermostat
Control Switch
Bin Control Thermostat Bracket
10
2. KM-2500SRH3 (remote air-cooled)
Spray Tubes
Evaporator Assembly
Check Valve
(water)
Inlet Water Valve
Expansion Valves
Water Supply Inlet
Check Valves
(Refrigeration Circuit)
Junction Boxes
Hot Gas Valve
Strainer
Headmaster
(C.P.R.)
Shut-Off Valve
(Factory Use Only)
Control Box
Service Valves
Receiver Tank
Water Pump
Float Switch
Bin Control Bulb Holder
Bin Control "Z" Bracket
Bin Control Extension Bracket
Cleaning Valve
Compressor
Drier
Liquid Line Valve
Main Transformer
Box
Bin Control Thermostat
Control Switch
Bin Control Thermostat Bracket
11
B. Sequence of Operation
1. Sequence Cycles and Shutdown
The steps in the sequence are as outlined below. When power is supplied and BC is
closed, CB red "POWER OK" LED comes on. There is a 5-second delay before startup.
Note that the order of the LEDs from the outer edge of CB is 1, 4, 3, 2.
a) 1-Minute Fill Cycle
LED 4 is on. WV energizes and the 1-minute ll cycle begins. After 1 minute, CB checks
for a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV remains energized
through additional 1-minute ll cycles until water enters the tank and closes F/S. This
serves as a low water safety to protect PM.
b) Initial Harvest Cycle
LEDs 1, 4, and 2 are on. WV remains energized, Comp, FMR, and HGV energize.
CBmonitors the warming of the evaporator via the thermistor located on the suction line.
When the thermistor warms to 48°F (9°C), CB reads a 3.9 kΩ signal from the thermistor
and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2) which is
factory set for normal conditions. The harvest timer has settings of 60, 90, 120, and 180
seconds. For details, see "II.C.4.b) Harvest Timer (S4 Dip Switch 1 & 2)." When the
harvest timer terminates, the harvest cycle is complete. At the end of harvest, CB checks
the position of F/S and proceeds to the next cycle if it is closed or calls for a 1-minute ll
cycle if it is open. The minimum total time allowed by CB for a complete harvest cycle is
2minutes. WV is energized during harvest for a maximum of 6 minutes or the length of
harvest, whichever is shorter.
c) Freeze Cycle
LED 1 is on. Comp and FMR remain energized. PM and LLV energize. HGV and WV
de-energize. For the rst 5 minutes, CB will not accept a signal from F/S. This 5-minute
minimum freeze time is short cycle protection for Comp. At the end of 5minutes, F/S
assumes control of freeze termination. As ice builds on the evaporator, the water level
in the tank lowers. The freeze cycle continues until F/S opens, then CB terminates the
freeze cycle.
d) Pump-Out Cycle
LEDs 1, 3, and 2 are on. LED 4 is on when S4 dip switch 3 & 4 are set to 3 off and 4on.
Comp and FMR remain energized. HGV energizes, LLV de-energizes. WV energizes
if S4 dip switch 3 & 4 are set to 3 off and 4 on. PM stops for 2 seconds then reverses,
taking water from the bottom of the tank and forcing pressure against the check valve
seat allowing water to go through the check valve and down the drain. At the same time,
water ows through the small F/S tube to power ush F/S. When the pump-out timer (S4
dip switch 3 & 4) terminates, pump-out is complete.
The rst pump-out occurs after the rst freeze cycle and every cycle thereafter. The
pump-out frequency control is factory set to drain the water tank every cycle, and
generally no adjustment is required. The pump-out frequency control (S4 dip switch 5
& 6) can be set to have a pump out occur every cycle, or every 2, 5, or 10 cycles. For
details, see "II.C.4.d) Pump-Out Frequency Control (S4 Dip Switch 5& 6)."
12
e) Harvest Cycle
Same as the initial harvest cycle. See "II.B.1.b) Initial Harvest Cycle."
Note: Unit continues to cycle until BC is satised or power is turned off. The unit always
restarts at the 1-minute ll cycle.
f) Shutdown
When ice contacts the thermostatic bulb (BC switch open), BC shuts down the unit within
10 seconds. BC is factory set, and generally no adjustment is required. However,
adjustment may be needed in some conditions, particularly at higher altitude
locations. CAUTION! Do not adjust S4 dip switch 7 out of the factory default
position on this model. This dip switch must be left in the factory default position
or this unit will not operate correctly.
Legend: BC–bin control; CB–control board; Comp–compressor; FMR–fan
motor-remote; F/S–oat switch; HGV–hot gas valve; LLV–liquid line valve;
PM–pump motor; WV–inlet water valve
13
2. Sequence Flow Chart
cycle (S4 dip switch
5 & 6)
2 sec., then reverses
for 10/20 sec. (S4 dip
• Pump motor stops for
switch 3 & 4)
F/S in control
• Factory set for every
4. Pump-Out Cycle
Comp continues
FMR continues
HGV energized
WV energized if dip switch
3& 4 set to 3 off and 4on.
LLV de-energized
PM de-energizes for 2 sec.,
then reverses for 10/20 sec.
F/S open or freeze
timer expires
"E" Control Board Sequence Flow Chart
KM-2500SWH3, KM-2500SRH3
2. Harvest Cycle 3. Freeze Cycle
1. 1-Minute Fill
• Minimum freeze time: 5 min.
• Maximum freeze time: freeze timer setting
whichever is shorter.
• WV time: 6 min. or the length of harvest,
Cycle
(S4 dip switch 9 & 10
• Maximum harvest time: 20 min.
5-min. timer
in control
1 to 3-min. timer in control
(S4 dip switch 1 & 2)
Thermistor in control
F/S closed
F/S Check
F/S closed
F/S Check
Comp continues
FMR continues
LLV energized
Thermistor temp
warms to 48°F (9°C)
(3.9 kΩ or less)
WV continues
Comp energized
FMR energized
F/S open
WV energized
PM energized
Harvest timer starts
HGV energized
HGV de-energized
WV de-energized
F/S open
If F/S is open, compressor stops and cycle returns to 1-Minute Fill Cycle
3. Ice Level Lowered
2. Icemaker Off
1. Bin Full
To 1 above
Ice level lowered. No ice
touching thermostatic
bulb. Icemaker starts at
"1. 1-Minute Fill Cycle."
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
TBC closed
All components
de-energized.
Unit shuts down
within 10 sec.
after ice contacts
thermostatic bulb.
TBC open
All components
de-energized
control switch is placed in the "ICE" position.
Cycle Steps
Startup begins
here after
5-sec. delay
14
Shutdown
Legend:
Comp–compressor
FMR–fan motor-remote
F/S–oat switch
HGV–hot gas valve
LLV–liquid line valve
PM–pump motor
TBC–thermostatic bin control
WV–inlet water valve
Ice contacts
thermostatic bulb
and Restart
TBC Operation
C. Control Board
• A Hoshizaki exclusive control board is employed in KM-2500SWH3 and KM-2500SRH3
Stackable Crescent Cubers.
• All models are pretested and factory-adjusted.
• For a control board check procedure, see "IV.B. Control Board Check."
CAUTION
1. The control board is fragile; handle very carefully.
2. The control board contains integrated circuits, which are susceptible to failure
due to static discharge. It is especially important to touch the metal part of
the unit before handling or replacing the control board.
3. Do not touch the electronic devices on the control board or the back of the
control 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 oat switch. K4 is
not connected.
5. Always replace the whole control board assembly if it goes bad.
6. Do not short out power supply to test for voltage.
15
1. Control Board Layout
"E" Control Board
• "ALARM RESET" Button
• "F TIMER"
Freeze Timer LED
• "H TIMER"
Harvest Backup
Timer LED
• Alarm Buzzer
• "Power OK" LED
(red) (lights when
power is supplied to
the control board)
• Relay LEDs (4)
(indicate which relays
are energized as
listed below)
• LED 2 (X2 Relay)
Hot Gas Valve (HGV)
Fan Motor (FM) (FM
off when LED on)
• LED 3 (X3 Relay)
Pump Motor (PM)
(on at pump-out only)
• LED 4 (X4 Relay)
Inlet Water Valve (WV)
• LED 1 (X1 Relay)
Compressor
(Comp)
Fan Motor-Remote
(FMR)
• K2 Connector
Transformer
• S4 Dip Switch
• "OUTPUT TEST" Button
(used to test relays on control board)
• WHITE K3 Connector
Harvest Control
(thermistor)
• RED K4 Connector
Open (not connected)
• Microprocessor
(control board
revision level
indicated by last 2
digits on label)
• BLACK K5 Connector
Float Switch
• Part Number
• K1 Ten-Pin Connector
Pins #1 through #10
#1, 9 Magnetic Contactor (CR)
Fan Motor-Remote (FMR)
#2 Hot Gas Valve (HGV)
#3 Fan Motor (FM)
Liquid Line Valve (LLV)
#4 Pump Motor (icemaking)
#5 Pump Motor (pump-out)
#6 Inlet Water Valve (WV)
#7, 10 Component Power
Supply
#8 Open
• Switch for "C" Control Board
and "ALPINE" Control Board
(service boards only)
"E" Control Board
Part Number 2A1410-01 (factory); 2A1410-02 (service)
16
2. Features
a) Maximum Water Supply Period – 6 minutes
The inlet water valve remains energized during harvest for 6 minutes or the length of
harvest whichever is shorter.
b) Harvest Backup Timer and Freeze Timer
The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest
cycle takes more than 20 minutes to complete. The control board signals with the
"HTimer" LED and 2beeps every 3 seconds.
The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle
takes longer than the time specied by the freeze timer (S4 dip switch 9 & 10). The
control board signals with the "F Timer" LED and 3 beeps every 3 seconds. The freeze
timer is factory set and no adjustment is required.
To reset either of these safeties, press the "ALARM RESET" button on the control board
with power on.
c) High Temperature Safety
The temperature of the suction line in the refrigeration circuit is limited by the high
temperature safety. This protects the unit from excessively high temperatures. If the
evaporator temperature reaches 127±7°F (53±4°C), the control board reads a .8 kΩ
signal from the thermistor and shuts down the icemaker.
The control board signals with 1 beep every 3 seconds. To reset this safety, press the
"ALARM RESET" button on the control board with power on.
d) Low Water Safety
The control board checks the position of the oat switch at the end of the initial 1-minute
ll cycle and at the end of each harvest cycle. If the oat switch is in the up position
(electrical circuit closed), the control board proceeds to the next cycle. If the oat switch
is in the down position (electrical circuit open), the control board returns to the 1-minute
ll cycle until water enters the tank and the oat switch closes. Once the oat switch
closes, the control board proceeds to the next cycle. The unit should not start without
adequate water in the tank. This serves as a low water safety to protect the pump motor
from mechanical seal failure.
For water-cooled model, if the water is shut off, the unit is protected by the high-pressure
switch.
e) High Voltage and Low Voltage Cut-outs
The maximum and minimum allowable supply voltages of this unit are limited by the high
voltage and low voltage cut-outs.
Miswiring (especially on single phase 3 wire models) may cause excessive voltage
(147VAC±5% or more).
If high voltage (147VAC±5% or more) is present, the icemaker automatically stops and
the control board signals with 7 beeps every 3 seconds.
If low voltage (92VAC±5% or less) is present, the icmaker automatically stops and the
control board signals with 6 beeps every 3 seconds.
When the proper supply voltage is resumed, the icemaker automatically starts running
again.
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3. LED Lights and Audible Alarm Safeties
At startup, a 5-second delay occurs while the control board conducts an internal timer
check. A beep occurs when power is turned off. The red LED indicates proper control
voltage and remains on unless a control voltage problem occurs. The green LEDs 1
through 4 energize and sequence from startup as listed in the table below. Note that
the order of the LEDs from the outer edge of the control board is 1, 4, 3, 2. For more
information, see "II.B. Sequence of Operation."
Sequence Step LED Energized
1-Minute Fill Cycle 4 WV 1 minute
Harvest Cycle 1, 4, 2 Comp, FMR,
WV, HGV
Freeze Cycle 1 Comp, FMR,
PM, LLV
Pump-Out Cycle 1, 4*, 3, 2 Comp, FMR,
WV*, PM,
HGV
The built in safeties shut down the unit and have alarms as listed below.
No. of Beeps
(every 3 sec.)
1 High Evaporator Temp.
(temperature > 127°F)
(53°C)
2 Harvest Backup Timer
(harvest > 20 min. for
twocycles in a row)
3 Freeze Timer
(freeze > freeze timer
setting for two cycles in a
row)
Timer is factory set using
S4 dip switch 9 & 10
To reset the above safeties, press the "ALARM RESET" button with the power supply on.
6 Low Voltage
(92VAC±5% or less)
7 High Voltage
(147VAC±5% or more)
Type of Alarm Notes
Check for harvest problem (stuck HGV or
relay), hot water entering unit, stuck HM, or
shorted thermistor.
Orange "H TIMER" LED on.
Check for open thermistor, HGV not opening,
TXV or LLV leaking by, WRV leaking by, low
charge, or inefficient Comp.
Yellow "F TIMER" LED on.
Check for F/S stuck closed (up), WV leaking
by, HGV leaking by, PM not pumping, TXVnot
feeding properly, LLV not opening, low charge,
HM not bypassing, or inefficient Comp.
Red LED turns off if voltage protection
operates.
The control voltage safeties automatically reset
when voltage is corrected.
Min. Max. Avg.
2 minutes 20 minutes 3 to 5 minutes
5 minutes freeze timer
10 seconds 20 seconds *pump-out timer
Time LEDs are On
30 to 35 minutes
setting
setting
Legend: Comp–compressor; FMR–fan motor-remote; F/S–oat switch; HGV–hot gas
valve; HM–headmaster (C.P.R.); LLV–liquid line valve; PM–pump motor;
TXV–thermostatic expansion valve; WRV–water regulating valve; WV–inlet
water valve
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4. Controls and Adjustments
CAUTION
Dip switches are factory set. Failure to maintain factory settings may adversely
affect performance and warranty coverage. For more information, contact
Hoshizaki Technical Support at 1-800-233-1940.
a) Default Dip Switch Settings
The dip switches are factory-adjusted to the following positions:
S4 Dip Switch
S4 Dip Switch No. 1 2 3 4 5 6 7 8 9 10
KM-2500SWH3 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON
KM-2500SRH3 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON
Freeze Timer (9 & 10)
Factory Use (8)
Bin Control Selector (7)
Pump-Out Frequency Control (5 & 6)
Pump-Out Timer (3 & 4)
Harvest Timer (1 & 2)
b) Harvest Timer (S4 dip switch 1 & 2)
The harvest timer starts when the thermistor warms to 48°F (9°C) at the evaporator
outlet and the control board reads the thermistor's 3.9 kΩ signal. The harvest timer is
factory set, and generally no adjustment is required. However, a setting longer than the
factory setting may be advised in cases where the ush provided at harvest needs to be
prolonged for extra cleaning. Before changing this setting, contact Hoshizaki Technical
Support at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest
timer to a longer setting will decrease 24 hour production.
Note that the pump-out timer (S1 dip switch 3 & 4) acts in place of the harvest timer
during cycles with a pump-out. For details, see "II.C.4.c) Pump-Out Timer (S1 dip
switch 3 & 4)."
S4 Dip Switch Setting Time
No. 1 No. 2
OFF OFF 60
ON OFF 90
OFF ON 120
ON ON 180
(seconds)
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