Hoshizaki KM-2500SRH3, KM-2500SWH3 User Manual

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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 qualied 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 qualied 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.

IMPORTANT

This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualied 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. Specications ...................................................................................................................... 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

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

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 qualied 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.

I. Specications

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 specications and design without prior

notice.

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 specications and design without prior

notice.

B. Condenser Unit

1. URC-23F

Unit: mm (inches)

Note: We reserve the right to make changes in specications and design without prior

notice.

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 specications and design without prior

notice.

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

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

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. CBmonitors 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 2minutes. 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 5minutes, 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 4on. 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)."

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 satised 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

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 4on.

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

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.

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)

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 "HTimer" LED and 2beeps 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 specied 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.

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 twocycles 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, TXVnot 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

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

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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