Hoshizaki KM-255BAH, KM-255BWH Manuel de service

Hoshizaki
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models KM-255BAH KM-255BWH
Self-Contained Crescent Cuber
Hoshizaki America, Inc.
Number: 73146 Issued: 1-2-2007
SERVICE MANUAL
®
1
IMPORTANT
Only qualified service technicians should attempt to install, service or maintain this icemaker. No installation, service or maintenance should be undertaken until the technician has thoroughly read this Service Manual.
HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker.
Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, write or send an e-mail message to the HOSHIZAKI Technical Support Department.
HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City, GA 30269
Attn: HOSHIZAKI Technical Support Department
Phone: 1-800-233-1940 Technical Service (770) 487-2331 Fax: 1-800-843-1056 (770) 487-3360 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
Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should service and maintain the icemaker. This manual should be made available to the technician prior to service or maintenance.
CONTENTS
I. Specifications ...................................................................................................................... 5
A. Icemaker ....................................................................................................................... 5
1. KM-255BAH (air-cooled) ......................................................................................... 5
2. KM-255BWH (water-cooled) ....................................................................................
II. General Information ........................................................................................................... 7
A. Construction .................................................................................................................. 7
1. KM-255BAH (air-cooled) ......................................................................................... 7
2. KM-255BWH (water-cooled) .................................................................................... 8
B. Sequence of Operation ................................................................................................. 9
1. One Minute Fill Cycle .............................................................................................. 9
2. Initial Harvest Cycle ................................................................................................ 9
3. Freeze Cycle ........................................................................................................... 9
4. Normal Harvest Cycle ............................................................................................ 9
C. Control Board .............................................................................................................. 12
1. Control Board Layout ............................................................................................. 13
2. Features ................................................................................................................ 14
a) Maximum Water Supply Period – 6 minutes ....................................................... 14
b) Harvest Backup Timer and Freeze Timer ........................................................... 14
c) High Temperature Safety .................................................................................... 14
d) Low Water Safety ............................................................................................... 14
e) High Voltage and Low Voltage Cut-outs ............................................................. 14
f) LED Lights and Audible Alarm Safeties ............................................................... 15
3. Controls and Adjustments ..................................................................................... 16
a) Default Dip Switch Settings ................................................................................ 16
b) Harvest Control – Thermistor ............................................................................. 16
c) Harvest Timer (S4 dip switch 1 & 2) ................................................................... 17
d) S4 dip switch 3, 4, 5, 6, 7, & 8 ............................................................................ 17
e) Freeze Timer (S4 dip switch 9 & 10)................................................................... 17
f) Float Switch Control and Refill Counter (S5 dip switch 1 through 5) ................... 17
g) Bin Control .......................................................................................................... 18
4. Bin Control Troubleshooting ................................................................................... 18
a) Machine Will Not Start ........................................................................................ 18
b) Machine Will Not Shut Off .................................................................................. 18
5. Float Switch Troubleshooting ................................................................................. 18
6. Control Board Check Procedure ............................................................................ 19
7. Control Board Replacement .................................................................................. 20
III. Technical Information ...................................................................................................... 21
A. Water Circuit and Refrigeration Circuit ........................................................................ 21
1. KM-255BAH (air-cooled) .......................................................................................
2. KM-255BWH (water-cooled) ..................................................................................
21 22
6
3
B. Wiring Diagram ............................................................................................................ 23
1. KM-255BAH (air-cooled) .......................................................................................
2. KM-255BWH (water-cooled) ..................................................................................
C. Performance Data ....................................................................................................... 25
1. KM-255BAH (air-cooled) ....................................................................................... 25
2. KM-255BWH (water-cooled) .................................................................................. 26
IV. Service Diagnosis ........................................................................................................... 27
A. 10-Minute Diagnostic Procedure ................................................................................
B. Diagnostic Charts ........................................................................................................ 28
1. No Ice Production .................................................................................................. 28
2. Evaporator is Frozen Up ........................................................................................ 32
3. Low Ice Production ................................................................................................ 33
4. Abnormal Ice ......................................................................................................... 33
5. Other ...................................................................................................................... 33
V. Removal and Replacement of Components .................................................................... 35
A. Servicing the Refrigeration Circuit .............................................................................. 35
1. Refrigerant Recovery ............................................................................................. 35
2. Evacuation and Recharge (R-404A) ...................................................................... 35
B. Brazing ........................................................................................................................ 36
C. Removal and Replacement of Compressor ................................................................ 36
D. Removal and Replacement of Drier ............................................................................ 37
E. Removal and Replacement of Expansion Valve .......................................................... 38
F. Removal and Replacement of Hot Gas Valve .............................................................. 39
G. Removal and Replacement of Evaporator .................................................................. 40
H. Removal and Replacement of Air-Cooled Condenser ................................................ 40
I. Removal and Replacement of Water-Cooled Condenser ............................................. 41
J. Removal and Replacement of Water Regulating Valve - Water-Cooled Model Only ... 42
K. Adjustment of Water Regulating Valve - Water-Cooled Model Only ............................ 42
L. Removal and Replacement of Thermistor ................................................................... 43
M. Removal and Replacement of Fan Motor ................................................................... 44
N. Removal and Replacement of Freeze or Harvest Water Valve ................................... 44
O. Removal and Replacement of Wash Valve ................................................................. 45
P. Removal and Replacement of Pump Motor ................................................................. 45
Q. Removal and Replacement of Spray Tube .................................................................. 46
VI. Cleaning and Maintenance Instructions ......................................................................... 47
A. Cleaning ...................................................................................................................... 47
1. Cleaning Procedure ...............................................................................................
2. Sanitizing Procedure - Following Cleaning Procedure ..........................................
B. Maintenance ................................................................................................................ 49
C. Preparing the Icemaker for Long Storage ................................................................... 50
23 24
27
47 49
4
AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY N/A MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 * 235 (107) 227 (103) 207 (94) Reference without *marks 80 229 (104) 216 (98) 191 (87)
90 227 (103) * 207 (94) 184 (83)
100 211 (96) 202 (91) 163 (74) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 4 lbs. ( 1.8 kg ) 204 pcs. APPROXIMATE STORAGE CAPACITY 120 lbs. ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 828 (9.6) 744 (7.6) WATER gal./24HR (gal./100 lbs.) 51 (24.7) 82 (35.0) EXTERIOR DIMENSIONS (WxDxH) 30" x 28" x 39" (762 x 711 x 990 mm)
Includes 6" leg EXTERIOR FINISH Stainless steel; Galvanized steel (rear) WEIGHT Net 203 lbs. ( 92 kg ), Shipping 220 lbs. ( 100 kg ) CONNECTIONS - ELECTRIC Cord Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT CUBE CONTROL SYSTEM N/A (Internal programming) 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 Mechanical Level Switch and Timer COMPRESSOR Hermetic, Model SC12MLX CONDENSER Air cooled, Fin and Tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 1 lb. 1 oz. (475 g) DESIGN PRESSURE High 467 PSIG, Low 240 PSIG 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 Ice Scoop; 6" Leg, 4 pcs.
-REQUIRED N/A OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
I. Specifications

A. Icemaker

1. KM-255BAH (air-cooled)

Note: We reserve the right to make changes in specifications and design without prior
notice.
5

2. KM-255BWH (water-cooled)

Intentionally Left Blank
Note: We reserve the right to make changes in specifications and design without prior
notice.
6

II. General Information

A. Construction

1. KM-255BAH (air-cooled)

Harvest Water Valve
Wash Valve
Rear View of Icemaker
Freeze Water Valve
Expansion Valve
Spray Tube
Control Box
Condenser
Fuse
Electrical Box
Evaporator
Control Switch
Compressor
Drier
Water Tank, Bin Control & Pump Motor
Bin Control Switch (back side of tank)
Water Tank
Float Switch
Rear View of Compressor & Condenser
Bin Control Detector
Pump Motor
Fan Motor
Hot Gas Valve
Strainer
7

2. KM-255BWH (water-cooled)

Harvest Water Valve
Wash Valve
Rear View of Icemaker
Freeze Water Valve
Expansion Valve
Spray Tube
Control Box
Condenser
Fuse
Electrical Box
Evaporator
Control Switch
Compressor
Drier
Water Tank, Bin Control & Pump Motor
Bin Control Switch (back side of tank)
Water Tank
Float Switch
Rear View of Compressor & Condenser
Bin Control Detector
Pump Motor
Water Regulator
Hot Gas
Strainer
8
Valve

B. Sequence of Operation

The steps in the sequence are as outlined below. When power is supplied, the red LED on the control board comes on. A 5 second delay occurs at startup. Note that the order of the green LEDs from the outer edge of the board is 1, 4, 3, 2.

1. One Minute Fill Cycle

LED 4 is on. FWV opens and the fill period begins. After 1 minute, the board checks for a closed LF/S. If LF/S is closed, the harvest cycle begins. If not, FWV will remain energized through additional 1 minute cycles until water enters the sump and LF/S closes. This serves as a low water safety to protect the water pump.

2. Initial Harvest Cycle

LEDs 1, 4 and 2 are on. FWV closes, HGV opens, water valve relay energizes and HWV opens, Comp energizes, and harvest begins. The control board monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), the control board reads a 3.9 kΩ signal from the thermistor and turns harvest termination over to the adjustable harvest timer which is factory set for normal conditions. The timer has settings of 60, 90, 120, and 180 seconds (S4 dip switch 1 & 2). When the harvest timer completes its count down, the harvest cycle is complete and the freeze cycle starts. The minimum total time allowed by the board for a complete harvest cycle is 2 minutes. HWV is open during harvest for a maximum of 6 minutes or the length of harvest minus 50 seconds, whichever is shorter. PM energizes and runs for the last 50 seconds of harvest. At the end of harvest, the control board checks the position of LF/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute fill if it is open.

3. Freeze Cycle

LED 1 is on. Comp and PM continue to run, FMS energizes, HGV closes, water valve relay de-energizes and HWV closes, and the freeze cycle starts. For the first 5 minutes the control board will not accept a signal from LF/S. This 5 minute minimum freeze acts as a short cycle protection. At the end of 5 minutes, LF/S assumes control. As ice builds on the evaporator, the water level in the sump lowers and UF/S opens. 15 seconds after UF/S opens, FWV opens (LED 4 is on when FWV is open) and allows water in. After UF/S closes again, FWV closes 3 seconds later. This continues until the tank has refilled the number of times determined by the refill counter (S5 dip switch is factory set - do not adjust). The KM-255BAH and KM-255BWH refill 10 times. After the final refill, the freeze continues until LF/S opens and terminates the freeze cycle.
Note: After the first freeze following startup and every 10th cycle thereafter, LEDs 1, 3,
and 2 come on between freeze and harvest. Comp continues to run, HGV opens and FMS de-energizes. PM stops for 2 seconds. PM restarts and runs for 10 seconds.

4. Normal Harvest Cycle

LEDs 1, 4 and 2 are on. Comp continues to run, HGV opens, water valve relay energizes and HWV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer. When the harvest timer completes its count down, the harvest cycle is complete and the next freeze cycle starts. The minimum total time allowed by the board for a complete harvest cycle is 2 minutes. HWV is open during harvest for a maximum of 6 minutes or
9
the length of harvest minus 50 seconds, whichever is shorter. PM energizes and runs for the last 50 seconds of harvest. At the end of harvest, the control board checks the position of LF/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute fill if it is open. The unit continues to cycle through freeze and harvest cycles until the bin control activates and shuts the unit down.
Legend: Comp–compressor; FMS–self-contained fan motor; FWV–freeze water valve;
HGV–hot gas valve; HWV–harvest water valve; LF/S–lower float switch; PM–pump
motor; UF/S–upper float switch
10
End of 1st
freeze and
every 10th
cycle thereafter
• Minimum freeze time: 5 minutes
• Maximum freeze time: freeze timer setting
Pump motor stops
for 2 sec. and then
runs for 10 sec.
Lower float
switch in
control
5 minute timer
in control
complete water tank refills (10 refills for
KM-255BAH and KM-255BWH)
• Upper float switch used to initiate and
LF/S closed
Comp continues
HGV energized
Freeze cycle
operation turned
over to LF/S
Comp continues
HGV de-energized
HWV de-energized
FMS de-energized
PM continues
FMS energized
FWV energized/
de-energized
for refills only
50 sec.
LF/S Check
1 to 3 minute timer
in control
2. Harvest Cycle 3. Freeze Cycle
Thermistor in
(HWV time is 6 minutes or the length of
harvest minus 50 sec., whichever is shorter.
PM energizes and runs for the last 50 sec. of
• Maximum harvest water valve time: 6 minutes
harvest.)
• Maximum harvest time: 20 minutes
Fill Cycle
control
LF/S closed
LF/S Check
1. One Minute
KM-255BAH and KM-255BWH Sequence Flow Chart and Component Operation
PM energized
Thermistor temp
reaches 48°F (9°C)
Comp energized
HGV energized
FWV de-energized
LF/S open
FWV Energized
(3.9 kΩ or less)
Harvest timer starts
HWV energized
LF/S open
If LF/S is open, compressor stops and cycle returns to 1 minute fill
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 machine. When in
the WASH position, power is supplied to the pump motor and the wash valve. This allows cleaner and
sanitizer to flow over both the inside and outside of the evaporator plate assembly.
Cycle Steps
"G" board will have
Initial startup always
begins here
5 second delay
11
Legend:
Comp - compressor
FMS - self-contained fan motor
FWV - freeze water valve
HGV - hot gas valve
HWV - harvest water valve
LF/S - lower float switch
PM - pump motor
UF/S - upper float switch

C. Control Board

• A HOSHIZAKI exclusive solid-state control is employed in KM-255BAH and KM-255BWH Self-Contained Crescent Cubers.
• All models are pretested and factory-adjusted.
CAUTION
1. Fragile, handle very carefully.
2. A 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 when handling or replacing the board.
3. Do not touch the electronic devices on the board or the back of the board to prevent damage to the board.
4. Do not change wiring and connections. Do not misconnect K3, K4 and K5, because the same connector is used for the thermistor, float switch and mechanical bin control.
5. Always replace the whole board assembly if it goes bad.
6. Do not short out power supply to test for voltage.
12

1. Control Board Layout

Control Products "G" Control Board
Switch for "C" board and "ALPINE" board (service boards only)
Connector K1
Pins #1 through #10 #1, 9 Magnetic Contactor #2 Hot Gas Valve (HGV) Water Valve Relay (for harvest water valve operation) #3 Self-Contained Fan Motor (FMS) #4 Pump Motor (icemaking) #5 Pump Motor (harvest) #6 Freeze Water Valve (FWV) #7, 10 Supply Voltage #8 Open
Label (board revision level indicated on label on side of relay)
Connector K5 Float Switch
S5 Dip Switch (factory set ­do not adjust)
Connector K4 Mechanical Bin Control
Connector K3 Harvest Control (thermistor)
Connector K2 Transformer
Relay LEDs (4) (indicate which relays are energized as listed below)
LED 1 (green) Compressor (Comp)
LED 4 (green) Freeze Water Valve (FWV) (when LED 2 is off) Harvest Water Valve (HWV) (when LED 2 is on)
LED 3 (green) Pump Motor (PM) (PM on, but LED off, at freeze cycle)
LED 2 (green) Hot Gas Valve (HGV) Harvest Water Valve (HWV) (when LED 4 is on) Self-Contained Fan Motor (FMS) (FMS off when LED on)
Power LED (red) (lights when power is supplied to the board)
Alarm Buzzer
Part Number
Bin Control Switch Open LED (yellow)
Bin Control Switch Closed LED (green)
Output Test Switch (used to test relays on board)
S4 Dip Switch
Control Board
Part Number 2A3792-01 (factory); 2A3792-02 (service)
13
Alarm Reset Switch

2. Features

a) Maximum Water Supply Period – 6 minutes
The harvest water valve will be open during harvest for 6 minutes or the length of harvest minus 50 seconds, 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 will signal this problem using 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 specified to complete. The control board will signal this problem using 3 beeps every 3 seconds. The time is factory set using S4 dip switch 9 &
10. The reset button on the control board must be pressed with power on to reset either of these safeties.
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 rises above 127 ± 7°F (53 ± 4°C), the control board reads a .804 kΩ signal from the thermistor and operates the safety. This shuts down the circuit and the icemaker automatically stops. The control board will signal this problem using 1 beep every 3 seconds. The reset button on the control board must be pressed with power on to reset the safety.
d) Low Water Safety
The control board checks the position of the lower float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle. If the lower float switch is closed, the control board proceeds to the next cycle. If the lower float switch is open, the control board calls for a one minute water fill cycle. After one minute, the control board checks the position of the float and either proceeds to the next cycle if the lower float switch is closed or calls for an additional one minute fill if the switch is open. This serves as a low water safety to protect the water pump. For water-cooled model, if the water is shut off, the unit is also protected by the high pressure switch.
e) High Voltage and Low Voltage Cut-outs
High voltage and low voltage cut-outs help protect the icemaker from supply voltages outside of the accepted range. If miswiring causes excessive voltage (147Vac ±5% or more for 3 seconds) on the control board, the high voltage cut-out shuts down the circuit and the icemaker automatically stops. The control board will signal this problem using 7 beeps every 3 seconds. The icemaker also automatically stops in cases of insufficient voltage (92Vac ±5% or less). The control board will signal this problem using 6 beeps every 3 seconds. When the proper supply voltage is resumed, the icemaker automatically starts running again.
14
f) LED Lights and Audible Alarm Safeties
The red LED indicates control voltage (10 to 12V at K2) and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A beep occurs when the control switch is moved to the ICE position. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3,
2. For more information, see "II.B. Sequence of Operation."
Sequence Step LED
1 Minute Fill Cycle Harvest Cycle 1, 4 and 2 HWV, HGV,
Last 50 seconds of harvest, HWV de-energizes and PM energizes (LEDs 1, 3 and 2 are on)
Freeze Cycle 1 (and 4 at
After the first freeze following startup and every 10th cycle thereafter, are energized for 10 seconds between freeze and harvest (LEDs 1, 3 and 2 are on)
The built in safeties shut down the unit and have alarms as listed below.
No. of Beeps
(every 3 sec.)
1 High Evaporator Temp.
4 FWV 60 seconds
refills)
Type of Alarm Notes
(temperature > 127°F) (53°C)
Energized
Components
Comp
Comp, PM, FMS (FWV at refills)
Min. Max. Avg.
2 minutes 20 minutes 3 to 5 minutes
5 minutes freeze timer
Check for harvest problem (stuck HGV or relay), hot water entering unit, or shorted thermistor.
Time LEDs are On
30 to 35 minutes
setting
Comp, HGV, and PM
2 Harvest Backup Timer
(harvest > 20 min. for two cycles in a row)
3 Freeze Timer
(freeze > specified setting for two cycles in a row) Timer is factory set using S4 dip switch 9 & 10
To manually 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)
Legend: Comp–compressor; FMS–self-contained fan motor; FWV–freeze water valve;
HGV–hot gas valve; HWV–harvest water valve; PM–pump motor; TXV
thermostatic expansion valve; WRV–water regulating valve
Check for open thermistor, HGV not opening, TXV leaking by, low charge, inefficient Comp, or WRV leaking by (water-cooled model only).
Check for a float switch stuck closed (up), HWV or FWV leaking by, HGV leaking by, TXV not feeding properly, low charge, or inefficient compressor.
Red LED will turn off if voltage protection operates. The control voltage safeties automatically reset when voltage is corrected.
15

3. Controls and Adjustments

a) Default Dip Switch Settings
The dip switches are factory-adjusted to the following positions:
S4 Dip Switch
Dip Switch No. 1 2 3 4 5 6 7 8 9 10
KM-255BAH OFF ON OFF ON ON ON ON OFF OFF OFF
KM-255BWH
S5 Dip Switch (Do Not Adjust)
Dip Switch No. 1 2 3 4 5
KM-255BAH
KM-255BWH ON OFF ON OFF ON
ON OFF OFF ON ON ON ON OFF OFF OFF
ON OFF ON OFF ON
S4
S5 (do not adjust)
Freeze Timer (9 & 10)
Do not adjust (3, 4, 5, 6, 7, & 8)
Float switch control and refill counter. Do not
Harvest Timer (1 & 2)
adjust.
b) Harvest Control – Thermistor
A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer. No adjustment is required. If necessary, check for resistance between thermistor leads, and visually check the thermistor mounting, located on the suction line next to the evaporator outlet.
Temperature (°F) Temperature (°C)
Resistance (k)
0 -18 14.401 10 -12 10.613 32
0 6.000 50 10 3.871 70 21 2.474 90 32 1.633
Check a thermistor for resistance by using the following procedure:
1) Disconnect the connector K3 on the board.
2) Remove the thermistor. See "V.L. Removal and Replacement of Thermistor." 16
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