Hoshizaki KM-630MRH, KM-630MAH, KM-630MWH User Manual

Download

NO.: ISSUED:

73114

JUNE 23, 2004

HOSHIZAKI

MODULAR CRESCENT CUBER

MODEL

KM-630MAH KM-630MWH KM-630MRH

SER VICE MANUAL

IMPORTANT

Only qualified service technicians should attempt to service or maintain this icemaker. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual.

HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker.

Should the reader have any questions or concerns which have not been satisfactorily addressed, please call or write to the HOSHIZAKI Technical Support Depar tment for assistance.

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: (770) 487-3360

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

information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem

• Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations 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

1. KM-630MAH................................................................................................................ 5

2a. KM-630MWH Serial #L00001D - M20270B................................................................ 6

2b. KM-630MWH Serial #M20301E - ............................................................................... 7

3. KM-630MRH................................................................................................................ 8

4. CONDENSER UNIT .................................................................................................... 9

URC-6F...................................................................................................................... 9

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

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

[a] KM-630MAH........................................................................................................ 11

[b] KM-630MWH....................................................................................................... 12

[c] KM-630MRH........................................................................................................ 13

2. CONTROLLER BOARD............................................................................................. 14

[a] SOLID-STATE CONTROL ................................................................................... 14

[b] CONTROLLER BOARD...................................................................................... 14

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

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

[e] CHECKING THE CONTROLLER BOARD ......................................................... 25

3. MECHANICAL BIN CONTROL.................................................................................. 26

[a] PROXIMITY SWITCH.......................................................................................... 26

[b] EXPLANATION OF OPERATION........................................................................ 26

[c] TROUBLESHOOTING (MECHANICAL BIN CONTROL ONLY).......................... 27

III. TECHNICAL INFORMATION........................................................................................ 28

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT.................................................... 28

[a] KM-630MAH........................................................................................................ 28

[b] KM-630MWH....................................................................................................... 29

[c] KM-630MRH........................................................................................................ 30

2. WIRING DIA GRAMS .................................................................................................. 31

[a1] KM-630MAH (with auxiliary codes L-0, M-0, and M-1) and KM-630MWH

(with auxiliary codes L-0, M-0, M-1, and M-2).................................................... 31

[a2] KM-630MAH (with auxiliary codes M-2 and after) and KM-630MWH

(with auxiliary codes M-3 and after)................................................................... 32

[b1] KM-630MRH (with auxiliary codes L-0, M-0, M-1) ............................................. 33

[b2] KM-630MRH (with auxiliary codes M-2 and after) ............................................. 34

3. TIMING CHART.......................................................................................................... 35

4. PERFORMANCE DATA ............................................................................................. 37

[a] KM-630MAH........................................................................................................ 37

[b1] KM-630MWH Serial #L00001D - M20270B ...................................................... 38

[b2] KM-630MWH Serial #M20301E - ...................................................................... 39

[c] KM-630MRH........................................................................................................ 40

IV. SERVICE DIAGNOSIS ................................................................................................. 41

1. NO ICE PRODUCTION.............................................................................................. 41

2. EVAPORATOR IS FROZEN UP................................................................................. 44

3. LOW ICE PRODUCTION ........................................................................................... 45

4. ABNORMAL ICE ........................................................................................................ 45

5. OTHERS .................................................................................................................... 45

V. REMOVAL AND REPLACEMENT OF COMPONENTS................................................ 46

1. SERVICE FOR REFRIGERANT LINES .................................................................... 46

[a] REFRIGERANT RECOVERY ............................................................................. 46

[b] EVACUATION AND RECHARGE [R-404A] ........................................................ 46

2. BRAZING ................................................................................................................... 47

3. REMOVAL AND REPLACEMENT OF COMPRESSOR ............................................ 48

4. REMOVAL AND REPLACEMENT OF DRIER ........................................................... 50

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE...................................... 5 0

6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND LINE VALVE ............. 51

7. REMOVAL AND REPLACEMENT OF EVAPORATOR.............................................. 53

8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE -

WA TER-COOLED MODEL ONLY.............................................................................. 54

9. ADJUSTMENT OF WATER REGULATING VALVE - WATER-COOLED

MODEL ONLY ........................................................................................................... 55

10. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE

REGULATOR (C.P.R.) - REMO TE AIR-COOLED MODEL ONLY ............................ 56

11. REMOVAL AND REPLACEMENT OF THERMISTOR............................................. 57

12. REMOVAL AND REPLACEMENT OF FAN MOTOR ............................................... 58

13. REMOVAL AND REPLACEMENT OF WATER VALVE ............................................ 5 9

14. REMOVAL AND REPLACEMENT OF PUMP MOTOR ............................................ 59

15. REMOVAL AND REPLACEMENT OF SPRAY TUBES ........................................... 6 0

VI. CLEANING AND MAINTENANCE INSTRUCTIONS................................................... 6 1

1. PREPARING THE ICEMAKER FOR LONG STORAGE ............................................. 6 1

2. CLEANING AND SANITIZING PROCEDURES ........................................................ 63

[a] CLEANING PROCEDURE ................................................................................. 64

[b] SANITIZING PROCEDURE................................................................................ 66

3. MAINTENANCE......................................................................................................... 67

I. SPECIFICATIONS

1. KM-630MAH

AC SUP P LY VOLTAGE 208-230/60/1 (3 wire wit h neut ral for 115V) AM P E RA GE 7.5 A ( 5 Mi n. Freeze A T 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs . /day ( k g/ day ) 70 *600 (272) 562 (255) 514 (233) Reference wi t hout * marks 80 571 (259) 512 (232) 466 (211)

90 562 (255) * 470 (213) 422 (191)

100 554 (251) 459 (208) 378 (171) SHAPE OF ICE Cresc ent Cube ICE PRODUCTION PER CYCLE 14.3 lbs. (6. 5 k g) 720 pc s. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs .) 1332 (6.8) 1250 (5.0) WATER gal./ 24HR (gal./100 lbs. ) 157 (33.4) 341 (56. 9) EXTERIOR DIMENS IONS (WxDx H) 22" x 27-1/ 2" x 37-1/2" (560 x 695 x 950 mm ) EXTERIOR FINISH St ai nless Steel, Gal vanized Steel (Rear) WEIGHT Net 154 lbs . ( 70 kg ), S hi ppi ng 185 lbs. (84 kg) CONNECTIONS - ELE CTRIC Permanent - Connec t i on

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" OD P i pe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAK ING W ATER CONTROL Timer Cont roll ed. Overfl ow P i pe COOLING WA TE R CO NTROL N/A BIN CONTROL SYSTEM Proximity Switch with Delay COMPRESSOR Hermetic , Model RS64C1E-CAV CONDENSER Air-c ool ed, F i n and t ube t ype EV A PORATOR V ert i cal type, S t ai nl ess S teel and Copper REFRIGERANT CONTROL Thermos tatic Expansion V al ve REFRIGERANT CHARGE R-404A, 1 lb. 7.6 oz. ( 670 g ) DESIGN PRE S SURE High 467 PS IG, Low 230 PSIG P.C. BOA RD CIRCUIT PRO TE CTION High V olta ge Cut-out ( Int er nal ) COMPRESSOR PROTECTION Auto-reset Overload P rotector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW W ATER 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 specifications and design without prior notice.

2a. KM-630MWH Serial #L00001D - M20270B

AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PE R 24 HR. Temp.(°F) 50 70 lbs . /day ( k g/ day ) 70 *619 (281) 596 (270) Referenc e wit hout *marks 80 602 (273) 566 (257)

SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 14.3 lbs. (6. 5 k g) 720 pc s. APPROXIMATE STORAGE CAPACITY N/A ELE CTRIC & WATER CONSUMP TION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1306 (5.7) 1290 (5.0) WATER gal./ 24HR (gal./100 lbs.) 196 (36.3) 335 (54.1) WATER COOLED CONDENSER 844 (156) 458 (74) gal./24HR (gal./100 lbs.) EXTERIOR DIMENS IONS (W xDxH) 22" x 27-1/ 2" x 37-1/2" (560 x 695 x 950 mm ) EXTERIOR FINISH St ai nless Steel, G alvanized Steel (Rear) WEIGHT Net 154 lbs . ( 70 kg ), Shipping 185 lbs . (84 kg) CONNECTIONS - ELE CTRIC Permanent - Connec t i on

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

CUBE CONTROL SYSTEM Float Switc h HARVESTING CONTROL SYSTE M Hot Gas and Wat er, Thermistor and Timer ICE MAK ING W ATER CONTROL Timer Cont roll ed. Overflow Pi pe COOLING WA TE R CO NTROL N/A BIN CO NTROL SYSTEM Pro xim ity S witch wi th Del ay COMPRE SSO R Hermet ic, Mo de l RS64C1E-CA V CONDENSER Water-cooled, Tube in tube t ype EV A PORATOR V ert i cal type, S tainles s St eel and Copper REFRIGERA NT CONTROL Thermostatic Ex pansion Valve REFRIGERA NT CHARGE R-404A, 1 lb. 3 oz. ( 525 g ) DESIGN PRESSURE High 427 PSIG, Low 230 PSIG P.C. BOA RD CIRCUIT PRO TE CTION Hi g h Vol tage Cut-out ( Int ern al ) COMPRE S SOR PROTECTION A uto-reset Overload Protector ( Internal ) REF R IGERANT CIRCUIT PROTE CTION Aut o -re set High P re ss ur e Co ntrol Switch LOW W ATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin OP ERATING CON DITIONS VO LTA G E RANG E

208-230/60/1 (3 wire wit h neut ral for 115V)

6.5 A ( 5 M in. Freeze A T 104°F / WT 80°F) 15 A 15 A

90 596 (270) *541 (245)

100 589 (267) 533 (242)

Condenser Inlet 1/ 2" F P T Condenser Outl et 3/8" FP T

3/8" OD P i pe

AMBIENT TEMP. WATER SUPPLY TEMP. WATER SUPPLY PRESSURE

90 563 (256) 533 (242) 507 (230) 476 (216)

187 - 253 V

45 -100° F

45 - 90° F

10 - 113 PSIG

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

2b. KM-630MWH Serial #M20301E -

AC SUP P LY VOLTAGE 208-230/60/1 (3 wire wit h neut ral for 115V) AM P E RA GE 6.5 A ( 5 Mi n. Freeze A T 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WA TER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs . /day ( k g/ day ) 70 *621 (282) 603 (273) 563 (256) Reference wi t hout * marks 80 607 (275) 578 (262) 532 (241)

90 603 (273) * 558 (253) 514 (233)

100 590 (268) 548 (248) 473 (215) SHAPE OF ICE Cresc ent Cube ICE PRODUCTION PER CYCLE 14.3 lbs. (6.5 kg) 720 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs .) 1279 (5.5) 1268 (4.9) WATER gal./ 24HR (gal./100 lbs. ) 156 (27.9) 299 (48.1) WATER COOLED CONDENSER 536 (96) 354 (57) gal./24HR (gal./100 lbs.) EXTERIOR DIMENS IONS (W xDxH) 22" x 27-1/ 2" x 37-1/2" (560 x 695 x 950 mm) EXTERIOR FINISH St ai nless Steel, Gal vanized Steel (Rear) WEIGHT Net 154 lbs . ( 70 kg ), Shi ppi ng 185 lbs. (84 kg) CONNECTIONS - ELE CTRIC Permanent - Connec t i on

- WA TER S UPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT

- DRAIN Outl et 3/ 4" FPT Condenser Outl et 3/8" FP T

3/8" OD P i pe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAK ING W ATER CONTROL Timer Controlled. O verfl ow P i pe COOLING WA TE R CO NTROL Pre ss ur e Re g ul a tor BIN CONTROL SYSTEM Proximity Switch with Delay COMPRESSOR Hermetic , Model RS64C2E-CAV-219 CONDENSER Water-cooled, Tube in tube t ype EV A PORATOR V ert i cal type, S t ai nl ess S teel and Copper REFRIGERANT CONTROL Thermos tatic Ex pansion Valve REFRIGERANT CHARGE R-404A, 1 lb. 4.3 oz. ( 575 g ) DESIGN PRE S SURE High 427 PSIG, Low 230 PSIG P.C. BOA RD CIRCUIT PRO TE CTION Hi g h Voltage Cu t-out ( Inte rn al ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Int ernal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW W ATER 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 SUPP LY P RE S SURE 10 - 113 PSIG

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

3. KM-630MRH

AC SUP P LY VOLTAGE 208-230/60/1 (3 wire wit h neut ral for 115V) AM P E RA GE 6.5 A ( 5 Mi n. Freeze A T 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs . /day ( k g/ day ) 70 *603 (274) 573 (260) 531 (241) Reference wi t hout * marks 80 580 (263) 532 (242) 491 (223)

90 573 (260) * 499 (226) 457 (207)

100 564 (256) 489 (222) 418 (190) SHAPE OF ICE Cresc ent Cube ICE PRODUCTION PER CYCLE 14.3 lbs. (6.5 kg) 720 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs .) 1414 (6.8) 1332 (5.3) WATER gal./ 24HR (gal./100 lbs. ) 166 (33.3) 323 (53.6) EXTERIOR DIMENS IONS (WxDx H) 22" x 27-1/ 2" x 37-1/2" (560 x 695 x 950 mm) EXTERIOR FINISH St ai nless Steel, Gal vanized Steel (Rear) WEIGHT Net 154 lbs . ( 70 kg ), Shi ppi ng 185 lbs. (84 kg) CONNECTIONS - ELE CTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

Condensing P res sure Regulator on URC-6F REFRIGERANT CHARGE R-404A, 4 lb. 4 oz. ( 1950 g )

( Icemak er 2 lbs. 6 oz . Cond. 1 lbs . 14 oz. ) DESIGN PRE S SURE High 467 PS IG, Low 230 PSIG P.C. B O ARD CIRCUIT PROTE CTION Hi g h Voltage Cu t-out ( Inte rn al ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Int ernal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW W ATER 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 specifications and design without prior notice.

4. CONDENSER UNIT

URC-6F

24"

(610 mm.)

23-1/32"

(585 mm.)

18-1/8"

(460 mm.)

17-1/8"

(435 mm.)

14-9/16"

(370 mm.)

19-11/16"

(500 mm.)

18-1/8"

(460 mm.)

20-15/32"

(520 mm.)

21-15/16"

(557 mm.)

6/16" x 3/4" (10 mm. x 20 mm.)

4 x 2 (SLOTTED HOLES)

14-1/8"

(358 mm.)

14-15/16"

15-11/16"

(380 mm.)

(398 mm.)

17-7/8"

(454 mm.)

14-15/16"

(380 mm.)

2-1/2"

(63 mm.)

7/8" DIA. HOLE

(23 mm. DIA.)

6-5/16"

(160 mm.)

2-15/16"

(75 mm.)

MODEL: URC-6F

SPECIFICATIONS

EXTERIOR

DIMENSIONS (W x D x H)

REFRIGERANT CHARGE

WEIGHT

CONNECTIONS

REFRIGERANT ELECTRICAL

CONDENSER

HEAD PRESSURE CONTROL

AMBIENT CONDITION

Galvanized Steel

21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 453.8 mm.)

R404A 1 lb. 2 oz. (505 g)

Net 61 lbs. (28 kg) Shipping 68 lbs. (31 kg)

One Shot Couplings (Aeroquip) Permanent Connection

Air-cooled

Condensing Pressure Regulator

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

II. GENERAL INFORMATION

1. CONSTRUCTION

[a] KM-630MAH

Spray Tubes Water Supply Inlet

Control Switch

Bin Control Thermostat (except models with Mechanical Bin Control)

Expansion Valve Fan Motor

Compressor Float Switch

Water Pump

Mechanical Bin Control (except models with Thermostat)

Condenser Hot Gas Valve

Condenser Drier Control Box

[b] KM-630MWH

Spray Tubes Water Supply Inlet

Control Switch

Bin Control Thermostat (except models with Mechanical Bin Control)

Water Regulator

Expansion Valve Hot Gas Valve

Compressor Float Switch Drier

Water Pump Control Box

Mechanical Bin Control (except models with Thermostat)

[c] KM-630MRH

Spray Tubes Water Supply Inlet

Control Switch

Bin Control Thermostat (except models with Mechanical Bin Control)

Expansion Valve Receiver Tank

Compressor

Junction Box

Float Switch Drier

Water Pump Hot Gas Valve

Line Valve

Control Box

Mechanical Bin Control (except models with Thermostat)

2. CONTROLLER BOARD

[a] SOLID-STATE CONTROL

1) A HOSHIZAKI exclusive solid-state control is employed in Modular Crescent Cubers.

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

3) All models are pretested and factory-adjusted.

[b] CONTROLLER BOARD

CAUTION

1. Fragile, handle very carefully.

2. A controller board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit when handling or replacing the board.

3. Do not touch the electronic devices on the board or the back of the board to prevent damage to the board.

4. Do not change wiring and connections. Do not misconnect K3, K4 and K5, because the same connector is used for the Thermistor (white), Float Switch (black), and Mechanical Bin Control (red).

(For machines with thermostat, there is no connection on K4.)

5. Always replace the whole board assembly when it goes bad.

6. Do not short out power supply to test for voltage.

PART NUMBER TYPE

2A1410-01 HOS-001A (Control Products)

Features of Control Products “E” Controller Board

1) Maximum Water Supply Period - 6 minutes Water Solenoid Valve opening, in the Defrost (Harvest) Cycle, is limited by the defrost

timer. The Water Valve cannot remain open longer than the maximum period. The Water Valve can close in less than six minutes if the defrost cycle is completed.

2) Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle.

But the Defrost Timer does not start counting until the Thermistor senses 48°F at the Evaporator outlet. The period from the end of the freeze cycle up to the point of the Thermistor's sensing varies depending on the ambient and water temperatures.

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

Temperature Safety. During the defrost cycle the Evaporator temperature rises. The Thermistor senses 48°F and starts the Defrost Timer. After the Defrost Timer counts down to zero, the normal freeze cycle begins. If the Evaporator temperature continues to rise, the Thermistor will sense the rise in temperature and at 127 ± 7°F the Thermistor operates the High Temperature Safety. This High Temperature Safety shuts down the circuit and the icemaker automatically stops. This High Temperature Safety protects the unit from excessive temperature. The Control Board will Beep every 3 seconds. The white Reset Button on the Control Board must be pressed with power on to reset the Safety.

4) Low Water Safety If the Pump Motor is operated without water, the mechanical seal can fail. To prevent this

type of failure, the Controller Board checks the position of the Float Switch at the end of the initial one minute water fill cycle and at the end of each defrost cycle. If the Float Switch is in the up position (electrical circuit closed), the Controller Board changes to the ice making cycle. If the Float Switch is in the down position (electrical circuit open), the Controller Board changes to a one minute water fill cycle before starting the ice making cycle. This method allows for a Low Water Safety shut down to protect the Water Pump from mechanical seal failure. For water-cooled model, if the water is shut off, the unit is protected by the High Pressure Switch.

5) High Voltage Cutout The maximum allowable supply voltage of this icemaker is limited by the High Voltage Cutout.

If miswiring (especially on single phase 3 wire models) causes excessive voltage on the Controller Board, the High Voltage Cutout shuts down the circuit in 3 seconds and the icemaker automatically stops. When the proper supply voltage is resumed, the icemaker automatically starts running again. The Control Board will signal this problem using 7 Beeps every 3 seconds.

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

problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned ON or OFF.

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

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

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

{LED 1 – Comp; LED 2 - HGV/CFM; LED 3 – PM; LED 4 - WV} The built in safeties shut down the unit and have alarms as follows:

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

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

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

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

4 beeps every 3 sec. = Short Circuit between the K4 connection on

Machines with mechanical bin control ONLY

the control board and the bin control relay. Check connections and replace wire harness if necessary.

5 beeps every 3 sec. = Open Circuit between the K4 connection on the control board and the bin control relay. Check connections and replace wire harness if necessary.

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

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

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

The Output Test switch “S3” provides a relay sequence test. With power OFF, place S3 ON and switch power to ICE. The correct lighting sequence should be none, 2, 3, 4, 1, & 4, normal sequence every 5 seconds. S3 should remain in the “OFF” position for normal operation.

The application switch located between relay X3 & X4 must be set to match the original board application. Place this switch in the ALP position if there is no white wire supplied to the K1 connector. If there is a white wire, place the switch in the C position. If this switch is placed in the wrong position, either the compressor contactor will remain energized with the control switch OFF, or the unit will not start.

The dip switches should be adjusted per the adjustment chart published in the Tech Specs book. Number 8 must remain in the OFF position.

(Control Products HOS-001A Board)

[c] SEQUENCE

1st Cycle

1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts.

2. After 1 minute, Defrost cycle starts.

3. Thermistor reads 48° F. Defrost Timer starts counting.

5. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens.

IMPORTANT

Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.

IMPORTANT

Water Valve opening is limited to 6 minutes.

4. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts.

IMPORTANT

1. Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.

2. Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting.

2nd Cycle and after with pump drain

IMPORTANT

Freeze cycle time is limited to 60 minutes even if Float Switch does not open.

1. Float Switch opens and signals to complete freeze cycle. Drain timer starts counting.

2. Drain timer stops counting. Pump drain is completed

3. Thermistor reads 48° F. Defrost Timer starts counting.

IMPORTANT

Water Valve opening is limited to 6 minutes.

5. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens.

IMPORTANT

Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.

4. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts.

IMPORTANT

1. Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.

2. Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting.

2nd Cycle and after with no pump drain

IMPORTANT

Freeze cycle time is limited to 60 minutes even if Float Switch does not open.

1. Float Switch opens and signals to complete freeze cycle.

2. Thermistor reads 48° F. Defrost Timer starts counting.

IMPORTANT

Water Valve opening is limited to 6 minutes.

4. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens.

IMPORTANT

Board never accepts freeze completion signal within the first 5 minutes in freeze cycle.

3. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts.

IMPORTANT

1. Board never accepts defrost completion signal within the first 2 minutes in defrost cycle.

2. Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting.

[d] CONTROLS AND ADJUSTMENTS

The Dip Switch is factory-adjusted to the following positions:

FOR MODELS WITH MECHANICAL BIN CONTROL:

DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10

KM-630MAH OFF OFF OFF OFF ON ON ON OFF ON OFF KM-630MWH OFF OFF OFF OFF ON ON ON OFF OFF OFF KM-630MRH OFF OFF OFF OFF ON ON ON OFF ON OFF

FOR MODELS WITH THERMOSTAT :

DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10

KM-630MAH OFF OFF OFF OFF ON ON OFF OFF ON OFF KM-630MWH OFF OFF OFF OFF ON ON OFF OFF OFF OFF KM-630MRH OFF OFF OFF OFF ON ON OFF OFF ON OFF

Switch Nos. 1 and 2:

Used for adjustment of the Defrost Timer. The Defrost Timer starts counting when the Thermistor reads a certain temperature

at the Evaporator outlet. Switch Nos. 3 and 4:

Used for adjustment of the Drain Timer.

When a freeze cycle is completed, the Pump Motor stops, and the icemaker resumes operation in 2 seconds. Then the Pump Motor drains the Water Tank for the time determined by the Drain Timer. The Drain Timer also determines the time to restrain completion of a defrost cycle, i.e. the minimum defrost time.

Switch Nos. 5 and 6:

Used for adjustment of the Drain Counter.

The Pump Motor drains the Water Tank at the frequency determined by the Drain Counter.

Switch No. 7: Used only on models with mechanical bin control. Dip Switch should be set “ON”.

(Models with bin thermostat, Switch No. 7 should be set in the “OFF” position.) Switch No. 8:

Used only for checking the Controller Board. Usually set in OFF position.

Switch Nos. 9 and 10: Used for adjustment of Freeze Timer.

The Freeze Timer determines maximum freeze cycle time. Upon termination of Freeze Timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem.

1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor. The resistance

varies depending on the Suction Line temperatures. The Thermistor detects the temperature of the Evaporator outlet to start the Defrost 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) Resistance (kΩ)

0 14.401 10 10.613 32 6.000 50 3.871 70 2.474

90 1.633 Check a thermistor for resistance by using the following procedures. (i) Disconnect the connector K3 on the board. (ii) Remove the Thermistor. See “V. 11. REMOVAL AND REPLACEMENT OF

THERMISTOR.”

(iii) Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3

minutes.

(iv) Check for a resistance between Thermistor leads.

Normal reading is within 3.5 to 7 kΩ. Replace the Thermistor if it exceeds the normal reading.

2) Defrost Timer No adjustment is required under normal use, as the Defrost Timer is adjusted to the suitable

position. However, if necessary when all the ice formed on the Evaporator does not fall into the bin in the harvest cycle, adjust the Defrost Timer to longer setting by adjusting the Dip Switch (No. 1 & 2) on the Controller Board.

SETTING TIME

Dip Switch Dip Switch

No. 1 No. 2

OFF OFF 60 seconds O N OFF 90 seconds OFF ON 120 seconds ON ON 180 seconds

3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required.

SETTING TIME

Dip Switch Dip Switch

No. 3 No. 4 T1 T 2

OFF OFF 10 seconds 150 seconds ON OFF 10 seconds 180 seconds OFF ON 10 seconds 120 seconds ON ON 20 seconds 180 seconds

T1: Time to drain the Water Tank T2: Time to restrain defrost completion

4) Drain Counter

CAUTION

Do not adjust the Drain Counter, or the Evaporator may freeze up.

The Drain Counter is factory-adjusted to drain the Water Tank every 10 cycles, and no adjustment is required. However, where water quality is bad and the icemaker needs a pump drain more often, the Drain Counter can be adjusted as shown in the table below:

SETTING FREQUENCY

Dip Switch Dip Switch

No. 5 No. 6

OFF OFF every cycle ON OFF every 2 cycles OFF ON every 5 cycles ON O N every 10 cycles

5) Freeze Timer

CAUTION

Adjust to proper specification, or the unit may not operate correctly.

Two new dip switches numbered 9 and 10 have been added to the improved “E” board to better prevent possible freeze ups. These settings come factory set to the default setting of 60 min. (OFF, OFF). Check the adjustment chart published in the Tech Specs for proper settings. If the old board does not have these two dip switches, (only 8 instead of 10), leave setting as OFF, OFF.

6) Bin Control

MODELS WITH THERMOSTAT

When the ambient temperature is below 45°F, the Bin Control Thermostat operates to stop the icemaker even if the Ice Storage Bin is empty. When the Thermostat is set in the prohibited range, the icemaker operates continuously even if the Ice Storage Bin is filled with ice. Setting in the prohibited range might cause severe damage to the icemaker resulting in failure.

SETTING TIME

Dip Switch Dip Switch

No. 9 No. 10

OFF OFF 60 min. O N OFF 70 min. OFF O N 50 min. ON ON 60 min.

CAUTION

No adjustment is required under normal use, as the Bin Control is factory-adjusted. Adjust it, if necessary, so that the icemaker stops automatically within 10 seconds after ice contacts the Bin Control Thermostat Bulb.

MODELS WITH MECHANICAL BIN CONTROL

CAUTION

Dip Switch No. 7 must be set to the ON position. If No. 7 is set to the OFF position, the machine will run continuously, causing a freeze-up condition.

No adjustment is required. The Bin Control is factory-adjusted.

[e] CHECKING THE CONTROLLER BOARD

1) Visually check the sequence with the icemaker operating.

2) Visually check the Controller Board by using the following procedures. (i) Adjust the Defrost Timer to minimum position.

Disconnect the Thermistor from the Controller Board. Connect a 1.5 kΩ - 3.5 kΩ resistor to the Connector K3 (pins #1 and #2), and energize the unit. After the 1 minute ± 5 second water supply cycle and the 2 minute ± 10 second defrost cycle, the unit should start the freeze cycle.

(ii) After the above step (i), disconnect the Float Switch leads from the Controller Board

within the first 5 minutes of the freeze cycle. The unit should go into the defrost cycle after the first 5 minutes ± 20 seconds of the

freeze cycle.

(iii) Reconnect the Float Switch Connector to the Controller Board. After the first 5

minutes of the freeze cycle, disconnect the Float Switch leads from the Controller Board.

At this point, the unit should start the defrost cycle.

(iv) After Step (iii), de-energize the unit and confirm that the Defrost Timer is in the

minimum position. Disconnect the resistor from the Controller Board, and energize the unit. After the 1 minute water supply cycle, the defrost cycle starts. Reconnect a 1.5 kΩ - 3.5 kΩ resistor to the Connector K3 (pins #1 and #2) after the first 2 minutes of the defrost cycle.

The unit should start the freeze cycle after 1 minute ± 5 seconds from the resistor connection.

3) Check the Controller Board by using test program of the Controller Board. The Output Test Switch “S3” provides a relay sequence test. With power OFF, place S3 on

and switch power to ICE. The correct lighting sequence should be none, 2, 3, 4, 1, and 4, normal sequence every 5 seconds. S3 should remain in the “OFF” position for normal operation.

3. MECHANICAL BIN CONTROL

(THESE INSTRUCTIONS NOT APPLICABLE TO MODELS WITH THERMOSTAT)

[a] PROXIMITY SWITCH

1) This machine uses a lever-actuated proximity switch (hereafter called “mechanical bin control”) to control the ice level in the storage bin.

[b] EXPLANATION OF OPERATION

1) The startup and shutdown of the ice machine is controlled via the controller board. Dip Switch number 7 must be in the ON position for the controller board to receive input from the bin control.

(i) The controller board receives a resistance value input via the red K4 connector from the bin control. A resistor wire harness is connected from the bin control to the controller board.

(ii) When the bin control is activated in the bin full position (pushed to the right), a

15.8 KΩ signal will be sent to the control board to shut down the unit. (iii) When the bin control is in the normal position (bin is not full), a 7.9 KΩ reading is

sent to the control board to continue operation.

2) During operation, the controller board will only shut down the machine if a 15.8 KΩ signal is received from the bin control during the first 5 minutes of the freeze cycle.

(i) If ice pushes the lever to the right after the first five minutes of the freeze cycle, the controller board will allow the machine to complete the freeze cycle and the following harvest cycle before shutting down the machine. This will prevent incomplete batches of ice from forming on the evaporator.

[c] TROUBLESHOOTING (MECHANICAL BIN CONTROL ONLY)

1) Machine will not start (i) Move dip switch No. 7 to the “OFF” position. If the machine starts up within a few

seconds, the bin control is the likely problem. If the machine does not start up,

refer to Section “IV. Service Diagnosis” to verify that non-bin control related issues

are resolved.

(ii)

Check to make sure shipping tape has been removed and the wires are connected

properly. (iii) Check to make sure no obstruction prevents the lever from moving to the bin empty

position.

2) Machine will not shut off

(i)

Refer to Section “IV. Service Diagnosis” to verify that non-bin control related issues

are resolved. (ii) Dip switch No. 7 should be in the on position. If the switch is in the off position, the

controller board will not receive input from the bin control. (iii) Move the lever to the far right.

a. If the machine does not shut off, check the resistance values of the resistor

wire harness. You should read approximately 15.8 KΩ between the black terminal and the red terminal that connect to the K4 connector on the controller board, when the lever is in the bin full position (far right). If this reads approximately 7.9 KΩ, the resistors may be miswired. Switch the black and

white wires in the terminal housing or order a replacement wire harness. b. Check the stainless steel bracket that the bin control is mounted to. c. If the preceding items do not resolve the problem, replace the Bin Control

Assembly.

III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

[a] KM-630MAH

[b] KM-630MWH

[c] KM-630MRH

2. WIRING DIAGRAMS

[a1] KM-630MAH (with auxiliary codes L-0, M-0, and M-1) and KM-630MWH (with auxiliary codes L-0, M-0, M-1, and M-2)

Note: Pressure Switch

MAH

Cut-out 412 PSIG

+ 21

- 0

Cut-in 327 ± 21 PSIG

MWH

Cut-out 384 PSIG

+ 21

- 0

Cut-in 284 ± 21 PSIG

[a2] KM-630MAH (with auxiliary codes M-2 and after) and KM-630MWH (with auxiliary codes M-3 and after)

[b1] KM-630MRH (with auxiliary codes L-0, M-0, M-1)

Note: Pressure Switch

Cut-out 412 PSIG

+ 21

- 0

Cut-in 327 ± 21 PSIG

U1GMA0179608

[b2] KM-630MRH (with auxiliary codes M-2 and after)

3. TIMING CHART

4. PERFORMANCE DATA

[a] KM-630MAH

APPROXIMATE ICE PRO DUCTION P ER 24 HR.

lbs./day kg./day APPROXIMATE ELECTRIC

CONSUMPTI ON

watts 100/38 APPRO XIMATE WA TER CONS UMPTION P ER 24 HR.

gal./day m3/day 100/38 223 0.84 152 0.57 115 0.43 FRE EZING CYCLE TIME

min. 100/38 HARVEST CYCLE TIME

min. 100/38 HEAD PRES SURE

PSIG kg/cm2G SUCTION PRESSURE

PSIG kg/cm2G 100/38 44 3.1 47 3.3

AMBIENT TEMP.

(ºF/ºC)

70/21 80/27 571 259 512 232 466 211 90/32 562 255

100/38 554 251 459 208 378 171

70/21 80/27 90/32

70/21 80/27 300 1.14 216 0.82 204 0.77 90/32 287 1.09

70/21 80/27

90/32

70/21 80/27

90/32

70/21 80/27 262 18.4 296 20.8 324 22.7 90/32 267 18.8

100/38 272 19.1 327 23.0 375 26.4

70/21 80/27 44 3.1 46 3.2 47 3.3 90/32 44 3.1

50/10 70/21 90/32

600

1250

1268 1274 1275

341

33 34 35

4.4

4.0

3.8

3.1

245

WATE R TEMP. (ºF/ºC)

272 562 255 514 233

470

1.29

17.2

3.0 44 3.1 46 3.2

287 1.09 253 0.96

157

267 18.8 296 20.8

320

213

1274 1305

1332

1336

0.59

34 37

3.8

3.0

2.4

22.5

3.3

422 191

1297 1323 1352 1370

135 0.51

38 41

44 48

3.5

2.9

2.2

2.0

349 24.5

49 3.4

3.5

TOTA L HE AT OF REJE CTION FROM CONDENS E R 9639 BTU/h [A T 90ºF (32ºC) / WT 70ºF (21ºC)]

Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only.

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

[b1] KM-630MWH Serial #L00001D - M20270B

APPROXIMATE ICE PRODUCTION PER 24 HR.

lbs./day kg./day APPROXIMATE ELECTRIC

CONSUMPTI ON

watts 100/38 A PPR O XIMATE WATER CONS UMPTION P ER 24 HR.

gal./day m3/day 100/38 1190 4.51 1100 4.17 *1532 5.80 FRE EZING CYCLE TIME

min. 100/38 HARVEST CYCLE TIME

min. 100/38 HEAD PRESSURE

PSIG kg/cm2G SUCTION PRESSURE

PSIG kg/cm2G

AMBIENT TEMP.

(ºF/ºC)

70/21 *619 281 596 270 563 256 80/27 602 273 566 257 533 242 90/32 596 270 *541 245 507 230

100/38 589 267 533 242 *476 216

70/21 80/27 90/32

70/21 *793 3.00 80/27 848 3.21 1024 3.88 1240 4.69 90/32 1150 4.35 *1040 3.94 1297 4.91

70/21 80/27

90/32

70/21 80/27

90/32

70/21 *280 19.7 80/27 280 19.7 280 19.7 292 20.5 90/32 280 19.7 *280 19.7 290 20.4

100/38 283 19.9 285 20.0 300 21.1

70/21 *43 3.0 44 3.1 46 3.2 80/27 44 3.1 46 3.2 47 3.3 90/32 44 3.1 *47 3.3 49 3.4

100/38 44 3.1 47 3.3 *50 3.5

50/10 70/21 90/32

*1290

1293 1294 1298

*31

32 32

*4.2

3.8

3.7

WATER TEMP. (ºF/ºC)

1294 1301

*1306

1309

865 3.28 1080 4.09

32 34

*36

3.7

3.0

2.4

280 19.7 288 20.2

1305 1313 1318

*1329

35 37

*41

3.3

2.9

2.2*2.5

*2.0

TOTAL HE AT OF RE JECTION FROM CO NDENSER TOTA L HE AT OF REJE CTION FROM COMPRESSOR 2156 BTU/h [A T 90ºF (32º C) / WT 70ºF (21ºC)] WATER FLOW F OR CONDENSER 58.3 gal. / h (AT 100ºF (38ºC) / WT 90ºF (32ºC)) PRESSURE DROP OF COOLING WATE R LINE less than 10 PSIG

12635 BTU/h [A T 90ºF (32ºC) / WT 70ºF (21ºC)]

Note: Pressure data is recorded at 5 minutes into freeze cycle. The data without * should be used for reference only.

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

[b2] KM-630MWH Serial #M20301E -

APPROXIMATE ICE PRO DUCTION P ER 24 HR.

lbs./day kg./day APPROXIMATE ELECTRIC

CONSUMPTI ON

watts 100/38 APPRO XIMATE WA TER CONS UMPTION P ER 24 HR.

gal./day m3/day 100/38 739 2.80 737 2.79 *1068 4.04 FRE EZING CYCLE TIME

min. 100/38 HARVEST CYCLE TIME

min. 100/38 HEAD PRES SURE

PSIG kg/cm2G SUCTION PRESSURE

PSIG kg/cm2G

AMBIENT TEMP.

(ºF/ºC)

70/21 *621 282 603 273 563 256 80/27 607 275 578 262 532 241 90/32 603 273 *558 253 514 233

100/38 590 268 548 248 *473 21 5

70/21 80/27 90/32

70/21 *653 2.47 80/27 661 2.50 720 2.73 903 3.42 90/32 664 2.51 *691 2.62 887 3.36

70/21 80/27

90/32

70/21 80/27

90/32

70/21 *280 19.7 80/27 280 19.7 280 19.7 288 20.2 90/32 280 19.7 *280 19.7 288 20.2

100/38 282 19.9 285 20.0 295 20.7

70/21 *47 3.3 47 3.3 48 3.4 80/27 47 3.3 48 3.4 49 3.4 90/32 47 3.3 *48 3.4 49 3.4

100/38 48 3.3 48 3.4 *50 3.5

50/10 70/21 90/32

*1268

1270 1271

*31

32 32

*3.8

3.5

3.4

WATE R TEMP. (ºF /ºC)

1271 1275

*1279

1280

664 2.51 814 3.08

32 34

*35

3.4

2.8

*2.3

2.3

280 19.7 286 20.1

1275 1278 1282

*12851271

35 37

*41

3.1

2.7

2.1

*2.0

TOTAL HE AT OF RE JECTION FROM CO NDENSER TOTA L HE AT OF REJE CTION FROM COM P RE S SOR 1894 BTU/h [AT 90ºF (32º C) / WT 70ºF (21ºC)] WATER FLOW F OR CONDENSER 39 gal. / h (A T 100ºF (38ºC) / WT 90ºF (32ºC)) PRESSURE DROP OF COOLING W A TER LINE less t han 10 P SIG

8770 BTU/h [A T 90ºF (32ºC) / WT 70ºF (21ºC)]

Note: Pressure data is recorded at 5 minutes into freeze cycle. The data without * should be used for reference only.

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

[c] KM-630MRH

APPROXIMATE ICE PRO DUCTION P ER 24 HR.

lbs./day kg./day APPROXIMATE ELECTRIC

CONSUMPTI ON

watts 100/38 APPRO XIMATE WA TER CONS UMPTION P ER 24 HR.

gal./day m3/day 100/38 221 0.84 161 0.61 121 0.46 FRE EZING CYCLE TIME

min. 100/38 HARVEST CYCLE TIME

min. 100/38 HEAD PRES SURE

PSIG kg/cm2G SUCTION PRESSURE

PSIG kg/cm2G 100/38 44 3.1 44 3.1

AMBIENT TEMP.

(ºF/ºC)

70/21 80/27 580 263 532 242 491 223 90/32 573 260

100/38 564 256 489 222 418 190

70/21 80/27 90/32

70/21 80/27 288 1.09 217 0.82 201 0.76 90/32 277 1.05

70/21 80/27

90/32

70/21 80/27

90/32

70/21 80/27 238 16.8 251 17.6 281 19.8 90/32 240 16.9

100/38 249 17.5 266 18.7 313 22.0

70/21 80/27 42 3.0 43 3.0 47 3.3 90/32 42 3.0

50/10 70/21 90/32

603

1332

1350 1356 1326

323

33 33 34

4.1

3.7

3.6 2.2

3.0

232

WATE R TEMP. (ºF/ºC)

274 573 260 531 241

499

1.22

16.3

3.0 42 3.0 45 3.2

277 1.05 245 0.93

166

240 16.9 263 18.5

260

226

1356 1387

1414

1401

0.63

33 36

3.6

2.9

2.4

18.3

3.0

457 207

1322 1316 1358 1306

143 0.54

37 40

43 47

3.3

2.8

2.0

288 20.2

47 3.3

3.5

TOTA L HE AT OF REJE CTION FROM CONDENS E R 8512 BTU/h [A T 90ºF (32ºC) / WT 70ºF (21ºC)] TOTA L HE AT OF REJE CTION FROM COM P RE S SOR 1775 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] CONDE NSER VOLUME 40 CU. IN (U RC-6F)

Note: Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only.

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

IV. SERVICE DIAGNOSIS

1. NO ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY

[1] The icemaker a) Power Supply 1. “OFF” position. 1. Move to “ON” position will not start 2. Loose connections. 2. Tighten

3. Bad contacts. 3. Check for continuity and replace.

4. Voltage too high. 4. Check and get recommended voltage.

b) Fuse (Inside Fused 1. Blown out. 1. Check for short circuit Disconnect, if any) and replace c) Control Switch 1. “OFF” position. 1. Move to “ICE” position.

2. Bad contacts. 2. Check for continuity and replace.

d) Bin Control 1. Tripped with bin filled 1. Remove ice. Thermostat with ice.

2. Ambient temperature 2. Increase ambient

too cool. temperature.

3. Set too warm. 3. See “II.2.[d]

For mechanical CONTROLS AND bin control ADJUSTMENTS, 5) Bin see “II. 3. [c]” Control.”

4. Bulb out of position. 4. Place in position.

5. Bad contacts or leaks 5. Check for continuity and

bulb. replace. e) High Pressure 1. Bad contacts. 1. Check for continuity and Control replace. f) Transformer 1. Thermal fuse blown out 1. Replace.

or coil winding opened. g) Wiring to 1. Loose connections or 1. Check for continuity and Controller Board open. replace. h) Thermistor 1. Leads short-circuit or 1. See “II.2.[d] CONTROLS

open and High AND ADJUSTMENTS, 1)

Temperature Safety Defrost Control.”

operates. i) Hot Gas Solenoid 1. Continues to open in 1. Check for power off in Valve freeze cycle and High freeze cycle and replace.

Temperature Safety

operates. j) Water Supply Line 1. Water supply off and 1. Check and get

water supply cycle does recommended pressure.

not finish.

2. Condenser water pressure 2. Check and get

too low or off and Pressure recommended pressure.

Control opens and closes

frequently to finally operate

High Temperature Safety. k) Water Solenoid 1. Mesh filter or orifice gets 1. Clean.

clogged and water supply

cycle does not finish.

2. Coil winding opened. 2. Replace.

3. Wiring to Water Valve. 3. Check for loose connection or open, and replace.

PROBLEM POSSIBLE CAUSE REMEDY

l) Controller Board 1. Defective 1. See “II.2[e] CHECKING

CONTROLLER BOARD.” m) Interlock Switch 1. “CLOSED” position. 1. Move to “OPEN” position. (Cleaning Valve) 2. Bad contacts. 2. Check for continuity and

replace.

[2] Water a) Float switch 1. Connector disconnected. 1. Place in position. continues to 2. Leads opened or defective 2. Check and replace. be supplied, switch. and the ice- 3. Float does not move freely. 3. Clean or replace. maker will not b) Controller Board 1. Defective. 1. Replace. start. [3] Compressor a) Wash Switch 1. “WASH” position. 1. Move to “ICE” position.

2. Bad contacts. 2. Check and replace. b) High Pressure 1. Dirty Air Filter or 1. Clean. Controller Condenser.

2. Ambient or condenser 2. Reduce ambient temp.

water temp. too warm.

3. Refrigerant overcharged. 3. Recharge.

4. Condenser water pressure 4. Check and get

too low or off. [Water- recommended pressure. cooled model only].

5. Fan not operating. [Except 5. See chart 1 - [6].

water-cooled model].

6. Refrigerant line or 6. Clean and replace Drier.

components plugged. c) Water Regulator 1. Set too high. 1. Adjust lower. d) Overload Protector 1. Bad contacts. 1. Check for continuity and

replace.

2. Voltage too low. 2. Increase voltage.

3. Refrigerant overcharged or 3. Recharge.

undercharged.

4. Line Valve continues to 4. Check Line Valve's

close in freeze cycle and operation in freeze cycle

Overload Protector and replace.

operates. e) Starter 1. Bad contacts. 1. Check and replace.

2. Coil winding opened. 2. Replace. f) Start Capacitor or 1. Defective. 1. Replace. Run Capacitor g) Magnetic Contactor 1. Bad contacts. 1. Check for continuity and

replace.

2. Coil winding opened. 2. Replace. h) Compressor 1. Wiring to Compressor. 1. Check for loose

connection or open, and replace.

2. Defective. 2. Replace.

3. Protector tripped. 3. Reduce temperature. i) Controller board 1. Defective. 1. See “II.2. [e] CHECKING

CONTROLLER BOARD.” [4] Water a) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks continues to Valve with icemaker off. be supplied in b) Controller Board 1. Defective. 1. See “II.2.[e] CHECKING freeze cycle. CONTROLLER BOARD.”

PROBLEM POSSIBLE CAUSE REMEDY

[5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get comes from water level in Water Tank recommended pressure.

Spray Tubes. too low. Water Pump b) Water Solenoid 1. Dirty mesh filter or orifice 1. Clean. will not start, or Valve and water level in Water freeze cycle Tank too low. time is too c) Water System 1. Water leaks. 1. Check connections for short. water leaks, and replace.

2. Clogged. 2. Clean.

d) Pump Motor 1. Motor winding opened. 1. Replace.

2. Bearing worn out. 2. Replace.

3. Wiring to Pump Motor. 3. Check for loose connection or open, and replace.

4. Defective Capacitor. 4. Replace.

5. Defective or bound impeller. 5. Replace and clean.

6. Mechanical Seal worn out. 6. Check and replace.

e) Controller Board 1. Defective. 1. See “II.2. [e] CHECKING

CONTROLLER BOARD.”

[6] Fan Motor will a) Fan Motor 1. Motor winding opened. 1. Replace. not start, or is 2. Bearing worn out. 2. Replace. not operating. 3. Wiring to Fan Motor. 3. Check for loose

connection or open, and

replace.

4. Defective Capacitor. 4. Replace

5. Fan blade bound. 5. Check and replace.

b) Controller Board 1. Defective. 1. See “II.2. [e] CHECKING

CONTROLLER BOARD.”

[7] All components a) Refrigerant 1. Undercharged. 1. Check for leaks and run but no ice recharge. is produced. 2. Air or moisture trapped. 2. Replace Drier, and

recharge.

b) Compressor 1. Defective valve. 1. Replace. c) Hot Gas Solenoid 1. Continues to open in freeze 1. Check and replace. Valve cycle. d) Line Valve 1. Continues to close in 1. Check and replace

freeze cycle.

e) Water Supply Line 1. Condenser water pressure 1. Check and get

[Water-cooled model too low or off and Pressure recommended pressure.

only] Control opens and closes

frequently.

2. EVAPORATOR IS FROZEN UP

PROBLEM POSSIBLE CAUSE REMEDY

[1] Freeze cycle a) Float Switch 1. Leads short-circuit or 1. Check and replace. time is too defective switch. long. 2. Float does not move freely. 2. Clean or replace.

b) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks Valve with icemaker off. c) Controller Board 1. Defective. 1. See “II.2[e] CHECKING

CONTROLLER BOARD.” [2] All ice formed a) Evaporator 1. Scaled up. 1. Clean. on Evaporator b) Water Supply Line 1. Water pressure too low. 1. Check and get does not fall recommended pressure. into bin in c) Water Solenoid 1. Dirty mesh filter or orifice. 1. Clean. harvest cycle. Valve 2. Diaphragm does not close. 2. Check for water leaks

with icemaker off.

d) Ambient and/or 1. Too cool. 1. Increase temperature. water temperature e) Line Valve 1. Continues to open in 1. Check operation in

harvest cycle. harvest cycle and replace.

f) Thermistor 1. Out of position or loose 1. See “V. 11. REMOVAL

attachment.. AND REPLACEMENT OF

THERMISTOR.”

g) Controller Board 1. Defrost Timer is set too 1. Adjust longer, referring

short. to “II. 2. [d] CONTROLS

AND ADJUSTMENT, 2)

Defrost Timer.”

2. Defective. 2. See “II. 2.[e] CHECKING CONTROLLER BOARD.”

[3] Others a) Spray Tubes 1. Clogged. 1. Clean.

2. Out of position. 2. Place in position.

b) Water System 1. Dirty. 1. Clean. c) Refrigerant 1. Undercharged. 1. Check for leaks and

recharge.

d) Expansion Valve 1. Bulb out of position or 1. Place in position.

loose attachment.

2. Defective. 2. Replace.

e) Hot Gas Solenoid 1. Coil winding opened. 1. Replace. Valve 2. Plunger does not move. 2. Replace.

3. Wiring to Hot Gas Valve. 3. Check for loose connection or open, and replace.

f) Water Supply Line 1. Too small; requires 3/8” 1. Increase Water Line size.

OD line dedicated per

machine. g) Water Filter (if 1. Flow rate too small. 1. Replace with filter with installed) larger flow rate.

3. LOW ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY

[1] Freeze cycle a) See chart 1 - [3], and check dirty Air Filter or Condenser, ambient or water time is long. temperature, water pressure, Water Regulator or refrigerant charge.

b) See chart 2 - [1], and check Float Switch, Water Solenoid Valve or Controller

Board. [2] Harvest cycle a) See chart 2 - [2], and check Controller Board, Thermistor, Evaporator, ambient time is long and/or water temperature, water supply line, Water Solenoid Valve, or Expansion

Valve.

4. ABNORMAL ICE

PROBLEM POSSIBLE CAUSE REMEDY

[1] Small Cube a) Ice Cube Guide 1. Out of position. 1. Place in position.

Circulated water falls into

bin. b) See chart 1 - [5], and check water supply line, Water Solenoid Valve, water system, Pump Motor or Controller Board. c) Drain Valve 1. Dirty. 1. Clean.

[2] Cloudy or a) See chart 2 - [1] and - [3], and check Float Switch, Water Solenoid Valve, irregular cube Controller Board, Spray Tubes, water system, refrigerant charge or Expansion

Valve. b) Spray Guide 1. Dirty. 1. Clean. c) Water Quality 1. High hardness or contains 1. Install a water filter or

impurities. softener.

5. OTHERS

PROBLEM POSSIBLE CAUSE REMEDY

[1] Icemaker will a) Bin Control 1. Set too cold. 1. Adjust warmer. not stop when Thermostat 2. Defective. 2. Replace. bin is filled with ice. For mechanical

bin control see “II. 3. [c]”

[2] Abnormal a) Pump Motor 1. Bearings worn out. 1. Replace. noise b) Fan Motor 1. Bearings worn out. 1. Replace.

2. Fan blade deformed. 2. Replace fan blade.

3. Fan blade does not move 3. Replace.

freely. c) Compressor 1. Bearings worn out, or 1. Replace.

cylinder valve broken.

2. Mounting pad out of 2. Reinstall

position. d) Refrigerant Lines 1. Rub or touch lines or other 1. Replace.

surfaces.

[3] Ice in storage a) Bin Drain 1. Plugged. 1. Clean. bin often melts.

V. REMOVAL AND REPLACEMENT OF COMPONENTS

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced.

IMPORTANT

1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture quickly. Therefore it is important to prevent moisture from entering the system when replacing or servicing parts.

2. Always install a new filter drier every time the sealed refrigeration system is opened.

3. Do not leave the system open for longer than 5 minutes when replacing or

servicing parts.

1. SERVICE FOR REFRIGERANT LINES

[a] REFRIGERANT RECOVERY

The icemaker unit is provided with two Refrigerant Access Valves–one on the low-side and one on the high-side line. Using proper refrigerant practices recover the refrigerant from the Access Valves and store it in an approved container. Do not discharge the refrigerant into the atmosphere.

[b] EVACUATION AND RECHARGE [R-404A]

1) Attach Charging Hoses, a Service Manifold and a Vacuum Pump to the system. Be sure to connect charging hoses to both High and Low -side Access Valves.

IMPORTANT

The vacuum level and Vacuum Pump may be the same as those for current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils.

2) Turn on the Vacuum Pump. Never allow the oil in the Vacuum Pump to flow backward.

3) Allow the Vacuum Pump to pull down to a 29.9" Hg vacuum. Evacuating period depends on pump capacity.

4) Close the Low-side Valve and High-side Valve on the Service Manifold.

5) Disconnect the Vacuum Pump, and attach a Refrigerant Service Cylinder to the High-side line. Remember to loosen the connection, and purge the air from the Hose. See the Nameplate for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

6) A liquid charge is recommended for charging an R-404A system. Invert the service cylinder. Open the High-side, Service Manifold Valve.

7) Allow the system to charge with liquid until the pressures balance.

8) If necessary, add any remaining charge to the system through the Low-side. Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the Low-side access port with the unit running.

9) Close the two Refrigerant Access Valves, and disconnect the Hoses and Service Manifold.

10) Cap the Access Valves to prevent a possible leak.

2. BRAZING

1. Refrigerant R-404A itself is not flammable at atmospheric pressure and temperatures up to 176° F.

2. Refrigerant R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames) R-404A can be decomposed

to form hydrofluoric acid and carbonyl fluoride both of which are hazardous.

3. Always recover the refrigerant and store it in an approved container. Do not discharge the refrigerant into the atmosphere.

4. Do not use silver alloy or copper alloy containing Arsenic.

5. Do not use R-404A as a mixture with pressurized air for leak testing. Refrigerant leaks can be detected by charging the unit with a little refriger-

ant, raising the pressure with nitrogen and using an electronic leak detector.

DANGER

Note: All brazing-connections inside the Evaporator Case are clear-paint coated. Sandpaper the brazing connections before unbrazing the components. Use a good abrasive cloth to remove coating.

3. REMOVAL AND REPLACEMENT OF COMPRESSOR IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

Note: When replacing a Compressor with a defective winding, be sure to install the new Start

Capacitor and Start Relay supplied with the replacement Compressor. Due to the ability of the POE oil in the compressor to absorb moisture quickly, the Compressor must not be opened more than 15 minutes for replacement or service. Do not mix lubricants of different compressors even if both are charged with R-404A, except when they use the same lubricant.

1) Turn off the power supply.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the Terminal Cover on the Compressor, and disconnect the Compressor Wiring.

5) Remove the Discharge and Suction Pipes using brazing equipment.

6) Remove the Hold-down Bolts, Washers and Rubber Grommets.

7) Slide and remove the Compressor. Unpack the new Compressor package. Install the new Compressor.

8) Attach the Rubber Grommets of the prior Compressor.

9) Sandpaper the Suction, Discharge and Process Pipes.

10) Place the Compressor in position, and secure it using the Bolts and Washers.

11) Remove plugs from the Suction, Discharge and Process Pipes.

12) Braze the Process, Suction and Discharge lines (Do not change this order), while purging with nitrogen gas flowing at the pressure 3 - 4 PSIG.

13) Install the new Filter Drier.

14) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

15) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment.

16) Connect the Terminals, and replace the Terminal Cover in its correct position.

17) Replace the panels in their correct positions.

18) Turn on the power supply.

4. REMOVAL AND REPLACEMENT OF DRIER

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

1) Turn off the power supply.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the Drier.

5) Install the new Drier, with the arrow on the Drier, in the direction of the refrigerant flow. Use nitrogen gas at the pressure of 3 - 4 PSIG when brazing the tubings.

6) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

7) Evacuate the system, and charge it with refrigerant. For air-cooled and watercooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment.

8) Replace the panels in their correct positions.

9) Turn on the power supply.

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE

IMPORTANT

Sometimes moisture in the refrigerant circuit exceeds the Drier capacity and freezes up at the Expansion Valve. Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

1) Turn off the power supply.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the insulation and the Expansion Valve Bulb on the suction line.

5) Remove the Expansion Valve Cover, and disconnect the Expansion Valve using brazing equipment.

6) Braze the new Expansion Valve, with nitrogen gas flowing at the pressure of 3 - 4 PSIG.

WARNING

Always protect the valve body by using a damp cloth to prevent the valve from overheating. Do not braze with the valve body exceeding 250°F.

7) Install the new Drier.

8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

9) Evacuate the system, and charge it with refrigerant. For air-cooled and water cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment.

10) Attach the Bulb to the suction line in position. Be sure to secure it with clamps and to insulate it.

11) Place the new set of Expansion Valve Covers in position.

12) Replace the panels in their correct positions.

13) Turn on the power supply.

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

CAUTION

Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced.

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

1) Turn off the power supply.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the screw and the Solenoid.

5) Disconnect the Hot Gas Valve or Line Valve using brazing equipment.

6) Install the new valve.

WARNING

Always protect the valve body by using a damp cloth to prevent the valve from overheating. Do not braze with the valve body exceeding 250°F.

7) Install the new Drier.

8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

10) Cut the leads of the Solenoid allowing enough lead length to reconnect using closed end connectors.

11) Connect the new Solenoid leads.

12) Attach the Solenoid to the valve body, and secure it with a screw.

13) Replace the panels in their correct positions.

14) Turn on the power supply.

7. REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repairs or replacement have been made.

1) Turn off the power supply.

2) Remove the panels and the Top Insulation over the Evaporator.

3) Recover the refrigerant and store it in an approved container.

4) Remove the Spray Tubes and the Insulations at the “U” shaped notch where the refrigeration tubings go through the molded chassis.

5) Remove the Insulation Tube, and disconnect the Evaporator Inlet Tubing at the Tee

next to the Expansion Valve.

6) Lift up the Evaporator, and disconnect the Evaporator Outlet Tubing.

7) Install the new Evaporator.

8) Install the new Drier.

9) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

10) Evacuate the system, and charge it with refrigerant. For air-cooled and water cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment.

11) Replace the removed parts in the reverse order of which they were removed.

12) Replace the Top Insulation and the panels in their correct positions.

13) Turn on the power supply.

8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE WATER-COOLED MODEL ONLY

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

1) Turn off the power supply.

2) Close the Water Supply Line Shut-off Valve.

3) Remove the panels.

4) Recover the refrigerant and store it in an approved container.

5) Disconnect the Capillary Tube at the Condenser outlet using brazing equipment.

6) Disconnect the Flare-connections of the valve.

7) Remove the screws and the valve from the Bracket.

8) Install the new valve, and braze the Capillary Tube.

9) Install the new Drier.

10) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

11) Evacuate the system, and charge it with refrigerant. See the Nameplate for the

required refrigerant charge.

12) Connect the Flare-connections.

13) Open the Water Supply Line Shut-off Valve.

14) Check for water leaks.

15) Replace the panels in their correct positions.

16) Turn on the power supply.

9. ADJUSTMENT OF WATER REGULATING VALVE - WATER-COOLED MODEL ONLY

The Water Regulating Valve (also called “WATER REGULATOR”) is factory-adjusted. No adjustment is required under normal use. Adjust the Water Regulator, if necessary, using the following procedures.

1) Attach a pressure gauge to the high-side line of the system. Or prepare a

thermometer to check for the condenser drain temperature.

2) Rotate the adjustment screw by using a flat blade screwdriver, so that the pressure

gauge shows the temperature specified in the table, 5 minutes after a freeze cycle or icemaking process starts. When the pressure exceeds 270 PSIG, or the condenser drain temperature exceeds the temperature range, rotate the adjustment screw counterclockwise. See Fig. 1.

3) Check that the pressure or the condenser drain temperature holds a stable setting.

Fig. 1

10. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE REGULATOR (C.P.R.) - REMOTE AIR-COOLED MODEL ONLY

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made.

1) Turn off the power supply.

2) Remove the panels from the remote condenser unit.

3) Recover the refrigerant and store it in an approved container.

4) Before heating, break off the stub on the dome to release the dome charge.

5) Disconnect the C.P.R. using brazing equipment.

6) Install the new C.P.R. Use nitrogen gas at the pressure of 3 - 4 PSIG when brazing the C.P.R.

WARNING

Always protect the C.P.R. body by using a damp cloth to prevent the C.P.R. from overheating. Do not braze with the C.P.R. body exceeding 250° F.

7) Install the new Drier in the icemaker.

8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

9) Evacuate the system and charge it with refrigerant. See the Charge Label in the machine compartment in the icemaker.

10) Replace the panels in their correct positions.

11) Turn on the power supply.

11. REMOVAL AND REPLACEMENT OF THERMISTOR CAUTION

1. Fragile, handle very carefully.

2. Always use a recommended sealant (High Thermal Conductive Type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 or equivalent.

3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent.

4. Do not shorten or cut the Thermistor leads when installing it.

1) Turn off the power supply.

Thermistor Lead Cable Tie

2) Remove the panels.

3) Remove the Control Box Cover.

4) Disconnect the Thermistor leads from the K3 Connector on the Controller Board.

5) Remove the Plastic Cable Ties, Foam Insulation, Thermistor Holder and Thermistor. See Fig. 2.

Foam Insulation Thermistor Holder

Fig. 2

6) Scrape away the old sealant on the Thermistor Holder and the Suction Pipe.

7) Wipe off moisture or condensation on the Suction Pipe.

8) Smoothly apply recommended sealant (KE4560RTV, Part Code 60Y000-11 or 4A0683-01) to the Thermistor Holder concave.

9) Attach the new Thermistor to the Suction Pipe very carefully to prevent damage to the leads. And secure it using the Thermistor Holder and recommended foam insulation.

Note: For models with the Liquid Bypass, the Thermistor should be located upstream from the Liquid Bypass outlet, and its end should be 4-3/4" or more away from the outlet. See Fig. 3.

Min. 4-3/4"

Liquid Bypass

Flow

Fig. 3

10) Secure the insulation using the Plastic Cable Ties.

11) Connect the Thermistor leads through the bushing of the Control Box to the K3 Connector on the Controller Board.

Note: Do not cut the leads of the Thermistor while installing it.

12) Replace the Control Box Cover and the panels in their correct positions.

13) Turn on the power supply.

12. REMOVAL AND REPLACEMENT OF FAN MOTOR

Note: When replacing a Fan Motor with defective winding, it is recommended that a new capacitor be installed.

1) Turn off the power supply.

2) Remove the panels.

3) Remove the Junction Box Cover from the remote condenser unit (Remote Air-cooled model).

4) Remove the closed end connectors from the Fan Motor leads.

5) Remove the Fan Motor Bracket and Fan Motor.

6) Install the new Fan Motor, and replace the removed parts in the reverse order of which they were removed.

7) Replace the panels in their correct positions.

8) Replace the Junction Box Cover in its correct position (Remote Air-cooled model).

9) Turn on the power supply.

13. REMOVAL AND REPLACEMENT OF WATER VALVE

1) Turn off the power supply.

2) Close the Water Supply Line Shut-off Valve.

3) Remove the Front Panel.

4) Remove the Valve Outlet Tubing by releasing the Clamp.

5) Remove the Bracket from the unit.

6) Remove the Fitting Nut and Water Valve.

7) Disconnect the Terminals from the Water Valve.

8) Install the new Water Valve, and replace the removed parts in the reverse order of which they were removed.

9) Open the Water Supply Line Shut-off Valve.

10) Turn on the power supply.

11) Check for leaks.

12) Replace the Front Panel in its correct position.

14. REMOVAL AND REPLACEMENT OF PUMP MOTOR

1) Turn off the power supply.

2) Remove the Front Panel.

3) Remove the Base Cover.

4) Drain the Water Tank by removing one end of the Pump Tubing.

5) Replace the removed parts in their correct positions.

6) Disconnect the Pump Suction and Discharge Hoses.

7) Remove the screws and the Pump Motor Bracket.

8) Remove the closed end connectors from the Pump Motor leads.

9) Remove the two screws and the Pump Motor Bracket.

10) Remove the Pump Housing, and check the Impeller.

11) If the Impeller is defective, install a new Impeller.

12) Install the new motor or new parts, and replace the removed parts in the reverse order of which they were removed.

13) Turn on the power supply, and check for leaks.

14) Replace the Base Cover in its correct position.

15) Replace the Front Panel in its correct position.

15. REMOVAL AND REPLACEMENT OF SPRAY TUBES

1) Turn off the power supply.

2) Remove the Front Panel and the Insulation Panel.

3) Remove the Rubber Hoses from the Spray Tubes (Water Supply Pipe).

4) Release the Clamps, and disconnect the Rubber Hoses.

5) Remove the Spray Tubes by squeezing the side tabs.

6) Install the new Spray Tubes, and replace the removed parts in the reverse order of which they were removed.

7) Replace the panels in their correct positions.

8) Turn on the power supply. 60

VI. CLEANING AND MAINTENANCE INSTRUCTIONS

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment.

1. PREPARING THE ICEMAKER FOR LONG STORAGE

WARNING

When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice from the Storage Bin. The Storage Bin should be cleaned and dried. Drain the icemaker to prevent damage to the water supply line at sub-freezing temperatures, using air or carbon dioxide. Shut off the icemaker until the proper ambient temperature is resumed.

• When the icemaker is not used for two or three days, it is sufficient to only move the Control Switch to the “OFF” position, unless the icemaker will be at sub-freezing temperatures.

[1] On water-cooled model only, first remove the water from the water-cooled condenser:

1) Remove the Front Panel.

2) Move the Control Switch, on the Control Box, to the “OFF” position.

3) Wait 3 minutes.

4) Move the Control Switch to the “ICE” position.

5) Allow 5 minutes for the icemaker to fill with water and the Water Pump to start operating.

6) Close the Water-cooled Condenser Water Supply Line Shut-off Valve.

7) Open the Drain Valve for the water-cooled condenser water supply line.

8) Allow the line to drain by gravity.

9) Attach compressed air or carbon dioxide supply to the Condenser Water Line Drain Valve.

10) Quickly blow the water-cooled Condenser out, using compressed air or carbon

[2] Remove the water from the potable water supply line:

1) Remove the Front Panel. (Except water-cooled model)

2) Move the Control Switch, on the Control Box, to the “OFF” position.

3) Wait 3 minutes.

4) Close the Potable Water Supply Line Shut-off Valve and open the Potable Water Supply Line Drain Valve.

5) Allow the line to drain by gravity.

6) Attach compressed air or carbon dioxide supply to the Potable Water Line Drain Valve.

7) Move the Control Switch to the “ICE” position.

8) Blow the potable water line out using compressed air or carbon dioxide.

[3] Drain the Potable Water Tank:

1) Turn off the power supply.

2) Move the Control Switch to the “OFF” position.

3) Drain the Water Tank by removing the base cover and one end of the pump tubing. See Fig. 4.

4) Replace the removed parts in their correct positions.

5) Remove all ice from the Storage Bin, and clean the Storage Bin.

Fig. 4

6) Replace the Front Panel in its correct position.

7) Close the Drain Valve. 62

2. CLEANING AND SANITIZING PROCEDURES

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment.

W ARNING

1. HOSHIZAKI recommends cleaning this unit at least once a year. More frequent cleaning, however, may be required in some existing water conditions.

2. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.

3. Always wear liquid-proof gloves for safe handling of the cleaning and sanitizing solution. This will prevent irritation in case the solution comes into contact with skin.

IMPORTANT

1. The Cleaning Valve is used to allow solution flow to the inside of the

Evaporator during the cleaning and sanitizing operation. It should be closed for all icemaking operation. The Compressor will not operate unless this valve is completely closed.

2. To open the Cleaning Valve, the Valve Handle should be parallel to the

valve body. To close the valve, the Valve Handle should be at a right angle to the valve body.

[a] CLEANING PROCEDURE

1) Dilute 16 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 3 gal. of water.

2) Remove all ice from the Evaporator and the Storage Bin. Note: To remove cubes on the Evaporator, turn off the power supply and turn

it on after 3 minutes. The defrost cycle starts and the cubes will be removed from the Evaporator.

3) Turn off the power supply.

4) Remove the Front Panel and then remove the Insulation Panel, by first removing

the thumbscrew, lifting the panel slightly and pulling it toward you.

5) Remove the Base Cover.

6) Drain the Water Tank by removing one end of the Pump Tubing. See Fig. 4.

7) Replace the removed parts in their correct positions.

8) Pour the cleaning solution into the Water Tank.

9) Fully open the Cleaning Valve on the left side wall of the machine compartment.

10) Move the Control Switch, on the Control Box, to the “WASH” position.

11) Replace the Insulation Panel and the Front Panel in their correct positions.

12) Turn on the power supply, and start the washing process.

13) Turn off the power supply after 30 minutes.

14) Remove the Front Panel and the Insulation Panel.

15) Drain the Water Tank. (See the above step 6).

16) Replace the removed parts in their correct positions.

17) Move the Control Switch to the “ICE” position.

18) Close the Cleaning Valve. Note: The icemaker will not operate unless the Cleaning Valve is completely

closed.

19) Replace the Front Panel in its correct position.

20) Turn on the power supply to fill the Water Tank with water.

21) Turn off the power supply after 3 minutes.

22) Remove the Front Panel, and fully open the Cleaning Valve.

23) Move the Control Switch to the “Wash” position.

24) Replace the Front Panel in its correct position.

25) Turn on the power supply to rise off the cleaning solution.

26) Turn off the power supply after 5 minutes.

27) Remove the Front Panel and Insulation Panel.

28) Drain the Water Tank by removing one end of the Pump Tubing. See Fig. 4.

29) Replace the removed parts in their correct positions. Note: Do not replace the Insulation Panel when you proceed to

“[b] SANITIZING PROCEDURE.”

28) Repeat the above steps 17 through 29 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 9 in “[b] SANITIZING

PROCEDURE.”

[b] SANITIZING PROCEDURE

Following Cleaning Procedure

1) Dilute a 5.25 % Sodium Hypochlorite solution with water (Add 1.5 fl. oz. of sanitizer to 3 gal. of water).

2) Remove the Insulation Panel, if it is in its usual position.

3) Pour the sanitizing solution into the Water Tank.

4) Replace the Insulation Panel and the Front Panel in their correct positions. Note: Make sure that the Control Switch is in the “WASH” position and the

Cleaning Valve is open.

5) Turn on the power supply, and start the sanitizing process.

6) Turn off the power supply after 15 minutes.

7) Remove the Front Panel and if necessary, the Insulation Panel.

8) Drain the Water Tank. See the above step 5) in “[a] CLEANING PROCEDURE.”

9) Replace the removed parts and the Insulation Panel in their correct position.

10) Repeat the above steps 17) through 29) in “[a] CLEANING PROCEDURE” two times to rinse thoroughly.

11) Close the Cleaning Valve.

12) Move the Control Switch to the “ICE” position.

13) Replace the Front Panel in its correct position.

14) Clean the Storage Bin with water.

15) Turn on the power supply, and start the automatic icemaking process.

3. MAINTENANCE

This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker.

1) Stainless Steel Exterior

To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up.

2) Storage Bin and Scoop

• Wash your hands before removing ice. Use the plastic scoop provided.

• The Storage Bin is for ice use only. Do not store anything else in the bin.

• Keep the scoop clean. Clean it by using a neutral cleaner and rinse thoroughly.

IMPORTANT

• Clean the bin liner by using a neutral cleaner. Rinse thoroughly after cleaning.

3) Condenser (Except water-cooled model)

Check the Condenser once a year, and clean, if required, by using a brush or vacuum cleaner. More frequent cleaning may be required depending on the location of the icemaker.

Hoshizaki KM-630MRH, KM-630MAH, KM-630MWH User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

I. SPECIFICATIONS

1. KM-630MAH

2a. KM-630MWH Serial #L00001D - M20270B

2b. KM-630MWH Serial #M20301E -

3. KM-630MRH

4. CONDENSER UNIT

URC-6F

II. GENERAL INFORMATION

1. CONSTRUCTION

[a] KM-630MAH

[b] KM-630MWH

[c] KM-630MRH

2. CONTROLLER BOARD

[a] SOLID-STATE CONTROL

[b] CONTROLLER BOARD

[c] SEQUENCE

[d] CONTROLS AND ADJUSTMENTS

[e] CHECKING THE CONTROLLER BOARD

3. MECHANICAL BIN CONTROL

[a] PROXIMITY SWITCH

[b] EXPLANATION OF OPERATION

[c] TROUBLESHOOTING (MECHANICAL BIN CONTROL ONLY)

III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

[a] KM-630MAH

[b] KM-630MWH

[c] KM-630MRH

2. WIRING DIAGRAMS

[b1] KM-630MRH (with auxiliary codes L-0, M-0, M-1)

[b2] KM-630MRH (with auxiliary codes M-2 and after)

3. TIMING CHART

4. PERFORMANCE DATA

[a] KM-630MAH

[b1] KM-630MWH Serial #L00001D - M20270B

[b2] KM-630MWH Serial #M20301E -

[c] KM-630MRH

IV. SERVICE DIAGNOSIS

1. NO ICE PRODUCTION

2. EVAPORATOR IS FROZEN UP

3. LOW ICE PRODUCTION

4. ABNORMAL ICE

5. OTHERS

V. REMOVAL AND REPLACEMENT OF COMPONENTS

1. SERVICE FOR REFRIGERANT LINES

[a] REFRIGERANT RECOVERY

[b] EVACUATION AND RECHARGE [R-404A]

2. BRAZING

3. REMOVAL AND REPLACEMENT OF COMPRESSOR IMPORTANT

4. REMOVAL AND REPLACEMENT OF DRIER

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE

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

7. REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT

9. ADJUSTMENT OF WATER REGULATING VALVE - WATER-COOLED MODEL ONLY

10. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE REGULATOR (C.P.R.) - REMOTE AIR-COOLED MODEL ONLY

11. REMOVAL AND REPLACEMENT OF THERMISTOR CAUTION

12. REMOVAL AND REPLACEMENT OF FAN MOTOR

13. REMOVAL AND REPLACEMENT OF WATER VALVE

14. REMOVAL AND REPLACEMENT OF PUMP MOTOR

15. REMOVAL AND REPLACEMENT OF SPRAY TUBES

VI. CLEANING AND MAINTENANCE INSTRUCTIONS

1. PREPARING THE ICEMAKER FOR LONG STORAGE

2. CLEANING AND SANITIZING PROCEDURES

[a] CLEANING PROCEDURE

[b] SANITIZING PROCEDURE

3. MAINTENANCE