Hoshizaki KML-200MWE User Manual
NO.:
ISSUED:
REVISED:
73095
FEB. 4, 1998
NOV. 29, 2000
HOSHIZAKI
MODULAR CRESCENT CUBER
MODEL
KML-200MAE
KML-200MWE
SERVICE MANUAL
FOREWORD
IMPORT ANT
Only qualified service technicians should attempt to service or maintain this icemaker.
No such 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 Care Department for assistance.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: HOSHIZAKI Care 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
2
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
PAGE
I. SPECIFICATIONS .................................................................................................... 5
1. KML-200MAE (Air-cooled) .................................................................................. 5
2. KML-200MWE (Water-cooled)............................................................................. 6
II. GENERAL INFORMATION ...................................................................................... 7
1. CONSTRUCTION ............................................................................................... 7
[a] KML-200MAE (Air-cooled) ............................................................................ 7
[b] KML-200MWE (Water-cooled)....................................................................... 8
2. CONTROLLER BOARD...................................................................................... 9
[a] SOLID-STATE CONTROL ............................................................................ 9
[b] CONTROLLER BOARD................................................................................ 9
[c] SEQUENCE ................................................................................................ 12
[d] CONTROLS AND ADJUSTMENTS ........................................................... 15
[e] CHECKING CONTROLLER BOARD ......................................................... 18
3. SWITCHES ....................................................................................................... 20
III. TECHNICAL INFORMATION ............................................................................... 21
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT .......................................... 21
[a] KML-200MAE (Air-cooled) .......................................................................... 21
[b] KML-200MWE (Water-cooled)..................................................................... 22
2. WIRING DIAGRAMS ......................................................................................... 23
[a] KML-200MAE (Air-cooled) .......................................................................... 23
[b] KML-200MWE (Water-cooled)..................................................................... 23
3. TIMING CHART ................................................................................................ 24
4. PERFORMANCE DATA ................................................................................... 26
[a] KML-200MAE (Air-cooled) .......................................................................... 26
[b] KML-200MWE (Water-cooled)..................................................................... 27
IV. SERVICE DIAGNOSIS ........................................................................................ 28
1. NO ICE PRODUCTION..................................................................................... 28
2. EVAPORATOR IS FROZEN UP ....................................................................... 31
3. LOW ICE PRODUCTION .................................................................................. 31
4. ABNORMAL ICE ............................................................................................... 32
5. OTHERS ........................................................................................................... 32
3
V. REMOVAL AND REPLACEMENT OF COMPONENTS..........................................33
1. SERVICE FOR REFRIGERANT LINES ..............................................................33
[a] REFRIGERANT RECOVERY........................................................................ 33
[b] EVACUATION AND RECHARGE .................................................................33
2. BRAZING ............................................................................................................. 34
3. REMOVAL AND REPLACEMENT OF COMPRESSOR......................................34
4. REMOVAL AND REPLACEMENT OF DRIER .................................................... 36
5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE.............................. 36
6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND ..............................
LINE VALVE ........................................................................................................ 37
7. REMOVAL AND REPLACEMENT OF EVAPORATOR ...................................... 39
8. REMOVAL AND REPLACEMENT OF WATER-REGULATING VALVE .................
- WATER COOLED MODEL ONLY ....................................................................40
9. ADJUSTMENT OF WATER-REGULATING VALVE ...............................................
- WATER COOLED MODEL ONLY ....................................................................41
10. REMOVAL AND REPLACEMENT OF THERMISTOR ........................................ 42
11. REMOVAL AND REPLACEMENT OF FAN MOTOR ........................................... 43
12. REMOVAL AND REPLACEMENT OF WATER VALVE ...................................... 44
13. REMOVAL AND REPLACEMENT OF PUMP MOTOR........................................ 44
14. REMOVAL AND REPLACEMENT OF SPRAY TUBE ......................................... 45
VI. CLEANING AND MAINTENANCE INSTRUCTIONS ............................................. 46
1. PREPARING THE ICEMAKER FOR LONG STORAGE......................................46
2. CLEANING........................................................................................................... 48
3. SANITIZING ......................................................................................................... 50
4. MAINTENANCE................................................................................................... 51
4
I. SPECIFICATIONS
1. KML-200MAE
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROX. ICE PRODUCTION
PER 24 HR.
lbs./day ( kg./day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W ( KWH/100 lbs. )
WATER gal./24 HR. ( gal./100 lbs. )
EXTERIOR DIMENSIONS ( WxDxH )
EXTERIOR FINISH
WEIGHT
CONNECTIONS - ELECTRIC
- WATER SUPPLY
- DRAIN
115/60/1
10.8 A (5 Min. Freeze AT 104° F / WT 80° F)
20A
20A
Ambient Water Temp. (°F)
Temp. (°F) 50 70 90
70 *250 (113)
80
90 230 (104) *214 ( 97) 199 ( 90)
100
Crescent Cube
3.9 lbs. (1.8 kg) 180 pcs.
N/A
90°F/70°F 70°F/50°F
820 (9.2) 760 (6.7)
64 (29.9) 81 (30.8)
30"x27-3/8"x22" (762x695x560 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 150 lbs. (68 kg)
Permanent Connection
Inlet 1/2" FPT
Outlet 3/4" FPT
241 (109) 226 (103) 210 ( 95)
218 (
99)
240 (109) 220 (100)
203 (
92) 187 ( 85)
CUBE CONTROL SYSTEM
HARVESTING CONTROL SYSTEM
ICE MAKING WATER CONTROL
COOLING WATER CONTROL
BIN CONTROL SYSTEM
COMPRESSOR
CONDENSER
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE
DESIGN PRESSURE
P.C. BOARD CIRCUIT PROTECTION
COMPRESSOR PROTECTION
REFRIGERANT CIRCUIT PROTECTION
LOW WATER PROTECTION
ACCESSORIES - SUPPLIED
- REQUIRED
OPERATION CONDITIONS
Float Switch
Hot gas and water, thermistor and timer
Timer controlled, Overflow pipe
N/A
Thermostat
Hermetic, Model RSU4-0050-CAA
Air-cooled, fin and tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R22, 1lb. (465g)
High 427 PSIG, Low 206 PSIG
High Voltage Cut-out (Internal)
Auto-reset Overload Protector (Internal)
Auto-reset High Pressure Control Switch
Float Switch
N/A
Ice Storage Bin
VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100°F
WATER SUPPLY TEMP. 45 - 90°F
WATER SUPPLY PRESS. 10 - 113PSIG
* We reserve the right to make changes in specifications and design without prior notice.
5
2. KML-200MWE
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROX. ICE PRODUCTION
PER 24 HR.
lbs./day ( kg./day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W ( KWH/100 lbs. )
WATER gal./24 HR. ( gal./100 lbs. )
WATER COOLED CONDENSER
gal./24 hr. ( gal./100 lbs. )
EXTERIOR DIMENSIONS ( WxDxH )
EXTERIOR FINISH
WEIGHT
CONNECTIONS - ELECTRIC
- WATER SUPPLY
- DRAIN
CUBE CONTROL SYSTEM
HARVESTING CONTROL SYSTEM
ICE MAKING WATER CONTROL
COOLING WATER CONTROL
BIN CONTROL SYSTEM
COMPRESSOR
CONDENSER
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE
DESIGN PRESSURE
P.C. BOARD CIRCUIT PROTECTION
COMPRESSOR PROTECTION
REFRIGERANT CIRCUIT PROTECTION
LOW WATER PROTECTION
ACCESSORIES - SUPPLIED
- REQUIRED
OPERATION CONDITIONS
115/60/1
8.3 A ( 5 Min. Freeze AT 104° F / WT 80° F )
20A
20A
Ambient Water Temp. (°F)
Temp. (°F) 50 70 90
70
80
90
100
*238 (108) 220 (100) 190 (86)
232 (105) 208 ( 94) 184 (83)
223
(101) *199 ( 90)
215 (
98)
190 ( 86) *167 (76)
175 (79)
Crescent Cube
3.9 lbs. ( 1.8 kg. ) 180 pcs.
N/A
90° F / 70° F 70° F / 50° F
713 ( 8.6 ) 700 ( 7.0 )
72 ( 36.3 ) 88 ( 36.8 )
330 ( 166 ) 138 ( 57.6 )
30" x 273¦8" x 22" ( 762 x 695 x 560 mm. )
Stainless steel, Galvanized Steel ( Rear )
Net 150 lbs. ( 60 kg. )
Permanent Connection
Inlet
Outlet
1
¦2" FPT Condenser Inlet1¦2" FPT
3
¦4" FPT Condenser Outlet3¦8" FPT
Float Switch
Hot Gas and Water, Thermistor and Timer
Timer Controlled, Overflow Pipe
Pressure Regulator
Thermostat
Hermetic, Model RSU4-0050-CAA
Water-cooled, Tube in Tube type
Vertical type, Stainless Steel and Copper
Thermostatic ExpansionValve
R22, 10 oz. ( 290 g. )
High 395 PSIG, Low 206 PSIG
High Voltage Cut-out Relay ( Internal )
Auto-reset Overload Protector ( Internal )
Auto-reset High Pressure Control Switch
Float Switch
N/A
Ice Storage Bin
VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESS. 10 - 113 PSIG
* We reserve the right to make changes in specifications and design without prior notice.
6
II. GENERAL INFORMATION
1. CONSTRUCTION
[a] KML-200MAE
7
[b] KML-200MWE
8
2. CONTROLLER BOARD
[a] SOLID-STATE CONTROL
1) A HOSHIZAKI exclusive solid-state control is employed in KML-200 Series Modular
Crescent Cubers.
2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and
high quality control system.
3) All models are pre-tested 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. Especially, never misconnect
K3, K4 and K5, because the same connector is used for the Thermistor
and Float Switch. K4 is not connected.
5. Do not fix the electronic devices or parts on the board in the field.
Always replace the whole board assembly when it goes bad.
6. Do not short out power supply to test for voltage.
PART NUMBER TYPE
2U0127-01 MY9KM910 (Alpine)
Note: (1) Maximum Water Supply Period - 6 minutes
Water Solenoid Valve opening, in the Defrost (Harvest) Cycle, is limited by
maximum period of the defrost timer. The Water Valve cannot remain open
longer than the maximum period. The Water Valve can close in less than the
maximum period if the defrost cycle is completed.
9
(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. To reset the safety, turn the power off and back on again.
This High Temperature Safety protects the unit from excessive temperature.
(4) Low Water Safety
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.
For water-cooled model, if the water is shut off, the unit is protected by the
High Pressure Switch.
(5) High Voltage Cut-out
The maximum allowable supply voltage of this icemaker is limited by the High
Voltage Cut-out.
If miswiring causes excessive voltage on the Controller Board, the High Voltage Cut-out 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.
10
Connector K1
Pin #1 thru #10
#1, 9 Magnetic Contactor
#2 Hot Gas Valve
#3 Line Valve
#4 Pump Motor (icemaking)
#5 Pump Motor (drain)
#6 Water Valve
#7, 10 Power (line, Bin Control)
#8 Open
Dip Switch
Defrost Timer, Drain Timer
& Drain Counter
Connector K5
Float Switch
Connector K4
Open
(not connected)
Connector K3
Defrost Control
(Thermistor)
(Alpine “C”/Alpine Board)
11
[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 (adjustable from
1 to 3 minutes) 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.
12
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.
10/20 second Drain Timer starts counting.
,
2. Drain Timer stops counting.
Pump drain is completed
3. Thermistor reads 48° F.
Defrost Timer (adjustable
from 1 to 3 minutes) starts
counting.
IMPORTANT
Water Valve
opening is limited
to 6 minutes.
& LINE V AL VE
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.
13
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 (adjustable from
1 to 3 minutes) 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.
14
[d] CONTROLS AND ADJUSTMENTS (Alpine/Alpine “C” Board)
The Dip Switch is factory-adjusted to the following positions:
DIP SWITCH NO. 1 2 3 45678
KML-200MAE,
KML-200MWE
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.
OFF OFF OFF ON ON ON OFF OFF
OFF ON OFF ON ON ON OFF OFF
Switch Nos. 7 and 8:
Used only for checking the Controller Board.
Usually set in OFF position.
15
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 (kW)
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 THER-
MISTOR.”
(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 7kW. 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 position
by setting the Dip Switch (No. 1 & 2) on the Controller Board.
SETTING TIME
Dip Switch Dip Switch
No. 1 No. 2
OFF OFF 60 seconds
ON OFF 90 seconds
OFF ON 120 seconds
ON ON 180 seconds
16
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