Hoshizaki KMS-1401MLJ User Manual

Download

Page 1

Hoshizaki America, Inc.

Hoshizaki

Modular Crescent Cuber Serenity Series

Model

KMS-1401MLJ

“A Superior Degree

of Reliability”

www.hoshizaki.com

Including Condensing Unit Models

SRK-14J/3

SERVICE MANUAL

Number: 73192 Issued: 12-28-2011

Page 2

WARNING

Only qualied service technicians should install and service the icemaker. To obtain the name and phone number of your local Hoshizaki Certied Service Representative, visit www.hoshizaki.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the icemaker in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. Proper installation is the responsibility of the installer. Product failure or property damage due to improper installation is not covered under warranty.

Hoshizaki provides this manual primarily to assist qualied service technicians in the service of the icemaker.

Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance.

Phone: 1-800-233-1940; (770) 487-2331 Fax: 1-800-843-1056; (770) 487-3360

E-mail: techsupport@hoshizaki.com

HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City, GA 30269 Attn: Hoshizaki Technical Support Department

Web Site: www.hoshizaki.com

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

following information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem.

Page 3

IMPORTANT

This manual should be read carefully before the icemaker is serviced. Read the warnings and guidelines contained in this booklet carefully as they provide essential information for the continued safe use, service, and maintenance of the icemaker. Retain this booklet for any further reference that may be necessary.

CONTENTS

Important Safety Information ................................................................................................. 5

I. Specications ...................................................................................................................... 7

A. Icemaker ....................................................................................................................... 7

1. KMS-1401MLJ with SRK-14J ................................................................................... 7

2. KMS-1401MLJ with SRK-14J3 ............................................................................... 8

B. Condensing Unit ............................................................................................................ 9

1. SRK-14J ................................................................................................................... 9

2. SRK-14J3 .............................................................................................................. 10

II. General Information ..........................................................................................................11

A. Construction ................................................................................................................11

1. Icemaker ................................................................................................................11

2. Condensing Unit ................................................................................................... 12

B. Sequence of Operation ............................................................................................... 13

1. Sequence Cycles and Shutdown ........................................................................... 13

a) 1-Minute Fill Cycle ............................................................................................ 13

b) Initial Harvest Cycle ........................................................................................ 13

c) Freeze Cycle ................................................................................................... 13

d) Pump-Out Cycle ............................................................................................... 14

e) Harvest Cycle .................................................................................................. 14

f) Shutdown ......................................................................................................... 14

2. Sequence Flow Chart ............................................................................................ 15

C. Control Board .............................................................................................................. 16

1. Control Board Layout ............................................................................................. 17

2. LED Lights and Audible Alarm Safeties ................................................................. 18

3. Controls and Adjustments ...................................................................................... 19

a) Default Dip Switch Settings .............................................................................. 19

b) Harvest Timer (S4 dip switch 1 & 2) ................................................................. 19

c) Pump-Out Timer (S4 dip switch 3 & 4) ............................................................. 20

d) Pump-Out Frequency Control (S4 dip switch 5 & 6)......................................... 20

e) Harvest Pump Timer (S4 dip switch 7) ............................................................. 21

f) Factory Use (S4 dip switch 8) ........................................................................... 21

g) Freeze Timer (S4 dip switch 9 & 10) ................................................................ 21

h) Float Switch Selector (S5 dip switch 1) ............................................................ 22

i) Rell Counter (S5 dip switch 2 through 5) ......................................................... 22

Page 4

D. Control and Service Switches ..................................................................................... 23

1. Control Switch ........................................................................................................ 23

2. Service Switch ....................................................................................................... 23

a) DRAIN .............................................................................................................. 23

b) CIRC. ............................................................................................................... 23

c) WASH ............................................................................................................... 23

III. Technical Information ...................................................................................................... 24

A. Water Circuit and Refrigeration Circuit ........................................................................ 24

B. Wiring Diagrams .......................................................................................................... 25

1. KMS-1401MLJ with SRK-14J ................................................................................. 25

2. KMS-1401MLJ with SRK-14J3 .............................................................................. 26

3. Wire Harness Connections .................................................................................... 27

C. Performance Data ....................................................................................................... 28

1. KMS-1401MLJ with SRK-14J ................................................................................. 28

2. KMS-1401MLJ with SRK-14J3 .............................................................................. 29

IV. Service Diagnosis ........................................................................................................... 30

A. Diagnostic Procedure .................................................................................................. 30

B. Control Board Check ................................................................................................... 34

C. Bin Control Check and Cleaning ................................................................................. 35

1. Bin Control Check .................................................................................................. 35

2. Bin Control Cleaning .............................................................................................. 36

D. Float Switch Check and Cleaning ............................................................................... 37

1. Float Switch Check ................................................................................................ 37

2. Float Switch Cleaning ............................................................................................ 38

E. Thermistor Check ........................................................................................................ 39

F. Diagnostic Charts ........................................................................................................ 40

1. No Ice Production ................................................................................................... 40

2. Freeze-Up .............................................................................................................. 41

3. Low Ice Production ................................................................................................ 43

V. Replacement of Components .......................................................................................... 44

A. Service for Refrigerant Lines ....................................................................................... 44

1. Refrigerant Recovery ............................................................................................. 44

2. Brazing .................................................................................................................. 45

3. Evacuation and Recharge (R-404A) ...................................................................... 45

B. Important Notes for Component Replacement ............................................................ 47

VI. Cleaning and Maintenance ............................................................................................ 48

A. Cleaning and Sanitizing Instructions ........................................................................... 48

1. Cleaning Procedure ................................................................................................ 49

2. Sanitizing Procedure - Following Cleaning Procedure ........................................... 50

B. Maintenance ................................................................................................................ 51

C. Preparing the Icemaker for Periods of Non-Use .......................................................... 52

VII. Disposal ......................................................................................................................... 54

Page 5

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the icemaker, or damage to property.

WARNING Indicates a hazardous situation which could result in death or

serious injury.

NOTICE Indicates a situation which could result in damage to the

appliance or property.

IMPORTANT Indicates important information about the use and care of the

appliance.

WARNING

This icemaker should be destined only to the use for which it has been expressly conceived. Any other use should be considered improper and therefore dangerous. The manufacturer cannot be held responsible for injury or damage resulting from improper, incorrect, and unreasonable use. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.

To reduce the risk of death, electric shock, serious injury, or re, follow basic precautions including the following:

• Only qualied service technicians should install and service this icemaker.

• This icemaker must be installed in accordance with applicable national, state, and

local codes and regulations. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage to the appliance.

• To reduce the risk of electric shock, do not touch the control switch or service switch

with damp hands.

• Before Servicing the KMS or SRK: To reduce the risk of electric shock, move

the control switch to the "OFF" position and turn off the power supply to the SRK condensing unit. Place the KMS disconnect (if applicable) in the "OFF" position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.

• Do not make any alterations to the icemaker. Alterations could result in electric

shock, injury, re, or damage to the icemaker.

• This appliance is not intended for use by persons (including children) with reduced

physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

• Children should be properly supervised around this appliance.

• Do not climb, stand, or hang on the icemaker or allow children or animals to do so.

Serious injury could occur or the icemaker could be damaged.

• Do not use combustible spray or place volatile or ammable substances near the

icemaker. They might catch re.

• Keep the area around the icemaker clean. Dirt, dust, or insects in the icemaker

could cause harm to individuals or damage to the icemaker.

Page 6

WARNING, continued

• Power supply and ground connection are supplied from the SRK remote condensing

For KMS

unit via the wire harness provided. Do not connect the wire harness leads to an external power source.

• Wire harness routing (conduit) and disconnect (if required) must meet national,

state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage to the appliance.

• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker could result in death, serious injury, or damage to the appliance.

For SRK

• Electrical connection must be hard-wired and must meet national, state, and local

electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or damage to the appliance.

• The remote condensing unit requires an independent power supply of proper

capacity. See the nameplate for electrical specications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuses, damage to existing wiring, or component failure. This could lead to heat generation or re.

• THE REMOTE CONDENSING UNIT MUST BE GROUNDED. Failure to properly ground the remote condensing unit could result in death, serious injury, or damage to the appliance.

NOTICE

• Follow the instructions in this manual carefully to reduce the risk of costly water

damage.

• In areas where water damage is a concern, install in a contained area with a oor

drain.

• Install the icemaker in a location that stays above freezing. Normal operating

ambient temperature must be within 45°F to 100°F (7°C to 38°C).

• Do not leave the icemaker on during extended periods of non-use, extended

absences, or in sub-freezing temperatures. To properly prepare the icemaker for these occasions, follow the instructions in "VI.C. Preparing the Icemaker for Periods of Non-Use."

• Do not place objects on top of the icemaker.

• The dispenser unit/storage bin is for ice use only. Do not store anything else in the

dispenser unit/storage bin.

Page 7

I. Specications

A. Icemaker

1. KMS-1401MLJ with SRK-14J

AC SUPPLY VOLTAGE 115VAC Supplied by SRK-14J via Factory Supplied

Wire Harness APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lb./day ( kg/day ) 70 *1420 (644) 1379 (626) 1278 (580) Reference without *marks 80 1389 (630) 1325 (601) 1199 (544)

90 1379 (626) *1280 (581) 1162 (527)

100 1344 (609) 1252 (568) 1054 (478)

SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 25.8 lb. (11.7 kg) 1248pcs. ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F KMS/SRK COMBINED ELECTRIC W (kWH/100 lb.) 2510(4.70) 2410(4.07) WATER gal./24HR (gal./100 lb.) 250(19.5) 682(48.0) CEE TIER 1 ENERGY STAR YES EXTERIOR DIMENSIONS (WxDxH) 30"x24"x28" (762x610x711 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 143 lb. (65 kg), Shipping 177 lb. (80 kg) CONNECTIONS - ELECTRIC Wire Harness Connection from SRK to KMS

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

-CONDENSATION DRAIN OUTLET 5/8" OD Hard Tube

-REFRIGERATION Liquid Line 1 1/16" - 12 UNF Fitting (#10 Parker)

Suction Line 1 1/8" - 12 UNF Fitting (#11 Parker) CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled, Overflow Pipe, and Float Switch COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Mechanical Bin Control COMPRESSOR In SRK CONDENSER Air-Cooled Remote Condensing Unit SRK-14J EVAPORATOR Vertical Type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve

Headmaster (C.P.R.) in SRK-14J (160 PSI) REFRIGERANT CHARGE R404A, 16 lb. 5 oz. (7400g)

(Icemaker 0 lb. 7.1 oz. (200g))

(Cond. Unit 15 lb. 14 oz. (7200g)) DESIGN PRESSURE High 467PSIG, Low 230PSIG CONTROL BOARD CIRCUIT PROTECTION High Voltage Cut-Out (Internal) REFRIGERANT CIRCUIT PROTECTION Auto-Reset High-Pressure Switch in SRK-14J

Auto-Reset Discharge Line Thermostat in SRK-14J LOW W ATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A

-REQUIRED Dispenser Unit or Ice Storage Bin

SRK-14J Remote Condensing Unit OPERATING CONDITIONS VOLTAGE RANGE 187-253VAC

AMBIENT TEMP. 45-100°F

WATER SUPPLY TEMP. 45-90°F

WATER SUPPLY PRESSURE 10-113 PSIG

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

notice.

Page 8

2. KMS-1401MLJ with SRK-14J3

Data Pending

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

notice.

Page 9

B. Condensing Unit

1. SRK-14J

AC SUPPLY VOLTAGE 208-230/60/1 ( 3 wire with neutral for 115V )

(115VAC Supplied to KMS via Factory Wire Harness)

AMPERAGE 13.5 A ( 5 Min. Freeze AT 104°F / WT 80°F )

MINIMUM CIRCUIT AMPACITY 20 A

MAXIMUM FUSE SIZE 20 A

EXTERIOR DIMENSIONS (WxDxH) 50" x 17" x 28" ( 1270 x 432 x 711 mm )

DIMENSIONS INCLUDING LEGS (WxDxH) 52-3/8" x 19-1/2" x 43" ( 1330 x 495 x 1092 mm )

EXTERIOR FINISH Galvanized steel

WEIGHT Net 230 lb. (104 kg) Shipping 275 lb. (125 kg)

CONNECTIONS - ELECTRIC Main Power Supply: Permanent Connection

SRK to KMS: Wire Harness Connection

- REFRIGERANT

COMPRESSOR Hermetic, Model CS16K6E-PFV-255

CONDENSER Air Cooled, Fin and Tube Type

COMPRESSOR PROTECTION Auto-Reset Overload Protector (Internal)

FAN MOTOR PROTECTION Thermal Protection

REFRIGERANT CIRCUIT PROTECTION Auto-Reset High-Pressure Switch

REFRIGERANT CONTROL Headmaster (C.P.R.) (160 PSI)

REFRIGERANT CHARGE 16 lb. 5 oz. (7400g))

DESIGN PRESSURE High 467 PSIG, Low 230 PSIG

OPERATING CONDITIONS VOLTAGE RANGE 187 - 253VAC

ACCESSORIES -SUPPLIED Leg 2 pcs

Liquid Line 1 1/16" - 12 UNF Fitting (#10 Parker)

Suction Line 1 1/8" - 12 UNF Fitting (#11 Parker)

Auto-Reset Discharge Line Thermostat

(Condensing Unit 15 lb. 14 oz. (7200g))

(Icemaker 0 lb. 7.1 oz. (200g))

AMBIENT TEMP. (Outdoor use) -20 - 122°F

Hex Head Bolt w/Washer M8x16 8 pcs

Hex Nut M8 8 pcs

-REQUIRED Compatible KMS Icemaker

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

notice.

Page 10

2. SRK-14J3

Data Pending

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

notice.

Page 11

II. General Information

A. Construction

1. Icemaker

Harvest Water Valve (WV2)

Spray Tubes

Wash Valve

Hot Gas Valve

Liquid Line Valve

Service Valve (High Side)

Drier

Service Valve (Low Side)

Thermistor

Fill/Rell Water Valve (WV1)

Control Switch

Service Switch

Fuse

Switch Box

Drain Water Valve

Switch Cover

Switch Mount

Extension Bracket

Control Board

Control Box

Pump Motor

Float Switch

Bin Control

Switch Bracket

Bin Control

Page 12

2. Condensing Unit

SRK-14J Control Box SRK-14J3 Control Box

Fuse

Condenser

Headmaster (C.P.R.)

Hot Gas Valves

Liquid Line Valve

Fuse

Shut-Off Valve (Low Side)

Check Valve

Receiver

Fan Motors and Fan Blades

Shut-Off Valve (High Side)

High Pressure Switch

Compressor

Accumulator

Thermostat (Discharge Pipe)

Page 13

B. Sequence of Operation

1. Sequence Cycles and Shutdown

The steps in the sequence are as outlined below. When power is supplied, the red "POWER OK" LED and the green "BC CLOSED" LED on the CB turn on (If yellow "BC OPEN" LED is on, the icemaker will not start. In this case clear ice away from BC actuator paddle in the storage bin area). A 5-second delay occurs at startup. Note that the order of the green sequence LEDs from the outer edge of the board is 1, 4, 3, 2.

a) 1-Minute Fill Cycle

LED 4 is on. WV1 opens and the ll period begins. After 1-minute, CB checks for closed F/S. If F/S is closed, the harvest cycle begins. If not, WV1 will remain energized through additional 1-minute cycles until water enters the water tank and F/S closes. This serves as a low water safety to protect the water pump.

b) Initial Harvest Cycle

LEDs 1, 4 and 2 are on. Comp, FMRs, HGVs, X10 relay, WV2, X12 relay, and X13 relay energize. WV1 de-energizes. CBmonitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the adjustable harvest timer (S4 dip switch1 & 2). The harvest timer has settings of 60, 90, 120, and 180 seconds. The pump-out timer (S4 dip switch 3&4) acts in place of the harvest timer during cycles with a pump-out (S4 dip switch 5&6). WV2 and X12 relay are energized during harvest for a maximum of 6 minutes or the length of harvest minus 50 seconds, whichever is shorter. 50seconds before the harvest timer terminates, harvest pump timer starts. LED 4 turns off, WV2 and X12 relay de-energize.

Harvest Pump Timer: LEDs 1, 3, and 2 are on. Comp, FMRs, HGVs, X10 relay, and X13 relay continue. LED 4 turns off, WV2 and X12 relay de-energize. LED 3 turns on and X11 relay energizes, allowing PM to energize for the last 50 seconds of harvest. NOTICE!

S4 dip switch 7must remain in the factory default position of 7 on. Otherwise, PM will not energize during the last 50 seconds of harvest. The minimum total

time allowed by CB for a complete harvest cycle is 2 minutes. At the end of harvest, CB checks position of F/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute ll if it is open.

c) Freeze Cycle

LED 1 and LED 4 are on. Comp, FMRs, and PM remain energized. LLVs energize. WV1 and LED 4 energize for 1 min. HGVs, X10, X11, and X13 relays de-energize. For the rst 5 minutes, CB will not terminate the freeze cycle. At the end of 5 minutes, F/S assumes control of the freeze cycle. As ice builds on the evaporator, the water level in the water tank lowers. Freeze continues until F/S opens, provided the 5-minute minimum freeze timer has terminated.

Page 14

d) Pump-Out Cycle

LEDs 1, 3, and 2 are on. Comp and FMRs remain energized, HGVs and X10 relay energize. LLVs de-energize. PM stops for 2 seconds, then X11 relay energizes, allowing PM and DV to energize for 10 or 20 seconds (S4 dip switch 3 & 4). Water is removed

from the bottom of the water tank and sent down the drain. At the same time, water ows through the small F/S tube to power ush F/S. When the pump-out timer terminates,

pump-out is complete.

The 1st pump-out occurs after the 11th freeze cycle, then every 10th cycle thereafter. The pump-out frequency control is factory set, and generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump-out frequency can be adjusted. The pump-out frequency control (S4dip switch5&6) can be set to have a pump-out occur every cycle, or every 2, 5, or 10cycles. Timing of the rst pump-out is dependent on S4dip switch 5 & 6 settings. See the table below.

S4 Dip Switch Setting

No. 5 No. 6

OFF OFF Every cycle After 2nd freeze cycle

ON OFF Every 2 cycles After 3rd freeze cycle

OFF ON Every 5 cycles After 6th freeze cycle

ON ON Every 10 cycles After 11th freeze cycle

Pump-Out

Frequency

1st Pump-Out

e) Harvest Cycle

LEDs 1, 4, and 2 are on. Same as the initial harvest cycle. See "II.B.1.b) Initial Harvest Cycle."

Note: Icemaker continues to cycle until BC is satised or power is turned off. The

icemaker always restarts at the 1-minute ll cycle.

f) Shutdown

When BC is activated (BC open), the yellow "BC OPEN" LED comes on. The icemaker then shuts down as outlined in the table below.

Cycle at Bin Control Activation

Fill Cycle 15 seconds after activation.

Harvest Cycle At the end of the harvest cycle, or up to 15 seconds into the freeze cycle if activated

Freeze Cycle 15 seconds after activation if activated at least 15 seconds before the 5-minute short

Shutdown

at the end of the harvest cycle.

cycle protection timer terminates. Otherwise, at the end of the next harvest cycle.

Legend: CB–control board; Comp–compressor; DV–drain valve; FMRs –fan

motors-remote; F/S–oat switch; HGVs–hot gas valves; LLVs–liquid line valves; PM–pump motor; WV1–ll/rell water valve; WV2–harvest water valve

Page 15

2. Sequence Flow Chart

Factory set forevery

10th cycle.

(S4 dip switch 5 & 6)

4. Pump-Out Cycle

Comp continues

FMRs continue

HGVs energized

DV & PM de-energized 2 sec., then

energized for 10/20sec.

To 1 above

LLVs de-energized

"G" Control Board Sequence Flow Chart

KMS-1401MLJ with SRK-14J/3

3. Freeze Cycle

• Minimum freeze time: 5 min.

• Maximum freeze time: freeze timer setting

(S4 dip switch 9 & 10).

F/S in control

5-min. minimum

freeze timer in

1 to 3-min. harvest timer in control

(S4 dip switch 1 & 2)

control

Rell

HarvestPump

Timer

F/S closed

1 min.

50 sec.

F/S opens or freeze

timer terminates

Comp continues

FMRs continue

PM continues

LLVs energized

WV1 energized rst 1 min. of freeze

HGVs de-energized

F/S check

PM energized

WV2 de-energized

Thermistor temperature reaches

48°F (9°C) (3.9 kΩ or less).

Harvest timer starts (1 to 3 min.).

F/S open

3. Ice Level Lowered

2. Icemaker Off

Icemaker starts at "1. 1-Minute Fill Cycle."

BC closed (BC actuator paddle disengaged)

Green "BC CLOSED" LED on

Yellow "BC OPEN" LED off

All components

de-energized.

Yellow "BC OPEN" LED continues

All components de-energized

Power is supplied to the pump and drain valve. This drains the water tank.

Power is supplied to the pump only. This operation can be used to circulate cleaner and

sanitizer over the outside surface of the evaporator for extended periods of time.

Power is supplied to the pump and wash valve. This operation is used to circulate cleaner

and sanitizer over both the inside and outside surfaces of the evaporator.

DRAIN

CIRC.

Components Energized when the Control Switch is in the "SERVICE" Position

When in the "SERVICE" position, the control switch supplies power to the service switch and the icemaker is in service mode.

The service switch has three positions: "DRAIN," "CIRC." and "WASH." See the information below for details of each function.

WASH

Thermistor

(S4 dip switch 7), whichever is shorter.

• WV2 time: 6 min. or the length of harvest minus 50 sec.

• Maximum harvest time: 20 min.

2. Harvest Cycle

1. 1-Minute

Fill Cycle

Cycle

Steps

in control

F/S closed

Startup

Comp energized

FMRs energized

HGVs energized

WV2 energized

WV1 de-energized

freeze cycle if activated at the end of the harvest cycle.

• Fill Cycle – 15 sec. after activation.

Shutdown Delay:

F/S check

F/S open

WV1 energized

1. Bin Full

If F/S is open, Comp stops and cycle returns to 1-min. ll.

Shutdown

andRestart

the 5-min. short cycle protection timer terminates.

• Harvest Cycle – At the end of the harvest cycle, or up to 15 sec. into the

• Freeze Cycle – 15 sec. after activation if activated at least 15 sec. before

Otherwise, at the end of the next harvest cycle.

BC open (BC actuator paddle engaged)

Green "BC CLOSED" LED off

Yellow "BC OPEN" LED on

BC Operation

Legend:

Comp-compressor

DV-drain valve

FMRs-fan motors-remote

F/S-oat switch

HGVs-hot gas valves (KMS and SRK)

LLVs-liquid line valves (KMS and SRK)

PM-pump motor

WV1-ll/rell water valve

WV2-harvest water valve

Page 16

C. Control Board

• A Hoshizaki exclusive control board is employed in the Hoshizaki icemakers.

• All models are pretested and factory adjusted.

• For a control board check procedure, see "IV.B. Control Board Check."

NOTICE

• Fragile, handle very carefully.

• The control board contains integrated circuits, which are susceptible to failure

due to static discharge. It is especially important to touch the metal part of the icemaker when handling or replacing the control board.

• Do not touch the electronic devices on the control board or the back of the control

board.

• Do not change wiring and connections. Do not misconnect terminals.

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

• Always replace the whole control board assembly if it goes bad.

Page 17

1. Control Board Layout

"G" Control Board

• "ALARM RESET" Button • S4 Dip Switch

• Bin Control Switch Closed LED (green)

• Bin Control Switch Open LED (yellow)

• Part Number

• Alarm Buzzer

• Power LED (red)

(lights when

10.5VAC is supplied to K2 connector)

• Relay LEDs

(4) (indicate which relays are energized and which K1 connector pins are energized

• LED 2 (X2 Relay)

LED 2 on: K1 Connector Pin #2 LED 2 off: K1 Connector Pin #3

• LED 3 (X3 Relay) LED 3 on: K1 Connector Pin #5 (energized during harvest pump timer) LED 3 off: K1 Connector Pin #4 (energized in freeze)

• LED 4 (X4 Relay) K1 Connector Pin #6

• LED 1 (X1 Relay)

K1 Connector Pin #1, #9

• K2 Connector

Control Transformer (10.5VAC)

• "OUTPUT TEST" Button

(used to test relays on control board)

• K3 (white) Connector

Harvest Control (thermistor)

• K4 (red) Connector

Bin Control

• S5 Dip Switch

• K5 (black) Connector

Float Switch

• Label

(control board revision level indicated on label on side of relay)

• K1 Connector

Pins #1 through #10 #1, 9 Magnetic Contactor, X13 Relay (holding circuit during Harvest Pump Timer), and Drain Valve (during Pump-Out) #2 Hot Gas Valves (KMS and SRK) and X10 Relay #3 Liquid Line Valves #4 Pump Motor (freeze) #5 X11 Relay (Pump Motor in Harvest Pump Timer and Drain Valve in Pump-Out) #6 Fill Water Valve (InitialFill and Freeze Fill only); Harvest WaterValve and X12 Relay (Harvest only) #7, 10 Supply Voltage #8 Open

"G" Control Board

Part Number 2A3792-01

Page 18

2. LED Lights and Audible Alarm Safeties

At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below. Note that the order of the LEDs from the outer edge of the control board is 1, 4, 3, 2. For details, see "II.B. Sequence of Operation."

Sequence Step LED

1-Minute Fill Cycle 4 WV1 1 minute Harvest Cycle 1, 4, 2 Comp, FMRs

Harvest Pump Timer 1, 3, 2 Comp, FMRs,

Freeze Cycle 1 (and 4 for rst

1 min.)

Pump-Out Cycle 1, 3, 2 Comp, FMRs,

Energized

Components

WV2, HGVs

PM, HGVs Comp, FMRs,

PM, LLVs (WV1 for rst 1 min.)

PM, HGVs, DV

Min. Max. Avg.

2 minutes 20 minutes 3 to 5 minutes

0 seconds 50 seconds harvest pump

5 minutes freeze timer

10 seconds 20 seconds

Time LEDs are On

timer setting 30 to 35 minutes

setting

The built in safeties shut down the icemaker and have alarms as listed below.

No. of Beeps

(every 3 sec.)

1 High Evaporator Temp.

(temperature > 127°F (53°C))

2 Harvest Backup Timer

(harvest > 20 min. for two cycles in a row)

3 Freeze Timer

(freeze > specied setting for two cycles in a row) Timer is factory set using S4 dip switch 9 & 10

To reset the above safeties, press the "ALARM RESET" button with the power supply on.

Type of Alarm Notes

Check for harvest problem (stuck HGVs or relay), hot water entering icemaker, stuck HM, or shorted thermistor.

Check for open thermistor, HGVs not opening, TXVs or LLVs leaking by, low charge, or inefficient Comp.

Check for a F/S stuck closed (up), WV1 or WV2 leaking by, HGVs leaking by, PM not pumping, TXVs not feeding properly, LLVs not opening, low charge, HM not bypassing, or inefficient compressor.

6 Low Voltage

(92Vac±5% or less)

7 High Voltage

(147Vac±5% or more)

Red LED will turn off if voltage protection operates. The control voltage safeties automatically reset when voltage is corrected.

Legend: Comp–compressor; DV–drain valve; FMRs–fan motors-remote; F/S–oat switch; HGVs–hot gas valves; HM–headmaster (C.P.R.); LLVs–liquid line valves; PM–pump motor; TXVs–thermostatic expansion

valves; WV1–ll/rell water valve; WV2–harvest water valve

Page 19

3. Controls and Adjustments

NOTICE

Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact Hoshizaki Technical Support at 1-800-233-1940.

a) Default Dip Switch Settings

The dip switches are factory-adjusted to the following positions:

S4 Dip Switch

Dip Switch No. 1 2 3 4 5 6 7 8 9 10

KMS-1401MLJ OFF OFF OFF ON ON ON ON OFF OFF OFF

S5 Dip Switch (Do Not Adjust)

Dip Switch No.

KMS-1401MLJ ON ON OFF OFF OFF

1 2 3 4 5

S4 Dip Switch

1 2 3 4 5 6 7 8 9 10

Freeze Timer (9 & 10)

Factory Use (8)

Harvest Pump Timer (7) (Do not adjust)

Pump-Out Frequency Control (5 & 6)

Pump-Out Timer (3 & 4)

Harvest Timer (1 & 2)

S5 Dip Switch

Do Not Adjust

1 2 3 4 5

Rell Counter (2 through 5)

Float Switch Selector (1)

b) Harvest Timer (S4 dip switch 1 & 2)

The harvest timer starts counting when the thermistor reads 48°F (9°C) at the evaporator outlet and the control board reads the thermistor's 3.9 kΩ signal. The harvest timer is factory set, and generally no adjustment is required. However, a setting longer than the

factory setting may be advised in cases where the ush provided at harvest needs to be

prolonged for extra cleaning. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting decreases 24-hour production. Note that the pump-out timer (S4dip switch 3 & 4) acts in place of the harvest timer during cycles with a pump-out. For details, see "II.C.3.c) Pump-Out Timer (S4 dip switch 3 & 4)."

Dip Switch Setting

No. 1

OFF

No. 2

OFF 60

OFF 90

ON 120

ON 180

Time (seconds)

Page 20

c) Pump-Out Timer (S4 dip switch 3 & 4)

The 1st pump-out occurs after the 11th freeze cycle, then every 10th cycle thereafter. When a pump-out is called for, the X10relay is energized and the X13 relay is de-energized to allow the drain valve to energize. The pump motor stops for 2seconds, then the X11 relay energizes, allowing the pump motor and drain valve to energize. Water is removed from the bottom of the water tank and sent down the drain. At the

same time, water ows through the small oat switch tube to power ush the oat switch.

The pump-out drains the water tank for the time determined by the pump-out timer. The pump-out timer also acts in place of the harvest timer during cycles with a pump-out. The pump-out timer is factory set, and generally no adjustment is required. The pump-out timer control can be set to pump-out for 10 or 20 seconds.

S4 Dip Switch Setting Time (seconds)

No. 3 No. 4

OFF OFF 10 150 closed

ON OFF 10 180 closed

OFF ON 10 120

ON ON 20 180 closed

open if rell = 0; closed if rell 1 or greater

Inlet Water Valve

T1: Time to drain the water tank T2: Harvest timer at pump-out

d) Pump-Out Frequency Control (S4 dip switch 5 & 6)

The pump-out frequency control is factory-adjusted to drain the water tank every 10cycles, and generally no adjustment is required. However, where water quality is bad and the icemaker needs a more frequent pump-out, the pump-out frequency can be adjusted as shown in the table below.

Timing of the rst pump-out is dependent on S4 dip switch 5 & 6 settings. See the table below.

S4 Dip Switch Setting

No. 5 No. 6

OFF OFF Every cycle After 2nd freeze cycle

ON OFF Every 2 cycles After 3rd freeze cycle

OFF ON Every 5 cycles After 6th freeze cycle

ON ON Every 10 cycles After 11th freeze cycle

Pump-Out

Frequency

1st Pump-Out

Page 21

e) Harvest Pump Timer (S4 dip switch 7)

NOTICE

Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the icemaker.

Depending on the harvest pump timer setting, the pump motor either stays off or is energized the last 50 seconds of harvest. When the pump motor is energized, water circulates over the evaporator. The harvest water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus 0 or 50 seconds (determined by the harvest pump timer setting), whichever is shorter. When S4 dip switch 7 is in the on position and harvest begins, X10 relay energizes and allows the harvest water valve, X12, and X13 relays to energize. A lockout circuit is created using the X10, X12, and X13 relays. This prevents the drain valve from energizing during harvest pump timer. See "III.B. Wiring Diagram." 50 seconds before harvest termination, LED 4 goes off de-energizing WV2 (harvest water valve) and X12 relay. X13 relay remains energized through the holding circuit through X10 and X13 relays. Next, LED 3 on the control board turns on and X11relay energizes, allowing the pump motor to energize. The pump motor is energized the last 50seconds of harvest.

S4 Dip Switch Setting

No. 7

ON 50

OFF 0

Pump Motor

Time (seconds)

f) Factory Use (S4 dip switch 8)

Factory set for proper operation. Do not adjust. This must be left in the factory default position.

g) Freeze Timer (S4 dip switch 9 & 10)

NOTICE

Adjust to proper specication, or the icemaker may not operate correctly.

The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, the control board initiates the harvest cycle. After 2 consecutive freeze timer terminations, the control board shuts down the icemaker. In this case, see "IV.F.3. Low Ice Production" for possible solutions. The freeze timer is factory set, and generally no adjustment is required. Before changing this setting, contact your local Hoshizaki distributor or Hoshizaki Technical Support for recommendations.

Dip Switch Setting

No. 9 No. 10

OFF OFF 60

OFF ON 50

ON OFF 70

ON ON 60

Time

(minutes)

Page 22

h) Float Switch Selector (S5 dip switch 1)

NOTICE

Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly.

On icemakers with a double oat switch, the oat switch selector determines which oat

switch (upper or lower) the control board monitors for rell initiation during the freeze cycle, and the rell counter (S5 dip switch 2 through 5) determines the number of rells.

The KMS-1401MLJ uses a single oat switch with a double oat switch, upper oat switch rell initiation oat switch selector setting and is set for 1 rell. When the freeze cycle starts, the control board monitors the upper oat switch. If an upper oat switch exists, rell is initiated by an open upper oat switch and is terminated by a closed upper oat switch. There is a maximum rell time of 1 minute. In a single oat switch application with a double oat switch setting, no upper oat switch exists, therefore the control board reads an open upper oat switch immediately when the freeze cycle starts and initiates a rell. Since there is no upper oat switch to close and terminate the rell, the rell lasts

for the maximum 1-minute. During the 1-minute rell, LED 4 is on.

S5 Dip Switch Setting

No. 1

OFF Single or Double Lower Float Switch

ON Double Upper Float Switch

Float Switch Type

Rell Initiation with

Double Float Switch

i) Rell Counter (S5 dip switch 2 through 5)

NOTICE

Do not adjust. These must be left in the factory default position or the icemaker will not operate correctly.

Factory set. S5 dip switch 2 through 5 allows for rells during the freeze cycle. The KMS-1401MLJ is factory set for 1 rell. Do not adjust.

S5 Dip Switch Setting

No. 2 No. 3 No.4 No. 5

ON OFF OFF OFF 1 Rell

Note: When rell set > 0, water valve is off during pump-out even if S4 dip switch 3 & 4

are set to 3 off and 4 on. See "II.C.3.c) Pump-Out Timer (S4 dip switch 3 & 4)."

No. of Rells

Page 23

D. Control and Service Switches

2 switches are used to control the operation of the icemaker. These switches are referred to as control switch and service switch. They are located on the KMS switch box.

1. Control Switch

The control switch has three positions: "OFF" for power off; "ICE" for icemaking, and "SERVICE" to activate the service switch.

2. Service Switch

When the control switch is in the "SERVICE" position, the control switch supplies power to the service switch and water pump. The service switch has three positions: "DRAIN," "CIRC." and "WASH."

Note:

1. When the service switch is active (control switch in the "SERVICE" position), power is supplied to the water pump in all three positions.

2. When the control switch is in the "OFF" or "ICE" position, the service switch is de-activated. In this state, it can be left in any position.

a) DRAIN

This icemaker utilizes a pump-out drain system. When the control switch is in the "SERVICE" position and the service switch is placed in the "DRAIN" position, power is supplied to the water pump and drain valve.

b) CIRC.

When the service switch is active and placed in the "CIRC." position, power is supplied to the water pump only. This water pump operation is used during cleaning to circulate cleaner for extended periods of time over the outside surface of the evaporator.

c) WASH

This icemaker utilizes a solenoid operated wash (bypass) valve. When the service switch is active and placed in the "WASH" position, power is supplied to the pump motor and wash valve. This operation is used to circulate cleaner and sanitizer over both the inside and outside of the evaporator.

Page 24

III. Technical Information

A. Water Circuit and Refrigeration Circuit

SRK-14J/3

Condenser

Headmaster

Fan

Receiver

Shutoff

Val ve

Service Valve

Drier

Liquid Line Valve

(C.P. R.)

Access Valve

Check Valve

High-Pressure

Switch

Strainers

Hot Gas Valves

OS Quick

Liquid Line Valve

Suction Line

Strainer

Thermistor

Thermostat

Strainer

Discharge

Line

Hot Gas

Val ve

Compressor

Accumulator

Check Valves

Expansion Valves

KMS-1401MLJ

Water Supply

Harvest

Wash Valve

Water Valve

Spray Tube

Evaporator

Fill/Rell

Float Switch

Drain Valve

Drain

Pump Motor

Water Tank

Water Valve

Page 25

B. Wiring Diagrams

1. KMS-1401MLJ with SRK-14J

Control Transformer

Output 10.5V at 115V

Thermostat Switch

Cut-out 266°F±9°F (130°C± 5°C)

PSIG

Cut-in 239°F±9°F (115°C±5°C)

* High-Pressure Switch

Cut-out 426±

Cut-in 341±22 PSIG

Page 26

2. KMS-1401MLJ with SRK-14J3

Control Transformer

Output 10.5V at 115V

Thermostat Switch

Cut-out 266°F±9°F (130°C± 5°C)

Cut-in 239°F±9°F (115°C±5°C)

PSIG

* High-Pressure Switch

Cut-out 426±

Cut-in 341±22 PSIG

Page 27

3. Wire Harness Connections

P BK

V P

Neutral

LLV

HGV

KMS Icemaker Unit

(factory connected)

Wire Harness Connections

Fuse 10A

GND

SRK Condensing Unit

BK W

LLV

HGV

Fuse 10A

Neutral

Contactor

Legend:

GND-ground

HGV-hot gas valve

Wire Color Code:

BK-black

BR-brown

CB-control board

GR-green

LLV-liquid line valve

L2-single phase power supply

P-pink

V-violet

L3-three phase power supply

W-white

Page 28

C. Performance Data

1. KMS-1401MLJ with SRK-14J

APPROXIMATE ICE PRODUCTION PER 24 HR.

lbs./day kg./day APPROXIMATE ELECTRIC

CONSUMPTION

watts 100/38 APPROXIMATE WATER CONSUMPTION PER 24 HR.

gal./day m3/day FREEZING 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) 50/10 70/21 90/32

70/21 1420 644 1379 626 1278 580

80/27 1389 630 1325 601 1199 544

90/32 1379 626 1280 581 1162 527

100/38 1344 609 1252 568 1054 478

70/21

80/27

90/32

70/21 682 2.58

80/27 585 2.22 388 1.47 386 1.46

90/32 555 2.10 250 0.94 220 0.83

100/38 411 1.56 243 0.92 193 0.73

70/21

80/27

90/32

70/21

80/27 90/32

70/21 178 12.5

80/27 192 13.5 221 15.6 241 17.0 90/32 197 13.8 242 17.0 263 18.5

100/38 200 14.1 247 17.4 283 19.9

70/21 46 3.2 47 3.3 50 3.5

80/27 47 3.3 49 3.5 52 3.7 90/32 47 3.3 51 3.6 54 3.8

100/38 48 3.4 52 3.6 56 3.9

WATER TEMP. (ºF/ºC)

2410

2432

2439

2454

4.6

4.0

3.9 2.2

3.1

2439

2478

2510

2523

555 2.10 492 1.86

3.9

3.0

2.2

197 13.8 219 15.4

2492

2537

2567

2620

3.6

3.1

2.12.2

TOTAL HEAT OF REJECTION FROM CONDENSER

CONDENSER VOLUME 226 CU. IN (SRK-14J)

28,800 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]

Note:

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

2. We reserve the right to make changes in specications and design without prior notice.

Page 29

2. KMS-1401MLJ with SRK-14J3

Data Pending

Note:

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

2. We reserve the right to make changes in specications and design without prior notice.

Page 30

IV. Service Diagnosis

WARNING

• This icemaker should be diagnosed and repaired only by qualied service

personnel to reduce the risk of death, electric shock, serious injury, or re.

• Risk of electric shock. Use extreme caution and exercise safe electrical practices.

• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.

• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are

securely in place after the icemaker is serviced. Make sure that none have fallen into the dispenser unit/storage bin.

• Make sure all food zones in the icemaker and dispenser unit/storage bin are clean

after service. For cleaning procedures, see "VI. Cleaning and Maintenance."

A. Diagnostic Procedure

The diagnostic procedure is basically a sequence check which can be used at icemaker startup or for system diagnosis. This procedure allows you to diagnose electrical system and component failures. Before conducting the diagnostic procedure, check for correct installation, proper voltage per unit nameplate, and adequate water supply. Check CB using the steps in "IV.B. Control Board Check." Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10 and S5 dip switch 1 through 5 are in the factory default

position. S4 dip switch 1, 2, 5, 6 are cleaning adjustments and the settings are exible.

For factory default settings, see "II.C.3.a) Default Dip Switch Settings." As you go through the procedure, check to assure the components energize and de-energize correctly. If not, those components and controls are suspect.

1) Turn off the power supply, then access the control box. Clear any ice from BC.

2) Turn on the power supply, then move the control switch to the "ICE" position. A5-second delay occurs. The red "POWER OK" LED and the green "BC CLOSED" LED on CB come on. If the yellow "BC OPEN" LED is on, check BC. See"IV.C.Bin Control Check and Cleaning."

3) 1-Minute Fill Cycle – LED 4 is on. WV1 energizes. After 1 minute, CB checks for a closed F/S. If F/S is closed, the harvest cycle begins. If closed, continue to step 4. If F/S is open, WV1 remains energized through additional 1-minute ll cycles until water enters the water tank and F/S closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: Conrm that water enters the water tank. If not, check that the water supply shut-off valve is open and screens or external lters are clear. Check supply voltage at WV1 solenoid. If no voltage is present, see "IV.B. Control Board Check." If voltage is present, check solenoid continuity. If the water tank lls, but the icemaker fails to start harvest, check for open F/S. See "IV.D. 1. Float Switch Check." Check termination of 1-minute timer in CB. See "IV.B. Control Board Check."

Page 31

4) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. Comp, FMRs, HGVs, X10 relay, WV2, X12, and X13 relays energize. WV1 de-energizes. CBmonitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2). The harvest timer has settings of 60, 90, 120, and 180 seconds. The pump-out timer (S4 dip switch 3 & 4) acts in place of the harvest timer during cycles with a pump-out (S4 dip switch 5 & 6). WV2 and X12 relay are energized during harvest for a maximum of 6 minutes or the length of harvest minus 50seconds, whichever is shorter. 50seconds before the harvest timer terminates, harvest pump timer starts. LED 4 turns off, WV2 and X12 relay de-energize.

Harvest Pump Timer – LEDs 1, 3, and 2 are on. Comp, FMRs, HGVs, and X10 relay continue. LED 4 turns off, WV2 and X12 relay de-energize (CB K1 connector pin #6(O wire)). LED 3 turns on and X11 relay energizes (CB K1 connector pin #5 (DBU wire)), allowing PM to energize for the last 50 seconds of harvest (S4 dip switch 7 setting). NOTICE! S4 dip switch 7 must remain in the factory default position of 7 on. Otherwise, PM will not energize during the last 50 seconds of harvest. The minimum total time allowed by CB for a complete harvest cycle is 2 minutes. At the end of harvest, CB checks the position of F/S and proceeds to the next cycle if it is closed, or calls for a 1-minute ll cycle if it is open.

Diagnosis: Check that evaporator is warming and Comp, FMRs, and HGVs remain energized. WV2 is energized during harvest for a maximum of 6 minutes or the length of harvest minus 50 seconds (Harvest Pump Timer (S4 dip switch 7)), whichever is shorter. Average initial harvest cycle at factory setting is 2 to 3 minutes. 1.5 minutes after initial harvest begins, touch Comp discharge line. Is it hot? If not, check that Comp is energized, refrigerant pressures are in range, HGVs are energized and open, LLVs are de-energized and closed. If discharge line is hot, place a thermometer on the suction line next to the thermistor. Has it warmed to 48°F (9°C) or warmer? Conrm thermistor status. See "IV.E. Thermistor Check." If temperature has been reached, check that WV2de-energizes (LED 4 off) and X11 relay energizes (LED 3 on), allowing PM to energize and circulate water over the evaporator for the last 50 seconds of harvest. If not, make sure S4 dip switch 7 is in the factory default position. Check CB K1 connector pin #5 (DBU wire) and X11 relay for 115VAC. If 1-minute ll cycle starts after harvest, see "IV.D. Float Switch Check and Cleaning." If the thermistor reading is in proper range and CB fails to terminate the harvest cycle and initiate the freeze cycle, replace CB.

Page 32

5) Freeze Cycle – LED 1 and 4 are on. Comp, FMRs, and PM remain energized (CB K1 connector pin #5 (DBU wire) de-energizes and K1 connector pin #4 (R wire) energizes to prevent PM interruption). LLVs energize. WV1 and LED 4 energize for 1 min. HGVs, X10, X11, and X13 relays de-energize.

Rell – LEDs 1 and 4 are on. The KMS-1401MLJ uses a single F/S with a double

F/S, UF/S rell initiation oat switch selector setting (S5 dip switch1) and is set for

1 rell (S5 dip switch 2 through 5). When the freeze cycle starts, CB monitors UF/S. No UF/S exists on the KMS-1401MLJ, therefore CB reads an open UF/S immediately when the freeze cycle starts and initiates a rell (CB energizes WV1 through X10 relay). Since there is no UF/S to close and terminate the rell, the rell lasts for the maximum 1-minute. During the 1-minute rell, LED 4 is on. Comp, FMRs, LLVs, and PM remain energized.

Freeze Termination – LED 1 is on. The icemaker is held in freeze by a 5-minute short cycle protection timer. When F/S opens, the freeze cycle terminates.

Diagnosis: Minimum freeze time is 5 minutes. During the rst 5 minutes of freeze,

conrm that Comp, FMRs, PM, and LLVs are energized, WV1 is energized for 1 min., and HGVs and WV2 are de-energized and not bypassing. The evaporator temperature should be dropping. Make sure TXVsand HM are operating properly. Check that DV is

not leaking by (water owing down the potable drain). Check for proper unit pressures

(see "III.C. Performance Data") or an inoperative Comp. Disconnect the black K5 F/S connector. When 5 or more minutes have elapsed in the freeze cycle, the icemaker should switch out of the freeze cycle. After the icemaker switches out of freeze, reconnect the black K5 F/S connector to CB. If the icemaker remains in freeze with F/S disconnected, replace CB. To check F/S, see "IV.D. Float Switch Check and Cleaning."

Note: Normal freeze cycle will last 30 to 35 minutes depending on model and

conditions. Cycle times and pressures should follow performance data provided in this manual. See "III.C. Performance Data."

Page 33

6) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out) – The 1st pump-out occurs after the 11th freeze cycle, then every 10th cycle thereafter. Comp and FMRs remain energized. HGVs and X10 relay energize. LLVs de-energize. PMde-energizes for 2 seconds, then X11 relay energizes, allowing PM and DV to energize for 10seconds. PM energized through X11 relay (energized) terminal #4 (BR wire) and terminal #6 (R wire), then through control switch terminal #6 (R wire) and terminal #5(R wire). DV energized through X10 relay (energized) terminal #5 (V wire) and terminal #3 (Y wire), then through X13 relay (de-energized) terminal #6 (Y wire) and terminal #2 (LBU wire), then through X11 relay (energized) terminal #3 (LBU wire) and terminal #5 (GY wire). This pump-out removes contaminants from the water tank through DV and allows for a power ush of F/S. Diagnosis: PM Operation: If PM does not come on, check CB K1 connector pin #5 (DBU wire) (X11 relay coil voltage) to a neutral (W wire) for 115VAC. If LED 3 is on and 115VAC is not present, replace CB. If 115VAC is present, X11 relay should energize and X11 terminals #4 (BR wire) and #6 (R wire) should be closed. Check X11 relay terminal #6 (R wire) for 115VAC to a neutral (W wire). If 115VAC is not present, check X11 relay coil and contact continuity. If 115VAC is present and PM is still not energized, check control switch continuity between terminal #5 (R wire) and #6 (R wire). If closed, check PM windings and capacitor. DV Operation: If water does not pump out, check CB K1 connector pin #1 (V wire) (power supply for DV operation) and CB K1 connector pin #2 (P wire) (X10 relay coil voltage for DV operation) to a neutral (W wire) for 115VAC. If 115VAC is not present on either circuit, replace CB. If 115VAC is present, X10 relay terminals #1 (Y wire) and #5 (V wire) should be closed. Check X10 relay terminal #3 (Y wire) to a neutral (W wire) for 115VAC. If 115VAC is not present on terminal #3 (Y wire), check X10 relay coil and contact continuity. If 115VAC is present on X10 relay terminal #3(Y wire), go to X13 relay and check X13relay terminal #2 (LBU wire) to a neutral (W wire) for 115VAC. If 115VAC is not present, check X13 relay contact continuity between terminal #2 (LBU wire) and terminal #6 (Y wire). If contacts are open, conrm X13 is de-energized. If 115VAC is present, check X11 relay terminal #5 (GY wire) to a neutral (W wire) for 115VAC. If 115VAC is not present, check continuity between X11 relay (energized) terminal #3 (LBU wire) and terminal #5 (GY wire). If 115VAC is present on X11 terminal #5 (GY wire), check continuity on DV coil. Next, remove DV housing and check/clean DV assembly, make sure that the drain line is not clogged.

7) Normal Harvest Cycle – Same as the initial harvest cycle. Return to step 4. Note: Icemaker continues to cycle until BC is satised or power is switched off. The

icemaker always restarts at the 1-minute ll cycle.

Legend: CB–control board; Comp–compressor; DV–drain valve; FMRs–fan

motors-remote; F/S–oat switch; HGVs–hot gas valves; HM–headmaster (C.P.R.); LLVs–liquid line valves; PM–pump motor; TXVs–thermostatic expansion valves; UF/S–upper oat switch; WV1–ll/rell water valve; WV2–harvest water valve; X10–WV1 and WV2 control relay; X11–drain valve/harvest pump timer relay; X12–drain valve lockout relay 1; X13–drain valve lockout relay 2

Page 34

B. Control Board Check

Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis.

Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB

while CB is beeping. WARNING!Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the icemaker starts at the 1-minute ll cycle. For audible alarm information, see "II.C.2. LED Lights and Audible Alarm Safeties."

1) Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10, and S5 dip switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, 6 are

cleaning adjustments and the settings are exible. For factory default settings, see

"II.C.3.a) Default Dip Switch Settings."

2) Move the control switch to the "ICE" position. If the red "POWER OK" LED is on, control voltage is good, continue to step 3. If the red "POWER OK" LED is off, check CT secondary circuit. CT output is 10.5VAC at 115VAC primary input. If the secondary circuit has proper voltage and the red LED is off, replace CB.

If the secondary circuit does not have proper voltage, check CT primary circuit. Check

for 115VAC at CB K1 connector pin #10 (BRwire) to a neutral (W wire) for 115VAC. (Always choose a neutral (W wire) to establish a good neutral connection when checking voltages.) For additional checks, see "IV.F.1. No Ice Production."

3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control switch is in the "ICE" position, then press the "OUTPUT TEST" button. The correct lighting sequence is 1, 4, 3, 2. Note that the order of the LEDs from the outer edge of CB is 1, 4, 3, 2. Components (e.g., compressor) will cycle during the test. Following the test, the icemaker begins operation at the 1-minute ll cycle. If the LEDs do not light as described above, replace CB.

4) To verify voltage output from CB to the components, slide the CB K1 connector out far enough to allow multimeter lead contact. With the icemaker in the cycle to be tested, check output voltage from the corresponding pin on CB K1 connector to ground. If output voltage is not found and the appropriate LED is on, replace CB.

Legend: CB–control board; CT–control transformer.

Page 35

C. Bin Control Check and Cleaning

This icemaker uses a BC with a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required.

1. Bin Control Check

To check BC, follow the steps below.

1) Turn off the power supply.

2) Remove the front panel, then move the control switch to the "OFF" position.

3) Remove the top and right side panels. Remove the control box cover, then clear any ice away from BC.

4) Check BC wire harness connections. See Fig. 1.

5) Disconnect BC connector from CB K4 (red) connector.

6) Check for continuity across the wires of BC connector. When the actuator paddle is not engaged, BC switch is closed. If open, check that the wire harness connector is properly connected and that the actuator paddle is not sticking. Clean if necessary. See "IV.C.2. Bin Control Cleaning." If BC switch still reads open, replace BC.

7) Press and hold the actuator paddle; check for continuity across the wires of BC connector. When the actuator paddle is engaged, BC switch is open. If closed, check that the actuator paddle is not restricted. Clean if necessary. See "IV.C.2. Bin Control Cleaning." If BC switch still reads closed, replace BC.

8) Reconnect BC connector to CB K4 (red) connector, then move the control switch to the "ICE" position. Turn on the power supply.

9) Check that the green "BC CLOSED" LED on CB is on.

10) Allow the icemaker to cycle on. Press and hold the actuator paddle. The yellow "BC OPEN" LED should be on and the icemaker should shut down according to the chart below. If it does not, replace CB.

Cycle at Bin Control Activation

Fill Cycle 15 seconds after activation.

Harvest Cycle At the end of the harvest cycle, or up to 15 seconds into the freeze cycle if activated

Freeze Cycle 15 seconds after activation if activated at least 15 seconds before the 5-minute short

Shutdown

at the end of the harvest cycle.

cycle protection timer terminates. Otherwise, at the end of the next harvest cycle.

Legend: BC–bin control; CB–control board

Page 36

2. Bin Control Cleaning

Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick. In this case, BC should be cleaned.

WARNING

CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are

securely in place after the icemaker is serviced. Make sure that none have fallen into the dispenser unit/storage bin.

1) Turn off the power supply.

2) Remove the front panel, then move the control switch to the "OFF" position.

3) Remove the top and right side panels. Remove the control box cover, then clear any ice away from BC.

4) Disconnect BC connector from CB K4 (red) connector, then remove BC from the icemaker.

5) Remove the actuator paddle from the switch mount. See Fig. 1.

6) Wipe down BC with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water.

7) Reassemble BC and replace it in its correct position. Note: If the magnet was removed for

cleaning, be sure to replace it in its correct position.

8) Reconnect BC connector to CB K4 (red) connector.

Bin Control Proximity Switch Closed (calling for ice)

To Control Board K4 (red) Connector

Bin Control

Proximity Switch

Actuator Paddle

Bin Control Proximity Switch Open (bin full, icemaker off or shutting down)

9) Move the control switch to the "ICE" position.

10) Replace the control box cover, right side, top, and front panels in their correct positions.

11) Turn on the power supply to start the automatic icemaking process.

Actuator Paddle

Switch Mount

Magnet

Fig. 1

Page 37

D. Float Switch Check and Cleaning

F/S is used to determine that there is sufficient water in the water tank after the 1-minute ll cycle and after each harvest cycle. F/S is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle. No adjustment is required.

1. Float Switch Check

To check F/S, follow the steps below.

1) Turn off the power supply.

2) Remove the front panel.

3) Place the control switch in the "SERVICE" position. Then place the service switch in the "DRAIN" position.

4) Replace the front panel in its correct position, then turn on the power supply for 2minutes.

5) Turn off the power supply.

6) Remove the front panel, then move the control switch to the "OFF" position.

7) Remove the top and right side panels.

8) Remove the control box cover, then disconnect F/S connector from CB K5 (black) connector.

9) Check for continuity across F/S leads. With the water tank empty, F/S should be open. If open, continue to step 10. If closed, follow the steps in "IV.D.2. Float Switch Cleaning." After cleaning F/S, check it again. Replace if necessary.

10) Reconnect F/S connector to CB K5 (black) connector, then replace the control box cover, right side, and top panels in their correct positions.

11) Move the control switch to "ICE" position. Replace the front panel.

12) Turn on the power supply.

13) As water lls the water tank, F/S contacts should close. After 1 minute, the 1-minute ll cycle should end and the initial harvest cycle should begin.

14) Once the harvest cycle starts, turn off the power supply.

15) Remove the front panel, then move the control switch to the "OFF" position.

16) Remove the top and right side panels.

17) Remove the control box cover, then disconnect F/S connector from CB K5 (black) connector.

18) Check for continuity across F/S leads. With the water tank full, F/S should be closed. If F/S is closed and the icemaker will not switch from the 1-minute ll cycle to the initial harvest cycle, replace CB.

19) If open, conrm that the water tank is full. If the water tank is not full, check the water supply, water lters, and ll/rell water valve. If the water tank is full, follow the steps in "IV.D.2. Float Switch Cleaning." After cleaning F/S, check it again. Replace if necessary.

Page 38

20) Reconnect F/S connector to CB K5 (black) connector, then replace the control box cover, right side, and top panels in their correct positions.

21) Move the control switch to the "ICE" position.

22) Replace the front panel in its correct position.

23) Turn on the power supply to start the automatic icemaking process.

Legend: CB–control board; F/S–oat switch

2. Float Switch Cleaning

Depending on local water conditions, scale may build up on F/S. Scale can cause F/S to stick. In this case, F/S should be cleaned.

1) Turn off the power supply.

2) Remove the front panel.

3) Place the control switch in the "SERVICE" position. Then place the service switch in the "DRAIN" position.

4) Replace the front panel in its correct position, then turn on the power supply for 2minutes.

5) Turn off the power supply.

6) Remove the front, top, and right side panels, then move the control switch to the "OFF" position.

7) Disconnect the vent tube and the ush tube from the top of F/S housing, then remove

F/S assembly. Remove the rubber boot from the bottom of F/S assembly. See Fig. 2.

8) Remove the retainer rod from the bottom of F/S assembly, then remove the oat. Be

careful not to bend the retainer rod excessively when removing it.

9) Wipe down F/S assembly's housing, shaft, oat, and retainer rod with a mixture of 1 part

Hoshizaki "Scale Away" and 25 parts warm water. Clean the inside of the rubber boot and hose with cleaning solution. Rinse the parts thoroughly with clean water.

10) Reassemble F/S assembly and replace it and the rubber boot in their correct positions. Reconnect the vent tube and the

ush tube.

11) Replace the right side and top panels in

Flush Tube

Vent Tube

their correct positions.

12) Move the control switch to the "ICE"

Shaft

position.

13) Replace the front panel in its correct

Float Switch Housing

position.

14) Turn on the power supply to start the automatic icemaking process.

Legend: CB–control board; F/S–oat switch

Fig. 2

Rubber Boot and Hose

Float

Retainer Rod

Page 39

E. Thermistor Check

To check thermistor resistance, follow the steps below.

1) Turn off the power supply.

2) Remove the front panel, then move the control switch to the "OFF" position.

3) Remove the top and right side panels, then remove the control box cover.

4) Remove the thermistor.

5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes.

6) Disconnect the thermistor connector from CB K3 (white) connector and check resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ. If outside the normal range, replace the thermistor. See "V.B. Important Notes for Component Replacement." If within the normal range, continue to next step.

7) Replace the thermistor in its correct position. See "V.B. Important Notes for Component Replacement."

8) Reconnect the thermistor connector to CB K3 (white) connector.

9) Replace the control box cover, right side, and top panels in their correct positions.

10) Move the control switch to the "ICE" position.

11) Replace the front panel in its correct position.

12) Turn on the power supply.

13) Once the harvest cycle starts (Comp energizes), begin timing the harvest cycle.

14) The harvest timer and harvest cycle should terminate within 2 to 5 minutes. If the harvest cycle does not terminate within 2 to 5 minutes, replace CB.

Legend: CB–control board; Comp–compressor

Page 40

F. Diagnostic Charts

1. No Ice Production

No Ice Production - Possible Cause

1. Power Supply a) Off, blown fuse, or tripped breaker.

b) Not within specications.

2. Main Transformer (208-230VAC/115VAC) (3 Phase Only)

3. Water Supply a) Water supply off or improper water pressure.

4. Fuse (SRK Control Box) a) Blown.

5. High-Pressure Switch (SRK) a) Dirty condenser.

6. Discharge Line Thermostat (SRK)

7. Wire Harness (From SRK to KMS)

8. Fuse (KMS Switch Box) a) Blown.

9. Control Switch a) In "SERVICE" or "OFF" position.

10. Control Transformer (115VAC/10.5VAC)

11. Control Board See "IV.B. Control Board Check"

12. Bin Control See "IV.C. Bin Control Check and Cleaning"

13. Fill/Rell or Harvest Water Valve a) Screen or orice clogged.

14. Float Switch See "IV.D. Float Switch Check and Cleaning"

a) Voltage tap switch not set to proper voltage.

b) Coil winding open or shorted.

b) External water lters clogged.

b) Condensing unit fan(s) not operating.

c) Headmaster (C.P.R.) open.

d) Refrigerant overcharged.

e) Bad contacts.

f) Refrigerant lines or components plugged.

a) Ambient temperature too warm.

b) Compressor or compressor components faulty.

c) Defective.

d) Hot gas valves open.

e) Dirty condenser.

f) Condensing unit fan not operating.

a) Disconnected or loose connection.

b) Bad contacts.

a) Coil winding open or shorted.

a) In alarm.

b) Yellow "BC OPEN" LED on (bin full).

c) Defective.

a) Tripped with bin lled with ice.

b) Actuator does not move freely.

c) Defective.

b) Coil winding open.

c) Water valve open in freeze cycle.

a) Float does not move freely.

b) Defective.

Page 41

No Ice Production - Possible Cause

15. Compressor a) Compressor relay/magnetic contactor contacts bad or coil winding open.

b) Start capacitor or run capacitor defective (single phase only).

c) Internal protector open.

d) Start relay contacts bad or coil winding open (single phase only).

e) Protector tripped.

f) Compressor defective.

16. Hot Gas Valves (KMS & SRK) a) Closed in harvest cycle.

b) Open in freeze cycle.

1 7. Thermistor

See "IV.E. Thermistor Check"

18. Pump Motor a) Motor winding open.

19. Thermostatic Expansion Valve a) Bulb loose.

20. Liquid Line Valves (KMS & SRK) a) Closed in freeze cycle.

2 1. Fan Motors-Remote a) Motor winding open.

22. Headmaster (C.P.R.) a) Defective.

23. Water System a) Water leaks causing short freeze time.

a) Loose, disconnected, or defective.

b) Bearing worn out or locked rotor.

c) Defective capacitor.

d) Mechanical seal worn out.

b) Operating erratically.

b) Open in harvest cycle.

b) Bearing worn out or locked rotor.

c) Defective capacitor.

2. Freeze-Up

Defrost and clean the icemaker prior to diagnosing freeze-up. See "VI.A. Cleaning and Sanitizing Instructions." Fill out a freeze-up checklist. The freeze-up checklist can be found in the Hoshizaki Technician's Pocket Guide or contact your local distributor for a copy of the freeze-up checklist.

Freeze-Up - Possible Cause

Harvest Cycle

1. Evaporator a) Scaled up.

b) Damaged.

2. Cube Guides a) Out of position.

b) Damaged.

3. Spray Tubes and/or Spray Guides

4. Water Supply a) Low water pressure.

5. Harvest Water Valve a) Screen or orice clogged.

a) Dirty.

b) Out of position.

b) External water lters clogged.

c) Insufficient water line size.

Minimum 3/8" nominal ID copper water tubing or equivalent.

b) Defective.

Page 42

Freeze-Up - Possible Cause

6. Float Switch See "IV.D. Float Switch Check and Cleaning"

7. Refrigerant Charge a) Low.

8. Control Board See "II.C.3. Controls and Adjustments" and "IV.B. Control Board Check"

9. Bin Control See "IV.C. Bin Control Check and Cleaning"

10. Thermistor See "IV.E. Thermistor Check"

11. Thermostatic Expansion Valve a) Defective.

12. Hot Gas Valves (KMS & SRK) a) Closed or restricted.

13. Liquid Line Valves (KMS & SRK) a) Open.

1. Evaporator a) Scaled up.

2. Spray Tubes and/or Spray Guides

3. Refrigerant Charge a) L ow.

4. Control Board See "IV.B. Control Board Check"

5. Fill/Rell or Harvest Water Valve a) Leaking by.

6. Float Switch See "IV.D. Float Switch Check and Cleaning"

7. Pump Motor a) RPM too slow.

8. Thermostatic Expansion Valve a) Bulb loose or defective.

9. Headmaster (C.P.R.) a) Defective.

10. Liquid Line Valves (KMS & SRK) a) Restricted.

a) Dirty, sticking.

b) Defective.

a) Harvest timer (S4 dip switch 1 & 2) set too short.

b) Harvest pump timer (S4 dip switch 7) not in factory default position.

c) Defective.

a) Actuator does not move freely.

a) Loose, disconnected, or defective.

Freeze Cycle

b) Damaged.

a) Dirty.

b) Out of position.

a) Freeze timer (S4 dip switch 9 & 10) set incorrectly.

b) Defective.

a) Float does not move freely.

b) Defective.

b) Impeller damaged.

Page 43

3. Low Ice Production

Low Ice Production - Possible Cause

Long Harvest Cycle

1. Evaporator a) Scaled up.

2. Spray Tubes and/or Spray Guides

3. Refrigerant Charge a) L ow.

4. Water Supply a) Low water pressure.

5. Control Board See "IV.B. Control Board Check"

6. Thermistor See "IV.E. Thermistor Check"

7. Hot Gas Valves (KMS & SRK) a) Erratic or closed.

8. Harvest Water Valve a) Screen or orice clogged.

9. Compressor a) Inefficient or off.

10. Liquid Line Valves (KMS & SRK) a) Erratic or open.

11. Termostatic Expansion Valve (TXV)

12. Headmaster (C.P.R.) a) Defective.

1. Evaporator a) Scaled up, dirty.

2. Float Switch See "IV.D. Float Switch Check and Cleaning"

3. Fill/Rell or Harvest Water Valve a) Leaking by.

4. Hot Gas Valves (KMS & SRK) a) Erratic or open.

5. Condenser a) Clogged.

6. Control Board See "IV.B. Control Board Check"

7. Refrigerant Charge a) Low.

8. Thermostatic Expansion Valve (TXV)

9. Compressor a) Inefficient or off.

10. Pump Motor a) RPM too slow.

11. Liquid Line Valves (KMS & SRK) a) Erratic or restricted.

12. Headmaster (C.P.R.) a) Defective.

a) Dirty.

b) Out of position.

b) External water lters clogged.

c) Insufficient water line size.

Minimum 3/8" nominal ID copper water tubing or equivalent.

d) Too cold.

a) Thermistor connection loose (K3).

b) Defective.

a) Loose, disconnected, or defective.

a) Defective.

Long Freeze Cycle

a) Scaled up, dirty.

b) Float sticking.

c) Defective switch.

a) Float switch connection loose (K5).

b) Defective.

a) Bulb loose.

b) Defective.

Page 44

V. Replacement of Components

WARNING

• This icemaker should be diagnosed and repaired only by qualied service

personnel to reduce the risk of death, electric shock, serious injury, or re.

• Move the control switch to the "OFF" position and turn off the power supply

before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently.

• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the dispenser unit/storage bin.

• Make sure all food zones in the icemaker and dispenser unit/storage bin are clean

after service. For cleaning procedures, see "VI. Cleaning and Maintenance."

A. Service for Refrigerant Lines

WARNING

• Repairs requiring the refrigeration circuit to be opened must be performed by

properly trained and EPA-certied service personnel.

• Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of

refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

NOTICE

• Always recover the refrigerant and store it in an approved container. Do not

discharge the refrigerant into the atmosphere.

• Do not leave the system open for longer than 15 minutes when replacing or

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

• 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. Install the new drier with the arrow on the drier in the direction of the refrigerant

ow.

• When brazing, protect the drier by using a wet cloth to prevent the drier from

overheating. Do not allow the drier to exceed 250°F (121°C).

1. Refrigerant Recovery

The condensing unit is provided with refrigerant shutoff valves and the icemaker is provided with refrigerant service valves. Using proper refrigerant practices, recover the refrigerant. Recovery via the condensing unit's refrigerant shutoff valves is recommended. Store the refrigerant in an approved container. Do not discharge the refrigerant into the atmosphere.

Page 45

2. Brazing

WARNING

• R-404A itself is not ammable at atmospheric pressure and temperatures up to

176°F (80°C).

• R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open ames), R-404A can be decomposed to form hydrouoric acid and carbonyl uoride both of which are hazardous.

• Do not use silver alloy or copper alloy containing arsenic.

• Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of

refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

1) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

Note: Because the pipes in the evaporator case are specially coated to resist corrosion,

it is important to make connections outside the evaporator case when possible. If it is necessary to braze inside the evaporator case, use sandpaper to remove the coating from the brazing connections before unbrazing the components.

NOTICE

• 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. Install the new drier with the arrow on the drier in the direction of the refrigerant

ow.

• When brazing, protect the drier by using a wet cloth to prevent the drier from

overheating. Do not allow the drier to exceed 250°F (121°C).

2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

3. Evacuation and Recharge (R-404A)

The condensing unit is provided with refrigerant shutoff valves and the icemaker is provided with refrigerant service valves. Evacuation and recharge via the condensing unit's refrigerant shutoff valves is recommended.

1) Attach a vacuum pump to the system. Be sure to connect the charging hoses to both high and low-side refrigerant shutoff 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.

Page 46

2) Turn on the vacuum pump. Open the gauge manifold valves, then open the high and

low-side refrigerant shutoff valves. Never allow the oil in the vacuum pump to ow

backwards.

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 gauge manifold.

5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the nameplate on the condensing unit or the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

6) A liquid charge is required when charging an R-404A system (to prevent fractionation). Place the service cylinder on the scales; if the service cylinder is not equipped with a dip tube, invert the service cylinder, then place it on the scales. Open the high-side valve on the gauge manifold.

7) Allow the system to charge with liquid until the proper charge weight is met.

8) If necessary, add any remaining charge to the system through the low-side. NOTICE!To

prevent compressor damage, use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low-side refrigerant shutoff valve with the icemaker running.

9) Close the high and low-side refrigerant shutoff valves. Close the high and low-side gauge manifold valves, then disconnect the gauge manifold hoses.

10) Cap the refrigerant shutoff valves to prevent a possible leak.

Page 47

B. Important Notes for Component Replacement

NOTICE

When replacing a component listed below, see the notes to help ensure proper operation.

Component Notes

Compressor 1 Phase: Install a new start capacitor, run capacitor, and start relay.

3 Phase: Install a new magnetic contactor.

Thermostatic Expansion Valve

Hot Gas Valves Liquid Line Valves

Fan Motor Install a new capacitor.

Pump Motor Install a new capacitor.

Thermistor • Attach the new thermistor to the suction line in the same location as the previous

• Attach the thermostatic expansion valve bulb to the suction line in the same location as

the previous bulb.

• The bulb should be between the 10 and 2 o'clock positions on the tube.

• Secure the bulb with the clamp and holder, then insulate it.

• Replace the strainer if applicable.

• Use copper tube of the same diameter and length when replacing valve lines.

thermistor.

• The thermistor should be at the 12 o'clock position on the tube.

• Smoothly ll the recessed area of the thermistor holder with high thermal conductive

type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound 10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu Silicones), or equivalent are recommended.

• Secure the thermistor with the holder, then insulate it.

• Be very careful to prevent damage to the leads.

Page 48

VI. Cleaning and Maintenance

This icemaker must be cleaned and maintained in accordance with the instruction manual and labels provided with the icemaker. Consult with your local Hoshizaki Certied Service Representative about cleaning and maintenance service.

WARNING

• Only qualied service technicians should service this icemaker.

• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are

securely in place after any cleaning or maintenance is done to the icemaker. Make sure that none have fallen into the dispenser unit/storage bin.

NOTICE

The dispenser unit/storage bin is for ice use only. Do not store anything else in the dispenser unit/storage bin.

A. Cleaning and Sanitizing Instructions

This icemaker must be cleaned and sanitized at least once a year. More frequent cleaning and sanitizing may be required in some water conditions.

WARNING

• To prevent injury to individuals and damage to the icemaker, do not use ammonia

type cleaners.

• Carefully follow any instructions provided with the bottles of cleaning and

sanitizing solution.

• Always wear liquid-proof gloves and goggles to prevent the cleaning and sanitizing

solutions from coming into contact with skin or eyes.

NOTICE

To prevent damage to the water pump seal, do not operate the icemaker with the control switch in the "SERVICE" position when the water tank is empty.

Insulation Panel

Fig. 3

Float Switch

Front Panel

Splash Curtain

Page 49

1. Cleaning Procedure

1) Dilute 22 . oz. (650 ml) of Hoshizaki "Scale Away" with 4 gal. (15 l) of warm water.

2) Remove all ice from the evaporator and the dispenser unit/storage bin. Note: To remove cubes on the evaporator, turn off the power supply and turn it back on

after 3 minutes. The harvest cycle starts and the cubes will be removed from the evaporator.

3) Turn off the power supply.

4) Remove the front panel, then place the control switch in the "SERVICE" position. Place the service switch in the "DRAIN" position.

5) Replace the front panel in its correct position, then turn on the power supply for 2 minutes.

6) Turn off the power supply.

7) Remove the front panel.

8) In bad or severe water conditions, clean the oat switch as described below. Otherwise,

continue to step 9.

a. Remove the right side panel.

b. Disconnect the vent tube and the ush tube from the top of the oat switch housing,

then remove the oat switch assembly. Remove the rubber boot from the bottom of the oat switch assembly.

c. Remove the retainer rod from the bottom of the oat switch assembly, then remove

the oat. Be careful not to bend the retainer rod excessively when removing it.

d. Wipe down the oat switch assembly's housing, shaft, oat, and retainer rod with

cleaning solution. Clean the inside of the rubber boot and hose with cleaning solution. Rinse the parts thoroughly with clean water.

e. Reassemble the oat switch assembly and replace it and the rubber boot in their

correct positions. Reconnect the vent tube and the ush tube.

f. Replace the right side panel in its correct position.

9) Remove the insulation panel and splash curtain, then pour the cleaning solution into the water tank.

10) Move the service switch to the "WASH" position.

11) Replace the splash curtain, insulation panel, and front panel in their correct positions.

12) Turn on the power supply to start the washing process.

13) Turn off the power supply after 30 minutes. Remove the front panel.

14) Move the service switch to the "DRAIN" position.

15) Replace the front panel in its correct position, then turn on the power supply for 2 minutes.

16) Turn off the power supply, then remove the front panel.

17) Move the control switch to the "ICE" position.

18) Replace the front panel in its correct position.

19) Turn on the power supply to ll the water tank with water.

20) Turn off the power supply after 3 minutes.

Page 50

21) Remove the front panel.

22) Move the control switch to the "SERVICE" position, then move the service switch to the "WASH" position.

23) Replace the front panel in its correct position.

24) Turn on the power supply to rinse off the cleaning solution.

25) Turn off the power supply after 5 minutes.

26) Remove the front panel.

27) Move the service switch to the "DRAIN" position.

28) Replace the front panel in its correct position, then turn on the power supply for 2 minutes.

29) Turn off the power supply. Remove the front panel.

30) Repeat steps 17 through 29 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 13 in "2. Sanitizing Procedure."

2. Sanitizing Procedure - Following Cleaning Procedure

1) Dilute 2 . oz. (60 ml or 4 tbs) of a 5.25% sodium hypochlorite solution (chlorine bleach)

with 4 gal. (15 l) of warm water.

2) Remove the front panel, insulation panel, and splash curtain if they are in their normal positions.

3) Pour the sanitizing solution into the water tank.

4) Move the service switch to the "WASH" position.

5) Replace the splash curtain, insulation panel, and front panel in their correct positions.

6) Turn on the power supply to start the sanitizing process.

7) Turn off the power supply after 15 minutes. Remove the front panel.

8) Move the service switch to the "DRAIN" position.

9) Replace the front panel in its correct position, then turn on the power supply for 2 minutes.

10) Turn off the power supply. Remove the front panel.

11) Repeat steps 17 through 29 in "1. Cleaning Procedure" two times to rinse thoroughly.

12) Repeat steps 1 through 11 one more time.

13) Move the control switch to the "ICE" position.

14) Replace the front panel in its correct position.

15) Clean the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.

16) Turn on the power supply to start the automatic icemaking process.

Page 51

B. Maintenance

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

WARNING

• Only qualied service technicians should service this icemaker.

• Move the control switch to the "OFF" position and turn off the power supply to

the SRK condensing unit before servicing the KMS or SRK. Place the KMS disconnect (if applicable) in the off position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.

1. Stainless Steel Exterior

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

2. Storage Bin Scoop

• Wash your hands before removing ice from the storage bin. Use the plastic scoop

provided (storage bin accessory).

• Clean the scoop using a neutral cleaner. Rinse thoroughly after cleaning.

3. Dispenser Unit/Storage Bin

• The dispenser unit/storage bin is for ice use only. Do not store anything else in the

dispenser unit/storage bin.

• Clean the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after

cleaning.

4. Condenser

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

Page 52

C. Preparing the Icemaker for Periods of Non-Use

NOTICE

• When storing the icemaker for an extended time or in sub-freezing temperatures,

follow the instructions below to prevent damage.

• To prevent damage to the water pump, do not operate the icemaker with the

control switch in the "SERVICE" position when the water tank is empty.

When the icemaker is not used for two or three days under normal conditions, it is sufficient to move the control switch to the "OFF" position. When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below.

1) Turn off the power supply, then remove the front panel.

2) Move the control switch on the control box to the "OFF" position. Conrm that the service switch is in the "CIRC." position.

3) Remove the front insulation, front frame, right side panel, and control box cover.

4) Disconnect the thermistor connector from the control board K3 (white) connector, then unplug the water pump connector at the water pump.

5) Wait 3 minutes, then move the control switch to the "ICE" position. Conrm that the bin control switch is closed and calling for ice. The green "BC CLOSED" LED on the control board should be on.

6) Once LED 1 and 2 on the control board energize (the order of the LEDs from the outer edge of the control board is 1, 4, 3, 2), close the inlet water supply line shut-off valve and open the inlet water supply line drain valve. Allow the line to drain by gravity.

7) Disconnect the harvest water valve hose in the evaporator section and blow out the water line to the harvest water valve using compressed air or carbon dioxide. See Fig.4. This will clear water from the harvest water valve.

8) Move the control switch to the "OFF" position.

9) Move the service switch to the "WASH" position and the control switch to the "SERVICE" position.

10) Using the same hose as with the harvest water valve, blow out the wash valve using compressed air or carbon dioxide.

11) Move the service switch to the "CIRC." position and the control switch to the "OFF" position.

12) Remove the 4 hoses connected to the water tank. Allow the water tank and hoses to completely drain.

13) Move the control switch to the "ICE" position.

14) Using the ll/rell water valve hose, blow out the water line using compressed air or carbon dioxide. This will clear water from the ll/rell water valve.

15) Move the control switch to the "OFF" position.

16) Disconnect the oat switch ush tube from the drain hose tee. Move the service switch

to the "DRAIN" position and the control switch to the "SERVICE" position.

Page 53

17) From the tee on the drain hose, blow out the drain valve using compressed air or carbon dioxide.

18) Move the service switch to the "CIRC." position and the control switch to the "OFF" position.

19) Turn off the power supply.

20) Reconnect the thermistor connector to the control board K3 (white) connector. Reconnect the water pump connector.

21) Close the inlet water supply line drain valve.

22) Remove all ice from the dispenser unit/storage bin and clean the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.

23) Replace all removed parts and panels in their correct positions.

Harvest Water Valve Hose

Harvest Water Valve

Drain Hose Tee

Suction Hose

Wash Valve

Fill/Rell Water Valve Hose

Fill/Rell Water Valve

Float Switch Flush Tube

Drain Valve

Fig. 4

Page 54

VII. Disposal

This icemaker contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certied service personnel.

Hoshizaki KMS-1401MLJ User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important Safety Information

A. Icemaker

1. KMS-1401MLJ with SRK-14J

2. KMS-1401MLJ with SRK-14J3

B. Condensing Unit

1. SRK-14J

2. SRK-14J3

II. General Information

A. Construction

1. Icemaker

2. Condensing Unit

B. Sequence of Operation

1. Sequence Cycles and Shutdown

a) 1-Minute Fill Cycle

b) Initial Harvest Cycle

c) Freeze Cycle

d) Pump-Out Cycle

e) Harvest Cycle

f) Shutdown

2. Sequence Flow Chart

C. Control Board

1. Control Board Layout

2. LED Lights and Audible Alarm Safeties

3. Controls and Adjustments

a) Default Dip Switch Settings

b) Harvest Timer (S4 dip switch 1 & 2)

c) Pump-Out Timer (S4 dip switch 3 & 4)

d) Pump-Out Frequency Control (S4 dip switch 5 & 6)

e) Harvest Pump Timer (S4 dip switch 7)

f) Factory Use (S4 dip switch 8)

g) Freeze Timer (S4 dip switch 9 & 10)

h) Float Switch Selector (S5 dip switch 1)

D. Control and Service Switches

1. Control Switch

2. Service Switch

a) DRAIN

b) CIRC.

c) WASH

III. Technical Information

A. Water Circuit and Refrigeration Circuit

B. Wiring Diagrams

1. KMS-1401MLJ with SRK-14J

2. KMS-1401MLJ with SRK-14J3

3. Wire Harness Connections

C. Performance Data

1. KMS-1401MLJ with SRK-14J

2. KMS-1401MLJ with SRK-14J3

IV. Service Diagnosis

A. Diagnostic Procedure

B. Control Board Check

C. Bin Control Check and Cleaning

1. Bin Control Check

2. Bin Control Cleaning

D. Float Switch Check and Cleaning

1. Float Switch Check

2. Float Switch Cleaning

E. Thermistor Check

F. Diagnostic Charts

1. No Ice Production

2. Freeze-Up

3. Low Ice Production

V. Replacement of Components

A. Service for Refrigerant Lines

1. Refrigerant Recovery

2. Brazing

3. Evacuation and Recharge (R-404A)

B. Important Notes for Component Replacement

VI. Cleaning and Maintenance

A. Cleaning and Sanitizing Instructions

1. Cleaning Procedure

2. Sanitizing Procedure - Following Cleaning Procedure

B. Maintenance

C. Preparing the Icemaker for Periods of Non-Use

VII. Disposal