Hoshizaki KMS2000MLJ User Manual

Service Manual

Modular Crescent Cuber

Serenity Series

Model

KMS-2000MLJ

Including

Condensing Unit Models

SRK-20J/3

Number: 73225

hoshizakiamerica.com	Issued: 6-15-2018

WARNING

Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service

Representative, visit www.hoshizaki.com. No installation or service should be undertaken until the technician has thoroughly read this Service Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation. Failure to install, operate, 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. 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 qualified service technicians in the installation, maintenance, and service of the appliance.

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: [phone]

Fax: [phone]

E-mail: [e-mail]

618 Highway 74 South

Peachtree City, GA 30269

Attn: Hoshizaki Technical Support Department

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

•Model Number

•Serial Number

•Complete and detailed explanation of the problem.

2

IMPORTANT
This manual should be read carefully before the appliance is serviced. Read
the warnings and guidelines contained in this manual carefully as they provide
essential information for the continued safe use, service, and maintenance of the
appliance. Retain this manual for any further reference that may be necessary.
CONTENTS
Important Safety Information..................................................................................................	5
I. Construction and Water/Refrigeration Circuit Diagram........................................................	7
A. Construction..................................................................................................................	7
1. Icemaker...................................................................................................................	7
2. Condensing Unit .....................................................................................................	8
B. Water Circuit and Refrigeration Circuit...........................................................................	9
II. Sequence of Operation and Service Diagnosis................................................................	10
A. Sequence of Operation Flow Chart.............................................................................	10
1. Operation Flow Chart ............................................................................................	10
2. Shutdown Flow Chart..............................................................................................	11
3. Freeze-Time Correction Chart................................................................................	12
B. Service Diagnosis........................................................................................................	13
C. Freeze-Time Correction Cycle (90 min.)......................................................................	20
D. Control Board Check....................................................................................................	22
E. Bin Control Check........................................................................................................	24
F. Float Switch Check and Cleaning.................................................................................	26
G. Thermistor Check........................................................................................................	28
H. Switches......................................................................................................................	29
1. Control Switch.........................................................................................................	29
2. Service Switch........................................................................................................	29
I. Diagnostic Tables..........................................................................................................	30
J. Freeze-Up Check List...................................................................................................	34
III. Controls and Adjustments................................................................................................	35
A. Control Board Layout...................................................................................................	36
B. LED Lights and Audible Alarm Safeties.......................................................................	37
C. Settings and Adjustments............................................................................................	38
1. Default Dip Switch Settings.....................................................................................	38
2. Harvest Timer (S4 dip switch 1 & 2).......................................................................	39
3. Pump-Out Timer/Harvest Time During Pump-Out (S4 dip switch 3 & 4)................	39
4. Pump-Out Frequency Control (S4 dip switch 5).....................................................	40
5. Harvest Pump Time (Harvest Assist Duration) (S4 dip switch 6)............................	40
6. Harvest Pump Time (Harvest Assist)/Freeze-Time Correction (S4 dip switch 7)....	41
7. Factory Use (S4 dip switch 8).................................................................................	42
8. Freeze Timer (S4 dip switch 9 & 10).......................................................................	42
9. Float Switch Control Selector (S5 dip switch 1)......................................................	42
10. Refill Counter (S5 dip switch 2 and 3)..................................................................	43
11. Minimum Harvest Time (S5 dip switch 4)..............................................................	43
12. Anti-Slush (S5 dip switch 5)..................................................................................	43

3

IV. Refrigeration Circuit and Component Service Information..............................................	44
A. Refrigeration Circuit Service Information.....................................................................	44
B. Component Service Information..................................................................................	47
V. Maintenance.................................................................................................................	48
VI. Preparing the Appliance for Periods of Non-Use........................................................	49
VII. Disposal.........................................................................................................................	51
VIII. Technical Information....................................................................................................	52
A. Specification and Performance Data Sheets...............................................................	52
1. KMS-2000MLJ with SRK-20J.................................................................................	52
2. KMS-2000MLJ with SRK-20J3...............................................................................	53
3. SRK-20J.................................................................................................................	54
4. SRK-20J3...............................................................................................................	55
B. Wiring Diagrams..........................................................................................................	56
1. Wire Harness Connections.....................................................................................	56
2. KMS-2000MLJ with SRK-20J.................................................................................	57
3. KMS-2000MLJ with SRK-20J3...............................................................................	58

4

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, 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 appliance 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 fire, follow basic precautions including the following:

•Only qualified service technicians should install and service this appliance.

•This appliance 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, fire, 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 appliance. Alterations could result in electric shock, injury, fire, or damage to the appliance.

•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 appliance or allow children or animals to do so.

Serious injury could occur or the appliance could be damaged.

•Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire.

•Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance.

5

WARNING, continued

For KMS

•Risk of electric shock. Control switch in "OFF" position does not de-energize all loads.

•Power supply and ground connection are supplied from the SRK remote condensing 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, fire, or damage to the appliance.

•THE APPLIANCE MUST BE GROUNDED. Failure to properly ground the appliance 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, fire, or damage to the appliance.

•The remote condensing unit requires an independent power supply of proper capacity. See the nameplate for electrical specifications. 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 fire.

•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 floor drain.

•Install the appliance 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 appliance on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the appliance for these occasions, follow the instructions in "VI. Preparing the Appliance for Periods of Non-Use."

•Do not place objects on top of the appliance.

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

6

I. Construction and Water/Refrigeration Circuit Diagram

A.Construction

1.Icemaker

Top Panel

Top Insulation
	Inlet Water Valve
Spray Guides	Wash Valve
Spray Tubes			Hot Gas Valve
Insulation Panel			Strainer
			Suction Line
Evaporator
			Shutoff Valve
			Thermostatic Expansion Valves
			Liquid Line
			Shutoff Valve
			Thermistor
			Control Box
		Drier	Liquid Line Valve
		Pump Motor
	Drain Valve	Float Switch
Front Panel
Control Box		Bin Control		Left Side Panel
	Switch Cover		Switch Bracket
Control Switch	Switch Mount
Service Switch	Extension Bracket
Fuse (KMS)	Bin Control

7

2. Condensing Unit

Main Transformer	Top Panel
(Three Phase Only)	Condenser

Right Side Panel

Control Box

			Fan Motors
			Liquid Line
			Shutoff Valve 2
			High-Pressure
	Suction Line		Switch
			Compressor
	Shutoff Valve
		Liquid Line	Crankcase Heater	Louver Panel
			Junction Box
		Shutoff Valve
				Front Panel

Discharge Line Thermostat
	Liquid Line Valve
	Strainers	Left Side Upper Panel Right
	Left Side Upper
Hot Gas Valves	Panel
Headmaster
(C.P. R.)

Accumulator

Receiver

Left Side Lower Panel

8

9

								Water .B
	KMS-2000MLJ			SRK-20J/3		Headmaster		Circuit
						(C.P. R.)
	Spray Tube	Water Supply		Strainer	Condenser		Discharge Line
								and
			Liquid Line				Thermostat
Evaporator
		Inlet Water Valve
			Valve
							Check Valve
		Heat Exchanger						Refrigeration
			Suction Line		Fans		Access Valve
		Wash Valve
			Shutoff Valves
							Hot Gas
							Valves
			Liquid Line
			Shutoff Valves					Circuit
		Thermistor	Liquid Line				Strainers
			Valve
					Suction Line
			Drier
			Strainer				Liquid Line
							Shutoff Valve 2
			Hot Gas				High-Pressure
			Valve			Discharge	Switch
						Line

Water Tank	Pump Motor	Drain	Float Switch	Check Valves	Accumulator
			Drain Valve	Thermostatic	Receiver Compressor
				Expansion Valves

Operation Flow Chart

.1

Operation

Cycle

1. 1-Minute

2. Harvest Cycle

3. Freeze Cycle

4. Pump-Out Cycle

Steps

Fill Cycle

• WV time: 6 min. or the length of harvest minus

• Minimum freeze time: 5 min.

• Factory set for every

HPT settings (S4 dip switch 6), whichever is

• Maximum freeze time: freeze timer setting

10th cycle.

shorter.

(S4 dip switch 9 & 10)

(S4 dip switch 5)

Flow

• Maximum harvest time: 20 min.

• Pump motor stops for

2 sec., then energized

1 to 3-min. timer in control

5-min. minimum

for 10/20 sec.

Chart

(S4 dip switch 1 & 2)

freeze timer in

FS in control

(S4 dip switch 3 & 4)

Thermistor

control

in control

Harvest Pump Timer

FS opens or freeze

timer terminates

Startup

50 sec.

begins

F/S check

F/S closed

F/S check

FS closed

here after

WV energized

PM energized

Comp continues

Comp continues

5-sec. delay

WV continues

Anti-Slush

Comp energized

WV de-energized

FMRs continue

Thermistor

FMRs continue

F/S open

FMRs energized

Thermistor temperature

PM continues

temperature

HGVs energized

HGVs energized

reaches 48°F (9°C)

LLVs energized

drops to 36°F

DV energized

(3.9 kΩ or less)

HGVs de-energized

(2.2°C) (5.8 kΩ

PM de-energizes for 2 sec.,

Harvest timer starts.

or more).

then energized for 10/20 sec.

10

F/S open

PM de energizes

LLVs de-energized

If F/S is open, Comp and FMRs de-energize and cycle returns to 1-minute fill cycle

for 10 sec.

When freeze time differential exceeded, freeze-time correction cycle starts.

See "II.A.3. Freeze-Time Correction Chart."

Legend: BC-bin control

Comp-compressor

DV-drain valve FMRs-fan motors-remote

F/S-float switch

HGVs-hot gas valves (KMS and SRK) LLVs-liquid line valves (KMS and SRK)

PM-pump motor WV-inlet water valve

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.

DRAIN	Power is supplied to the pump motor and drain valve. This drains the water tank.
CIRC.	Power is supplied to the pump motor only. This operation can be used to circulate cleaner
	and sanitizer over the outside surface of the evaporator for extended periods of time.
WASH	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 surfaces of the evaporator.

Chart Flow Operation of Sequence .A	Service and Operation of Sequence .II
	Diagnosis

11

Shutdown Flow Chart

Shutdown

1. Bin Full

2. Icemaker Off

3. Ice Level Lowered

and Restart

Shutdown Delay:

All components

Icemaker starts at

• Fill Cycle–15 sec. after activation.

de-energized.

"1. 1-Minute Fill Cycle."

• Harvest Cycle–At the end of the harvest cycle, or up

to 15 sec. into the freeze cycle if

activated at the end of the harvest cycle.

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

15 sec. before the 5-min. short cycle

protection timer terminates.

Otherwise, at the end of the next harvest

cycle.

BC Operation

To 1. 1-Minute Fill Cycle

BC open (BC actuator paddle engaged)

Yellow "BC OPEN" LED continues.

BC closed

Green "BC CLOSED" LED off

All components de energized.

(BC actuator paddle disengaged)

Yellow "BC OPEN" LED on

Green "BC CLOSED" LED on

Yellow "BC OPEN" LED off

Legend:

Control board retains freeze-time correction count data

between bin control restarts.

BC–bin control

Chart Flow Shutdown .2

Freeze Time Differential Exceeded. Minimum and Maximum Freeze times have exceeded differential parameters.

Freeze-Time Correction function is enabled when S4 Dip Switch 7 is in the "ON" position.

CB monitors freeze time. After 3 freeze cycles, CB compares the minimum and maximum differential of the 3 freeze cycle times. Every freeze cycle time after the third freeze cycle time is added to the minimum/ maximum calculation.

Example: After 8 cycles, if the differential between the shortest cycle (minimum) and the longest cycle (maximum) is equal to or greater than 427 sec. a freeze-time correction cycle is initiated:

		Number of	Differential
		Freeze Cycles	Value in Sec.
		3	254
		4	309
		5	349
	12	6	380
		7	406
		8	427
		9	446
		10	462

Note: When 1st freeze-time correction cycle is initiated, CB "POWER OK" LED starts blinking. On 2nd freeze-time correction cycle, if CB "POWER OK" LED has been reset, CB "POWER OK" LED starts blinking. If CB

"POWER OK" had not been reset after 1st freeze-time correction cycle CB "POWER

OK" LED continues to blink.

After 3rd freeze time correction cycle in

36 hours, CB yellow "EXT HARVEST" LED starts blinking.

Appliance continues to operate and LEDs continue to blink until ALARM RESET button is pressed with power on.

	Freeze-Time Correction Flow Chart								3
										-Freeze .
Cycle Steps					1. 10-Minute Harvest Cycle with WV			2. 10-Minute Fill/		Time
Steps 1 and 2 repeat						• Do not adjust S4 dip switch 7 out of the factory position.		Overflow
						• After step 2 completes 4th sequence (80 min. completed), repeat
4 times (total 80 min.),						step 1 for 5th and final time.				Correction
then step 1 repeats for
a 5th time to complete
Freeze Time Correction
Cycle.
	Start									Chart
				Comp energized			WV energized
				FMRs energized			Comp de-energized
				HGVs energized			FMRs de-energized
				PM energized			HGVs de-energized
				WV energized			PM de-energized

Legend: Comp–compressor

FM–fan motor FMRs–fan motor-remote HGVs–hot gas valve

PM–pump motor WV–inlet water valve

After 5th 10-Minute Harvest Pump Cycle with WV Freeze-Time Correction Cycle Complete.

Go to Step "3. Freeze Cycle" in Operation Flow Chart.

Appliance Cycle Reset and Alarm Reset:

Cycle Reset: Power Supply or Control Switch Turned Off and On again: Appliance turns off, then re-starts at 1.Fill Cycle.

Alarm Reset: CB "ALARM RESET" pressed during or after a freeze-time correction cycle with power supply on:

Appliance continues cycle with no interruption or reset. CB red "POWER OK" LED blinking:

CB red "POWER OK" LED resets to solid. CB yellow "EXT HARVEST" LED blinking:

CB yellow "EXT HARVEST: LED turns off.

B. Service Diagnosis

WARNING

•The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire.

•Risk of electric shock. Control switch in "OFF" position does not de energize all loads. Use extreme caution and exercise safe electrical practices.

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

•Before servicing the appliance, move the control switch to the "OFF" position and turn off the power supply.

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

•Make sure all food zones in the appliance and dispenser unit/ice storage bin are clean after service.

1.Diagnostic Procedure

The diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, proper voltage per nameplate, and adequate water supply.

Note: • When checking high voltage (115VAC), always choose a neutral (W) to establish a good neutral connection.

•On 3-phase models, the neutral (W) is provided through MT. To confirm a good neutral (W), check for 60VAC from neutral (W) to ground (GND). If 60VAC is present, neutral (W) is good. If 60VAC is not present, check 208-230VAC main power supply to MT. If 208-230VAC is present, check MT continuity.

•When checking voltage from the CB K1 connector (10 pin connector), pull CB

K1 connector out slightly to allow room for multimeter test leads contact.

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

2)Check that the 115VAC 10A fuses in the KMS and SRK are good.

Confirm that the location meets installation requirements:

KMS-2000MLJ:

•The appliance is not intended for outdoor use. Normal operating ambient temperature should be within 45°F to 100°F (7°C to 38°C).

•Allow 6" (15 cm) clearance at sides, rear, and top of the appliance for proper air circulation and ease of maintenance and service.

•The appliance should not be located in a corrosive environment.

SRK-20J/3:

•A dry and well ventilated area with 24" (61 cm) clearance in both front and rear for proper air circulation and ease of maintenance and/or service should they be required.

13

3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5 sec. delay occurs. CB red "POWER OK" LED and CB green "BC CLOSED" LED turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check CB K4 red jumper. Move ice away from BC bulb.

Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is interrupted (K2 connector).

•Check CB using the steps in "II.D. Control Board Check."

a)Power On Diagnosis: If CB red "POWER OK" LED is off, confirm 10A fuse on both the KMS and the SRK are good. Confirm wire harness is connected and not damaged. Next, check SRK switches. Check for 115VAC at both HPS wires (BR) to neutral (W). If 115VAC is present on one and not the other, HPS is open. If HPS is open, see "b) HPS Diagnosis" below. If HPS is closed, check for 115VAC at both

DLT wires (BR) to neutral (W). If 115VAC is present on one and not the other, DLT is open. If DLT is open, see "c) DLT Diagnosis" below. If DLT is closed, go to KMS and check for 115VAC at BC wires (BR) to neutral (W). If 115VAC is present on one and not the other, BC is open. See "II.E. Bin Control Check." If BC is closed, check for 115VAC at control switch #1 (BR) to neutral (W) then at control switch

#2 (BK) to neutral (W). If 115VAC is present on #1 (BR) and not on #2 (BK), replace control switch. If 115VAC is present on control switch #2 (BK), check for 10.5VAC at

CB K2 #1 red wire to CB K2 #2 red wire. If 10.5VAC is not present, check CT wire connections and CT continuity. If open, replace CT.

b)HPS Diagnosis: Check that all shutoff valves (4 total) are open and the condenser coil is not clogged or restricted. Let refrigeration circuit pressures equalize. If HPS does not reset and pressures are equalized, replace HPS. If pressures are not equalized, reclaim refrigerant and diagnose refrigeration circuit restriction. Check that there are no restrictions in the refrigeration circuit.

Harvest Cycle: HGVs, strainer, or check valve.

Freeze Cycle: FMRs, TXV, HM, LLVs, strainer, check valve, drier, and damaged line set or fitting.

c)DLT Diagnosis: Check that the condenser coil is not clogged or restricted. Let discharge line thermostat cool, if DLT does not close, replace DLT. Once closed, restart appliance, once Comp starts, check voltage and amp draw.

See "5a),a) Comp Diagnosis" below.

4)1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGVs, and FMRs energized), continue to step 5a. If FS is open, WV remains energized until FS closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: Check that water enters the water tank. If not, check that the water

supply line shut-off valve is open and screens or external filters are clear. Check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, and WV does not energize, check for 115VAC at WV. If 115VAC is present, check WV coil continuity. If open, replace WV. If the water tank fills, but the appliance fails to start harvest (Comp energized), check for open FS. See "II.F. Float Switch

Check and Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace CB.

14

5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, FMRs, HGVs, and X10 relay energize. 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 and S5 dip switch 4). WV and X11 relay are energized during harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), whichever is shorter. See step 5b below.

a)Comp Diagnosis: Check that evaporator is warming. If not, confirm that Comp energizes. If not, check for 115VAC at CB K1 #1 (V) to neutral (W). If 115VAC is not present, check for 115VAC at CB K1 #10 (BR) to neutral (W). If 115VAC is present at #10 (BR) and not at #1 (V), replace CB. If 115VAC is present, check for 115VAC at MC solenoid (SRK). If 115VAC not present, check wire harness connections.

If 115VAC is present, confirm contacts are closed. If not, replace MC. If MC contacts are closed, check Comp start and run capacitors, start relay (single phase), and Comp motor winding.

b)HGVs Diagnosis: If Comp is energized and evaporator is not warming, check that HGVs energizes and open. Check for 115VAC at CB K1 #2 (P) to neutral (W).

If 115VAC is not present, replace CB. If 115VAC is present, check for 115VAC at HGVs coil (KMS and SRK) and check HGVs coils continuity. Replace as needed.

c)LLVs Diagnosis: Confirm that both LLVs are de-energized (KMS and SRK) and closed (not bypassing). If energized, replace CB. If de-energized and bypassing, replace LLVs (KMS and SRK).

5b) Harvest Pump Timer – LEDs 1, 3, and 2 are on. 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 and S5 dip switch 4). When WV de-energizes,

LED 4 turns off, X11 relay de-energizes and LED 3 turns on. PM and X12 relay energize. Comp, FMRs, HGVs, and X10 relay continue.

Diagnosis: Place a thermometer on the suction line next to the thermistor. Has it warmed to 48°F (9°C) or warmer? Confirm thermistor status. See "II.G. Thermistor Check." If the thermistor reading is in proper range, dip switch 7 is on, and PM does not energize before harvest terminates, replace CB. If WV continues, check for 115VAC at CB K1 #6 (O). If 115VAC is present, and LED 4 is off, replace CB. If 115VAC is not present, and WV continues, check WV diaphragm for leaking by. Clean or replace.

If LED 3 is on and PM is not energized, check for 115VAC at CB K1 #5 (DBU). If 115VAC is not present, replace CB. If 115VAC is present and PM is not energized, check for 115VAC at X10 relay terminal #8 (Y) to neutral (W). If 115VAC is not present, check for 115VAC at X10 relay terminal #4 (P) to neutral (W) and X10 relay terminal #6 (Y) to neutral (W). If 115VAC is present on terminal #4 (P) and not on terminal #6 (Y), replace

X10 relay. If 115VAC is present on X12 relay terminal #8 (P) and PM is not energized, check for 115VAC at X12 relay terminal #4 (W/R) to neutral (W) and terminal #6 (DBU) to neutral (W). If 115VAC is present on terminal #6 (DBU) and not on terminal #4 (W/R), replace X12 relay. If 115VAC is present on X12 relay terminal #4 (W/R). If 115VAC is present between X12 relay terminal #4 (W/R) and neutral (W), check PM capacitor and motor winding continuity.

15

5c) Initial Harvest Cycle Termination Diagnosis: 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 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.G. Thermistor Check." If 1-min. fill cycle

starts after harvest timer terminates, check that FS is clean and operating properly, see

"II.F. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle. If not, replace CB.

Note: The minimum total time allowed by CB for a complete harvest cycle is based on S5 dip switch 4. Maximum harvest time allowed is 20 min.

NOTICE! S4 dip switch 7 must remain on. Otherwise, PM will not energize during the last seconds of harvest.

6)Freeze Cycle – LED 1 is on. Comp, FMRs, and PM continue. LLVs energize. HGVs, X10 and X12 relays de energize. Appliance is held in freeze by a 5-min. short

cycle protection timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle terminates.

Note: PM power supply switches from CB K1 #5 (DBU) in HPT to K1 #4 (R) in freeze.

Anti-Slush: When anti-slush is enabled (S5 dip switch 5 "ON"), PM de-energizes when thermistor reaches 36°F (2.2°C) (5.8 kΩ) for 10 sec. then, energizes for the remainder of the freeze cycle.

a)Freeze Cycle Diagnosis: Confirm Comp, FMRs, and PM continue. Confirm that

LLVs energize. Next, confirm HGVs, X10 and X12 relays de-energize. During the first 5 min. of freeze, confirm evaporator is cooling. If not, confirm WV de-energized (not leaking by), HGVs de-energized (not bypassing), LLVs energizes, TXV and HM operate correctly, Comp is efficient, and refrigerant charge is correct.

See "VIII.A. Specification and Performance Data Sheets."

b)Comp and FMRs Diagnosis: If Comp and FMRs de-energize once freeze begins, check that appliance has not shut off on HPS or DLT ("POWER OK" LED off).

If so, check "3)b) HPS Diagnosis" or "3)c) DLT Diagnosis" above. If CB "POWER OK" LED is on (KMS), check for 115VAC at CB K1 #9 (V) to neutral (W). If 115VAC is not present and LED 1 is on, replace CB. If 115VAC is present, check for 115VAC at MC coil (SRK). If 115VAC is not present, check wire harness connections. Next, check for 115VAC at MC coil. If 115VAC is present, check MC coil and contacts continuity. Replace as needed. If MC is okay, check Comp start relay and start and run capacitors (single phase). Next, check Comp motor winding continuity. If Comp is energized but evaporator is not cooling, check for an inefficient Comp.

See "VIII.A. Specification and Performance Data Sheets."

FMRs Diagnosis: If Comp is energized but FMRs are not, check for 115VAC at MC terminal "NO" black (BK) wire to neutral (W). If 115VAC is not present, and MC is energized replace MC. If 115VAC is present, check FMRs capacitors, motor windings, and fan blades for binding.

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c)WV and HGVs Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB. If 115VAC is not present, replace WV (bypassing). If HGVs (KMS and SRK) did not de energize at the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral

(W). If 115VAC is present 50 sec. after PM energizes, replace CB. If 115VAC is not present, replace HGV(s) (bypassing).

d)PM Diagnosis: Confirm water is flowing over evaporator from PM and not WV. If PM de-energizes once freeze begins (except for anti-slush), check for 115VAC

at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized, check for 115VAC at control switch #5 (W/R) to neutral (W). If 115VAC is present at CB K1 #4 (R) and not at control switch #5 (W/R), check control switch continuity between #5 (W/R) and #4 (R). Replace as needed.

If 115VAC is present at control switch #5 (W/R) to neutral (W), check PM capacitor and motor winding continuity.

e)LLVs Diagnosis: If LLVs does not energize, check for 115VAC at CB K1 #3 (BK) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, check coil voltage and continuity.

f)Refrigerant Pressures, HM, and TXV Diagnosis: If evaporator is still not cooling, check refrigerant pressures. See "VIII.A. Specification and Performance Data Sheets." Next, check HM operation. If refrigeration pressures are above HM setpoint and HM is bypassing, replace HM. Check TXV for proper operation. Remove TXV bulb and hold it in your hand, refrigerant low-side pressure should rise, place

TXV bulb in ice water, refrigerant low-side pressure should drop. A 10 to 15 pound pressure swing between warm and cold conditions indicate a good TXV. If a 10 to 15 pound swing is not present, replace TXV.

g)Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with FS removed but would previously not switch out of freeze with FS connected (long freeze - 3 beep alarm), see "II.F. Float Switch Check and Cleaning."

Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions. Cycle times and pressures should follow performance data provided in this manual. See "VIII.A. Specification and Performance Data Sheets."

h)Short Freeze Cycle Diagnosis: Confirm water tank fills and overflows during 1 min. fill and harvest cycles. If not, check water supply filters, shut-off valve, WV screen.

If water tank empties before 5 min. timer terminates and freeze cycle is short, check that DV is not leaking by or energized (water flowing through DV). If DV is leaking by, remove and clean DV, replace as needed. If water tank is full, see "II.F. Float Switch

Check and Cleaning." for erratic operating FS.

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7)Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the first pump-out is determined by S4 dip switch 5. See the table below.

Control Board Settings

	S4 Dip Switch Setting	Pump-Out Frequency	Control Board
	No. 5
	OFF	Every 10 cycles	After 11th freeze cycle
	ON	Every cycle	After 2nd freeze cycle

Comp and FMRs continue, HGVs energize.

Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV and X11 relay energize, energizing X10 relay. NOTICE! S4 dip switch 3 & 4 must not be set to 3 off and 4 on. Otherwise, LED 4 turns on energizing WV and X11 relay. X11 relay energizes X10 relay. Once X10 relay energizes, X12 relay cannot energize. Preventing DV from energizing.

LLVs de energize. PM stops for 2 sec., then restarts for 10/20 sec. depending on pump out timer (S4 dip switch 3 & 4) setting. When the pump out timer terminates, pump out is complete. The pump-out frequency control (S4 dip switch 5) is factory set, and generally no adjustment is required. However, the pump out frequency control can be set to have a pump-out occur every 10 cycles or every cycle. For details, see "III.C.4. Pump Out Frequency Control (S4 dip switch 5)."

a)Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect CB black K5 connector (FS connector). Check that CB LEDs 1, 3, and 2 are on, PM stops, then restarts, DV energizes, and water is flowing down the drain through DV.

b)CB Diagnosis: Confirm LLVs de-energize. If LLVs are energized with LEDs 1, 3, and 2 on, replace CB. If PM does not stop and restart and DV does not energize, check that CB LEDs 1, 3, and 2 are on. If not, replace CB. If LEDs 1, 3, and 2 are on and X12 relay is not energized, check for 115VAC at CB K1 #5 (DBU) to neutral (W).

If 115VAC is not present, replace CB. If 115VAC is present at CB K1 #5 (DBU) and X12 relay is not energized, continue to "c) X12 Relay Diagnosis:" below. If X12 relay is energized and DV are not energized, check for 115VAC at CB K1 #2 (P) to neutral (W). If LED 2 is on and 115VAC is not present at CB K1 #2 (P), replace CB.

c)X12 Relay Diagnosis: If 115VAC is present at CB K1 #5 (DBU) and CB K1 #2 (P) and X12 relay and DV are not energized, check for 115VAC at X12 relay #8 (P) to neutral (W). If 115VAC is not present, check wiring connections from CB K1 #5 (DBU) to X12 relay #6 (DBU), then at X12 relay #4 (W/R). If 115VAC is present at X12 relay #6 (DBU) and not at X12 relay #4 (W/R), confirm X12 relay is de-energized, if X12 relay is de-energized, replace X12 relay (sticking contacts). If 115VAC is present

at X12 relay #5 (DBU) to neutral (W), and X12 is de energized, check relay coil continuity. Replace as needed.

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