Hoshizaki America KM-1600MRH Service Manual

NO.: ISSUED:

73121

SEP. 15, 2004

HOSHIZAKI

MODULAR CRESCENT CUBER

MODEL

KM-1600MRH KM-1600MRH3

SERVICE MANUAL

IMPORTANT

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

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

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

HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City, GA 30269

Attn: HOSHIZAKI Technical Support Department

Phone: 1-800-233-1940 Technical Service

(770) 487-2331

Fax: (770) 487-3360

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

following information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem

Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should service and maintain the icemaker. This manual should be made available to the technician prior to service or maintenance.

CONTENTS

I. Specifications .................................................................................................................... 5

1. Icemaker ....................................................................................................................... 5

KM-1600MRH ............................................................................................................ 5

KM-1600MRH3 .......................................................................................................... 6

2. Condensing Unit........................................................................................................... 7

URC-20F.................................................................................................................... 7

II. General Information .......................................................................................................... 9

1. Construction .................................................................................................................9

KM-1600MRH, KM-1600MRH3.................................................................................. 9

2. Controller Board ......................................................................................................... 10

[a] Solid-State Control .............................................................................................. 10

[b] Controller Board .................................................................................................. 10

[c] Sequence ............................................................................................................ 14

[d] Controls and Adjustments ................................................................................... 17

[e] Checking the Controller Board ............................................................................ 20

III. Technical Information ..................................................................................................... 22

1. Water Circuit and Refrigerant Circuit........................................................................... 22

KM-1600MRH, KM-1600MRH3................................................................................ 22

2. Wiring Diagrams ......................................................................................................... 23

[a] KM-1600MRH...................................................................................................... 23

[b] KM-1600MRH3 ................................................................................................... 24

3. Timing Chart ............................................................................................................... 25

4. Performance Data ....................................................................................................... 27

[a] KM-1600MRH...................................................................................................... 27

[b] KM-1600MRH3 ................................................................................................... 28

IV. Service Diagnosis .......................................................................................................... 29

1. No Ice Production ....................................................................................................... 29

2. Evaporator is Frozen Up ............................................................................................. 32

3. Low Ice Production ..................................................................................................... 34

4. Abnormal Ice .............................................................................................................. 34

5. Other ........................................................................................................................... 34

V. Removal and Replacement of Components ................................................................... 35

1. Service for Refrigerant Lines ...................................................................................... 35

[a] Refrigerant Recovery........................................................................................... 35

[b] Evacuation and Recharge [R-404A] .................................................................... 35

2. Brazing ....................................................................................................................... 36

3. Removal and Replacement of Compressor ................................................................ 37

4. Removal and Replacement of Drier ........................................................................... 38

5. Removal and Replacement of Expansion Valve......................................................... 39

6. Removal and Replacement of Hot Gas Valve and Line Valve .................................... 40

7. Removal and Replacement of Evaporator .................................................................. 41

8. Removal and Replacement of Condensing Pressure Regulator (C.P.R.) ................... 42

9. Removal and Replacement of Thermistor .................................................................. 43

10. Removal and Replacement of Fan Motor ................................................................. 44

11. Removal and Replacement of Water Valve............................................................... 45

12. Removal and Replacement of Pump Motor .............................................................. 45

13. Removal and Replacement of Spray Tubes.............................................................. 46

VI. Cleaning and Maintenance Instructions ........................................................................ 47

1. Preparing the Icemaker for Long Storage ................................................................... 47

2. Cleaning and Sanitizing Procedures .......................................................................... 49

[a] Cleaning Procedure ............................................................................................ 50

[b] Sanitizing Procedure - Following Cleaning Procedure ....................................... 52

3. Maintenance ............................................................................................................... 53

I. Specifications

1. Icemaker

KM-1600MRH

AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 18 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *1486 (674) 1444 (655) 1347 (611) Reference without *marks 80 1454 (660) 1389 (630) 1270 (576)

90 1444 (655) *1343 (609) 1231 (558)

100 1411 (640) 1317 (597) *1128 (512) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 28.6 lbs. (13 kg ) 1440 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 3190 (5.7) 2800 (4.5) WATER gal./24HR (gal./100 lbs.) 403 (30.0) 643 (43.3) EXTERIOR DIMENSIONS (WxDxH) 30" x 27-3/8" x 41-1/2" (762 x 695 x 1055 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 295 lbs. ( 134 kg ), Shipping 352 lbs . ( 160 kg ) CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" ID Pipe CUBE CONTROL SYSTEM Float S wit ch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WA TER CONTROL N/A BIN CONTROL SYSTEM Thermos tat COMP RESSOR Hermetic, Model CS20K6E-PFV CONDENSER Air-cooled Remote, Condeser Unit URC-20F EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-20F REFRIGERANT CHARGE R-404A, 14 lbs. 12 oz. ( 6700 g )

( Icemaker 7 lbs. 1 oz. Cond. Unit 7 lb. 11 oz. ) DESIGN PRESSURE High 467 PSIG, Low 230 PSIG P. C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Int ernal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERA NT CIRCUIT PROTECTION Auto-reset High Pres sure Control S witch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin, Remote Condenser Unit OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

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

KM-1600MRH3

AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 11 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *1524 (691) 1474 (669) 1392 (632) Reference without *marks 80 1486 (674) 1409 (639) 1319 (598)

90 1474 (669) *1354 (614) 1266 (574)

100 1453 (659) 1333 (605) *1185 (538) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 28.6 lbs. (13 kg ) 1440 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 2990 (5.3) 2850 (4.5) WATER gal./24HR (gal./100 lbs.) 416 (30.7) 635 (41.7) EXTERIOR DIMENSIONS (WxDxH) 30" x 27-3/8" x 41-1/2" (762 x 695 x 1055 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 295 lbs. ( 134 kg ), Shipping 352 lbs. ( 160 kg ) CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" ID Pipe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WA TER CONTROL N/A BIN CONTROL SYSTEM Thermos tat COMPRESSOR Hermetic, Model CS20K6E-TF5 CONDENSER Air-cooled Remote, Condenser Unit URC 20F EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-20F REFRIGERANT CHARGE R-404A, 14 lbs. 12 oz. ( 6700 g )

( Icemaker 7 lbs. 1 oz. Cond. Unit 7 lb. 11 oz. ) DESIGN PRESSURE High 467 PSIG, Low 230 PSIG P. C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin, Remote Condenser Unit OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

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

2. Condensing Unit

URC-20F

MODEL: URC-20F

SPECIFICATIONS

EXTERIOR

DIMENSIONS (W x D x H)

REFRIGERANT CHARGE

URC-20F

WEIGHT

CONNECTIONS

REFRIGERANT ELECTRICAL

CONDENSER

HEAD PRESSURE CONTROL

AMBIENT CONDITION

Galvanized Steel

46 - 3/8" x 15 - 11/16" x 25 - 15/16" (1178 x 398 x 659 mm)

R-404A 7 lbs.11 oz. (3500 g)

Net 104 lbs. (47 kg) Shipping 115 lbs. (52 kg)

One Shot Couplings (Aeroquip) Permanent Connection

Air-cooled

Condensing Pressure Regulator

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

II. General Information

1. Construction

KM-1600MRH, KM-1600MRH3

Evaporator

Cleaning Valve

Control Box

Control Switch

Bin Control Thermostat

Spray Tube

Water Valve

Water Supply Inlet

Hot Gas Valve

Junction Box

Check Valve

Expansion Valve

Line Valve

Receiver Tank

Float Switch

Water Pump

Compressor

Capacitor Box (KM-1600MRH) Transformer Box (KM-1600MRH3)

Drier

2. Controller Board

[a] Solid-State Control

1) A HOSHIZAKI exclusive solid-state control is employed in KM-1600MRH and KM1600MRH3 Modular Crescent Cubers.

2) A printed circuit board (hereafter called “controller board”) includes a stable and high quality control system.

3) All models are pretested and factory-adjusted.

[b] Controller Board

CAUTION

1. Fragile, handle very carefully.

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

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

4. Do not change wiring and connections. Do not misconnect K3, K4 and K5, because the same connector is used for the thermistor and float switch. K4 is not connected.

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

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

PART NUMBER TYPE

2A1410-01 HOS-001A (Control Products - 10 Pin)

Features of Control Products “E” Controller Board

1) Maximum Water Supply Period - 6 minutes

Water solenoid valve opening, in the defrost (harvest) cycle, is limited by the defrost timer. The water valve cannot remain open longer than the maximum period. The water valve can close in less than six minutes if the defrost cycle is completed.

2) Defrost Timer

The defrost cycle starts when the float switch opens and completes the freeze cycle. But the defrost timer does not start counting until the thermistor senses 48°F at the evaporator outlet. The period from the end of the freeze cycle up to the point of the thermistor's sensing varies depending on the ambient and water temperatures.

3) High Temperature Safety - 127 ± 7°F

The temperature of the suction line in the refrigerant circuit is limited by the high temperature safety. During the defrost cycle the evaporator temperature rises. The thermistor senses 48°F and starts the defrost timer. After the defrost timer counts down to zero, the normal freeze cycle begins. If the evaporator temperature continues to rise, the thermistor will sense the rise in temperature and at 127 ± 7°F the thermistor operates the high temperature safety. This high temperature safety shuts down the circuit and the icemaker automatically stops. To reset the safety, turn the power off and back on again. This high temperature safety protects the unit from excessive temperature. The control board will beep every 3 seconds. The white Reset button on the control board must be pressed with power on to reset the safety.

4) Low Water Safety

If the pump motor is operated without water, the mechanical seal can fail. To prevent this type of failure, the controller board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each defrost cycle. If the float switch is in the up position (electrical circuit closed), the controller board changes to the ice making cycle. If the float switch is in the down position (electrical circuit open), the controller board changes to a one minute water fill cycle before starting the ice making cycle. This method allows for a low water safety shut down to protect the water pump from mechanical seal failure. For water-cooled model, if the water is shut off, the unit is protected by the high pressure switch.

5) High Voltage Cut-out The maximum allowable supply voltage of this icemaker is limited by the high voltage cut-out. If miswiring (especially on single phase 3 wire models) causes excessive voltage on the controller board, the high voltage cut-out shuts down the circuit in 3 seconds and the icemaker automatically stops. When the proper supply voltage is resumed, the icemaker automatically starts running again. The control board will signal this problem using 7 beeps every 3 seconds.

6) LED Lights and Audible Alarm Safeties

The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned ON or OFF.

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

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

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

{LED 1 – Comp; LED 2 - HGV/CFM; LED 3 – PM; LED 4 - WV}

The built in safeties shut down the unit and have alarms as follows:

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

ter, or shorted thermistor.

2 beeps every 3 sec. = Defrost Back Up Timer. Defrost >20 minutes. Orange LED marked 20 MIN energizes. Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient compressor.

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

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

6 beeps every 3 sec. = Low Voltage. Voltage is 92 Vac or less.

7 beeps every 3 sec. = High Voltage. Control voltage > 147Vac ±5%.

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

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

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

The dip switches should be adjusted per the adjustment chart published in the Tech Specs book. 7 & 8 must remain in the OFF position.

(Control Products HOS-001A Board)

[c] Sequence

1st Cycle

2nd Cycle and after with pump drain

2nd Cycle and after with no pump drain

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