Hoshizaki American, Inc. KM-201BAH, KM-260BAH, KM-201BWH, KM-260BWH Service Manual

NO. F015-774

ISSUED: MAR. 18, 2009

REVISED: OCT. 16, 2009

HOSHIZAKI

SELF-CONTAINED

CRESCENT CUBER

MODEL

KM-201BAH

KM-260BAH KM-201BWH KM-260BWH

SERVICE MANUAL

IMPORTANT

Only qualified service technicians should install, service or maintain the product. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the equipment in accordance with this manual may adversely affect safety, performance, and warranty coverage.

Hoshizaki provides this manual primarily to assist qualiﬁed service technicians in the maintenance and service of the product.

Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, write, or send an e-mail message 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 Support (770) 487-2331 Fax: 1-800-843-1056 (770) 487-3360 E-mail: techsupport@hoshizaki.com

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.

IMPORTANT

This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualiﬁed service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety. Please retain this booklet for any further reference that may be necessary.

CONTENTS

I. SPECIFICATIONS -------------------------------------------------------------------------------------1

1. SPECIFICATIONS ----------------------------------------------------------------------------------1 [a] KM-201BAH -------------------------------------------------------------------------------------1 [b] KM-260BAH -------------------------------------------------------------------------------------2 [c] KM-201BWH -------------------------------------------------------------------------------------3 [d] KM-260BWH ------------------------------------------------------------------------------------4

II. GENERAL INFORMATION -------------------------------------------------------------------------5

1. CONSTRUCTION ----------------------------------------------------------------------------------5 [a] KM-201BAH, KM-260BAH -------------------------------------------------------------------5 [b] KM-201BWH ------------------------------------------------------------------------------------6 [c] KM-260BWH -------------------------------------------------------------------------------------7 [d] ICEMAKING COMPARTMENT -------------------------------------------------------------8

2. SEQUENCE OF OPERATION ------------------------------------------------------------------9 [a] ONE MINUTE FILL CYCLE ------------------------------------------------------------------9 [b] INITIAL HARVEST CYCLE ------------------------------------------------------------------9 [c] FREEZE CYCLE -------------------------------------------------------------------------------9 [d] PUMP-OUT CYCLE ---------------------------------------------------------------------------9 [e] NORMAL HARVEST CYCLE ------------------------------------------------------------- 10 [f] SHUTDOWN ---------------------------------------------------------------------------------- 10

3. CONTROL BOARD ------------------------------------------------------------------------------ 12 [a] CONTROL BOARD LAYOUT ------------------------------------------------------------- 13 [b] FEATURES ------------------------------------------------------------------------------------ 14 [c] CONTROLS AND ADJUSTMENTS ------------------------------------------------------ 16 [d] CONTROL BOARD CHECK PROCEDURE------------------------------------------- 19 [e] CONTROL BOARD REPLACEMENT --------------------------------------------------- 19

4. THERMISTOR ------------------------------------------------------------------------------------- 19

5. BIN CONTROL ------------------------------------------------------------------------------------ 20 [a] EXPLANATION OF OPERATION -------------------------------------------------------- 20 [b] BIN CONTROL CHECK PROCEDURE ------------------------------------------------ 21

6. SWITCHES ---------------------------------------------------------------------------------------- 21 [a] CONTROL SWITCH ------------------------------------------------------------------------- 21 [b] SERVICE SWITCH -------------------------------------------------------------------------- 21

PAGE

III. TECHNICAL INFORMATION -------------------------------------------------------------------- 23

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT --------------------------------------- 23

[a] KM-201BAH, KM-260BAH ----------------------------------------------------------------- 23 [b] KM-201BWH, KM-260BWH --------------------------------------------------------------- 24

2. WIRING DIAGRAM ------------------------------------------------------------------------------ 25

3. TIMING CHART ----------------------------------------------------------------------------------- 26

[a] KM-201BAH, KM-260BAH ----------------------------------------------------------------- 26 [b] KM-201BWH, KM-260BWH --------------------------------------------------------------- 27

4. PERFORMANCE DATA ------------------------------------------------------------------------- 28

[a] KM-201BAH ----------------------------------------------------------------------------------- 28 [b] KM-260BAH ----------------------------------------------------------------------------------- 29 [c] KM-201BWH ----------------------------------------------------------------------------------- 30 [d] KM-260BWH ---------------------------------------------------------------------------------- 31

IV. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 32

1. DIAGNOSTIC PROCEDURE ------------------------------------------------------------------ 32

2. NO ICE PRODUCTION ------------------------------------------------------------------------- 34

3. EVAPORATOR IS FROZEN UP -------------------------------------------------------------- 37

4. LOW ICE PRODUCTION ----------------------------------------------------------------------- 38

5. ABNORMAL ICE ---------------------------------------------------------------------------------- 38

6. OTHER ---------------------------------------------------------------------------------------------- 39

V. REMOVAL AND REPLACEMENT -------------------------------------------------------------- 40

1. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 40

[a] SERVICE INFORMATION ----------------------------------------------------------------- 40 [b] REFRIGERANT RECOVERY ------------------------------------------------------------- 41 [c] EVACUATION AND RECHARGE (R-404A) ------------------------------------------- 41

2. BRAZING ------------------------------------------------------------------------------------------- 42

3. COMPRESSOR ----------------------------------------------------------------------------------- 43

4. DRIER ----------------------------------------------------------------------------------------------- 44

5. HOT GAS VALVE --------------------------------------------------------------------------------- 45

6. EXPANSION VALVE ----------------------------------------------------------------------------- 47

7. AIR-COOLED CONDENSER ------------------------------------------------------------------ 48

8. WATER-COOLED CONDENSER ------------------------------------------------------------ 49

9. FAN MOTOR (AIR-COOLED MODEL)------------------------------------------------------ 50

10. WATER REGULATING VALVE (WATER-COOLED MODEL) ------------------------- 51

11. ADJUSTMENT OF WATER REGULATING VALVE (WATER-COOLED MODEL) ------------------------------------------------------------------- 53

12. PUMP MOTOR------------------------------------------------------------------------------------ 54

13. WATER VALVE------------------------------------------------------------------------------------ 55

14. DRAIN VALVE, CLEANING VALVE ---------------------------------------------------------- 56

15. FLOAT SWITCH ---------------------------------------------------------------------------------- 57

16. BIN CONTROL SWITCH ----------------------------------------------------------------------- 58

17. THERMISTOR ------------------------------------------------------------------------------------ 59

18. CONTROL BOX ---------------------------------------------------------------------------------- 60 [a] POWER SWITCH ---------------------------------------------------------------------------- 61 [b] FUSE -------------------------------------------------------------------------------------------- 61 [c] FUSE HOLDER ------------------------------------------------------------------------------- 61 [d] CONTROL BOARD -------------------------------------------------------------------------- 61

[e] POWER RELAY ------------------------------------------------------------------------------ 61 [f] CONTROL BOARD TRANSFORMER -------------------------------------------------- 62

19. WATER TANK ------------------------------------------------------------------------------------- 62

20. CUBE GUIDE ------------------------------------------------------------------------------------- 63

21. SEPARATOR -------------------------------------------------------------------------------------- 63

22. SPRAY TUBE, WATER SUPPLY PIPE, SPRAY GUIDE ------------------------------- 65

23. DOOR ----------------------------------------------------------------------------------------------- 66

VI. CLEANING AND MAINTENANCE INSTRUCTIONS -------------------------------------- 67

1. CLEANING ----------------------------------------------------------------------------------------- 67 [a] CLEANING PROCEDURE ----------------------------------------------------------------- 67 [b] SANITIZING PROCEDURE --------------------------------------------------------------- 68

2. MAINTENANCE ---------------------------------------------------------------------------------- 69 [a] EXTERIOR PANELS ------------------------------------------------------------------------ 69 [b] STORAGE BIN AND SCOOP ------------------------------------------------------------- 69 [c] AIR FILTER (AIR-COOLED MODEL) --------------------------------------------------- 70 [d] CONDENSER (AIR-COOLED MODEL) ------------------------------------------------ 70

3. PREPARING THE ICEMAKER FOR LONG STORAGE -------------------------------- 70

iii

I. SPECIFICATIONS

1. SPECIFICATIONS

[a] KM-201BAH

AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 6.1 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *201 (91) 190 (86) 176 (80) Reference without *marks 80 193 (88) 177 (80) 162 (73)

90 190 (86) *165 (75) 150 (68)

100 187 (85) 161 (73) *136 (62) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 4.0lbs. (1.82 kg) 182pcs. APPROXIMATE STORAGE CAPACITY 80 lbs(36Kg). ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 510(7.5) 490(5.8) WATER gal./24HR (gal./100 lbs.) 36(22.0) 72(35.6) CEC/CEE TIER LEVEL 3 ENERGY STAR Yes EXTERIOR DIMENSIONS (WxDxH) 24" x 28" x 39" (612 x 712 x 990 mm)

Including 6" legs EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 137 lbs. (62 kg), Shipping 165 lbs. (75 kg) CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic, Model NF7CLX CONDENSER Air-Cooled, Fin and tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 12 oz. (340g) DESIGN PRESSURE High 467PSIG, Low 230PSIG 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 Ice Scoop, 6" leg 4 pcs OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 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.

[b] KM-260BAH

AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.6 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *263 (119) 247 (112) 227 (103) Reference without *marks 80 251 (114) 226 (102) 207 (94)

90 247 (112) *208 (94) 189 (86)

100 244 (111) 203 (92) *171 (78) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 5.0.lbs. (2.26kg) 238 pcs. APPROXIMATE STORAGE CAPACITY 100 lbs(45Kg). ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 620(7.1) 590(5.4) WATER gal./24HR (gal./100 lbs.) 42(20.1) 78(29.7) CEC/CEE TIER LEVEL 3 ENERGY STAR Yes EXTERIOR DIMENSIONS (WxDxH) 30" x 28" x 39" (762 x 712 x 990 mm)

Including 6" legs EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 154 lbs. (70 kg), Shipping 187 lbs. (85 kg) CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic, Model SC10CL CONDENSER Air-Cooled, Fin and tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A 12.7oz (360g) DESIGN PRESSURE High 467PSIG, Low 230PSIG 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 Ice Scoop, 6" leg 4 pcs OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 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.

[c] KM-201BWH

AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 5.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *215 (98) 207 (94) 192 (87) Reference without *marks 80 209 (95) 195 (89) 180 (82)

90 207 (94) *186 (84) 171 (78)

100 203 (92) 182 (83) *157 (71) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 4.0lbs. (1.82 kg) 182pcs. APPROXIMATE STORAGE CAPACITY 80 lbs(36Kg). ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 460(5.93) 460(5.08) WATER gal./24HR (gal./100 lbs.) 45(24.0) 55(25.6) COND.WATER gal./24HR (gal./100 lbs) 226(141.3) 119(55.6) CEC/CEE TIER LEVEL 3 EXTERIOR DIMENSIONS (WxDxH) 24" x 28" x 39" (612 x 712 x 990 mm)

Including 6" legs EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 137 lbs. (62 kg), Shipping 165 lbs. (75 kg) CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT CONDENSER WATER Inlet 1/2" FPT

Outlet 1/2" FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic, Model NF7CLX CONDENSER Water-Cooled, Tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 11 oz. (310g) DESIGN PRESSURE High 467PSIG, Low 230PSIG 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 Ice Scoop, 6" leg 4 pcs OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 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.

[d] KM-260BWH

AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *268 (122) 259 (117) 242 (110) Reference without *marks 80 261 (118) 247 (112) 228 (103)

90 259 (117) *237 (108) 218 (99)

100 254 (115) 233 (106) *201 (91) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 5.0.lbs. (2.26kg) 238 pcs. APPROXIMATE STORAGE CAPACITY 100 lbs(45Kg). ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 630(6.37) 620(5.59) WATER gal./24HR (gal./100 lbs.) 62(26.3) 77(28.7) COND.WATER gal./24HR (gal./100 lbs) 285(120.6) 151(56.2) CEC/CEE TIER LEVEL 3 EXTERIOR DIMENSIONS (WxDxH) 30" x 28" x 39" (762 x 712 x 990 mm)

Including 6" legs EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 154 lbs. (70 kg), Shipping 187 lbs. (85 kg) CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT CONDENSER WATER Inlet 1/2" FPT

Outlet 1/2" FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Mechanical Level Switch with Delay COMPRESSOR Hermetic, Model SC10CL CONDENSER Water-Cooled, Tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A 13.8oz (390g) DESIGN PRESSURE High 467PSIG, Low 230PSIG 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 Ice Scoop, 6" leg 4 pcs OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 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.

II. GENERAL INFORMATION

1. CONSTRUCTION

[a] KM-201BAH, KM-260BAH

Top Panel

Side Panel (L)

Front Cover Rear Panel Door

Air Filter

Louver

Leg

Side Panel (R) Power Supply Cord

Top Cover Hot Gas Valve Thermistor Drain Valve Evaporator Condenser Fan Motor Cleaning Valve Separator Compressor

Water Tank Water Valve

Expansion Float Switch Valve Overﬂow Pipe Drier Pump Motor

Control Switch Service Switch

Control Box

Front View Rear View

Bin Control Switch

With Tank Removed

[b] KM-201BWH

Top Panel

Side Panel (L) Front Cover Rear Panel

Door

Side Panel (R)

Louver Power Supply Cord

Leg

Top Cover Drain Valve Hot Gas Valve

Cleaning Valve Thermistor

Water Regulator Evaporator Condenser

Separator Compressor

Water Tank Water Valve

Expansion Valve Float Switch

Overﬂow Pipe

Drier

Control Switch Service Switch Control Box



Front View Rear View

Bin Control Switch

With Tank Removed

[c] KM-260BWH

Top Panel

Front Cover

Side Panel (L) Rear Panel

Door

Side Panel (R)

Louver Power Supply Cord

Leg

Top Cover Drain Valve Hot Gas Valve Thermistor

Cleaning Valve Water Regulator Evaporator Condenser Separator

Water Tank Compressor Expansion Valve Water Valve

Overﬂow Pipe Drier

Control Switch Float Switch Service Switch Control Box

Front View Rear View

Bin Control Switch

With Tank Removed

[d] ICEMAKING COMPARTMENT

Spray Tube

Evaporator

Water Supply Pipe

Separator

Cube Guide

Water Tank

Overﬂow Pipe

Drain Valve

Cleaning Valve Separator

Water Valve

Pump Motor

Float Switch

2. SEQUENCE OF OPERATION

The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 9, 4, 7.

[a] ONE MINUTE FILL CYCLE

LED 8 is on. WV opens and the ﬁll period begins. After 1 minute, the board checks for a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV will remain energized through additional 1 minute cycles until water enters the sump and F/S closes. This serves as a low water safety to protect the pump motor.

[b] INITIAL HARVEST CYCLE

LEDs 5, 6, and 8 are on. WV remains open, Comp energizes, HGV opens, and harvest begins. As the evaporator warms, the thermistor located on the suction line checks for a 48°F (9°C) temperature. When 48°F (9°C) is reached, a 3.9 kΩ signal turns the harvest over to the adjustable harvest timer which is factory set for normal conditions. The timer has settings of 60, 90, 120, and 180 seconds (S1 dip switch 1 & 2). When the harvest timer completes its count down, the harvest cycle is complete and the freeze cycle starts. The minimum total time allowed by the board for a complete harvest cycle is 2 minutes. WV is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter. LED 8 goes off when WV closes. PM energizes and runs for the last 0, 10, 30, or 50 seconds of harvest depending on S1 dip switch 7 & 8 setting. LED 7 comes on when PM energizes. At the end of harvest, the control board checks the position of F/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute ﬁll if it is open.

[c] FREEZE CYCLE

LEDs 5 & 7 are on. Comp continues to run, PM and FMS energize, HGV closes and the freeze cycle starts. For the ﬁrst 5 minutes after the thermistor temperature reaches 36° F (2°C), the control board will not accept a signal from F/S. This minimum freeze period acts as a short cycle protection. At the end of this period, F/S assumes control. As the evaporator cools, the thermistor located on the suction line checks for a 50°F (10°C) temperature. When 50°F (10°C) is reached, the pump motor stops for 10 seconds. Then, the pump motor repeats a 50 second ON and 10 second OFF cycle. After the thermistor reaches 34°F (1°C), the pump motor stops for 10 seconds, runs for 50 seconds, stops again for 10 seconds, and runs until the end of freeze cycle. This is to prevent slushing (water-cooled model only). As ice builds on the evaporator the water level in the sump lowers. The freeze continues until F/S opens and terminates ice production.

[d] PUMP-OUT CYCLE

LEDs 4, 5, 6, and 7 are on. Comp continues to run, HGV opens, FMS de-energizes, and PM energizes. DV opens for 10 seconds to drain out the water tank. Pump-out cycle

always occurs on the 2nd harvest after startup. Then, depending on the control board setting, pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle (S1 dip switch 5 & 6).

[e] NORMAL HARVEST CYCLE

LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer. WV is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter. LED 8 goes off when WV closes. PM energizes and runs for the last 0, 10, 30, or 50 seconds of harvest depending on S1 dip switch 7 & 8 setting. LED 7 comes on when PM energizes. At the end of harvest, the control board checks the position of F/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute ﬁll if it is open. The unit continues to cycle through [c], [d], and [e] sequence until the bin control is activated and shuts the unit down. When the bin control is activated, the “POWER OK” LED ﬂashes.

[f] SHUTDOWN

When BC is activated (BC open), the “POWER OK” LED flashes. There is a delay before the shutdown sequence begins. The delay varies depending on the cycle the icemaker is in at the time of activation. For details, see the table below.

Cycle at Bin Control Activation Delay Before Shutdown Sequence Begins

Fill Cycle 15 seconds Harvest Cycle 15 seconds after the next freeze cycle starts Freeze Cycle 15 seconds if BC is activated between the beginning of

freeze and termination of the 5-minute short cycle protection timer (timer starts when the thermistor temperature drops to 36°F (2°C) (5.5 kΩ or more)). After this time, the unit will not shut down until the next harvest cycle is complete.

After the delay, all components de-energize. DV energizes after 2 seconds. PM energizes after 2 seconds. PM takes water from the tank and forces it through DV and down the drain. The water tank drains for a maximum of 5 minutes or until F/S opens. DV and PM (if applicable) then de-energize. When BC closes again calling for ice, the unit starts at the 1-minute ﬁll cycle. There is a 90-second minimum off time before the icemaker can restart.

Legend: BC–bin control; Comp–compressor; DV–drain valve; FMS–self-contained fan

motor; F/S–ﬂoat switch; HGV–hot gas valve; PM–pump motor; WV–inlet water valve

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

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

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

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

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 machine

is in service mode. The service switch has three positions: “DRAIN”, “CIRCULATE”, and “WASH”. See the

information below for details of each function.

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

3. CONTROL BOARD

* A HOSHIZAKI exclusive solid-state control is employed in crescent cubers.

* All models are pretested and factory-adjusted.

CAUTION

1. Fragile, handle very carefully.

2. A 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 unit before 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.

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

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

[a] CONTROL BOARD LAYOUT

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"H" Control Board

Part Number P00013-02

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[b] FEATURES

a) Maximum Water Supply Period - 6 minutes

The inlet water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter.

b) Harvest Backup Timer and Freeze Timer

The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete. The control board will signal this problem using 2 beeps every 3 seconds. The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle takes longer than the time specified to complete. The control board will signal this problem using 3 beeps every 3 seconds. The time is factory set using S1 dip switch 9 &

10. The alarm reset button on the control board must be pressed with power on to reset either of these safeties.

c) High Temperature Safety

The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety. This protects the unit from excessively high temperatures. If the evaporator temperature rises above 127°F (53°C) ± 7°F (4°C), the thermistor operates the safety. This shuts down the circuit and the icemaker automatically stops. The control board will signal this problem using 1 beep every 3 seconds. The alarm reset button on the control board must be pressed with power on to reset the safety.

d) Low Water Safety

The control 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 harvest cycle. If the float switch is in the up position (electrical circuit closed), the control board changes to the next cycle. If the ﬂoat switch is in the down position (electrical circuit open), the control board changes to additional one minute water ﬁll cycles until water enters the sump and the ﬂoat switch closes. When the ﬂoat switch closes, the control board changes to the next cycle. The unit will not start without adequate water in the sump. This serves as a low water safety to protect the water pump. For water-cooled model, if the condenser water supply is shut off, the unit is protected by the high-pressure switch.

e) High Voltage and Low Voltage Cut-outs

The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut-outs. If miswiring (especially on single phase 3 wire models) causes excessive voltage (147Vac ± 5% or more) on the control board, the high voltage cut-out shuts down the circuit in 3

seconds and the icemaker automatically stops. The control board will signal this problem using 7 beeps every 3 seconds. The icemaker also automatically stops in cases of insufﬁcient voltage (92Vac ± 5% or less). The control board will signal this problem using 6 beeps every 3 seconds. When the proper supply voltage is resumed, the icemaker automatically starts running again.

f) LED Lights and Audible Alarm Safeties

The control board includes LED indicator lights, audible alarm safeties, and an output test feature. The “POWER OK” LED indicates control voltage and will remain on unless a control voltage problem occurs. The “POWER OK” LED ﬂashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank. At startup, a 5 second delay occurs to stabilize the circuit. LEDs 4 through 8 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 board is 5, 6, 8, 9, 4, 7. For more information, see “2. SEQUENCE OF OPERATION”.

Sequence Step LED

1 Minute Fill Cycle

Harvest Cycle 5, 6, 8

Last 0, 10, 30, or 50 seconds (adjustable by dip switch) of harvest, WV de-energizes and PM energizes (LEDs 5, 6, and 7 are on)

Freeze Cycle 5, 7

Pump-Out Cycle 5, 6, 4, 7

8 WV 60 seconds

Energized

Components

WV, HGV, Comp

Comp, PM, FMS Comp, HGV, DV, PM

Min. Max. Avg.

2 minutes 20 minutes 3 to 5 minutes

5 minutes

10 seconds 20 seconds

Time LEDs are On

freeze timer setting

25 to 30 minutes

factory default setting

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

No. of Beeps

(every 3 sec.)

High Evaporator Temp. (temperature > 127

Type of Alarm Notes

Check for harvest problem (stuck HGV or

°F (53°C))

relay), hot water entering unit, stuck HM, or shorted thermistor.

Harvest Backup Timer

(harvest > 20 min. for two cycles in a row) Freeze Timer (freeze > speciﬁed setting for

two cycles in a row) Timer is factory set using S1

Check for open thermistor, HGV not opening, TXV leaking by, low charge, inefﬁcient Comp, or WRV leaking by. Check for a ﬂoat switch stuck closed (up), WV leaking by, HGV leaking by, PM not pumping, TXV not feeding properly, low charge, or inefﬁcient Comp.

dip switch 9 & 10

To reset the above safeties, press the

“ALARM RESET” button with the power supply

on.

Legend:

Low Voltage (92Vac

± 5% or less) High Voltage (147Vac

± 5% or more)

Comp–compressor; DV–drain valve; FMS–self-contained fan motor; HGV–hot

“

POWER OK” LED will turn off if voltage protection operates. The control voltage safeties automaticlly reset when voltage is corrected.

gas valve; PM–pump motor; TXV–thermostatic expansion valve; WRV–water regulating valve; WV–inlet water valve

[c] CONTROLS AND ADJUSTMENTS

CAUTION

Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage.

a) Default Dip Switch Settings

The dip switch is factory-adjusted to the following positions:

S1 Dip Switch No. 1 2 3 4 5 6 7 8 9 10

KM-201BAH

KM-260BAH KM-201BWH KM-260BWH

OFF OFF OFF OFF ON ON OFF ON ON OFF OFF OFF OFF OFF ON ON ON OFF ON OFF OFF OFF OFF OFF ON ON OFF ON ON OFF

ON OFF OFF OFF ON ON ON OFF OFF ON

S2 Dip Switch No. 1 2 3 4 5 6

KM-201BAH

KM-260BAH KM-201BWH KM-260BWH

ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON ON OFF OFF OFF ON OFF ON OFF OFF OFF ON OFF

Note: S2 dip switch is NOT adjustable.

S1 Dip Switch S2 Dip Switch

Freeze Timer (9 & 10)

Water Saver Timer (7 & 8)

Pump-Out Frequency Control (5 & 6)

Pump-Out Timer (3 & 4)

Harvest Timer (1 & 2)

Anti-Slush Control (5 & 6)

Reﬁll Counter (3 & 4)

Float Switch Selector (2)

Pump-Out/Drain Selector (1)

Fig. 1 Fig. 2

b) Harvest Timer (S1 dip switch 1 & 2)

Used for adjustment of the harvest timer. The harvest timer starts counting when the thermistor reads a certain temperature at the evaporator outlet.

Dip Switch Setting No. 1 No. 2

OFF OFF 60

ON OFF 90

OFF ON 120

ON ON 180

c) Pump-Out Timer (S1 dip switch 3 & 4)

Once every ten freeze cycles, the drain valve opens to drain the water tank for the time determined by the pump-out timer. These switches also determine the time to delay completion of a defrost cycle, i.e. the minimum defrost time. Do not change this setting, or the unit will not operate properly or produce high quality ice.

Dip Switch Setting Time (seconds) No. 3 No. 4 T1 T2

OFF OFF 10 120

ON OFF 10 180

OFF ON 20 120

ON ON 20 180

Time

(seconds)

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

Pump-out cycle always occurs on the 2nd harvest after startup. Then, depending on the pump-out frequency control setting (S1 dip switch 5 & 6), pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle.

d) Pump-Out Frequency Control (S1 dip switch 5 & 6)

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

Dip Switch Setting No. 5 No. 6

OFF OFF every cycle

ON OFF every 2 cycles

OFF ON every 5 cycles

ON ON every 10 cycles

e) Harvest Pump Timer (S1 dip switch 7 & 8)

The harvest pump timer allows the water valve to close and the pump motor to circulate water in the tank during the ﬁnal part of harvest. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (determined by the harvest pump timer setting), whichever is shorter. When the water valve closes, the pump motor energizes and runs for the time determined by the harvest pump timer setting.

Frequency

Dip Switch Setting No. 7 No. 8

OFF OFF 0

ON OFF 10

OFF ON 30

ON ON 50

f) Freeze Timer (S1 dip switch 9 & 10)

Time

(seconds)

CAUTION

Adjust to proper speciﬁcation, or the unit 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, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. The freeze timer is factory adjusted, and no adjustment is required.

Dip Switch Setting No. 9 No. 10

ON OFF 50 OFF OFF 60 OFF ON 70

ON ON 100

Time

(minutes)

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