Hoshizaki American, Inc. KML-451MAH, KML-451MWH Service Manual

Hoshizaki
Low-Profile Modular Crescent Cuber
Models KML-451MAH
“A Superior Degree
of Reliability”
www.hoshizaki.com
KML-451MWH
SERVICE MANUAL
Number: 73143 Issued: 3-1-2007
IMPORTANT
Only qualified service technicians should attempt to service or maintain this unit. No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual.
HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the unit.
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 Service (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
2
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
A. Icemaker ....................................................................................................................... 5
1. KML-451MAH (air-cooled) ....................................................................................... 5
2. KML-451MWH (water-cooled) .................................................................................
II. General Information ........................................................................................................... 7
A. Construction .................................................................................................................. 7
1. KML-451MAH (air-cooled) ....................................................................................... 7
2. KML-451MWH (water-cooled) ................................................................................. 8
B. Sequence of Operation ................................................................................................. 9
1. One Minute Fill Cycle .............................................................................................. 9
2. Initial Harvest Cycle ................................................................................................ 9
3. Freeze Cycle ........................................................................................................... 9
4. Pump-Out Cycle ..................................................................................................... 9
5. Normal Harvest Cycle ............................................................................................ 9
C. Control Board .............................................................................................................. 11
1. Control Board Layout ............................................................................................. 12
2. Features ................................................................................................................ 13
a) Maximum Water Supply Period – 6 minutes ....................................................... 13
b) Harvest Backup Timer and Freeze Timer ........................................................... 13
c) High Temperature Safety .................................................................................... 13
d) Low Water Safety ............................................................................................... 13
e) High Voltage and Low Voltage Cut-outs ............................................................. 13
f) LED Lights and Audible Alarm Safeties ............................................................... 14
3. Controls and Adjustments ..................................................................................... 15
a) Default Dip Switch Settings ................................................................................ 15
b) Harvest Timer (dip switch 1 & 2) ........................................................................ 15
c) Pump-Out Timer (dip switch 3 & 4) ..................................................................... 16
d) Pump-Out Frequency Control (dip switch 5 & 6) ................................................ 16
e) Freeze Timer (dip switch 9 & 10) ........................................................................ 17
4. Control Board Check Procedure ............................................................................ 17
5. Control Board Replacement .................................................................................. 17
D. Harvest Control – Thermistor ...................................................................................... 18
E. Bin Control .................................................................................................................. 18
F. Switches ...................................................................................................................... 18
1. Control Switch ....................................................................................................... 18
2. Service Switch ....................................................................................................... 19
a) DRAIN ................................................................................................................ 19
b) CIRCULATE ....................................................................................................... 19
c) WASH ................................................................................................................. 19
6
3
III. Technical Information ...................................................................................................... 20
A. Water Circuit and Refrigeration Circuit ........................................................................ 20
1. KML-451MAH (air-cooled) ..................................................................................... 20
2. KML-451MWH (water-cooled) ...............................................................................
B. Wiring Diagrams .......................................................................................................... 22
1. KML-451MAH (air-cooled) and KML-451MWH (water-cooled) ............................. 22
C. Performance Data ....................................................................................................... 23
1. KML-451MAH (air-cooled) ..................................................................................... 23
2. KML-451MWH (water-cooled) ...............................................................................
IV. Service Diagnosis ........................................................................................................... 25
A. 10-Minute Diagnostic Procedure ................................................................................ 25
B. Diagnostic Charts ........................................................................................................ 26
1. No Ice Production .................................................................................................. 26
2. Evaporator is Frozen Up ........................................................................................
3. Low Ice Production ................................................................................................ 31
4. Abnormal Ice ......................................................................................................... 31
5. Other ...................................................................................................................... 31
V. Removal and Replacement of Components .................................................................... 33
A. Service for Refrigerant Lines ...................................................................................... 33
1. Refrigerant Recovery ............................................................................................. 33
2. Brazing .................................................................................................................. 33
3. Evacuation and Recharge (R-404A) ...................................................................... 34
B. Removal and Replacement of Compressor ................................................................ 35
C. Removal and Replacement of Expansion Valve ......................................................... 36
D. Removal and Replacement of Hot Gas Valve or Line Valve ....................................... 36
E. Removal and Replacement of Evaporator .................................................................. 37
F. Removal and Replacement of Water Regulating Valve - Water Cooled Model Only.... 38
G. Adjustment of Water Regulating Valve - Water-Cooled Model Only ........................... 39
H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)
- Remote Air-Cooled Model Only .............................................................................. 39
I. Removal and Replacement of Thermistor .................................................................... 40
J. Removal and Replacement of Fan Motor .................................................................... 41
K. Removal and Replacement of Water Valves ............................................................... 41
L. Removal and Replacement of Pump Motor ................................................................. 42
VI. Cleaning and Maintenance Instructions ......................................................................... 43
A. Cleaning and Sanitizing Procedures ........................................................................... 43
1. Cleaning Procedure ............................................................................................... 43
2. Sanitizing Procedure – Following Cleaning Procedure ..........................................
B. Maintenance ................................................................................................................ 45
C. Preparing the Icemaker for Long Storage ................................................................... 45
21
24
30
44
4
I. Specifications
AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 10.3 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 *403 (183) 387 (176) 355 (161) Reference without *marks 80 391 (177) 366 (166) 328 (149)
90 387 (176) *349 (158) 313 (142)
100 377 (171) 340 (154) 279 (127) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 7.0 lbs. (3.2 kg) 360 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 970(6.7) 890(5.3) WATER gal./24HR (gal./100 lbs.) 64(18.3) 115(28.5) EXTERIOR DIMENSIONS (WxDxH) 30" x 27 3/8" x 22" (762 x 695 x 560 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 154 lbs. (70 kg), Shipping 185 lbs. (84 kg) CONNECTIONS - ELECTRIC Permanent - 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 Thermostat COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Air-Cooled, Fin and tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R404A, 1 lb. 13.1 oz. (825g) 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 N/A
-REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 -100° F WATER SUPPLY TEMP. 45 - 90° F WATER SUPPLY PRESSURE 10 - 113 PSIG

A. Icemaker

1. KML-451MAH (air-cooled)

Note: We reserve the right to make changes in specifications and design without prior
notice.
5

2. KML-451MWH (water-cooled)

AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.9 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 *404 (183) 402 (182) 384 (174) Reference without *marks 80 402 (183) 399 (181) 373 (169)
90 402 (182) *397 (180) 374 (169)
100 393 (178) 392 (178) 352 (160) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 6.8 lbs. (3.1 kg) 360 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 880(5.3) 860(5.1) WATER gal./24HR (gal./100 lbs.) 78(19.7) 125(31.0) WATER COOLED CONDENSER 548(138) 319(79)
gal./24HR (gal./100 lbs.) EXTERIOR DIMENSIONS (WxDxH) 30" x 27 3/8" x 22" (762 x 695 x 560 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 154 lbs. (70 kg), Shipping 185 lbs. (84 kg) CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT Condenser Outlet 3/8" 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 Water Regulator BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Water-cooled, Tube in tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 1 lb. 2.3 oz. (520g) DESIGN PRESSURE High 427PSIG, 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 N/A
-REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 -100° F WATER SUPPLY TEMP. 45 - 90° F WATER SUPPLY PRESSURE 10 - 113 PSIG
Note: We reserve the right to make changes in specifications and design without prior
notice.
6

II. General Information

A. Construction

1. KML-451MAH (air-cooled)

Spray Tubes
Drain Valve
Wash Valve
Inlet Water Valve
Water Supply Inlet
Condenser Fan Motor
Junction Box
Condenser
Water Pump
Float Switch
Expansion Valve
Control Switches
Control Box
Drier
Hot Gas Valve
Compressor
Bin Control Thermostat
7

2. KML-451MWH (water-cooled)

Water Supply Inlet
Spray Tubes
Drain Valve
Water Regulator
Wash Valve
Inlet Water Valve
Water Pump
Float Switch
Junction Box
Condenser
Control Box
Drier
Expansion Valve
Control Switches
Hot Gas Valve
Compressor
Bin Control Thermostat
8

B. 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 1, 4, 3, 2.

1. One Minute Fill Cycle

LED 4 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 water pump.

2. Initial Harvest Cycle

LEDs 1, 4, and 2 are on. WV remains open, Comp and FMR energize, 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 (dip switch 1 & 2). The water valve is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is shorter. 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.

3. Freeze Cycle

LED 1 is on. Comp and FMR continue to run, PM and FMS energize, LLV opens, HGV and WV close and the freeze cycle starts. For the first 5 minutes the control board will not accept a signal from F/S. This 5 minute minimum freeze acts as a short cycle protection. At the end of 5 minutes, F/S assumes control. As ice builds on the evaporator the water level in the sump lowers. The freeze continues until F/S opens and terminates ice production.

4. Pump-Out Cycle

LEDs 1, 3, and 2 are on. Comp and FMR continue to run, HGV opens, LLV closes, and FMS de-energizes. PM stops for 2 seconds. SR energizes, restarting PM and taking water from the sump and forcing it to go through DV and down the drain. When the pump-out timer stops counting, the pump out is complete. Pump out always occurs on the 2nd harvest after startup. Then, depending on the control board setting, pump out occurs every cycle, or every 2nd, 5th or 10th cycle (dip switch 5 & 6).

5. Normal Harvest Cycle

LEDs 1, 4, and 2 are on. Comp and FMR continue 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. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is shorter. When the harvest timer completes its count down, the harvest cycle is complete and the next freeze cycle starts. The unit continues to cycle through 3, 4 and 5 sequence until the bin control senses ice and shuts the unit down.
Legend: Comp–compressor; DV–Drain Valve; FMR–remote fan motor; FMS–self-contained
fan motor; F/S–float switch; HGV–hot gas valve; LLV–Liquid Line Valve; PM–pump
motor; SR–Service Relay; WV–inlet water valve
9
Cycle
4. Pump-Out
F/S in
control
5 minute timer
in control
• Minimum freeze time: 5 minutes
• Maximum freeze time: freeze timer setting
1 to 3 minute timer
in control
F/S closed
F/S Check
PM stops for 2 sec., SR
energizes, starting PM &
DV for 10/20 sec. each 1,
2, 5, or 10 cycles.
Freeze cycle
operation turned
over to F/S
Comp continues
FMR continues
HGV de-energized
WV de-energized
Thermistor temp
reaches 48°F (9°C)
(3.9 kΩ or less)
Harvest timer starts
Comp continues
PM energized
FMR continues
HGV energized
FMS energized
LLV energized
F/S open
FMS de-energized
LLV de-energized
Power is supplied to the pump and drain valve. This drains the water tank.
Power is supplied to the pump only. This operation can be used to circulate cleaner for
extended periods of time over the outside surface of the evaporator.
Power is supplied to the pump and wash valve. This operation is used to circulate cleaner
and sanitizer over both the inside and outside surfaces of the evaporator.
2. Harvest Cycle 3. Freeze Cycle
Thermistor in
• Maximum harvest time: 20 minutes
Fill Cycle
control
F/S closed
F/S Check
Comp energized
WV Energized
HGV energized
FMR energized
WV continues
F/S open
• Maximum inlet water valve time: 6 minutes
1. One Minute
KML-451MAH and KML-451MWH Sequence Flow Chart and Component Operation
Cycle Steps
"E" board will have
Initial startup always
5 second delay
begins here
LLV de-energized
10
If F/S is open, compressor stops and cycle returns to 1 minute fill
Legend:
Comp–compressor
DV–drain valve
FMR–remote fan motor
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.
FMS–self-contained fan motor
F/S–float switch
HGV–hot gas valve
LLV–liquid line valve
PM–pump motor
SR–service relay
DRAIN
CIRCULATE
WV–inlet water valve
WASH

C. Control Board

• A HOSHIZAKI exclusive solid-state control is employed in KML-451MAH and KML-451MWH Modular 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 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 if it goes bad.
6. Do not short out power supply to test for voltage.
11

1. Control Board Layout

Control Products "E" Control Board
Alarm Reset Switch
Backup Freeze Timer LED
Backup Harvest Timer LED
Alarm Buzzer
Dip Switch
Output Test Switch (used to test relays on board)
Connector K3 Harvest Control (thermistor)
Connector K4 Open (not connected)
Power LED (lights when power is supplied to the board)
Relay LEDs (4) (indicate which relays are energized as listed below)
LED 2 Hot Gas Valve (HGV) Self-Contained Fan Motor (FMS) (FMS off when LED on)
LED 3 Pump Motor (PM) (on at pump out only)
LED 4 Water Valve (WV)
LED 1 Compressor (Comp) Remote Fan Motor (FMR)
Transformer Connector
Microprocessor (board revision level indicated by last 2 digits on label)
Connector K5 Float Switch
Part Number
Connector K1
Pins #1 through #10 #1, 9 Magnetic Contactor #2 Hot Gas Valve #3 Line Valve Self-Contained Fan Motor (FMS) #4 Pump Motor (icemaking) #5 Pump Motor (drain) #6 Water Valve #7, 10 Power (line, bin control) #8 Open
Switch for "C" board and "ALPINE" board (service boards only)
Control Board
Part Number 2A1410-01 (factory); 2A1410-02 (service)
Type HOS-001A (Control Products - 10 Pin)
12

2. Features

a) Maximum Water Supply Period – 6 minutes
Inlet water valve opening, in the harvest cycle, is limited by the harvest timer. The water valve cannot remain open longer than the maximum period. The water valve can close in less than six minutes if the harvest cycle is completed.
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 dip switches 9 &
10. The 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 ± 7°F (53°C ± 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 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.
13
f) 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 OFF. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. For more information, see "II.B. Sequence of Operation."
Sequence Step LED
1 Minute Fill Cycle 4 WV 60 seconds Harvest Cycle 1, 4, and 2 WV, HGV,
Freeze Cycle 1 Comp, PM,
Pump Out 1, 3, and 2 Comp, HGV,
The built in safeties shut down the unit and have alarms as follows:
No. of Beeps
(every 3 sec.)
1 High Evaporator Temp.
(temperature > 127°F) (53°C)
2 Harvest Backup Timer
(harvest > 20 min. for two cycles in a row)
Type of Alarm Notes
Energized
Components
Comp, FMR
FMR/FMS, LLV
PM, FMR, SR, DV
Min. Max. Avg.
2 minutes 20 minutes 3 to 5 minutes
5 minutes freeze timer
10 seconds 20 seconds factory setting
Check for harvest problem (stuck HGV or relay), hot water entering unit, stuck HM, or shorted thermistor.
Orange LED marked H TIMER lights up. Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient compressor.
Time LEDs are On
30 to 35 minutes
setting
3 Freeze Timer
(freeze > specified setting for two cycles in a row) Timer is factory set using dip switches 9 & 10
To manually reset the above safeties, press the alarm reset button with the power supply on.
6 Low Voltage
(92Vac ±5% or less)
7 High Voltage
(147Vac ±5% or more)
Legend: Comp–compressor; DV–Drain Valve; FMR–remote fan motor; FMS–self- contained fan motor; F/S–float switch; HGV–hot gas valve; HM–headmaster (C.P.R.); LLV–Liquid Line Valve; PM–pump motor; SR–Service Relay; TXV–thermostatic expansion valve; WV–inlet water valve
Yellow LED marked F TIMER lights up. Check for F/S stuck closed (up), WV leaking by, HGV leaking by, TXV not feeding properly, low charge, HM not bypassing, or inefficient compressor.
Red LED will turn off if voltage protection operates. The control voltage safeties automatically reset when voltage is corrected.
14
Loading...
+ 32 hidden pages