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
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
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 VOLTAGE115/60/1
AMPERAGE10.3 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY20 A
MAXIMUM FUSE SIZE20 A
APPROXIMATE ICE PRODUCTIONAmbientWATER TEMP. (°F)
PER 24 HR.Temp.(°F)507090
lbs./day ( kg/day )70*403 (183)387 (176)355 (161)
Reference without *marks80391 (177)366 (166)328 (149)
90387 (176)*349 (158)313 (142)
100377 (171)340 (154)279 (127)
SHAPE OF ICECrescent Cube
ICE PRODUCTION PER CYCLE7.0 lbs. (3.2 kg) 360 pcs.
APPROXIMATE STORAGE CAPACITYN/A
ELECTRIC & WATER CONSUMPTION90/70°F70/50°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 FINISHStainless Steel, Galvanized Steel (Rear)
WEIGHTNet 154 lbs. (70 kg), Shipping 185 lbs. (84 kg)
CONNECTIONS - ELECTRICPermanent - Connection
- WATER SUPPLYInlet 1/2" FPT
- DRAINOutlet 3/4" FPT
CUBE CONTROL SYSTEMFloat Switch
HARVESTING CONTROL SYSTEMHot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROLTimer Controlled. Overflow Pipe
COOLING WATER CONTROLN/A
BIN CONTROL SYSTEMThermostat
COMPRESSORHermetic, Model RS43C2E-CAA-219
CONDENSERAir-Cooled, Fin and tube type
EVAPORATORVertical type, Stainless Steel and Copper
REFRIGERANT CONTROLThermostatic Expansion Valve
REFRIGERANT CHARGER404A, 1 lb. 13.1 oz. (825g)
DESIGN PRESSUREHigh 467PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTIONHigh Voltage Cut-out ( Internal )
COMPRESSOR PROTECTIONAuto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTIONAuto-reset High Pressure Control Switch
LOW WATER PROTECTIONFloat Switch
ACCESSORIES -SUPPLIEDN/A
-REQUIREDIce Storage Bin
OPERATING CONDITIONSVOLTAGE RANGE104 - 127 V
AMBIENT TEMP.45 -100° F
WATER SUPPLY TEMP.45 - 90° F
WATER SUPPLY PRESSURE10 - 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 VOLTAGE115/60/1
AMPERAGE8.9 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY20 A
MAXIMUM FUSE SIZE20 A
APPROXIMATE ICE PRODUCTIONAmbientWATER TEMP. (°F)
PER 24 HR.Temp.(°F)507090
lbs./day ( kg/day )70*404 (183)402 (182)384 (174)
Reference without *marks80402 (183)399 (181)373 (169)
90402 (182)*397 (180)374 (169)
100393 (178)392 (178)352 (160)
SHAPE OF ICECrescent Cube
ICE PRODUCTION PER CYCLE6.8 lbs. (3.1 kg) 360 pcs.
APPROXIMATE STORAGE CAPACITYN/A
ELECTRIC & WATER CONSUMPTION90/70°F70/50°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 CONDENSER548(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 FINISHStainless Steel, Galvanized Steel (Rear)
WEIGHTNet 154 lbs. (70 kg), Shipping 185 lbs. (84 kg)
CONNECTIONS - ELECTRICPermanent - Connection
- WATER SUPPLYInlet 1/2" FPTCondenser Inlet 1/2" FPT
- DRAINOutlet 3/4" FPTCondenser Outlet 3/8" FPT
CUBE CONTROL SYSTEMFloat Switch
HARVESTING CONTROL SYSTEMHot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROLTimer Controlled. Overflow Pipe
COOLING WATER CONTROLWater Regulator
BIN CONTROL SYSTEMThermostat
COMPRESSORHermetic, Model RS43C2E-CAA-219
CONDENSERWater-cooled, Tube in tube type
EVAPORATORVertical type, Stainless Steel and Copper
REFRIGERANT CONTROLThermostatic Expansion Valve
REFRIGERANT CHARGER-404A, 1 lb. 2.3 oz. (520g)
DESIGN PRESSUREHigh 427PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTIONHigh Voltage Cut-out ( Internal )
COMPRESSOR PROTECTIONAuto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTIONAuto-reset High Pressure Control Switch
LOW WATER PROTECTIONFloat Switch
ACCESSORIES -SUPPLIEDN/A
-REQUIREDIce Storage Bin
OPERATING CONDITIONSVOLTAGE RANGE104 - 127 V
AMBIENT TEMP.45 -100° F
WATER SUPPLY TEMP.45 - 90° F
WATER SUPPLY PRESSURE10 - 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 Cycle3. 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 Number2A1410-01 (factory); 2A1410-02 (service)
TypeHOS-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 StepLED
1 Minute Fill Cycle4WV60 seconds
Harvest Cycle1, 4, and 2WV, HGV,
Freeze Cycle1Comp, PM,
Pump Out1, 3, and 2Comp, HGV,
The built in safeties shut down the unit and have alarms as follows:
No. of Beeps
(every 3 sec.)
1High Evaporator Temp.
(temperature > 127°F)
(53°C)
2Harvest Backup Timer
(harvest > 20 min. for two
cycles in a row)
Type of AlarmNotes
Energized
Components
Comp, FMR
FMR/FMS,
LLV
PM, FMR,
SR, DV
Min.Max.Avg.
2 minutes20 minutes3 to 5 minutes
5 minutesfreeze 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
3Freeze 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.
6Low Voltage
(92Vac ±5% or less)
7High 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
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