HoshizakiメーカーKM-901MWHの使用説明書/サービス説明書
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Hoshizaki “A Superior Degree of Reliability” www .hoshizaki.com Models KM-901MAH KM-901MWH KM-901MRH/3 Modular Crescent Cuber Hoshizaki America, Inc.
IMPORTANT Only qualied service technicians should install, service, and maintain the icemaker. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual.
3 IMPORTANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualied service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety.
4 3. Controls and Adjustments ..................................................................................... 3 a) Default Dip Switch Settings ............................................................................. 3 b) Harvest Timer (S4 dip switch & ) .
5 V. Removal and Replacement of Components ................................................................... 68 A. Service for Refrigerant Lines ...................................................................................... 68 . Refrigerant Recovery .
6 Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury.
7 I. Specications A. Icemaker 1a. KM-901MAH (air-cooled) Auxiliary Code T-0, U-0 Note: We reserve the right to make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 11.
8 1b. KM-901MAH (air-cooled) Auxiliary Code U-1 and Later AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 11.4 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.
9 2a. KM-901MWH (water-cooled) Auxiliary Code T-0, U-0 Note: We reserve the right to make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 8.
0 2b. KM-901MWH (water-cooled) Auxiliary Code U-1 and Later AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 8.7A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.
3a. KM-901MRH (remote air-cooled) Auxiliary Code T-0, U-0 Note: We reserve the right to make changes in specications and design without prior notice.
3b. KM-901MRH (remote air-cooled) Auxiliary Code U-1 and Later AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 11.6A ( 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.
3 4a. KM-901MRH3 (remote air-cooled) Auxiliary Code T-0, U-0 Note: We reserve the right to make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 7.0A ( 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.
4 4b. KM-901MRH (remote air-cooled) Auxiliary Code U-1 and Later AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 7.0A ( 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.
5 B. Condenser Unit 1. URC-9F Unit: mm [in.].
6 Specications MODEL: URC-9F Note: We reserve the right to make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 1.
7 II. General Information A. Construction 1. KM-901MAH (air-cooled) Thermostatic Bin Control Auxiliary Code T-0, U-0 Water Supply Inlet Condenser Drier Control Box Spray Tubes Control Switch Water .
8 2. KM-901MWH (water-cooled) Water Supply Inlet Condenser Drier Control Box Spray Tubes Control Switch Water Pump Float Switch Compressor Expansion Valves Water Regulating Valve Hot Gas Valve Junc.
9 3. KM-901MRH/3 (remote air-cooled) Receiver Tank Water Supply Inlet Junction Boxes Drier Control Box Spray Tubes Control Switch Water Pump Float Switch Compressor Expansion Valves Hot Gas Valve L.
0 B. Sequence of Operation 1. Sequence Cycles and Shutdown a) "E" Control Board: Auxiliary Code T-0, U-0 The steps in the sequence are as outlined below. When power is supplied, CB red "POWER OK" LED comes on. There is a 5-second delay before startup.
(5) Harvest Cycle Same as the initial harvest cycle. See "II.B..a)() Initial Harvest Cycle." Note: Unit continues to cycle until TBC is satised or power is turned off.
(3) Freeze Cycle LED is on. Comp and FMR remain energized, PM, FM, and LLV energize. HGV and WV de-energize. For the rst 5 minutes, CB will not accept a signal from F/S. This minimum 5-minute freeze time is short cycle protection for Comp.
3 (6) Shutdown When MBC is activated (MBC open), the yellow "BC OPEN" LED comes on. The unit then shuts down as outlined in the table below.
4 2. Sequence Flow Chart a) "E" Control Board: Auxiliary Code T-0, U-0 4. Pump-Out Cycle • Factory set for every 0th cycle (S4 dip switch 5 & 6) • Pump motor stops for sec.
5 b) "G" Control Board: Auxiliary Code U-1 and Later • WV time: 6 min. or the length of harvest minus 0 or 50 sec. (S4 dip switch 7), whichever is shorter. DO NOT ADJUST S4 dip switch 7 on this model. • Maximum harvest time: 0 min.
6 C. Control Board • A Hoshizaki exclusive solid-state control board is employed in KM-90MAH, KM-90MWH, and KM-90MRH/3 Modular Crescent Cubers. • All models are pretested and factory set. CAUTION . The control board is fragile; handle very carefully.
7 1. Control Board Layout a) "E" Control Board: Auxiliary Code T-0, U-0 "E" Control Board Part Number A40-0 (factory); 2A1410-02 (service) "E" Control Boar.
8 "G" Control Board Part Number A379-0 "G" Control Board "ALARM RESET" Button "OUTPUT TEST" Button (used to test relays on control board) WHITE K3 C.
9 2. Features a) Maximum Water Supply Period - 6 minutes "E" control board: The inlet water valve is open during harvest for 6 minutes or the length of harvest, whichever is shorter.
30 f) LED Lights and Audible Alarm Safeties (1) "E" Control Board: Auxiliary Code T-0, U-0 At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when power is turned off. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs.
3 (2) "G" Control Board: Auxiliary Code U-1 and Later At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs.
3 3. Controls and Adjustments CAUTION Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage.
33 c) Pump-Out Timer (S4 dip switch 3 & 4) When a pump-out is called for, the pump motor de-energizes after the preceding freeze cycle. The pump motor energizes seconds later in the reverse di.
34 e) Bin Control Selector/Harvest Pump Timer (S4 dip switch 7) Depending on the control board, S4 dip switch 7 is either a bin control selector or harvest pump timer. CAUTION Do not adjust. This dip switch must be left in the factory default position or this unit will not operate correctly.
35 g) Freeze Timer (S4 dip switch 9 & 10) CAUTION Adjust to proper specication, 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 the freeze timer, the control board initiates the harvest cycle.
36 D. Bin Control 1. Thermostatic Bin Control: Auxiliary Code T-0, U-0 CAUTION When the ambient temperature is below 45°F (7°C), the thermostatic bin control switch opens and shuts down the icemaker even if the ice storage bin is empty.
37 III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-901MAH (air-cooled) Water Supply Cleaning Valve Float Switch Drain Check Valve Expansion Valves Compressor Hot Gas Valve .
38 2. KM-901MWH (water-cooled) Water Supply Cleaning Valve Float Switch Drain Check Valve Expansion Valves Compressor Hot Gas Valve Check Valves High Pressure Switch Strainer Water Regulating Valve Dr.
39 3. KM-901MRH/3 (remote air-cooled) Water Supply Cleaning Valve Float Switch Drain Check Valve Expansion Valves Compressor Hot Gas Valve Check Valves High Pressure Switch Strainer Fan Drier Condense.
40 B. Wiring Diagrams 1. Thermostatic Bin Control: Auxiliary Code T-0, U-0 a) KM-901MAH (air-cooled) and KM-901MWH (water-cooled) * Transformer Output 0.
4 b) KM-901MRH (remote air-cooled) * High Pressure Switch Cut-out 4± PSIG Cut-in 37± PSIG 0 * Transformer Output 0.5V at 5V Thermostatic Bin Control: Auxiliary Code.
4 c) KM-901MRH3 (remote air-cooled) * High Pressure Switch Cut-out 4± PSIG Cut-in 37± PSIG 0 * Transformer Output 0.5V at 5V Thermostatic Bin Control: Auxiliary Cod.
43 2. Mechanical Bin Control: Auxiliary Code U-1 and Later a) KM-901MAH (air-cooled) and KM-901MWH (water-cooled) Mechanical Bin Control: Auxiliary Code U- and Later * Transformer Output 0.
44 b) KM-901MRH (remote air-cooled) * High Pressure Switch Cut-out 4± PSIG Cut-in 37± PSIG 0 * Transformer Output 0.5V at 5V Mechanical Bin Control: Auxiliary Code U-.
45 c) KM-901MRH3 (remote air-cooled) Mechanical Bin Control: Auxiliary Code U- and Later * Transformer Output 0.5V at 5V * High Pressure Switch Cut-out 4± PSIG Cut-in 37±.
46 C. Performance Data 1. KM-901MAH (air-cooled) Note: . Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. . We reserve the right to make changes in specications and design without prior notice.
47 Note: . Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. . We reserve the right to make changes in specications and design without prior notice. 2. KM-901MWH (water-cooled) 70/21 912 414 889 403 849 385 80/27 895 406 860 390 815 370 90/32 889 403 835 379 791 359 lbs.
48 3. KM-901MRH (remote air-cooled) Note: . Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. . We reserve the right to make changes in specications and design without prior notice.
49 Note: . Pressure data is recorded at 5 minutes into freeze cycle. The data not in bold should be used for reference only. . We reserve the right to make changes in specications and design without prior notice. 4. KM-901MRH3 (remote air-cooled) 70/21 899 408 874 397 817 371 80/27 880 399 842 382 772 350 90/32 874 397 815 370 749 340 lbs.
50 IV. Service Diagnosis WARNING . This unit should be diagnosed and repaired only by qualied service personnel to reduce the risk of death, electric shock, serious injury, or re. . Risk of electric shock. Use extreme caution and exercise safe electrical practices.
5 3) 1-Minute Fill Cycle – LED 4 is on. WV energizes. After minute, CB checks for a closed F/S. If F/S is closed, the harvest cycle begins. If closed, continue to step 4. If open, WV remains energized through additional -minute ll cycles until water lls the tank and closes F/S (low water safety).
5 5) Freeze Cycle – LED 1 is on. Comp and FMR remain energized, PM, LLV, and FM energize. WV and HGV de-energize. The unit is held in freeze by a 5-minute short cycle protection timer (CB will not accept a signal from F/S). After the 5-minute short cycle protection timer expires, CB turns freeze termination over to F/S.
53 7) Normal Harvest Cycle – same as the initial harvest cycle – See "IV.A.4) Initial Harvest Cycle." 8) Shutdown a) Thermostatic Bin Control: Auxiliary Code T-0, U-0 When the unit is running hold ice in contact with the thermostatic bulb, TBC switch opens within 0 seconds, shutting down the unit.
54 3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control switch is in the "ICE" position, then press the "OUTPUT TEST" button. For the correct lighting sequence, see the table below. Note that the order of the LEDs from the outer edge of the control board is , 4, 3, .
55 2. Mechanical Bin Control Check and Cleaning: Auxiliary Code U-1 and Later a) Mechanical Bin Control Check To check the mechanical bin control switch, follow the steps below. ) Turn off the power supply. ) Remove the front panel, then move the control switch to the "OFF" position.
56 b) Mechanical Bin Control Cleaning Scale may build up on the mechanical bin control. Scale can cause the actuator paddle and magnet to stick. In this case, the mechanical bin control should be cleaned. WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced.
57 D. Float Switch Check and Cleaning 1. Float Switch Check To check the oat switch, follow the steps below. ) Turn off the power supply. ) Remove the front panel and move the control switch to the "OFF" position. 3) Remove the base cover, then disconnect one end of the pump tubing to drain the water tank.
58 2. Float Switch Cleaning Depending on local water conditions, scale may build up on the oat switch. Scale on the switch can cause the oat to stick. In this case, the oat switch should be cleaned. ) Turn off the power supply. ) Remove the front panel, then move the control switch to the "OFF" position.
59 E. Thermistor Check To check thermistor resistance, follow the steps below. ) Turn off the power supply. ) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor.
60 F. Diagnostic Charts 1. No Ice Production Problem Possible Cause Remedy [] The icemaker will not start. a) Power Supply . Off, blown fuse, or tripped breaker. . Turn on, replace, or reset. . Loose connection. . Tighten. 3. Bad contacts.
6 Problem Possible Cause Remedy [] The icemaker will not start. (continued) h) Transformer . Coil winding open or shorted. . Replace. i) Wiring to Control Board . Loose connections or open. . Check for continuity and replace. j) Interlock Switch (Cleaning Valve) .
6 Problem Possible Cause Remedy [3] Compressor will not start or stops operating. a) Magnetic Contactor . Bad contacts. . Check for continuity and replace. . Coil winding open. . Replace. b) Start Capacitor or Run Capacitor . Defective.
63 Problem Possible Cause Remedy [7] Fan motor will not start, or is not operating (except water-cooled model). a) Fan Motor . Motor winding open. . Replace. . Bearing worn out. . Replace. 3. Wiring to fan motor. 3. Check for loose connection or open, and replace.
64 Problem Possible Cause Remedy [] Freeze cycle time is too long. (continued) f) Thermistor . Disconnected, loose, or defective. . Connect, secure, check. See "V.L. Removal and Replacement of Thermistor." g) Refrigerant . Low charge.
65 Problem Possible Cause Remedy [] All ice formed on evaporator does not fall into bin in harvest cycle. (continued) l) Refrigerant . Low charge. . Check for leaks. Recover, repair, evacuate, and recharge. m) Water Regulating Valve (water-cooled model) .
66 Problem Possible Cause Remedy [] Freeze cycle time is long. (continued) n) Control Board . Float switch connection loose (K5). . Check and reconnect. . Defective. . See "IV.B. Control Board Check." [] Harvest cycle time is long.
67 Problem Possible Cause Remedy [] Cloudy or irregular cubes. a) Evaporator . Frozen up. . See chart . . Scaled up. . Clean 3. Damaged. 3. Replace. b) Water System . Water supply line too small; requires 3/8" OD line dedicated per machine.
68 V. Removal and Replacement of Components WARNING . This unit should be diagnosed and repaired only by qualied service personnel to reduce the risk of death, electric shock, serious injury, or re. . Move the control switch to the "OFF" position and turn off the power supply before servicing.
69 2. Brazing WARNING . R-404A itself is not ammable at atmospheric pressure and temperatures up to 76°F (80°C). . R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open ames), R-404A can be decomposed to form hydrouoric acid and carbonyl uoride both of which are hazardous.
70 4) Close the low-side valve and high-side valve on the gauge manifold. 5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge.
7 8) Attach the rubber grommets of the prior compressor to the new compressor. 9) Place the compressor in position and secure it using the bolts and washers. 0) Remove the drier, then place the new drier in position. ) Remove the plugs from the suction, discharge, and process pipes.
7 8) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (40 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.
73 0) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker. ) Replace the solenoid in its correct position.
74 F. Removal and Replacement of Air-Cooled Condenser CAUTION . Always install a new drier every time the sealed refrigeration system is opened. . Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.
75 G. Removal and Replacement of Water-Cooled Condenser CAUTION . Always install a new drier every time the sealed refrigeration system is opened. . Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.
76 H. Removal and Replacement of Remote Air-Cooled Condenser CAUTION . Always install a new drier every time the sealed refrigeration system is opened. . Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.
77 I. Removal and Replacement of Water Regulating Valve (water-cooled model) CAUTION . Always install a new drier every time the sealed refrigeration system is opened. . Do not replace the drier until after all other repair or replacement has been made.
78 Fig. 4 Adjustment Screw CW – Higher CCW – Lower Top View 8) Check for water leaks. 9) Replace the panels in their correct positions. 0) Turn on the power supply.
79 8) Braze all ttings with nitrogen gas owing at a pressure of 3 to 4 PSIG. 9) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (40 PSIG).
80 0) Secure the insulation using plastic cable ties. ) Connect the white thermistor connector through the bushing of the control box to the control board WHITE K3 connector. Note: Do not cut the leads of the thermistor. ) Replace the control box cover and the panels in their correct positions.
8 ) Replace the front panel in its correct position. 3) Turn on the power supply. O. Removal and Replacement of Pump Motor ) Turn off the power supply. ) Remove the front panel. 3) Remove the base cover, then disconnect one end of the pump tubing to drain the water tank.
8 P. Removal and Replacement of Control Board When replacing a control board follow the precautions below. CAUTION . The control board is fragile; handle very carefully. . The control board contains integrated circuits, which are susceptible to failure due to static discharge.
83 VI. Cleaning and Maintenance WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after any cleaning or maintenance is done to the unit.
84 1. Cleaning Procedure ) Dilute 6 . oz. (473 ml) of the recommended cleaner Hoshizaki "Scale Away" or "LIME-A-WAY" (Economics Laboratory, Inc.) with 3 gal. ( l) of warm water. ) Remove all ice from the evaporator and the storage bin.
85 9) Turn off the power supply after 3 minutes. 0) Remove the front panel and fully open the cleaning valve. ) Move the control switch to the "WASH" position. ) Replace the front panel in its correct position. 3) Turn on the power supply to rinse off the cleaning solution.
86 B. Maintenance This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. WARNING . Only qualied service technicians should attempt to service or maintain this icemaker. . Disconnect power before performing service or maintenance.
87 5) Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve. 6) Move the control switch to the "ICE" position. 7) Replace the front panel in its correct position, then turn on the power supply. 8) Blow the icemaker water supply line out using the compressed air or carbon dioxide supply.
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