Hoshizaki Ice Maker KM 650MAH User Manual

Hoshizaki America, Inc.  
Hoshizaki  
Modular Crescent Cuber  
Models  
KM-650MAH  
KM-650MWH  
KM-650MRH  
SERVICE MANUAL  
“A Superior Degree  
of Reliability”  
Number: 73147  
Issued: 12-12-2006  
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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  
3
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4
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I. Specifications  
A. Icemaker  
1. KM-650MAH (air-cooled)  
AC SUPPLY VOLTAGE  
AMPERAGE  
208-230/60/1 (3 wire with neutral for 115V)  
6.6 A ( 5 Min. Freeze AT 104°F / WT 80°F)  
MINIMUM CIRCUIT AMPACITY  
MAXIMUM FUSE SIZE  
APPROXIMATE ICE PRODUCTION  
PER 24 HR.  
15 A  
15 A  
Ambient  
WATER TEMP. (°F)  
Temp.(°F)  
50  
70  
90  
lbs./day ( kg/day )  
Reference without *marks  
70  
80  
90  
100  
*589 (267)  
572 (259)  
566 (257)  
555 (252)  
566 (257)  
537 (243)  
*512 (232)  
501 (227)  
526 (238)  
490 (222)  
467 (212)  
426 (193)  
SHAPE OF ICE  
Crescent Cube  
ICE PRODUCTION PER CYCLE  
APPROXIMATE STORAGE CAPACITY  
ELECTRIC & WATER CONSUMPTION  
ELECTRIC W (kWH/100 lbs.)  
WATER gal./24HR (gal./100 lbs.)  
EXTERIOR DIMENSIONS (WxDxH)  
EXTERIOR FINISH  
13.5 lbs. (6.1 kg) 720 pcs.  
N/A  
90/70°F  
1240(5.8)  
108(21.1)  
70/50°F  
1100(4.5)  
257(43.7)  
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)  
Stainless Steel, Galvanized Steel (Rear)  
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 kg)  
Permanent - Connection  
WEIGHT  
CONNECTIONS - ELECTRIC  
- WATER SUPPLY  
Inlet  
1/2" FPT  
- DRAIN  
Outlet  
3/4" FPT  
3/8" OD Tube  
CUBE CONTROL SYSTEM  
HARVESTING CONTROL SYSTEM  
ICE MAKING WATER CONTROL  
COOLING WATER CONTROL  
BIN CONTROL SYSTEM  
COMPRESSOR  
Float Switch  
Hot Gas and Water, Thermistor and Timer  
Timer Controlled. Overflow Pipe  
N/A  
Thermostat  
Hermetic, Model RS55C2E-CAV  
Air-Cooled , Fin and tube type  
Vertical type, Stainless Steel and Copper  
Thermostatic Expansion Valve  
R-404A, 1 lb. 8.7 oz. (700g)  
High 467PSIG, Low 230PSIG  
High Voltage Cut-out ( Internal )  
Auto-reset Overload Protector ( Internal )  
Auto-reset High Pressure Control Switch  
Float Switch  
CONDENSER  
EVAPORATOR  
REFRIGERANT CONTROL  
REFRIGERANT CHARGE  
DESIGN PRESSURE  
P.C. BOARD CIRCUIT PROTECTION  
COMPRESSOR PROTECTION  
REFRIGERANT CIRCUIT PROTECTION  
LOW WATER PROTECTION  
ACCESSORIES -SUPPLIED  
-REQUIRED  
N/A  
Ice Storage Bin  
OPERATING CONDITIONS  
VOLTAGE RANGE  
AMBIENT TEMP.  
187 - 253 V  
45 -100° F  
WATER SUPPLY TEMP.  
WATER SUPPLY PRESSURE  
45 - 90° F  
10 - 113 PSIG  
Note: We reserve the right to make changes in specifications and design without prior  
notice.  
5
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2. KM-650MWH (water-cooled)  
AC SUPPLY VOLTAGE  
AMPERAGE  
208-230/60/1 (3 wire with neutral for 115V)  
5.3 A ( 5 Min. Freeze AT 104°F / WT 80°F)  
MINIMUM CIRCUIT AMPACITY  
MAXIMUM FUSE SIZE  
APPROXIMATE ICE PRODUCTION  
PER 24 HR.  
15 A  
15 A  
Ambient  
WATER TEMP. (°F)  
Temp.(°F)  
50  
70  
90  
lbs./day ( kg/day )  
Reference without *marks  
70  
80  
90  
100  
*680 (308)  
676 (307)  
675 (306)  
651 (295)  
675 (306)  
668 (303)  
*662 (300)  
647 (294)  
626 (284)  
595 (270)  
598 (271)  
540 (245)  
SHAPE OF ICE  
Crescent Cube  
ICE PRODUCTION PER CYCLE  
APPROXIMATE STORAGE CAPACITY  
ELECTRIC & WATER CONSUMPTION  
ELECTRIC W (kWH/100 lbs.)  
WATER gal./24HR (gal./100 lbs.)  
WATER COOLED CONDENSER  
gal./24HR (gal./100 lbs.)  
EXTERIOR DIMENSIONS (WxDxH)  
EXTERIOR FINISH  
14.8 lbs. (6.7 kg) 720 pcs.  
N/A  
90/70°F  
1050(3.8)  
149(22.5)  
741(112)  
70/50°F  
1020(3.6)  
254(37.4)  
408(60)  
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)  
Stainless Steel, Galvanized Steel (Rear)  
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 kg)  
Permanent - Connection  
WEIGHT  
CONNECTIONS - ELECTRIC  
- WATER SUPPLY  
Inlet  
1/2" FPT  
Condenser Inlet 1/2" FPT  
Condenser Outlet 3/8" FPT  
- DRAIN  
Outlet  
3/4" FPT  
3/8" OD Tube  
CUBE CONTROL SYSTEM  
HARVESTING CONTROL SYSTEM  
ICE MAKING WATER CONTROL  
COOLING WATER CONTROL  
BIN CONTROL SYSTEM  
COMPRESSOR  
Float Switch  
Hot Gas and Water, Thermistor and Timer  
Timer Controlled. Overflow Pipe  
Pressure Regulator  
Thermostat  
Hermetic, Model RS55C2E-CAV  
Water-cooled, Tube in tube type  
Vertical type, Stainless Steel and Copper  
Thermostatic Expansion Valve  
R-404A, 1 lb. 5.7 oz. (615g)  
High 427PSIG, Low 230PSIG  
High Voltage Cut-out ( Internal )  
Auto-reset Overload Protector ( Internal )  
Auto-reset High Pressure Control Switch  
Float Switch  
CONDENSER  
EVAPORATOR  
REFRIGERANT CONTROL  
REFRIGERANT CHARGE  
DESIGN PRESSURE  
P.C. BOARD CIRCUIT PROTECTION  
COMPRESSOR PROTECTION  
REFRIGERANT CIRCUIT PROTECTION  
LOW WATER PROTECTION  
ACCESSORIES -SUPPLIED  
-REQUIRED  
N/A  
Ice Storage Bin  
OPERATING CONDITIONS  
VOLTAGE RANGE  
AMBIENT TEMP.  
187 - 253 V  
45 -100° F  
WATER SUPPLY TEMP.  
WATER SUPPLY PRESSURE  
45 - 90° F  
10 - 113 PSIG  
Note: We reserve the right to make changes in specifications and design without prior  
notice.  
6
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3. KM-650MRH (remote air-cooled)  
AC SUPPLY VOLTAGE  
AMPERAGE  
208-230/60/1 (3 wire with neutral for 115V)  
7.1 A ( 5 Min. Freeze AT 104°F / WT 80°F)  
MINIMUM CIRCUIT AMPACITY  
MAXIMUM FUSE SIZE  
APPROXIMATE ICE PRODUCTION  
PER 24 HR.  
15 A  
15 A  
Ambient  
WATER TEMP. (°F)  
Temp.(°F)  
50  
70  
90  
lbs./day ( kg/day )  
Reference without *marks  
70  
80  
90  
100  
*615 (279)  
601 (273)  
597 (271)  
583 (264)  
597 (271)  
574 (260)  
*554 (251)  
543 (246)  
556 (252)  
523 (237)  
506 (230)  
462 (210)  
SHAPE OF ICE  
Crescent Cube  
ICE PRODUCTION PER CYCLE  
APPROXIMATE STORAGE CAPACITY  
ELECTRIC & WATER CONSUMPTION  
ELECTRIC W (kWH/100 lbs.)  
WATER gal./24HR (gal./100 lbs.)  
EXTERIOR DIMENSIONS (WxDxH)  
EXTERIOR FINISH  
WEIGHT  
CONNECTIONS - ELECTRIC  
- WATER SUPPLY  
14.1 lbs. (6.4 kg ) 720 pcs.  
N/A  
90/70°F  
1250(5.4)  
111(20.0)  
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)  
Stainless Steel, Galvanized Steel (Rear)  
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 kg)  
Permanent - Connection  
70/50°F  
1150(4.5)  
266(43.2)  
Inlet  
1/2" FPT  
- DRAIN  
Outlet  
3/4" FPT  
3/8" OD Tube  
CUBE CONTROL SYSTEM  
HARVESTING CONTROL SYSTEM  
ICE MAKING WATER CONTROL  
COOLING WATER CONTROL  
BIN CONTROL SYSTEM  
COMPRESSOR  
CONDENSER  
EVAPORATOR  
REFRIGERANT CONTROL  
Float Switch  
Hot Gas and Water, Thermistor and Timer  
Timer Controlled. Overflow Pipe  
N/A  
Thermostat  
Hermetic, Model RS55C2E-CAV  
Air-cooled Remote, Condenser Unit URC-5F  
Vertical type, Stainless Steel and Copper  
Thermostatic Expansion Valve  
Condensing Pressure Regulator on URC-5F  
REFRIGERANT CHARGE  
R-404A,  
5 lbs. 11 oz. (2580 g)  
( Icemaker 3 lbs. 13 oz. Cond. Unit 1 lb. 14 oz. )  
High 467 PSIG, Low 230 PSIG  
High Voltage Cut-out ( Internal )  
Auto-reset Overload Protector ( Internal )  
Auto-reset High Pressure Control Switch  
Float Switch  
DESIGN PRESSURE  
P.C. BOARD CIRCUIT PROTECTION  
COMPRESSOR PROTECTION  
REFRIGERANT CIRCUIT PROTECTION  
LOW WATER PROTECTION  
ACCESSORIES -SUPPLIED  
-REQUIRED  
N/A  
Ice Storage Bin, Remote Condenser Unit  
VOLTAGE RANGE  
OPERATING CONDITIONS  
187 - 253 V  
45 -100° F  
AMBIENT TEMP.  
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.  
7
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B. Condensing Unit  
1. URC-5F  
ꢁ4"  
(6ꢀ0 mm.)  
ꢁ3-ꢀ/3ꢁ"  
(585 mm.)  
ꢀ9-ꢀꢀ/ꢀ6"  
(500 mm.)  
6/ꢀ6" x 3/4" (ꢀ0 mm. x ꢁ0 mm.)  
4 x ꢁ (SLOTTED HOLES)  
ꢀ8-ꢀ/8"  
(460 mm.)  
ꢁ0-ꢀ5/3ꢁ"  
(5ꢁ0 mm.)  
ꢁꢀ-ꢀ5/ꢀ6"  
(557 mm.)  
7/8" DIA. HOLE  
(ꢁ3 mm. DIA.)  
6-5/ꢀ6"  
(ꢀ60 mm.)  
ꢁ-ꢀ5/ꢀ6"  
(75 mm.)  
8
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Specifications  
MODEL: URC-5F  
AC SUPPLY VOLTAGE  
FAN MOTOR  
115/60/1 (Connection to Icemaker)  
115 V Total 1.3FLA  
65W  
EXTERIOR DIMENSIONS (WxDxH)  
DIMENSIONS INCLUDING LEGS (WxDxH)  
EXTERIOR FINISH  
21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 454 mm)  
24" x 18-1/8" x 32-13/16" (610 x 460 x 834 mm)  
Galvanized Steel  
WEIGHT  
Net 61 lbs. ( 28 kg )  
Shipping 68 lbs. ( 31 kg )  
CONNECTIONS - ELECTRIC  
- REFRIGERANT  
Permanent - Connection  
Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)  
Liquid Line 5/8"-18 UNF Fitting (#6 AEROQUIP)  
CONDENSER  
Air-cooled, Fin and tube type  
Thermal Protection  
FAN MOTOR PROTECTION  
REFRIGERANT CONTROL  
REFRIGERANT CHARGE  
DESIGN PRESSURE  
Condensing Pressure Regulator  
R-404A  
1 lb. 14 oz.  
(850g)  
High 467 PSIG  
VOLTAGE RANGE  
AMBIENT TEMP.  
Leg  
OPERATING CONDITIONS  
104 ~ 127 V  
-20 ~ 122 °F  
ACCESSORIES -SUPPLIED  
DRAWING NO. (DIMENSION)  
2 pcs  
8 pcs  
8 pcs  
Hex. Head Bolt w/Washer 8 x 16  
Hex. Nut  
441211  
8
Note: We reserve the right to make changes in specifications and design without prior  
notice.  
9
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II. General Information  
A. Construction  
1. KM-650MAH (air-cooled)  
Spray Tubes  
Water Supply Inlet  
Condenser  
Control Box  
Control Switch  
Bin Control Thermostat  
Fan Motor  
Expansion Valve  
Float Switch  
Hot Gas Valve  
Drier  
Compressor  
Water Pump  
ꢀ0  
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2. KM-650MWH (water-cooled)  
Spray Tubes  
Water Supply Inlet  
Water Regulator Valve  
Control Box  
Control Switch  
Bin Control Thermostat  
Expansion Valve  
Condenser  
Float Switch  
Water Pump  
Drier  
Hot Gas Valve  
Compressor  
ꢀꢀ  
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3. KM-650MRH (remote air-cooled)  
Spray Tubes  
Water Supply Inlet  
Junction Box  
Control Box  
Control Switch  
Bin Control Thermostat  
Receiver Tank  
Hot Gas Valve  
Drier  
Expansion Valve  
Float Switch  
Compressor  
Water Pump  
Liquid Line Valve  
ꢀꢁ  
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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  
ꢀ, 4, 3, ꢁ.  
1. One Minute Fill Cycle  
LED 4 is on. WV opens and the fill period begins. After ꢀ 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 ꢀ 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 ꢀ, 4, and ꢁ 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, ꢀꢁ0, and ꢀ80 seconds (dip switch ꢀ & ꢁ). 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 ꢁ minutes.  
3. Freeze Cycle  
LED ꢀ 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 ꢀ, 3, and ꢁ are on. Comp and FMR continue to run, HGV opens, LLV closes, and  
FMS deenergizes. PM stops for ꢁ seconds and reverses, taking water from the bottom of  
the sump and forcing pressure against the check valve seat allowing water to go through  
the check valve and down the drain. At the same time water flows through the small tube  
to power flush the F/S. When the pump-out timer stops counting, the pump out is complete.  
Pump out always occurs on the ꢁnd harvest after startup. Then, depending on the control  
board setting, pump out occurs every cycle, or every ꢁnd, 5th or ꢀ0th cycle (dip switch 5 &  
6).  
5. Normal Harvest Cycle  
LEDs ꢀ, 4, and ꢁ 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; FMR–remote fan motor; FMS–self-contained fan motor;  
F/S–float switch; HGV–hot gas valve; LLV–Liquid Line Valve; PM–pump motor;  
WV–inlet water valve  
ꢀ3  
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ꢀ4  
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C. Control Board  
• A HOSHIZAKI exclusive solid-state control is employed in KM-650MAH, KM-650MWH  
and KM-650MRH Modular Crescent Cubers.  
• All models are pretested and factory-adjusted.  
CAUTION  
ꢀ. Fragile, handle very carefully.  
ꢁ. 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.  
ꢀ5  
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1. Control Board Layout  
Control Products "E" Control Board  
Output Test Switch  
(used to test relays on board)  
Dip Switch  
Alarm Reset Switch  
Backup Freeze  
Timer LED  
Connector K3  
Harvest Control  
(thermistor)  
Backup Harvest  
Timer LED  
Connector K4  
Open  
(not connected)  
Alarm Buzzer  
Microprocessor  
Power LED  
(lights when  
power is supplied  
to the board)  
(board revision level  
indicated by last ꢁ  
digits on label)  
Relay LEDs (4)  
(indicate which  
Connector K5  
Float Switch  
relays are energized  
as listed below)  
Part Number  
Connector Kꢀ  
LED ꢁ  
Hot Gas Valve (HGV)  
Self-Contained Fan  
Motor (FMS) (FMS  
off when LED on)  
Pins #ꢀ through #ꢀ0  
#ꢀ, 9 Magnetic Contactor  
#ꢁ Hot Gas Valve  
#3 Line Valve  
Self-Contained Fan Motor (FMS)  
#4 Pump Motor (icemaking)  
#5 Pump Motor (drain)  
#6 Water Valve  
#7, ꢀ0 Power (line, bin control)  
#8 Open  
LED 3  
Pump Motor (PM)  
(on at pump out only)  
LED 4  
Water Valve (WV)  
LED ꢀ  
Switch for "C" board  
and "ALPINE" board  
(service boards only)  
Compressor (Comp)  
Remote Fan Motor  
(FMR)  
Transformer  
Connector  
Control Board  
Part Number  
Type  
ꢁAꢀ4ꢀ0-0ꢀ (factory); 2A1410-02 (service)  
HOS-00ꢀA (Control Products - ꢀ0 Pin)  
ꢀ6  
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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 ꢁ0 minutes to complete. The control board will signal this problem  
using ꢁ 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 &  
ꢀ0.  
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 ꢀꢁ7 7°F (53 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 ꢀ 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  
If the pump motor is operated without water, the mechanical seal can fail. To prevent this  
type of failure, 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 ice making 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 ice making cycle. The unit will not start without adequate water in the sump. This  
serves as a low water safety to protect the pump motor from mechanical seal failure.  
For water-cooled model, if the water 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 (ꢀ47Vac  
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 (9ꢁVac 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.  
ꢀ7  
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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 ꢀ 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 ꢀ, 4, 3,  
ꢁ. For more information, see "II.B. Sequence of Operation."  
Time LEDs are On  
Energized  
Components  
Sequence Step  
LED  
Min.  
Max.  
Avg.  
ꢀ Minute Fill Cycle 4  
WV  
60 seconds  
ꢁ minutes ꢁ0 minutes 3 to 5 minutes  
Harvest Cycle  
ꢀ, 4, and ꢁ WV, HGV,  
Comp, FMR  
Freeze Cycle  
Comp, PM, 5 minutes freeze timer 30 to 35 minutes  
FMR/FMS,  
LLV  
setting  
Reverse Pump Out ꢀ, 3, and ꢁ Comp, HGV, 0 seconds ꢁ0 seconds factory setting  
PM, FMR  
The built in safeties shut down the unit and have alarms as follows:  
No. of Beeps  
Type of Alarm  
Notes  
(every 3 sec.)  
High Evaporator Temp.  
(temperature > ꢀꢁ7°F)  
(53°C)  
Check for harvest problem (stuck HGV or  
relay), hot water entering unit, stuck HM,  
or shorted thermistor.  
3
Harvest Backup Timer  
(harvest > ꢁ0 min. for two Check for open thermistor, HGV not  
cycles in a row)  
Orange LED marked H TIMER lights up.  
opening, TXV leaking by, low charge, or  
inefficient compressor.  
Freeze Timer  
Yellow LED marked F TIMER lights up.  
(freeze > specified setting Check for F/S stuck closed (up), WV  
for two cycles in a row) leaking by, HGV leaking by, TXV not  
Timer is factory set using feeding properly, low charge, HM not  
dip switches 9 & ꢀ0 bypassing, or inefficient compressor.  
To manually reset the above safeties, press the alarm reset button with the power  
supply on.  
6
Low Voltage  
(9ꢁVac 5% or less)  
Red LED will turn off if voltage protection  
operates.  
The control voltage safeties automatically  
reset when voltage is corrected.  
7
High Voltage  
(ꢀ47Vac 5% or more)  
Legend: Comp–compressor; 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; TXV–thermostatic expansion valve; WV–inlet  
water valve  
ꢀ8  
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3. Controls and Adjustments  
a) Default Dip Switch Settings  
The dip switch is factory-adjusted to the following positions:  
Dip Switch No.  
KM-650MAH  
KM-650MWH  
KM-650MRH  
3
4
5
6
7
8
9
ꢀ0  
OFF OFF OFF OFF ON ON OFF OFF OFF OFF  
OFF OFF OFF OFF ON ON OFF OFF OFF OFF  
OFF OFF OFF OFF ON ON OFF OFF ON OFF  
Freeze Timer (9 & ꢀ0)  
Normally in the OFF position.  
Pump-Out Frequency Control (5 & 6)  
Pump-Out Timer (3 & 4)  
Harvest Timer (ꢀ & ꢁ)  
b) Harvest Control – Thermistor  
A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies  
depending on the suction line temperatures. The thermistor detects the temperature of  
the evaporator outlet to start the harvest timer. No adjustment is required. If necessary,  
check for resistance between thermistor leads, and visually check the thermistor  
mounting, located on the suction line next to the evaporator outlet.  
Temperature (°F) Temperature (°C) Resistance (k)  
0
-ꢀ8  
-ꢀꢁ  
0
ꢀ4.40ꢀ  
ꢀ0.6ꢀ3  
6.000  
3.87ꢀ  
ꢁ.474  
ꢀ.633  
ꢀ0  
3ꢁ  
50  
70  
90  
ꢀ0  
ꢁꢀ  
3ꢁ  
Check a thermistor for resistance by using the following procedure:  
ꢀ) Disconnect the connector K3 on the board.  
ꢁ) Remove the thermistor. See "V.K. Removal and Replacement of Thermistor."  
3) Immerse the thermistor sensor portion in a glass containing ice and water for ꢁ or 3  
minutes.  
4) Check for a resistance between thermistor leads. Normal reading is within 3.5 to 7 k.  
Replace the thermistor if it exceeds the normal reading.  
ꢀ9  
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c) Harvest Timer (dip switch 1 & 2)  
The harvest timer starts counting when the thermistor reads 48°F (9°C) at the  
evaporator outlet.  
No adjustment is required under normal use, as the harvest timer is adjusted to the  
suitable position. However, a setting longer than the factory setting may be advised in  
cases where the flush provided at harvest needs to be prolonged for extra cleaning.  
Before changing this setting, call the HOSHIZAKI Technical Support Department at  
ꢀ-800-ꢁ33-ꢀ940 for recommendations. Keep in mind that setting the harvest timer to a  
longer setting will decrease ꢁ4 hour production.  
Dip Switch Setting  
Time  
(seconds)  
No. ꢀ  
OFF  
ON  
No. ꢁ  
OFF  
OFF  
ON  
60  
90  
OFF  
ON  
ꢀꢁ0  
ꢀ80  
ON  
d) Pump-Out Timer (dip switch 3 & 4)  
When a freeze cycle is completed, the pump motor stops, and the icemaker resumes  
operation in ꢁ seconds. Then, during cycles when a pump out is called for, the pump  
motor drains the water tank for the time determined by the pump-out timer. The pump-  
out timer also acts in place of the harvest timer during cycles with a pump out.  
The pump-out timer is factory-adjusted, and no adjustment is required.  
Time (seconds)  
Dip Switch Setting  
Tꢀ  
ꢀ0  
ꢀ0  
ꢀ0  
ꢁ0  
No. 3  
OFF  
ON  
No. 4  
OFF  
OFF  
ON  
Tꢁ  
ꢀ50  
ꢀ80  
ꢀꢁ0  
ꢀ80  
OFF  
ON  
ON  
Tꢀ: Time to drain the water tank  
Tꢁ: Harvest timer at pump out  
Pump out always occurs on the ꢁnd harvest after startup. Then, depending on the pump-  
out frequency control setting (dip switch 5 & 6), pump out occurs every cycle, or every  
ꢁnd, 5th or ꢀ0th cycle.  
ꢁ0  
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e) Pump-Out Frequency Control (dip switch 5 & 6)  
The pump motor drains the water tank at the frequency set by the pump-out frequency  
control.  
The pump-out frequency control is factory-adjusted to drain the water tank every ꢀ0  
cycles, and no adjustment is required. However, where water quality is bad and the  
icemaker needs a pump drain more often, the pump-out frequency can be adjusted as  
shown in the table below.  
Dip Switch Setting  
Frequency  
No. 5  
OFF  
ON  
No. 6  
OFF  
OFF  
ON  
every cycle  
every ꢁ cycles  
every 5 cycles  
every ꢀ0 cycles  
OFF  
ON  
ON  
f) Freeze Timer (dip switch 9 & 10)  
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 ꢁ 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  
Time  
(minutes)  
No. 9  
OFF  
OFF  
ON  
No. ꢀ0  
OFF  
ON  
60  
50  
70  
60  
OFF  
ON  
ON  
g) Bin Control  
CAUTION  
When the ambient temperature is below 45°F (7°C), the bin control thermostat  
operates to stop the icemaker even if the ice storage bin is empty. When the  
thermostat is set in the prohibited range, the icemaker operates continuously  
even if the ice storage bin is filled with ice. Setting in the prohibited range might  
cause severe damage to the icemaker resulting in failure.  
No adjustment is required under normal use, as the bin control is factory-adjusted. Adjust  
it, if necessary, so that the icemaker stops automatically within ꢀ0 seconds after ice  
contacts the bin control thermostat bulb.  
ꢁꢀ  
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4. Control Board Check Procedure  
Before replacing a control board that does not show a visible defect and that you suspect  
is bad, always conduct the following check procedure. This procedure will help you verify  
your diagnosis.  
ꢀ) Check the dip switch settings to assure that #3, 4, 7, 8, 9, & ꢀ0 are in the factory default  
position. On units with a slide-type output test switch, the output test switch (S3) should  
be OFF. Switches ꢀ, ꢁ, 5, & 6 are cleaning adjustments and the settings are flexible.  
ꢁ) Turn the control switch to ICE and check for proper control voltage. If the red LED is ON,  
the control voltage is good. If the red LED is OFF, check the control transformer circuit.  
3) Check the ꢀꢀ5 volt input at the ꢀ0-pin connector. Check the brown wire at pin #ꢀ0 to a  
white neutral wire for ꢀꢀ5 volts. (Always choose a white neutral wire to establish a good  
neutral connection when checking voltages.) A jumper also feeds ꢀꢀ5 volts into pin #7.  
If no voltage is present, check the ꢀꢀ5 volt supply circuit.  
4) The output test switch provides a relay sequence test. On units with a slide-type output  
test switch, move the control switch to the OFF position, move the output test switch to  
the ON position, then move the control switch to the ICE position. On units with a push-  
type output test switch, make sure the control switch is in the ICE position, then press  
the output test switch. The correct lighting sequence should be none, ꢁ, 3, 4, ꢀ, and 4,  
normal sequence every 5 seconds. Components (e.g., the compressor) will cycle during  
the test. Note that the order of the relays from the outer edge of the board is ꢀ, 4, 3, ꢁ.  
Note: If the LEDs light in a different sequence or the 5–second interval does not occur,  
the control board is bad and should be replaced.  
5) After checking the sequence, place the output test switch back in the OFF position  
on units with a slide-type switch. The output test switch must remain in the OFF  
position during normal operation. On units with a push-type output test switch, the unit  
automatically resumes normal operation after the test. The unit begins normal operation  
with the ꢀ minute fill cycle.  
5. Control Board Replacement  
The application switch located between relay X3 & X4 must be set to match the original  
board application. Place this switch in the ALP position if there is no white wire supplied  
to the Kꢀ connector. If there is a white wire, place the switch in the C position. If this  
switch is placed in the wrong position either the compressor contactor will remain  
energized with the control switch OFF or the unit will not start.  
The dip switches should be adjusted to the factory default settings as outlined in this  
manual. Dip switch #8 must remain in the OFF position.  
ꢁꢁ  
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III.Technical Information  
A. Water Circuit and Refrigeration Circuit  
1. KM-650MAH (air-cooled)  
ꢁ3  
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2. KM-650MWH (water-cooled)  
ꢁ4  
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3. KM-650MRH (remote air-cooled)  
ꢁ5  
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B. Wiring Diagrams  
1. KM-650MAH (air-cooled) and KM-650MWH (water-cooled)  
*
ꢀꢁV  
* Pressure Switch  
Air-Cooled Model  
Water-Cooled Model  
Cut-out  
Cut-in  
4ꢀꢁ ꢁꢀ PSIG  
384 ꢁꢀ PSIG  
0
0
3ꢁ7 ꢁꢀ PSIG  
ꢁ84 ꢁꢀ PSIG  
ꢁ6  
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2. KM-650MRH (remote air-cooled)  
ꢀꢁV  
*
* Pressure Switch  
Cut-out  
Cut-in  
4ꢀꢁ ꢁꢀ PSIG  
0
3ꢁ7 ꢁꢀ PSIG  
ꢁ7  
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C. Performance Data  
1. KM-650MAH (air-cooled)  
APPROXIMATE ICE  
PRODUCTION PER 24 HR.  
WATER TEMP. (ºF/ºC)  
70/21  
AMBIENT TEMP.  
(ºF/ºC)  
50/10  
90/32  
70/21  
80/27  
589  
572  
267  
259  
566  
537  
257  
243  
526  
490  
238  
222  
90/32  
100/38  
566  
555  
257  
252  
512  
501  
232  
227  
467  
426  
212  
193  
lbs./day kg./day  
APPROXIMATE ELECTRIC  
CONSUMPTION  
70/21  
80/27  
90/32  
1100  
1131  
1141  
1138  
1141  
1195  
1240  
1245  
1170  
1209  
1261  
1280  
watts  
100/38  
70/21  
APPROXIMATE WATER  
CONSUMPTION PER 24 HR.  
257  
224  
214  
0.97  
0.85  
0.81  
214  
156  
108  
0.81  
0.59  
0.41  
190  
153  
95  
0.72  
0.58  
0.36  
80/27  
90/32  
gal./day m3/day  
100/38  
163  
0.62  
105  
0.40  
84  
0.32  
FREEZING CYCLE TIME  
70/21  
80/27  
30  
31  
32  
35  
35  
38  
90/32  
100/38  
70/21  
32  
33  
37  
38  
40  
43  
min.  
HARVEST CYCLE TIME  
4.6  
3.9  
3.6  
80/27  
90/32  
4.1  
3.9  
3.0  
2.2  
3.0  
2.1  
min.  
100/38  
70/21  
80/27  
90/32  
3.1  
2.2  
2.0  
HEAD PRESSURE  
225  
241  
246  
15.8  
17.0  
17.3  
246  
275  
298  
17.3  
19.3  
21.0  
270  
295  
320  
19.0  
20.7  
22.5  
PSIG kg/cm2G  
100/38  
70/21  
80/27  
90/32  
100/38  
249  
53  
54  
55  
56  
17.5  
3.7  
3.8  
3.9  
3.9  
303  
55  
57  
59  
60  
21.3  
3.9  
4.0  
4.2  
4.2  
341  
58  
61  
63  
67  
24.0  
4.1  
4.3  
4.4  
4.7  
SUCTION PRESSURE  
PSIG kg/cm2G  
TOTAL HEAT OF REJECTION FROM CONDENSER  
10,600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]  
Note:  
ꢀ. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold  
should be used for reference only.  
ꢁ. We reserve the right to make changes in specifications and design without prior  
notice.  
ꢁ8  
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2. KM-650MWH (water-cooled)  
APPROXIMATE ICE  
PRODUCTION PER 24 HR.  
WATER TEMP. (ºF/ºC)  
70/21  
AMBIENT TEMP.  
(ºF/ºC)  
50/10  
90/32  
70/21  
80/27  
680  
676  
308  
307  
675  
668  
306  
303  
626  
595  
284  
270  
90/32  
100/38  
675  
651  
306  
295  
662  
647  
300  
294  
598  
540  
271  
245  
lbs./day kg./day  
APPROXIMATE ELECTRIC  
CONSUMPTION  
70/21  
80/27  
90/32  
1020  
1027  
1029  
1028  
1029  
1040  
1050  
1051  
1036  
1044  
1055  
1060  
watts  
100/38  
70/21  
APPROXIMATE WATER  
CONSUMPTION PER 24 HR.  
662  
713  
729  
2.51  
2.70  
2.76  
729  
817  
890  
2.76  
3.09  
3.37  
1173  
1457  
1457  
4.44  
5.52  
5.52  
80/27  
90/32  
gal./day m3/day  
100/38  
980  
3.71  
1023  
3.87  
1977  
7.49  
FREEZING CYCLE TIME  
70/21  
80/27  
27  
28  
28  
30  
30  
32  
90/32  
100/38  
70/21  
28  
29  
31  
31  
33  
35  
min.  
HARVEST CYCLE TIME  
4.7  
4.1  
3.7  
80/27  
90/32  
4.3  
4.1  
3.4  
2.8  
3.1  
2.5  
min.  
100/38  
70/21  
80/27  
90/32  
3.4  
2.7  
2.1  
HEAD PRESSURE  
231  
231  
231  
16.2  
16.2  
16.2  
231  
231  
231  
16.2  
16.2  
16.2  
238  
242  
240  
16.7  
17.0  
16.9  
PSIG kg/cm2G  
100/38  
70/21  
80/27  
90/32  
100/38  
235  
50  
51  
51  
51  
16.5  
3.5  
3.6  
3.6  
3.6  
233  
51  
54  
56  
56  
16.4  
3.6  
3.8  
3.9  
3.9  
249  
53  
54  
56  
57  
17.5  
3.7  
3.8  
4.0  
4.0  
SUCTION PRESSURE  
PSIG kg/cm2G  
TOTAL HEAT OF REJECTION FROM CONDENSER  
10,000 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]  
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]  
77 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]  
TOTAL HEAT OF REJECTION FROM COMPRESSOR  
WATER FLOW FOR CONDENSER  
PRESSURE DROP OF COOLING WATER LINE  
less than 10 PSIG  
Note:  
ꢀ. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold  
should be used for reference only.  
ꢁ. We reserve the right to make changes in specifications and design without prior  
notice.  
ꢁ9  
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3. KM-650MRH (remote air-cooled)  
APPROXIMATE ICE  
AMBIENT TEMP.  
WATER TEMP. (ºF/ºC)  
70/21  
PRODUCTION PER 24 HR.  
(ºF/ºC)  
50/10  
90/32  
70/21  
80/27  
615  
601  
279  
273  
597  
574  
271  
260  
556  
523  
252  
237  
90/32  
100/38  
597  
583  
271  
264  
554  
543  
251  
246  
506  
462  
230  
210  
lbs./day kg./day  
APPROXIMATE ELECTRIC  
CONSUMPTION  
70/21  
80/27  
90/32  
1150  
1172  
1179  
1183  
1179  
1218  
1250  
1257  
1212  
1247  
1281  
1310  
watts  
100/38  
70/21  
APPROXIMATE WATER  
CONSUMPTION PER 24 HR.  
266  
231  
220  
169  
1.01  
0.87  
0.83  
0.64  
220  
161  
111  
108  
0.83  
0.61  
0.42  
0.41  
198  
160  
100  
91  
0.75  
0.61  
0.38  
0.34  
80/27  
90/32  
gal./day m3/day  
100/38  
FREEZING CYCLE TIME  
70/21  
80/27  
29  
30  
31  
33  
33  
36  
90/32  
100/38  
70/21  
31  
32  
34  
35  
37  
40  
min.  
HARVEST CYCLE TIME  
4.6  
3.8  
3.6  
80/27  
90/32  
4.0  
3.8  
2.8  
2.0  
3.0  
2.0  
min.  
100/38  
70/21  
80/27  
3.0  
2.0  
2.0  
HEAD PRESSURE  
214  
229  
15.1  
16.1  
233  
258  
16.4  
18.2  
254  
275  
17.8  
19.4  
90/32  
100/38  
233  
235  
16.4  
16.6  
279  
283  
19.6  
19.9  
298  
315  
21.0  
22.2  
PSIG kg/cm2G  
SUCTION PRESSURE  
70/21  
80/27  
90/32  
100/38  
51  
53  
53  
54  
3.6  
3.7  
3.8  
3.8  
53  
56  
58  
59  
3.8  
3.9  
4.1  
4.2  
56  
59  
61  
64  
4.0  
4.1  
4.3  
4.5  
PSIG kg/cm2G  
TOTAL HEAT OF REJECTION FROM CONDENSER  
TOTAL HEAT OF REJECTION FROM COMPRESSOR  
CONDENSER VOLUME  
9400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]  
1600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]  
40 CU. IN (URC-5F)  
Note:  
ꢀ. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold  
should be used for reference only.  
ꢁ. We reserve the right to make changes in specifications and design without prior  
notice.  
30  
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IV. Service Diagnosis  
A. 10-Minute KM Diagnostic Procedure  
The ꢀ0 minute check out procedure is basically a sequence check which can be used  
at unit start-up or for system diagnosis. Using this check out procedure will allow you  
to diagnose electrical system and component failures in approximately ꢀ0 minutes  
under normal operating conditions of 70°F or warmer air and 50°F or warmer water  
temperatures. Before conducting a ꢀ0 minute checkout, check for correct installation,  
proper voltage per unit nameplate and adequate water supply. As you go through the  
procedure, check to assure the components energize and de-energize correctly. If not,  
those components and controls are suspect. Check for voltage at the ꢀ0-pin connector.  
ꢀ) Turn power OFF and access the control box.  
ꢁ) Turn power ON and place the control switch in ICE position. A 5 second delay occurs.  
3) One Minute Fill Cycle – The inlet water valve is energized. After ꢀ minute, the control  
board checks the float switch. If the float switch is closed, the unit cycles to harvest. If  
closed, continue to step 4. If the float switch is open, the unit repeats the ꢀ minute fill  
cycle until water enters and the float switch closes (low water safety protection during  
initial start up and at the end of each harvest). Diagnosis: If the water valve does not  
open, check for no supply voltage at water valve terminals, bad coil, or plugged screen  
or external filter (no water flow). If unit fails to start harvest, check for open float switch  
or bad ꢀ minute timer in board.  
4) Initial Harvest Cycle – Inlet water valve remains energized, contactor coil energizes to  
start the compressor (and fan motor on a remote condenser unit), and the hot gas valve  
energizes. The evaporator warms and the thermistor senses 48°F (9°C). The control  
board then receives the thermistor's 3.9 kΩ signal and turns operation of harvest over  
to the harvest timer. The timer completes counting (ꢀ to 3 minutes). The unit then cycles  
to freeze. Diagnosis: Check if compressor is running, hot gas valve is open, water  
valve still open. Average harvest cycle at factory setting is ꢁ to 3 minutes. How long  
does initial harvest last? ꢀ.5 minutes after initial harvest begins, touch the compressor  
discharge line. Is it hot? If not check refrigerant pressures and compressor operation.  
If it is hot, touch the inlet line to the evaporator. Is it hot? If it is hot and the freeze cycle  
is not starting, check the harvest timer adjustment, the thermistor for open circuit, the  
discharge line temperature, compressor efficiency, and if the hot gas valve is fully open.  
5) Freeze Cycle – Compressor remains energized, pump motor, (line valve on remote  
condenser unit), and fan motor energize. The inlet water valve and hot gas valve  
de-energize. The unit is held in freeze by a 5 minute short cycle protection timer.  
After 5 minutes, the freeze cycle operation is transferred to the float switch for  
freeze termination. During the first 5 minutes of freeze, confirm that the evaporator  
temperature drops. After 7 minutes in freeze, remove the black float switch lead  
from the K5 connector. The unit should immediately switch to the pump-out cycle.  
Diagnosis: If the evaporator is not cold, check to see if the hot gas valve is still open  
or if the expansion valve is not opening properly, if the water valve is continuing to fill  
the reservoir, if there are improper unit pressures, an inoperative compressor, or an  
inoperative headmaster (C.P.R.) (remote condenser unit only). If the unit remains in  
3ꢀ  
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freeze with the float switch removed, replace the board.  
Note: Normal freeze cycle will last ꢁ0 to 40 minutes depending on model and  
conditions. Cycle times and pressures should follow performance data provided  
in this manual.  
6) Pump-Out Cycle (10/20 second pump out) – the compressor remains energized,  
the hot gas valve energizes, the fan motor de-energizes, the pump motor stops for  
ꢁ seconds and starts in reverse rotation for ꢀ0/ꢁ0 seconds. (This removes contaminants  
from the water reservoir through the check valve (drain valve) and down the drain and  
allows for a power flush of the float switch.) Check for clear tubing at the check valve  
housing and check the unit drain for water flow. Diagnosis: If the pump motor does not  
reverse, check the circuit and capacitor. If water does not pump out, remove the check  
valve (drain valve) housing and check/clean the valve assembly.  
7) Normal Harvest Cycle – same as the initial harvest cycle – Return to step 4.  
Note: Unit continues to cycle until bin control is satisfied or power is switched OFF. (The  
pump out cycle can be adjusted to occur every cycle, or every ꢁ, 5, or ꢀ0 cycles.  
The factory default is every ꢀ0 cycles.) The unit always restarts at the ꢀ minute fill  
cycle.  
B. Diagnostic Charts  
1. No Ice Production  
Problem  
Possible Cause  
Remedy  
[ꢀ] The icemaker will not a)Power Supply  
start.  
ꢀ. OFF position.  
ꢀ. Move to ON position.  
ꢁ. Tighten.  
ꢁ. Loose connection.  
3. Bad contacts.  
3. Check for continuity and  
replace.  
4. Voltage too high or too 4. Check and get  
low.  
recommended voltage.  
b)Fuse (Inside fused  
disconnect, if any)  
ꢀ. Blown.  
ꢀ. Check for short circuit and  
replace.  
c)Control Switch  
ꢀ. OFF position.  
ꢁ. Bad contacts.  
ꢀ. Move to ICE position.  
ꢁ. Check for continuity and  
replace.  
d)Bin Control Thermostat ꢀ. Tripped with bin filled ꢀ. Remove ice.  
with ice.  
ꢁ. Ambient temperature ꢁ. Increase ambient  
too cool.  
temperature.  
3. Set too warm.  
3. See "II.C.3. Controls  
and Adjustments, g) Bin  
Control."  
4. Bulb out of position.  
5. Bad contacts.  
4. Place in position.  
5. Check for continuity and  
replace.  
e)High Pressure Control ꢀ. Bad contacts.  
ꢀ. Check for continuity and  
replace.  
ꢁ. Dirty air filter or  
condenser.  
ꢁ. Clean.  
3ꢁ  
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Problem  
Possible Cause  
Remedy  
[ꢀ] The icemaker will not e)High Pressure Control 3. Ambient or condenser 3. Reduce temperature.  
start. (continued)  
(continued)  
water temperature too  
warm.  
4. Refrigerant  
overcharged.  
4. Recharge.  
5. Fan not operating.  
(except water-cooled  
model)  
5. See chart ꢀ.[6]  
6. Refrigerant line or  
components plugged.  
6. Clean and replace drier.  
7. Check and get  
7. Condenser water  
pressure too low or off. recommended pressure.  
(water-cooled model  
only)  
f) Transformer  
ꢀ. Coil winding opened ꢀ. Replace.  
or shorted.  
g)Wiring to Control Board ꢀ. Loose connections or ꢀ. Check for continuity and  
open.  
replace.  
h)Thermistor  
ꢀ. Leads shorted or  
opened and high  
ꢀ. See "II.C.3. Controls and  
Adjustments, b) Harvest  
temperature or harvest Control."  
backup timer safety  
operates. (ꢀ beep or ꢁ  
beep alarm)  
i) Hot Gas Valve  
ꢀ. Continues to open  
in freeze cycle and  
freeze timer safety  
operates. (3 beep  
alarm)  
ꢀ. Check for hot gas valve  
stuck open and replace.  
j) Water Supply Line  
ꢀ. Water supply off and ꢀ. Check and get  
water supply cycle  
does not finish.  
recommended pressure.  
ꢁ. Condenser water  
pressure too low  
or off and pressure  
control opens and  
closes frequently to  
finally operate high  
temperature safety.  
(ꢀ beep alarm)  
ꢁ. Check and get  
recommended pressure.  
k)Inlet Water Valve  
ꢀ. Mesh filter or orifice  
gets clogged and  
water supply cycle  
does not finish.  
ꢀ. Clean.  
ꢁ. Coil winding opened. ꢁ. Replace.  
3. Wiring to water valve. 3. Check for loose  
connection or open, and  
replace.  
l) Control Board  
ꢀ. Defective.  
ꢀ. See "II.C.4. Control Board  
Check Procedure."  
33  
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Problem  
Possible Cause  
Remedy  
[ꢀ] The icemaker will not m)Interlock Switch  
ꢀ. OFF position.  
ꢁ. Bad contacts.  
ꢀ. Move to ON position.  
start. (continued)  
(Cleaning Valve)  
ꢁ. Check for continuity and  
replace.  
n)Wash Switch  
a)Float Switch  
ꢀ. WASH position.  
ꢁ. Bad contacts.  
ꢀ. Move to ICE position.  
ꢁ. Check and replace.  
ꢀ. Place in position.  
[ꢁ] Water continues to  
be supplied, and the  
icemaker will not  
start.  
ꢀ. Connector  
disconnected.  
ꢁ. Leads opened or  
defective switch.  
ꢁ. Check and replace.  
3. Float does not move 3. Clean or replace.  
freely.  
b)Control Board  
ꢀ. Defective.  
ꢀ. Replace.  
[3] Compressor will  
not start or stops  
operating.  
a)Magnetic Contactor  
ꢀ. Bad contacts.  
ꢀ. Check for continuity and  
replace.  
ꢁ. Coil winding opened. ꢁ. Replace.  
b)Start Capacitor or Run ꢀ. Defective.  
Capacitor  
ꢀ. Replace.  
c)Internal Overload  
ꢀ. Loose terminal.  
ꢀ. Tighten or replace.  
Protector Open (check  
ꢀ through 3 to the right  
and d through f below)  
ꢁ. Voltage.  
ꢁ. Check and correct.  
3. Clean.  
3. Dirty condenser.  
d)Starter  
ꢀ. Bad contacts.  
ꢀ. Check and replace.  
ꢁ. Coil winding opened. ꢁ. Replace.  
e)Compressor  
ꢀ. Wiring to compressor. ꢀ. Check for loose  
connection or open, and  
replace.  
ꢁ. Defective.  
ꢁ. Replace.  
3. Protector tripped.  
3. Reduce temperature.  
f) Control Board  
a)Inlet Water Valve  
b)Control Board  
ꢀ. No power to contactor. ꢀ. See "II.C.4. Control Board  
Check Procedure."  
[4] Water continues to  
be supplied in freeze  
cycle.  
ꢀ. Diaphragm does not ꢀ. Check for water leaks with  
close.  
icemaker off.  
ꢀ. Defective.  
ꢀ. See "II.C.4. Control Board  
Check Procedure."  
[5] No water comes from a)Water Supply Line  
spray tubes. Water  
ꢀ. Water pressure too  
low and water level in  
water tank too low.  
ꢀ. Check and get  
recommended pressure.  
pump will not start, or  
freeze cycle time is  
too short.  
b)Inlet Water Valve  
ꢀ. Dirty mesh filter or  
orifice and water level  
in water tank too low.  
ꢀ. Clean.  
c)Water System  
ꢀ. Water leaks.  
ꢀ. Check connections for  
water leaks, and replace.  
34  
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Problem  
Possible Cause  
Remedy  
[5] No water comes from c)Water System  
ꢁ. Clogged.  
ꢁ. Clean.  
spray tubes. Water  
pump will not start, or  
freeze cycle time is  
too short. (continued)  
(continued)  
3. Pump out check valve 3. Check assembly and  
leaking by. clean.  
ꢀ. Motor winding opened. ꢀ. Replace.  
d)Pump Motor  
ꢁ. Bearing worn out.  
3. Wiring to pump motor. 3. Check for loose  
connection or open, and  
ꢁ. Replace.  
replace.  
4. Defective capacitor.  
4. Replace.  
5. Defective or bound  
impeller.  
5. Replace and clean.  
6. Mechanical seal worn 6. Check and replace.  
out.  
e)Control Board  
a)Fan Motor  
ꢀ. Defective.  
ꢀ. See "II.C.4. Control Board  
Check Procedure."  
[6] Fan motor will  
not start, or is not  
operating.  
ꢀ. Motor winding opened. ꢀ. Replace.  
ꢁ. Bearing worn out.  
3. Wiring to fan motor.  
ꢁ. Replace.  
3. Check for loose  
connection or open, and  
replace.  
4. Defective capacitor.  
5. Fan blade bound.  
ꢀ. Defective.  
4. Replace.  
5. Check and replace.  
b)Control Board  
a)Refrigerant  
ꢀ. See "II.C.4. Control Board  
Check Procedure."  
[7] All components  
run, but no ice is  
produced.  
ꢀ. Undercharged.  
ꢀ. Check for leaks and  
recharge.  
ꢁ. Air or moisture  
trapped.  
ꢁ. Replace drier and  
recharge.  
b)Compressor  
ꢀ. Defective valve.  
ꢀ. Replace.  
c)Hot Gas Valve  
ꢀ. Continues to open in ꢀ. Check and replace.  
freeze cycle.  
d)Line Valve  
ꢀ. Continues to close in ꢀ. Check and replace.  
freeze cycle.  
e)Inlet Water Valve  
ꢀ. Water valve is wide  
open during freeze.  
ꢀ. Check for water leaks with  
icemaker off.  
f) Headmaster (C.P.R.)  
(Remote Unit)  
ꢀ. Not operating properly ꢀ. Replace headmaster.  
and liquid line  
temperature too warm.  
g)Water Supply Line  
(water-cooled model  
only)  
ꢀ. Condenser water  
pressure too low or off  
and pressure control  
opens and closes  
frequently.  
ꢀ. Check and get  
recommended pressure.  
h)Water Regulator  
(water-cooled model  
only)  
ꢀ. Set too high.  
ꢀ. Adjust or replace. See  
"V.I. Adjustment of Water  
Regulating Valve."  
35  
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2. Evaporator is Frozen Up  
Problem  
Possible Cause  
Remedy  
[ꢀ]Freeze cycle time is a)Float Switch  
too long.  
ꢀ. Leads short-circuit or ꢀ. Check and replace.  
defective switch.  
ꢁ. Float does not move ꢁ. Clean or replace.  
freely.  
b)Inlet Water Valve  
c) Control Board  
ꢀ. Diaphragm does not ꢀ. Check for water leaks with  
close.  
icemaker off.  
ꢀ. Defective.  
ꢀ. See "II.C.4. Control Board  
Check Procedure."  
[ꢁ]All ice formed on  
evaporator does not  
fall into bin in harvest  
cycle.  
a)Evaporator  
ꢀ. Scaled up.  
ꢀ. Clean.  
b)Water Supply Line  
ꢀ. Water pressure too  
low.  
ꢀ. Check and get  
recommended pressure.  
c) Water Filter System  
d)Inlet Water Valve  
ꢀ. Dirty/Restricted  
ꢀ. Replace filter.  
ꢀ. Clean.  
ꢀ. Dirty mesh filter or  
orifice.  
ꢁ. Diaphragm does not ꢁ. Check for water leaks with  
close.  
icemaker off.  
e)Ambient and/or water ꢀ. Too cool.  
temperature.  
ꢀ. Increase temperature.  
f) Line Valve  
ꢀ. Continues to open in ꢀ. Check operation in harvest  
harvest cycle.  
cycle and replace.  
g)Thermistor  
h)Control Board  
ꢀ. Out of position or  
loose attachment.  
ꢀ. See "V.I. Removal  
and Replacement of  
Thermistor."  
ꢀ. Harvest timer is set  
too short.  
ꢀ. Adjust longer, referring  
to "II.C.3. Controls and  
Adjustments, c) Harvest  
Timer.  
ꢁ. Defective.  
ꢁ. See "II.C.4. Control Board  
Check Procedure."  
[3]Other  
a)Spray Tubes  
ꢀ. Clogged.  
ꢀ. Clean  
ꢁ. Out of position.  
ꢀ. Dirty.  
ꢁ. Place in position.  
ꢀ. Clean.  
b)Water System  
c) Refrigerant  
ꢀ. Undercharged.  
ꢀ. Check for leaks and  
recharge.  
d)Expansion Valve  
e)Hot Gas Valve  
ꢀ. Bulb out of position or ꢀ. Place in position.  
loose attachment.  
ꢁ. Defective.  
ꢁ. Replace.  
ꢀ. Coil winding opened. ꢀ. Replace.  
ꢁ. Plunger does not  
move.  
ꢁ. Replace.  
3. Wiring to hot gas  
valve.  
3. Check for loose  
connection or open, and  
replace.  
f) Ice Cube Guide  
ꢀ. Out of position and ice ꢀ. Place in position.  
trapped.  
36  
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Problem  
Possible Cause  
Remedy  
[3]Other (continued)  
g)Water Supply Line  
ꢀ. Too small; requires  
3/8" OD line dedicated  
per machine.  
ꢀ. Increase water line size.  
h)Water Filter  
ꢀ. Flow rate too small.  
ꢀ. Replace with filter that has  
larger flow rate.  
3. Low Ice Production  
Problem  
Possible Cause  
Remedy  
[ꢀ]Freeze cycle time is a)See chart ꢀ.[3] and check dirty air filter or condenser, ambient or water  
long.  
temperature, water pressure, condenser water regulating valve (water-cooled  
model), and refrigerant charge.  
b)See chart ꢁ.[ꢀ] and check float switch, inlet water valve and control board.  
c) Check pump, hot gas valve, headmaster (C.P.R.) (remote air-cooled model),  
expansion valve, refrigeration check valve, and compressor.  
[ꢁ]Harvest cycle time is a)See chart ꢁ.[ꢁ] and check control board, thermistor, evaporator, ambient and/or  
long.  
water temperature, water supply line, inlet water valve, line valve, and gas valve.  
4. Abnormal Ice  
Problem  
Possible Cause  
Remedy  
[ꢀ] Small cubes.  
a)Ice Cube Guide  
ꢀ. Out of position.  
Circulated water falls  
into bin.  
ꢀ. Place in position.  
b)See chart ꢀ.[5] and check water supply line, inlet water valve, water system,  
pump motor, and control board.  
c) Pump Out Check Valve ꢀ. Dirty.  
ꢀ. Clean.  
[ꢁ] Cloudy or irregular  
cubes.  
a)See chart ꢁ.[ꢀ] and ꢁ.[3], and check float switch, inlet water valve, control  
board, spray tubes, water system, refrigerant charge, and expansion valve.  
b)Spray Guide  
c) Water Quality  
ꢀ. Dirty.  
ꢀ. Clean.  
ꢀ. High hardness or  
contains impurities.  
ꢀ. Install a water softener or  
filter.  
5. Other  
Problem  
Possible Cause  
Remedy  
[ꢀ]Icemaker will not stop a)Bin Control Thermostat ꢀ. Set too cold.  
when bin is filled with  
ꢀ. Adjust warmer.  
ꢁ. Defective.  
ꢁ. Replace  
ice.  
[ꢁ] Abnormal noise.  
a)Pump Motor  
b)Fan Motor  
ꢀ. Bearings worn out.  
ꢀ. Bearings worn out.  
ꢀ. Replace  
ꢀ. Replace  
ꢁ. Fan blade deformed. ꢁ. Replace fan blade.  
3. Fan blade does not  
move freely.  
3. Replace.  
c) Compressor  
ꢀ. Bearings worn out or ꢀ. Replace.  
cylinder valve broken.  
37  
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Problem  
Possible Cause  
Remedy  
[ꢁ] Abnormal noise.  
(continued)  
c) Compressor  
(continued)  
ꢁ. Mounting pad out of  
position.  
ꢁ. Reinstall.  
d)Refrigerant Lines  
ꢀ. Rub or touch other  
lines or surfaces.  
ꢀ. Replace.  
[3]Ice in storage bin  
often melts.  
a)Drain Line(s)  
ꢀ. Plugged.  
ꢀ. Clean.  
b)Icemaker and Bin  
ꢀ. Drains not run  
separately.  
ꢀ. Separate the drain lines.  
c) Ice Cube Guide  
ꢀ. Out of position.  
Circulated water falls  
into bin.  
ꢀ. Place in position.  
38  
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V. Removal and Replacement of Components  
IMPORTANT  
Ensure all components, fasteners and thumbscrews are securely in place after  
the equipment is serviced.  
IMPORTANT  
ꢀ. The Polyol Ester (POE) oils used in R-404A units can absorb moisture  
quickly. Therefore it is important to prevent moisture from entering the system  
when replacing or servicing parts.  
ꢁ. 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.  
3. Do not leave the system open for longer than ꢀ5 minutes when replacing or  
servicing parts.  
A. Service for Refrigerant Lines  
1. Refrigerant Recovery  
The icemaker unit is provided with refrigerant access valves. Using proper refrigerant  
practices recover the refrigerant from the access valves and store it in an approved  
container. Do not discharge the refrigerant into the atmosphere.  
2. Evacuation and Recharge (R-404A)  
ꢀ) Attach service manifold hoses and a vacuum pump to the system. Be sure to connect  
charging hoses to both high and low-side access valves.  
IMPORTANT  
The vacuum level and vacuum pump may be the same as those for current  
refrigerants. However, the rubber hose and gauge manifold to be used for  
evacuation and refrigerant charge should be exclusively for POE oils.  
ꢁ) Turn on the vacuum pump. Never allow the oil in the vacuum pump to flow backward.  
3) Allow the vacuum pump to pull down to a ꢁ9.9" Hg vacuum. Evacuating period depends  
on pump capacity.  
4) Close the low-side valve and high-side valve on the service manifold.  
5) Disconnect the vacuum pump and attach a refrigerant service cylinder to the high-side  
line. 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. For remote air-cooled models, see the charge label in the machine  
compartment. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant  
which meets ARI Standard No. 700-88 be used.  
39  
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6) A liquid charge is recommended for charging an R-404A system. Invert the service  
cylinder and place it on scales. Open the high-side, service manifold valve.  
7) Allow the system to charge with liquid until the proper charge weight is met.  
8) If necessary, add any remaining charge to the system through the low-side. Use a  
throttling valve or liquid dispensing device to add the remaining liquid charge through  
the low-side access port with the unit running.  
9) Close the two refrigerant access valves, and disconnect the service manifold hoses.  
ꢀ0) Cap the access valves to prevent a possible leak.  
B. Brazing  
DANGER  
ꢀ. Refrigerant R-404A itself is not flammable at atmospheric pressure and  
temperatures up to ꢀ76°F (80°C).  
ꢁ. Refrigerant R-404A itself is not explosive or poisonous. However, when  
exposed to high temperatures (open flames) R-404A can be decomposed to  
form hydrofluoric acid and carbonyl fluoride both of which are hazardous.  
3. Always recover the refrigerant and store it in an approved container. Do not  
discharge the refrigerant into the atmosphere.  
4. Do not use silver alloy or copper alloy containing arsenic.  
5. Do not use R-404A as a mixture with pressurized air for leak testing.  
Refrigerant leaks can be detected by charging the unit with a little refrigerant,  
raising the pressure with nitrogen and using an electronic leak detector.  
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,  
it is important to make connections outside the evaporator case when possible. If  
it is necessary to braxe inside the evaporator case, use sandpaper to remove the  
coating from the brazing connections before unbrazing the components.  
C. Removal and Replacement of Compressor  
IMPORTANT  
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.  
Note: When replacing a compressor with a defective winding, be sure to install the  
new start capacitor and start relay supplied with the replacement compressor.  
Due to the ability of the POE oil in the compressor to absorb moisture quickly,  
the compressor must not be opened more than ꢀ5 minutes for replacement or  
service. Do not mix lubricants of different compressors even if both are charged  
with R-404A, except when they use the same lubricant.  
ꢀ) Turn off the power supply.  
40  
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ꢁ) Remove the panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the terminal cover on the compressor and disconnect the compressor wiring.  
5) Remove the hold-down bolts, washers and rubber grommets.  
6) Remove the discharge and suction pipes.  
7) Remove the compressor. Unpack the new compressor package.  
8) Attach the rubber grommets of the prior 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.  
ꢀꢁ) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
ꢀ3) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
ꢀ4) 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 charge label in the machine compartment.  
ꢀ5) Connect the terminals and replace the terminal cover in its correct position.  
ꢀ6) Replace the panels in their correct positions.  
ꢀ7) Turn on the power supply.  
D. Removal and Replacement of Drier  
IMPORTANT  
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.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the drier, then place the new drier in position. Install the new drier with the  
arrow on the drier in the direction of the refrigerant flow.  
5) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
6) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
7) 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 charge label in the machine compartment.  
8) Replace the panels in their correct positions.  
9) Turn on the power supply.  
4ꢀ  
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E. Removal and Replacement of Expansion Valve  
IMPORTANT  
Sometimes moisture in the refrigeration circuit exceeds the drier capacity and  
freezes up at the expansion valve. 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.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the insulation and the expansion valve bulb on the suction line.  
5) Remove the expansion valve cover and disconnect the expansion valve. Place the new  
expansion valve in position.  
6) Remove the drier, then place the new drier in position.  
7) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
WARNING  
Always protect the valve body by using a damp cloth to prevent the valve from  
overheating. Do not braze with the valve body exceeding ꢁ50°F (ꢀꢁꢀ°C).  
8) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
9) 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 charge label in the machine compartment.  
ꢀ0) Attach the expansion valve bulb to the suction line in the same location as the previous  
bulb. The bulb should be at the ꢀꢁ o'clock position on the tube. Be sure to secure the  
bulb with the clamp and holder and to insulate it.  
ꢀꢀ) Place the expansion valve cover in position.  
ꢀꢁ) Replace the panels in their correct positions.  
ꢀ3) Turn on the power supply.  
4ꢁ  
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F. Removal and Replacement of Hot Gas Valve and Line Valve  
IMPORTANT  
ꢀ. Always use a copper tube of the same diameter and length when replacing  
the hot gas lines; otherwise the performance may be reduced.  
ꢁ. 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.  
3. Always replace the strainer when replacing the hot gas valve.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the screw and the solenoid.  
5) Disconnect the hot gas valve or line valve. Remove the strainer.  
6) Place the new valve and strainer in position.  
7) Remove the drier, then place the new drier in position.  
8) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
CAUTION  
Always protect the valve body by using a damp cloth to prevent the valve from  
overheating. Do not braze with the valve body exceeding ꢁ50°F (ꢀꢁꢀ°C).  
9) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
ꢀ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 charge label in the machine compartment.  
ꢀꢀ) Cut the leads of the solenoid allowing enough lead length to reconnect using closed  
end connectors.  
ꢀꢁ) Connect the new solenoid leads.  
ꢀ3) Attach the solenoid to the valve body and secure it with a screw.  
ꢀ4) Replace the panels in their correct positions.  
ꢀ5) Turn on the power supply.  
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G. Removal and Replacement of Evaporator  
IMPORTANT  
Always install a new drier every time the sealed refrigeration system is opened.  
Do not replace the drier until after all other repairs or replacement have been  
made.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels and the top insulation over the evaporator.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the spray tubes and the insulations at the "U" shaped notch where the  
refrigeration tubings pass through the molded chassis.  
5) Disconnect the evaporator tubing.  
6) Remove the pop rivets securing the evaporator, lift out the evaporator.  
7) Install the new evaporator.  
8) Remove the drier, then place the new drier in position.  
9) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
ꢀ0) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
ꢀꢀ) 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 charge label in the machine compartment.  
ꢀꢁ) Replace the removed parts in the reverse order of which they were removed.  
ꢀ3) Replace the top insulation and the panels in their correct positions.  
ꢀ4) Turn on the power supply.  
H. Removal and Replacement of Water Regulating Valve -  
Water Cooled Model Only  
IMPORTANT  
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.  
ꢀ) Turn off the power supply.  
ꢁ) Close the water supply line shut-off valve.  
3) Remove the panels.  
4) Recover the refrigerant and store it in an approved container.  
5) Disconnect the capillary tube at the condenser outlet.  
6) Disconnect the flare-connections of the valve.  
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7) Remove the screws and the valve from the bracket.  
8) Install the new valve.  
9) Remove the drier, then place the new drier in position.  
ꢀ0) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
ꢀꢀ) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
ꢀꢁ) Evacuate the system, and charge it with refrigerant. See the nameplate for the required  
refrigerant charge.  
ꢀ3) Connect the flare-connections.  
ꢀ4) Open the water supply line shut-off valve.  
ꢀ5) Check for water leaks.  
ꢀ6) Replace the panels in their correct positions.  
ꢀ7) Turn on the power supply.  
I. Adjustment of Water Regulating Valve - Water-Cooled Model Only  
The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment  
is required under normal use. Adjust the water regulator, if necessary, using the following  
procedures.  
ꢀ) Prepare a thermometer to check the condenser drain temperature. Attach a pressure  
gauge to the high-side line of the system.  
ꢁ) Five minutes after a freeze cycle starts, confirm that the thermometer reads ꢀ04°F to  
ꢀꢀ5°F (40°C to 46°C). If it does not, rotate the adjustment screw by using a flat blade  
screwdriver until the temperature is in the proper range. See Fig. ꢀ. Next, check that  
the reference pressure is in the range indicated in the Head Pressure table in the  
Performance Data section. If it is not in the proper range, verify the refrigerant charge.  
3) Check that the condenser drain temperature is stable.  
Adjustment  
Screw  
CW – Higher  
CCW – Lower  
Top View  
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J. Removal and Replacement of Headmaster (Condensing Pressure  
Regulator - C.P.R.) - Remote Air-Cooled Model Only  
IMPORTANT  
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.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels from the remote condenser unit.  
3) Recover the refrigerant and store it in an approved container.  
4) Before heating, break off the stub on the dome to release the dome charge.  
5) Disconnect the headmaster.  
6) Place the new headmaster in position.  
7) Remove the drier, then place the new drier in position.  
8) Braze all fittings with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
CAUTION  
Always protect the headmaster body by using a damp cloth to prevent it from  
overheating. Do not braze with the headmaster body exceeding ꢁ50°F (ꢀꢁꢀ°C).  
9) Check for leaks using nitrogen gas (ꢀ40 PSIG) and soap bubbles.  
ꢀ0) Evacuate the system and charge it with refrigerant. See the charge label in the machine  
compartment for the required refrigerant charge.  
ꢀꢀ) Replace the panels in their correct positions.  
ꢀꢁ) Turn on the power supply.  
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K. Removal and Replacement of Thermistor  
IMPORTANT  
ꢀ. Fragile, handle very carefully.  
ꢁ. Always use a recommended sealant (High Thermal Conductive Type), Model  
KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-  
ꢀꢀ, or Part Code 4A0683-0ꢀ equivalent.  
3. Always use a recommended foam insulation (Non-absorbent Type) or  
equivalent.  
4. Do not shorten or cut the thermistor leads when installing.  
ꢀ) Turn off the power supply.  
Thermistor Lead  
Cable Tie  
ꢁ) Remove the panels.  
3) Remove the control box cover.  
4) Disconnect the thermistor leads from the  
K3 connector on the control board.  
5) Remove the plastic cable ties, foam  
insulation, thermistor holder and  
thermistor. See Fig. ꢁ.  
6) Scrape away the old sealant on the  
thermistor holder and the suction pipe.  
Foam Insulation  
Thermistor Holder  
Fig. 2  
7) Wipe off moisture or condensation on the  
suction pipe.  
8) Smoothly apply recommended sealant (KE4560RTV, Part Code 60Y000-ꢀꢀ or  
4A0683-0ꢀ) to the thermistor holder concave.  
9) Attach the new thermistor to the suction pipe in the same position as the previous  
thermistor. Be very careful to prevent damage to the leads. Secure it using the  
thermistor holder and recommended foam insulation.  
ꢀ0) Secure the insulation using the plastic cable ties.  
ꢀꢀ) Connect the thermistor leads through the bushing of the control box to the K3  
connector on the control board.  
Note: Do not cut the leads of the thermistor while installing it.  
ꢀꢁ) Replace the control box cover and the panels in their correct positions.  
ꢀ3) Turn on the power supply.  
L. Removal and Replacement of Fan Motor  
Note: When replacing a fan motor with defective winding, it is recommended that a new  
capacitor be installed.  
ꢀ) Turn off the power supply.  
ꢁ) Remove the panels.  
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3) Remove the junction box cover from the remote condenser unit (remote air-cooled  
model).  
4) Remove the closed end connectors from the fan motor leads.  
5) Remove the fan motor bracket and fan motor.  
6) Install the new fan motor and replace the removed parts in the reverse order of which  
they were removed.  
7) Replace the panels in their correct positions.  
8) Replace the junction box cover in its correct position (remote air-cooled model).  
9) Turn on the power supply.  
M. Removal and Replacement of Inlet Water Valve  
ꢀ) Turn off the power supply.  
ꢁ) Close the water supply line shut-off valve.  
3) Remove the front panel.  
4) Remove the valve outlet tubing by releasing the clamp.  
5) Loosen the fitting nut. Be careful not to lose the washer.  
6) Disconnect the terminals from the water valve.  
7) Remove bracket and valve from the unit.  
8) Remove the valve from the bracket. Attach new valve to the bracket, then install the  
valve.  
9) Replace the removed parts in the reverse order of which they were removed. Make sure  
the washer is in place in the fitting nut.  
ꢀ0) Open the water supply line shut-off valve.  
ꢀꢀ) Turn on the power supply.  
ꢀꢁ) Check for leaks.  
ꢀ3) Replace the front panel in its correct position.  
N. Removal and Replacement of Pump Motor  
ꢀ) Turn off the power supply.  
ꢁ) Remove the front panel.  
3) Remove the base cover.  
4) Drain the water tank by removing one end  
of the pump tubing. See Fig. 3.  
5) Replace the removed parts in their correct positions.  
6) Disconnect the pump suction and discharge hoses.  
Fig. 3  
7) Remove the closed end connectors from the pump motor leads.  
8) Remove the screw attaching the pump motor assembly to the base, then remove the  
pump motor assembly.  
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9) Remove the screw attaching the pump motor to the pump motor bracket.  
ꢀ0) Remove the screws attaching the pump housing to the pump motor. Remove the  
housing and check the impeller.  
ꢀꢀ) If the impeller is defective, install a new impeller.  
ꢀꢁ) Install the new motor or new parts, and replace the removed parts in the reverse order  
of which they were removed.  
ꢀ3) Turn on the power supply and check for leaks.  
ꢀ4) Replace the base cover in its correct position.  
ꢀ5) Replace the front panel in its correct position.  
O. Removal and Replacement of Spray Tubes  
ꢀ) Turn off the power supply.  
ꢁ) Remove the front panel and the insulation panel.  
3) Remove the rubber hoses from the spray tubes (water supply pipe).  
4) Release the clamps and disconnect the rubber hoses.  
5) Remove the spray tubes.  
6) Install the new spray tubes, and replace the removed parts in the reverse order of which  
they were removed.  
7) Replace the panels in their correct positions.  
8) Turn on the power supply.  
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VI. Cleaning and Maintenance Instructions  
IMPORTANT  
Ensure all components, fasteners and thumbscrews are securely in place after  
any maintenance or cleaning is done to the equipment.  
A. Cleaning and Sanitizing Procedures  
WARNING  
ꢀ. HOSHIZAKI recommends cleaning this unit at least once a year. More  
frequent cleaning, however, may be required in some existing water  
conditions.  
ꢁ. To prevent injury to individuals and damage to the icemaker, do not use  
ammonia type cleaners.  
3. Always wear liquid-proof gloves to prevent the cleaning and sanitizing  
solutions from coming into contact with skin.  
IMPORTANT  
ꢀ. The cleaning valve is used to allow solution flow to the inside of the  
evaporator during the cleaning and sanitizing operation. It should be closed  
for all icemaking operation. The compressor will not operate unless this valve  
is completely closed.  
ꢁ. To open the cleaning valve, the valve handle should be parallel to the valve  
body. To close the valve, the valve handle should be at a right angle to the  
valve body.  
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1. Cleaning Procedure  
ꢀ) Dilute approximately ꢀ6 fl. oz. of the recommended cleaner Hoshizaki "Scale Away" or  
"LIME-A-WAY" (Economics Laboratory, Inc.) with 3 gal. (ꢀꢀ l) of water.  
ꢁ) Remove all ice from the evaporator and the storage bin.  
Note: To remove cubes on the evaporator, turn off the power supply and turn it on  
after 3 minutes. The harvest cycle starts and the cubes will be removed from the  
evaporator.  
3) Turn off the power supply.  
4) Remove the front panel and the base  
cover, and then remove the insulation  
panel by lifting up the panel slightly and  
pulling it towards you.  
5) Remove one end of the pump tubing (see  
Fig. 4). Drain the water tank. Replace the  
Fig. 4  
pump tubing in its correct position.  
6) In bad or severe water conditions, clean the float switch assembly as described below.  
Otherwise, continue to step 7.  
a. Remove the float switch assembly from the mounting bracket and remove the  
rubber boot from the bottom of the assembly.  
b. Remove the retainer rod from the bottom of the float switch assembly, then remove  
the float. Be careful not to bend the retainer rod excessively when removing it.  
c. Wipe down the float switch assembly's housing, shaft, float, and retainer rod with  
cleaning solution. Wipe the inside of the rubber boot with cleaning solution.  
d. Reassemble the float switch assembly and replace it and the rubber boot in their  
correct positions.  
7) Pour the cleaning solution into the water tank.  
8) Fully open the cleaning valve on the left side wall of the machine compartment.  
9) Move the control switch on the control box to the "WASH" position.  
ꢀ0) Replace the insulation panel and the front panel in their correct positions.  
ꢀꢀ) Turn on the power supply and start the washing process.  
ꢀꢁ) Turn off the power supply after 30 minutes.  
ꢀ3) Remove the front panel.  
ꢀ4) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in  
its correct position.  
ꢀ5) Move the control switch to the "ICE" position.  
ꢀ6) Close the cleaning valve.  
Note: The icemaker will not operate unless the cleaning valve is completely closed.  
ꢀ7) Replace the front panel in its correct position.  
ꢀ8) Turn on the power supply to fill the water tank with water.  
ꢀ9) Turn off the power supply after 3 minutes.  
5ꢀ  
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ꢁ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.  
ꢁ4) Turn off the power supply after 5 minutes.  
ꢁ5) Remove the front panel.  
ꢁ6) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in  
its correct position.  
ꢁ7) Repeat steps ꢀ5 through ꢁ6 three more times to rinse thoroughly.  
Note: If you do not sanitize the icemaker, go to step ꢀ0 in "ꢁ. Sanitizing Procedure."  
2. Sanitizing Procedure - Following Cleaning Procedure  
ꢀ) Dilute a 5.ꢁ5% sodium hypochlorite solution (chlorine bleach) with water (add ꢀ.5 fl. oz.  
of sanitizer to 3 gal. of water).  
ꢁ) Remove the insulation panel.  
3) Pour the sanitizing solution into the water tank.  
4) Replace the insulation panel and the front panel in their correct positions.  
Note: Make sure that the control switch is in the "WASH" position and the cleaning valve  
is open.  
5) Turn on the power supply, and start the sanitizing process.  
6) Turn off the power supply after ꢀ5 minutes.  
7) Remove the front panel.  
8) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in  
its correct position.  
9) Repeat steps ꢀ5 through ꢁ6 in "ꢀ. Cleaning Procedure" two times to rinse thoroughly.  
ꢀ0) Close the cleaning valve.  
ꢀꢀ) Move the control switch to the "ICE" position.  
ꢀꢁ) Replace the front panel and the base cover in their correct positions.  
ꢀ3) Clean the storage bin with water.  
ꢀ4) Turn on the power supply, and start the automatic icemaking process.  
B. Maintenance  
IMPORTANT  
This icemaker must be maintained individually, referring to the instruction  
manual and labels provided with the icemaker.  
1. Stainless Steel Exterior  
To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a  
5ꢁ  
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damp cloth containing a neutral cleaner to wipe off oil or dirt build up.  
2. Storage Bin and Scoop  
• Wash your hands before removing ice. Use the plastic scoop provided (bin accessory).  
• The storage bin is for ice use only. Do not store anything else in the bin.  
• Keep the scoop clean. Clean it by using a neutral cleaner and rinse thoroughly.  
• Clean the bin liner by using a neutral cleaner. Rinse thoroughly after cleaning.  
3. Air Filters (air-cooled models only)  
The plastic mesh air filters located behind the louvers remove dirt or dust from the air,  
and keep the condenser from getting clogged. As the filters get clogged, the icemaker’s  
performance will be reduced. Check the filters at least twice a month. When they are  
clogged, use warm water and a neutral cleaner to wash the filters.  
4. Condenser (air-cooled and remote air-cooled models only)  
Check the condenser once a year, and clean if required by using a brush or vacuum  
cleaner. More frequent cleaning may be required depending on the location of the  
icemaker or condenser unit.  
C. Preparing the Icemaker for Long Storage  
WARNING  
When shutting off the icemaker for an extended time, drain out all water from  
the water tank and remove the ice from the storage bin. The storage bin should  
be cleaned and dried. Drain the icemaker to prevent damage to the water  
supply line at subfreezing temperatures, using air or carbon dioxide. Shut off  
the icemaker until the proper ambient temperature is resumed.  
When the icemaker is not used for two or three days, it is sufficient to only move the control  
switch to the "OFF" position, unless the icemaker will be at subfreezing temperatures.  
1. On water-cooled model only, first remove the water from the water-cooled  
condenser:  
ꢀ) Remove the front panel.  
ꢁ) Move the control switch on the control box to the "OFF" position.  
3) Wait 3 minutes.  
4) Move the control switch to the "ICE" position.  
5) Allow 5 minutes for the icemaker to fill with water and the water pump to start operating.  
6) Close the water-cooled condenser water supply line shut-off valve.  
7) Open the drain valve for the water-cooled condenser water supply line.  
8) Allow the line to drain by gravity.  
9) Quickly attach compressed air or carbon dioxide supply to the condenser water line  
drain valve.  
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ꢀ0) Blow the water-cooled condenser out, using compressed air or carbon dioxide until  
water stops coming out.  
2. Drain the potable water supply line:  
ꢀ) Remove the front panel.  
ꢁ) Move the control switch on the control box to the "OFF" position.  
3) Wait 3 minutes.  
4) Close the potable water supply line shut-off valve and open the potable water supply  
line drain valve.  
5) Allow the line to drain by gravity.  
6) Attach compressed air or carbon dioxide supply to the potable water line drain valve.  
7) Move the control switch to the "ICE" position.  
8) Blow the potable water line out using compressed air or carbon dioxide.  
3. Drain the potable water tank:  
ꢀ) Turn off the power supply.  
ꢁ) Move the control switch to the "OFF" position.  
3) Remove the front panel and the base  
cover, and then remove the insulation  
panel by lifting up the panel slightly and  
pulling it towards you.  
5) Remove one end of the pump tubing (see  
Fig. 5). Drain the water tank. Replace the  
pump tubing in its correct position.  
Fig. 5  
5) Remove all ice from the storage bin, and  
clean the storage bin.  
7) Replace the front panel in its correct position.  
8) Close the drain valve.  
54  
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