Hoshizaki KM-1301SAH-E, Service Manual

Page 1: ...Hoshizaki A Superior Degree of Reliability www hoshizaki com Models KM 1301SAH E KM 1301SWH E KM 1301SRH E Stackable Crescent Cuber Hoshizaki America Inc SERVICE MANUAL Number 73181 Issued 4 12 2011 ...

Page 2: ... maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call write or send an e mail message to the Hoshizaki Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn Hoshizaki Technical Support Department Phone 1 800 233 1940 Technical Support 770 487 2331 Fax 1 800...

Page 3: ...Alarm Safeties 20 2 Controls and Adjustments 21 a Default Dip Switch Settings 21 b Harvest Timer S4 dip switch 1 2 21 c Pump Out Timer S4 dip switch 3 4 22 d Pump Out Frequency Control S4 dip switch 5 6 22 e Harvest Pump Timer S4 dip switch 7 23 f Factory Use S4 dip switch 8 23 g Freeze Timer S4 dip switch 9 10 23 h Float Switch Control S5 dip switch 1 24 i Refill Counter S5 dip switch 2 through 5...

Page 4: ... Check KM 1301SAH E 40 2 Mechanical Bin Control Check and Cleaning KM 1301SWH E KM 1301SRH E 40 a Mechanical Bin Control Check 40 b Mechanical Bin Control Cleaning 42 D Float Switch Check and Cleaning 43 1 Float Switch Check 43 2 Float Switch Cleaning 44 E Thermistor Check 45 F Adjustment of Water Regulating Valve water cooled model 45 G Diagnostic Charts 46 1 No Ice Production 46 2 Freeze Up 48 3...

Page 5: ... must meet national state and local electrical code requirements Failure to meet these code requirements could result in death electric shock serious injury fire or severe damage to equipment This unit requires an independent power supply See the nameplate for proper voltage and breaker fuse size Failure to use a proper breaker or fuse can result in a tripped breaker blown fuse or damage to existi...

Page 6: ... WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT CONDENSATE DRAIN 3 8 OD Tube CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL N A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic Model CS14K6E PFJ 237 CONDENSER Air Cooled Fin and Tube Type EVAPORATOR Vertical Type Stainl...

Page 7: ...ction WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond Outlet 3 8 FPT CONDENSATE DRAIN 3 8 OD Tube CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL Water Regulating Valve BIN CONTROL SYSTEM Mechanical Level Switch and Timer COMPRESSOR Hermetic Model ...

Page 8: ...iquid Line 5 8 18 UNF Fitting 6 PARKER CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Level Switch and Timer COMPRESSOR Hermetic Model CS14K6E PFJ 279 CONDENSER Air Cooled Remote Condenser Unit URC 14FE EVAPORATOR Vertical Type Stainless...

Page 9: ...33 15 32 960 37 13 16 907 2 35 11 16 309 12 3 16 75 2 15 16 380 14 15 16 557 8 21 15 16 68 2 11 16 380 14 15 16 357 14 1 16 370 14 9 16 435 17 1 8 460 18 1 8 TOP VIEW FRONT VIEW URC FAN MOTOR CONNECTION 7 8 DIA OPENING AIR FLOW AIR FLOW 398 15 11 16 700 27 9 16 ...

Page 10: ... Discharge Line 1 1 16 12 UNF Fitting 10 PARKER Liquid Line 5 8 18 UNF Fitting 6 PARKER CONDENSER Air Cooled Fin and Tube Type FAN MOTOR PROTECTION Thermal Protection REFRIGERANT CONTROL Headmaster C P R 190 PSIG REFRIGERANT CHARGE R 404A 4 lb 6 5 oz 2000 g DESIGN PRESSURE High 467 PSIG 32 2 Bar OPERATING CONDITIONS VOLTAGE RANGE 104 127V AMBIENT TEMP 20 122 F ACCESSORIES SUPPLIED Leg 2 pcs Hex He...

Page 11: ...t Hot Gas Valve Junction Box Air Cooled Condenser Check Valves Control Box Drier Transformer Box Control Switch Thermostatic Bin Control Compressor Float Switch Water Pump Check Valve water Expansion Valves Liquid Line Valve Fan Motor Fan Blade Low Side Service Valve High Side Service Valve Separators Cube Guides High Pressure Switch ...

Page 12: ...ction Box Water Regulating Valve Check Valves Control Box Liquid Line Valve Drier Transformer Box Control Switch Mechanical Bin Control Compressor Float Switch Water Pump Check Valve water Expansion Valves Water Cooled Condenser Low Side Service Valve High Side Service Valve Separators Cube Guides High Pressure Switch ...

Page 13: ... Boxes Receiver Tank Check Valves Control Box Liquid Line Valve Drier Transformer Box Control Switch Compressor Float Switch Water Pump Check Valve water Expansion Valves Low Side Service Valve High Side Service Valve High Side Liquid Service Valve Access Valve Mechanical Bin Control Separators Cube Guides High Pressure Switch ...

Page 14: ...in energized HGV X1 relay auxiliary code T 0 U 0 X10 relay auxiliary code U 1 and later Comp and FMR energize CB monitors the warming of the evaporator via the thermistor located on the suction line When the thermistor reaches 48 F 9 C CB reads a 3 9 kΩ signal from the thermistor and turns harvest termination over to the harvest timer S4 dip switch 1 2 The harvest timer has settings of 60 90 120 a...

Page 15: ...alve and down the drain At the same time water flows through the small tube to power flush F S When the pump out timer terminates the pump out is complete The first pump out occurs after the 11th freeze cycle then every 10th cycle thereafter The pump out frequency control is factory set and generally no adjustment is required However where water quality is bad and the icemaker needs a pump out mor...

Page 16: ...cle At the end of the harvest cycle or up to 15 seconds into the freeze cycle if activated at the end of the harvest cycle Freeze Cycle 15 seconds after activation if activated at least 15 seconds before the 5 minute short cycle protection timer terminates Otherwise at the end of the next harvest cycle Legend BC bin control CB control board Comp compressor FM fan motor FMR fan motor remote F S flo...

Page 17: ...returns to 1 Minute Fill Cycle 5 min timer in control F S closed F S open or freeze timer terminates 0 or 50 sec PM energized WV de energized Harvest Pump Timer KM 1301SAH E KM 1301SWH E KM 1301SRH E NOTE Green BC CLOSED LED on continuously when the K4 jumper is in place 1 Bin Full Within 10 sec after ice contacts thermostatic bulb unit shuts down Thermostatic BC Shutdown and Restart KM 1301SAH E ...

Page 18: ...or replacing the control board 3 Do not touch the electronic devices on the control board or the back of the control board 4 Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor jumper KM 1301SAH E or mechanical bin control KM 1301SWH E KM 1301SRH E and float switch KM 1301SAH E utilizes a thermostatic bin control For KM 1301SAH ...

Page 19: ...3 Liquid Line Valve LLV Fan Motor FM 4 Pump Motor icemaking 5 Pump Motor pump out harvest if applicable 6 Inlet Water Valve WV 7 10 Component Power Supply 8 Open Bin Control Switch Open LED yellow mechanical bin control application only S4 Dip Switch Bin Control Switch Closed LED green on continuously in thermostatic bin control application Alarm Buzzer Power LED red lights when power is supplied ...

Page 20: ...hut down the unit and have alarms as listed below No of Beeps every 3 sec Type of Alarm Notes 1 High Evaporator Temp temperature 127 F 53 C Check for harvest problem stuck HGV or relay hot water entering unit stuck HM or shorted thermistor 2 Harvest Backup Timer harvest 20 min for two cycles in a row Check for open thermistor HGV not opening TXV or LLV leaking by low charge inefficient Comp or WRV...

Page 21: ...djust to 3 off and 4 on Harvest Timer 1 2 Harvest Pump Timer 7 Do not adjust Factory Use 8 b Harvest Timer S4 dip switch 1 2 The harvest timer starts when the thermistor reads 48 F 9 C at the evaporator outlet and the control board reads the thermistor s 3 9 kΩ signal The harvest timer is factory set and generally no adjustment is required However a setting longer than the factory setting may be a...

Page 22: ...set to pump out for 10 or 20 seconds S4 Dip Switch Setting Time seconds Inlet Water Valve No 3 No 4 T1 T2 OFF OFF 10 150 closed ON OFF 10 180 closed OFF ON 10 120 open ON ON 20 180 closed T1 Time to drain the water tank T2 Harvest timer at pump out d Pump Out Frequency Control S4 dip switch 5 6 The pump out frequency control is factory set to drain the water tank every 10 cycles and generally no a...

Page 23: ...se rotation as well as the harvest pump timer freeze rotation Therefore the harvest pump timer relays are needed to control the pump motor direction during the pump out and harvest cycles See III B Wiring Diagrams S4 Dip Switch Setting Pump Motor Time seconds No 7 ON 50 OFF 0 f Factory Use S4 dip switch 8 Factory set for proper operation Do not adjust This must be left in the factory default posit...

Page 24: ...E use a single float switch i Refill Counter S5 dip switch 2 through 5 CAUTION Do not adjust These must be left in the factory default position or the unit will not operate correctly Factory set S5 dip switch 2 through 5 allows for refills during the freeze cycle The KM 1301SAH E KM1301SWH E and KM 1301SRH E do not refill D Control Switch The control switch has three positions OFF for power off IC...

Page 25: ...nsion Valves Compressor Hot Gas Valve Check Valves High Pressure Switch Strainer Drier Condenser Evaporator Service Valve Discharge Line Suction Line Water Pump Thermistor Spray Tubes Inlet Water Valve Pump Out Water Tank Service Valve Refrigeration Circuit Water Circuit Liquid Line Valve Spray Tubes Fan Heat Exchanger Freeze Harvest Pump Timer ...

Page 26: ...sure Switch Strainer Drier Condenser Evaporator Service Valve Discharge Line Suction Line Water Pump Thermistor Spray Tubes Inlet Water Valve Pump Out Water Tank Service Valve Refrigeration Circuit Water Circuit Liquid Line Valve Spray Tubes Cond Water Outlet Water Regulating Valve Heat Exchanger Freeze Harvest Pump Timer Cond Water Inlet ...

Page 27: ...rainer Drier Remote Condenser Unit Evaporator Service Valve Discharge Line Suction Line Water Pump Thermistor Spray Tubes Inlet Water Valve Freeze Harvest Pump Timer Pump Out Water Tank Service Valve Refrigeration Circuit Water Circuit Fan Headmaster C P R Liquid Line Valve Receiver Tank Access Valve Fusible Plug Service Valve Spray Tubes Heat Exchanger Fan ...

Page 28: ...28 B Wiring Diagrams 1 Auxiliary Code T 0 U 0 a KM 1301SAH E air cooled Auxiliary Code T 0 U 0 Transformer Output 10 5V at 115V High Pressure Switch Cut out 412 21 PSIG Cut in 327 21 PSIG 0 ...

Page 29: ... Auxiliary Code U 1 and Later a KM 1301SAH E air cooled Auxiliary Code U 1 and Later Transformer Output 10 5V at 115V High Pressure Switch Cut out 412 21 PSIG Cut in 327 21 PSIG 0 Auxiliary Code U 1 and V 0 ...

Page 30: ...30 b KM 1301SWH E water cooled Transformer Output 10 5V at 115V High Pressure Switch Cut out 384 21 PSIG Cut in 284 21 PSIG 0 ...

Page 31: ...31 c KM 1301SRH E remote air cooled Transformer Output 10 5V at 115V High Pressure Switch Cut out 412 21 PSIG Cut in 327 21 PSIG 0 ...

Page 32: ...0 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 275 19 3 293 20 6 316 22 2 80 27 289 20 3 318 22 3 338 23 8 90 32 293 20 6 338 23 8 360 25 3 PSIG kg cm 2 G 100 38 297 20 9 343 24 1 380 26 7 70 21 57 4 0 58 4 1 61 4 3 80 27 58 4 1 59 4 2 64 4 5 90 32 58 4 1 60 4 2 64 4 5 PSIG kg cm2 G 100 38 59 4 2 61 4 3 68 4 8 19 000 BTU h AT 90ºF 32ºC WT 70ºF 21ºC 35 41 35 37 40 35 38 2 1 4 8 3 1 ...

Page 33: ...39 16 8 240 16 9 256 18 0 90 32 239 16 8 241 16 9 255 17 9 PSIG kg cm 2 G 100 38 244 17 2 244 17 2 267 18 8 70 21 50 3 5 51 3 6 52 3 6 80 27 50 3 5 51 3 6 52 3 7 90 32 51 3 6 52 3 7 53 3 7 PSIG kg cm 2 G 100 38 51 3 6 52 3 7 54 3 8 19 382 BTU h AT 90ºF 32ºC WT 70ºF 21ºC TOTAL HEAT OF REJECTION FROM COMPRESSOR 2 600 BTU h AT 90ºF 32ºC WT 70ºF 21ºC WATER FLOW FOR CONDENSER 117 gal h AT 100ºF 38ºC WT...

Page 34: ...1 210 14 8 225 15 8 238 16 7 80 27 221 15 6 244 17 2 254 17 8 90 32 225 15 8 260 18 3 271 19 1 PSIG kg cm2 G 100 38 225 15 8 263 18 5 282 19 8 70 21 50 3 5 51 3 6 55 3 8 80 27 51 3 6 52 3 7 57 4 0 90 32 51 3 6 53 3 7 58 4 1 PSIG kg cm2 G 100 38 53 3 7 54 3 8 62 4 4 18 982 BTU h AT 90ºF 32ºC WT 70ºF 21ºC 2 600 BTU h AT 90ºF 32ºC WT 70ºF 21ºC CONDENSER VOLUME 133 CU IN URC 14FE 34 36 33 4 1 3 3 2 6 ...

Page 35: ...gs As you go through the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect 1 Turn off the power supply then access the control box Clear any ice from BC 2 Turn on the power supply then move the control switch to the ICE position A 5 second delay occurs CB red POWER OK LED and green BC CLOSED LED come on If red POWER OK LED ...

Page 36: ...n of F S and proceeds to the next cycle if it is closed or calls for a 1 minute fill cycle if it is open The minimum total time allowed by CB for a complete harvest cycle is 2 minutes Diagnosis Check if Comp is running HGV and WV still energized Average harvest cycle at factory setting is 2 to 3 minutes How long does initial harvest last 1 5 minutes after initial harvest begins touch Comp discharg...

Page 37: ...t is complete The pump out frequency control is factory set for every 10th cycle and generally no adjustment is required However where water quality is bad and the icemaker needs a pump out more often the pump out frequency can be adjusted The pump out frequency control S4 dip switch 5 6 can be set to have a pump out occur every cycle or every 2 5 or 10 cycles Timing of the first pump out is depen...

Page 38: ...t is required However adjustment may be needed in some conditions particularly at higher altitude locations Diagnosis See IV C 1 Thermostatic Bin Control Check b Mechanical Bin Control KM 1301SWH E KM 1301SRH E See IV C 2 a Mechanical Bin Control Check Legend BC bin control CB control board Comp compressor FM fan motor FMR fan motor remote F S float switch HGV hot gas valve HM headmaster C P R LLV...

Page 39: ...e diagnosing a mechanical bin control unit and the red POWER OK LED is off check the fuse control switch contacts high pressure switch and control transformer secondary circuit Transformer output is 10 5V at 115V primary input If the secondary circuit has proper voltage and the red LED is off the control board is bad and should be replaced If the secondary circuit does not have proper voltage chec...

Page 40: ...ntinuity across the thermostatic bin control switch If closed continue to step 6 If open adjust or replace the thermostatic bin control 7 With the multimeter test leads still in place hold ice on the thermostatic bin control bulb to lower the temperature Within 10 seconds the thermostatic bin control switch should open no continuity If it remains closed adjust or replace the thermostatic bin contr...

Page 41: ...d be on and the unit should shut down according to the chart below If it does not replace the control board Cycle at Mechanical Bin Control Activation Shutdown Fill Cycle 15 seconds after activation Harvest Cycle At the end of the harvest cycle or up to 15 seconds into the freeze cycle if activated at the end of the harvest cycle Freeze Cycle 15 seconds after activation if activated at least 15 se...

Page 42: ...ector then remove the mechanical bin control assembly from the unit 5 Remove the actuator paddle from the switch mount See Fig 2 6 Wipe down the mechanical bin control assembly with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Rinse the parts thoroughly with clean water 7 Reassemble the mechanical bin control assembly and replace it in its correct position Note If the magnet wa...

Page 43: ... 8 Reconnect the black float switch connector to the control board BLACK K5 connector then replace the control box cover in its correct position 9 Move the control switch to the ICE position Replace the insulation panel and the front panel in their correct positions then turn on the power supply After 1 minute the 1 minute fill cycle should end and the initial harvest cycle should begin If the ini...

Page 44: ...oot from the bottom of the float switch assembly See Fig 4 6 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 7 Wipe down the float switch assembly s housing shaft float and retainer rod with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Clean the inside of the rubber b...

Page 45: ...e 12 The harvest timer should terminate and end the harvest cycle within 2 to 3 minutes If the harvest timer does not terminate and end the harvest cycle the harvest timer is bad and the control board should be replaced F Adjustment of Water Regulating Valve water cooled model The water regulating valve also called water regulator is factory set and generally no adjustment is required However when...

Page 46: ...a Tripped with bin filled with ice b Ambient temperature too cool c Set too warm d Bulb out of position e Bad contacts 5 Fuse Control Box a Blown 6 Control Switch a Bad contacts 7 High Pressure Switch a Bad contacts b Dirty air filter or condenser c Ambient or condenser water temperature too warm d Refrigerant overcharged e Fan not operating air cooled and remote air cooled models f Refrigerant li...

Page 47: ...ring worn out or locked rotor c Defective capacitor d Mechanical seal worn out 17 Pump Out Check Valve a Leaking by 18 Water System a Water leaks causing short freeze time 19 Fan Motor a Motor winding open b Bearing worn out or locked rotor c Defective capacitor 20 Liquid Line Valve if applicable a Closed in freeze cycle b Open in harvest cycle 21 Expansion Valve TXV a Bulb loose b Operating errat...

Page 48: ...Minimum 3 8 nominal ID 10 mm nominal OD 8 Thermostatic Bin Control See IV C 1 Thermostatic Bin Control Check a Extension bracket not installed b Bulb out of position c Bad contacts 9 Control Board See IV B Control Board Check a Harvest timer set too short b Defective 10 Mechanical Bin Control See IV C 2 Mechanical Bin Control Check and Cleaning a Actuator does not move freely 11 Thermistor See IV ...

Page 49: ...ard See IV B Control Board Check a Freeze timer set incorrectly b Defective 7 Inlet Water Valve a Leaking by 8 Float Switch See IV D Float Switch Check and Cleaning a Float does not move freely b Defective 9 Pump Motor a RPM too slow 10 Expansion Valve TXV a Defective 11 Headmaster C P R remote condenser unit a Defective 12 Water Regulating Valve water cooled model See IV F Adjustment of Water Reg...

Page 50: ...tive 12 Water Regulating Valve water cooled model a Leaking by Long Freeze Cycle 1 Evaporator a Scaled up 2 Refrigerant Charge a Low 3 Air Filter air cooled model a Clogged 4 Condenser air cooled and remote air cooled models a Clogged 5 Condenser water cooled model a Water temperature out of specification 6 Control Board See IV B Control Board Check a Float switch connection loose K5 b Defective 7...

Page 51: ...ronic 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 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing CAUTION 1 Do not leave the system open for longer than 15 minutes when replacing or servicing parts The Polyol Ester POE oils used in R 404A u...

Page 52: ...a new drier every time the sealed refrigeration system is opened 2 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 flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 2 Use an electronic le...

Page 53: ...ging an R 404A system to prevent fractionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge manifold 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...

Page 54: ...e copper tube of the same diameter and length when replacing valve lines Fan Motor Install a new capacitor Pump Motor Install a new capacitor Thermistor Attach the new thermistor to the suction line in the same location as the previous thermistor The thermistor should be at the 12 o clock position on the tube Smoothly fill the recessed area of the thermistor holder with high thermal conductive typ...

Page 55: ... by Qualified Service Technician Hoshizaki recommends cleaning and sanitizing this unit at least once a year More frequent cleaning and sanitizing however may be required in some existing water conditions WARNING 1 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 2 Carefully follow any instructions provided with the bottles of cleaning and sanitizing sol...

Page 56: ...float switch assembly s housing shaft float and retainer rod with cleaning solution Clean the inside of the rubber boot and hose with cleaning solution Rinse the parts thoroughly with clean water d Reassemble the float switch assembly and replace it and the rubber boot in their correct positions Reconnect the vent tube and the flush tube 8 Pour the cleaning solution into the water tank 9 Move the ...

Page 57: ...go to step 9 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute 2 5 fl oz 74 ml or 5 tbs of a 5 25 sodium hypochlorite solution chlorine bleach with 5 gal 19 l of warm water 2 Pour the sanitizing solution into the water tank 3 Replace the insulation panel and the front panel in their correct positions Note Make sure the control switch is in the WASH position 4 T...

Page 58: ... get clogged the icemaker s performance will be reduced Check the filters at least twice a month When clogged use warm water and a neutral cleaner to wash the filters 4 Condenser air cooled and remote air cooled models Performed by Qualified Service Technician The condenser should be checked and cleaned once a year Instructions for the service technician can be found in the Installation Manual sup...

Page 59: ...r correct positions Be careful not to cross thread the drain plug 4 Remove all ice from the storage bin Clean the storage bin using a neutral cleaner Rinse thoroughly after cleaning 5 Replace the front panel in its correct position 3 On water cooled model remove the water from the water cooled condenser 1 Make sure the power supply is off then remove the front panel and right side panel 2 Close th...