Hoshizaki KM-1340MAH, Service Manual

Page 1: ...hizaki A Superior Degree of Reliability www hoshizaki com Models KM 1340MAH KM 1340MWH KM 1340MRH Modular Crescent Cuber Hoshizaki America Inc Service Manual Number 73135 Issued 10 16 2006 Revised 11 30 2006 ...

Page 2: ...r have any questions or concerns which have not been satisfactorily addressed please call or write to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 1 800 843 1056 770 487 3360 Web Site www hoshizaki com NOTE To expedite a...

Page 3: ...e air cooled 12 B Sequence of Operation 13 1 One Minute Fill Cycle 13 2 Initial Harvest Cycle 13 3 Freeze Cycle 13 4 Pump Out Cycle 13 5 Normal Harvest Cycle 13 C Control Board 15 1 Control Board Layout 16 2 Features 17 a Maximum Water Supply Period 6 minutes 17 b Harvest Backup Timer and Freeze Timer 17 c High Temperature Safety 17 d Low Water Safety 17 e High Voltage and Low Voltage Cut outs 17 ...

Page 4: ...razing 42 C Removal and Replacement of Compressor 42 D Removal and Replacement of Drier 43 E Removal and Replacement of Expansion Valve 44 F Removal and Replacement of Hot Gas Valve and Line Valve 44 G Removal and Replacement of Evaporator 45 H Removal and Replacement of Water Regulating Valve Water Cooled Model Only 46 I Adjustment of Water Regulating Valve Water Cooled Model Only 46 J Removal an...

Page 5: ...tainless Steel Galvanized Steel Rear WEIGHT Net 276 lbs 125 kg Shipping 315 lbs 143 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT 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 C...

Page 6: ... WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond Outlet 3 8 FPT 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 Pressure Regulator BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic Model CS14K6E PFV CONDENSER Water cooled Tube in tube t...

Page 7: ... 131 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT 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 PFV CONDENSER Air Cooled Remote Condenser Unit...

Page 8: ...8 B Condensing Unit 1 URC 14F ...

Page 9: ...bs 36 kg Shipping 87 lbs 39 kg CONNECTIONS ELECTRIC Permanent Connection REFRIGERANT 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 FAN MOTOR PROTECTION Thermal Protection REFRIGERANT CONTROL Condensing Pressure Regulator REFRIGERANT CHARGE R 404A 4 lb 7 oz 2000g DESIGN PRESSURE High 467 PSIG OPERATING CONDITIONS VO...

Page 10: ...10 II General Information A Construction 1 KM 1340MAH air cooled ...

Page 11: ...11 2 KM 1340MWH water cooled ...

Page 12: ...12 3 KM 1340MRH remote air cooled ...

Page 13: ... will not accept a signal from F S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes F S assumes control As ice builds on the evaporator the water level in the sump lowers The freeze continues until F S opens and terminates ice production 4 Pump Out Cycle LEDs 1 3 and 2 are on Comp and FMR continue to run HGV opens LLV closes and FMS deenergizes PM stops for 2 s...

Page 14: ...mp motor stops for 2 sec and then reverses for 10 20 sec each 1 2 5 or 10 cycles Comp continues FMR continues HGV energized FMS de energized F S Check F S Check Maximum inlet water valve time 6 minutes Maximum harvest time 20 minutes Thermistor in control 1 to 3 minute timer in control Minimum freeze time 5 minutes Maximum freeze time freeze timer setting 5 minute timer in control F S in control I...

Page 15: ...e 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 Alwa...

Page 16: ...netic Contactor 2 Hot Gas Valve 3 Line Valve Self Contained Fan Motor FMS 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line bin control 8 Open Switch for C board and ALPINE board service boards only Alarm Reset Switch Backup Freeze Timer LED Dip Switch Backup Harvest Timer LED Alarm Buzzer Power LED lights when power is supplied to the board Relay LEDs 4 indicate which relays...

Page 17: ...ater 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 swi...

Page 18: ...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 Orange LED marked H TIMER lights up Check for open thermistor HGV not opening TXV leaking by low charge or inefficient compressor 3 Freeze Timer freeze specified sett...

Page 19: ...tects 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 kΩ 0 18 14 401 10 12 10 613 32 0 6 000 50 10 3 871 70 21 2 474 90 32 1 633 Check a thermistor for res...

Page 20: ...o 1 No 2 OFF OFF 60 ON OFF 90 OFF ON 120 ON ON 180 d Pump Out Timer dip switch 3 4 When a freeze cycle is completed the pump motor stops and the icemaker resumes operation in 2 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 pum...

Page 21: ...reeze up issues Upon termination of freeze timer machine initiates the harvest cycle After 2 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 No 10 OFF OFF 60 OFF ON 50 ON OFF 70 ON ON 60 g Bin Control CAUTION When the ambient temperature is below 45 F 7 C the ...

Page 22: ... 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 2 3 4 1 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 1 4 3 2 Note If the LEDs light in a different sequence or t...

Page 23: ...23 III Technical Information A Water Circuit and Refrigeration Circuit 1 KM 1340MAH air cooled ...

Page 24: ...24 2 KM 1340MWH water cooled ...

Page 25: ...25 3 KM 1340MRH remote air cooled ...

Page 26: ...26 B Wiring Diagrams 1 KM 1340MAH air cooled and KM 1340MWH water cooled Pressure Switch Air Cooled Model Water Cooled Model Cut out 412 21 3 PSIG 384 21 3 PSIG Cut in 327 21 3 PSIG 284 21 3 PSIG ...

Page 27: ...27 2 KM 1340MRH remote air cooled Pressure Switch Cut out 412 21 3 PSIG Cut in 327 21 3 PSIG ...

Page 28: ...28 C Timing Chart 1 The icemaker does not complete a harvest cycle in the first 2 or 3 minutes See II C 3 Controls and Adjustments ...

Page 29: ... motor waits for 2 seconds before starting a pump out drain cycle See II C 3 Controls and Adjustments 2 The icemaker does not complete a harvest cycle in the first 2 or 3 minutes See II C 3 Controls and Adjustments ...

Page 30: ...70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 251 17 6 272 19 1 293 20 6 80 27 267 18 8 299 21 0 316 22 2 90 32 272 19 1 322 22 6 341 24 0 PSIG kg cm 2 G 100 38 274 19 2 327 23 0 359 25 2 70 21 45 3 2 48 3 4 50 3 5 80 27 48 3 4 52 3 7 53 3 7 90 32 48 3 4 56 3 9 57 4 0 PSIG kg cm2 G 100 38 48 3 4 56 3 9 58 4 1 2 0 TOTAL HEAT OF REJECTION FROM CONDENSER 22 600 BTU h AT 90ºF 32ºC WT...

Page 31: ...9 16 8 243 17 1 258 18 2 90 32 240 16 9 246 17 3 260 18 3 PSIG kg cm 2 G 100 38 244 17 2 250 17 5 272 19 1 70 21 45 3 1 46 3 2 49 3 4 80 27 46 3 2 48 3 4 51 3 6 90 32 46 3 2 49 3 5 52 3 7 PSIG kg cm2 G 100 38 47 3 3 50 3 5 55 3 9 TOTAL HEAT OF REJECTION FROM COMPRESSOR WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG 2 800 BTU h AT 90ºF 32ºC WT 70ºF 21ºC 104 gal h AT ...

Page 32: ...1 208 14 6 226 15 9 247 17 4 80 27 221 15 6 250 17 6 269 18 9 90 32 226 15 9 270 19 0 290 20 4 PSIG kg cm 2 G 100 38 229 16 1 275 19 3 309 21 7 70 21 44 3 1 47 3 3 49 3 4 80 27 46 3 2 50 3 5 51 3 6 90 32 47 3 3 53 3 7 54 3 8 PSIG kg cm2 G 100 38 47 3 3 53 3 7 55 3 9 CONDENSER VOLUME 134 CU IN URC 14F 26 27 29 3 1 5 5 4 0 4 8 3 9 3 2 5 0 25 APPROXIMATE ICE PRODUCTION PER 24 HR APPROXIMATE ELECTRIC ...

Page 33: ...n 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 1 to 3 minutes The unit then cycles to freeze Diagnosis Check if compressor is running hot gas valve is open water valve still o...

Page 34: ...it 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 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle B Diagnostic Charts 1 No Ice Production Problem Possible Cause Remedy 1 The icemaker will not start a Power Supply 1 OFF position 1 Move to ON positi...

Page 35: ...s 1 beep or 2 beep alarm 1 See II C 3 Controls and Adjustments b Harvest Control i Hot Gas Valve 1 Continues to open in freeze cycle and freeze timer safety operates 3 beep alarm 1 Check for hot gas valve stuck open and replace j Water Supply Line 1 Water supply off and water supply cycle does not finish 1 Check and get recommended pressure 2 Condenser water pressure too low or off and pressure co...

Page 36: ... Loose terminal 1 Tighten or replace 2 Voltage 2 Check and correct 3 Dirty condenser 3 Clean d Starter 1 Bad contacts 1 Check and replace 2 Coil winding opened 2 Replace e Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature f Control Board 1 No power to contactor 1 See II C 4 Control Board Check Procedure...

Page 37: ...b Control Board 1 Defective 1 See II C 4 Control Board Check Procedure 7 All components run but no ice is produced a Refrigerant 1 Undercharged 1 Check for leaks and recharge 2 Air or moisture trapped 2 Replace drier and recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Valve 1 Continues to open in freeze cycle 1 Check and replace d Line Valve 1 Continues to close in freeze cycle 1 Check...

Page 38: ...f e Ambient and or water temperature 1 Too cool 1 Increase temperature f Line Valve 1 Continues to open in harvest cycle 1 Check operation in harvest cycle and replace g Thermistor 1 Out of position or loose attachment 1 See V I Removal and Replacement of Thermistor h Control Board 1 Harvest timer is set too short 1 Adjust longer referring to II C 3 Controls and Adjustments c Harvest Timer 2 Defec...

Page 39: ...ve line valve and gas valve 4 Abnormal Ice Problem Possible Cause Remedy 1 Small cubes a Ice Cube Guide 1 Out of position Circulated water falls into bin 1 Place in position b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board c Pump Out Check Valve 1 Dirty 1 Clean 2 Cloudy or irregular cubes a See chart 2 1 and 2 3 and check float switch inlet wa...

Page 40: ...rant Lines 1 Rub or touch other lines or surfaces 1 Replace 3 Ice in storage bin often melts a Drain Line s 1 Plugged 1 Clean b Icemaker and Bin 1 Drains not run separately 1 Separate the drain lines c Ice Cube Guide 1 Out of position Circulated water falls into bin 1 Place in position ...

Page 41: ...s a service manifold 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 2 Turn on the vacuum pump Never allow the oil in the ...

Page 42: ... 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 All brazing connections inside the evaporator case are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove the coating C Removal and Replacement of Compre...

Page 43: ...igerant charge For remote air cooled models see the charge label in the machine compartment 16 Connect the terminals and replace the terminal cover in its correct position 17 Replace the panels in their correct positions 18 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 u...

Page 44: ...Check for leaks using nitrogen gas 140 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 10 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be ...

Page 45: ...sed end connectors 11 Connect the new solenoid leads 12 Attach the solenoid to the valve body and secure it with a screw 13 Replace the panels in their correct positions 14 Turn on the power supply 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 ha...

Page 46: ...ved container 5 Disconnect the capillary tube at the condenser outlet using brazing equipment 6 Disconnect the flare connections of the valve 7 Remove the screws and the valve from the bracket 8 Install the new valve and braze the capillary tube 9 Install the new drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the name...

Page 47: ... not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply 2 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 using brazing equipment 6 Install the new headmaster Use nitrogen gas at ...

Page 48: ...m insulation thermistor holder and thermistor See Fig 2 6 Scrape away the old sealant on the thermistor holder and the suction pipe 7 Wipe off moisture or condensation on the suction pipe 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 9 Attach the new thermistor to the suction pipe very carefully to prevent damage to the leads Secur...

Page 49: ...placement of Inlet Water Valve 1 Turn off the power supply 2 Close the water supply line shut off valve 3 Remove the front panel 4 Remove the valve outlet tubing by releasing the clamp 5 Remove the bracket from the unit 6 Remove the fitting nut and water valve 7 Disconnect the terminals from the water valve 8 Install the new water valve and replace the removed parts in the reverse order of which t...

Page 50: ...oved parts in the reverse order of which they were removed 12 Turn on the power supply and check for leaks 13 Replace the front panel in its correct position O Removal and Replacement of Spray Tubes 1 Turn off the power supply 2 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 Rem...

Page 51: ...als 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 1 The cleaning valve is used to allow solution flow to the inside of the evaporator during the cleaning and sanitizing operations It should be closed for all icemaking operation The compressor will not operat...

Page 52: ... 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 8 Pour the cleaning solution into the wa...

Page 53: ...dure 28 Repeat steps 16 through 27 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to step 9 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute approximately 2 5 fl oz 74 ml of a 5 25 sodium hypochlorite solution chlorine bleach with 5 gallons 19 l of warm water 2 Pour the sanitizing solution into the water tank 3 Replace the ins...

Page 54: ...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 condens...

Page 55: ...es 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 supply 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 1 Turn off t...