HOSHIZAKI SELF-CONTAINED CRESCENT CUBER MANU… · The control board will signal this problem using...

SERVICE MANUAL

HOSHIZAKISELF-CONTAINEDCRESCENT CUBER

KM-30AKM-35AKM-50AKM-75A

NO. 15FD-742ISSUED: AUG.10,2007REVISED:SEP.30,2013

MODEL

i

CONTENTS PAGE

I. SPECIFICATIONS -------------------------------------------------------------------------------------11. DIMENSIONS/SPECIFICATIONS --------------------------------------------------------------1

[a] KM-30A, KM-35A -------------------------------------------------------------------------------1[b] KM-35A (Auxiliary code: V-1 or later, European model only)------------------------2[c] KM-50A -------------------------------------------------------------------------------------------3[d] KM-50A (Auxiliary code: V-1 or later, European model only)------------------------4[e] KM-75A -------------------------------------------------------------------------------------------5[f] KM-75A (Auxiliary code: V-1 or later, European model only) ------------------------6

II. GENERAL INFORMATION -------------------------------------------------------------------------71. CONSTRUCTION ----------------------------------------------------------------------------------7

[a] KM-30A, KM-35A, KM-50A ------------------------------------------------------------------7[b] KM-75A -------------------------------------------------------------------------------------------8[c] ICEMAKING COMPARTMENT -------------------------------------------------------------9

2. CONTROL BOARD ------------------------------------------------------------------------------ 10[a] SEQUENCE ----------------------------------------------------------------------------------- 11[b] CONTROL FEATURES --------------------------------------------------------------------- 14[c] CONTROL BOARD LAYOUT ------------------------------------------------------------- 16[d] CONTROLS AND ADJUSTMENTS ----------------------------------------------------- 17[e] ALARMS ---------------------------------------------------------------------------------------- 20[f] CHECKING THE CONTROL BOARD --------------------------------------------------- 21

3. SWITCHES ---------------------------------------------------------------------------------------- 22

III. TECHNICAL INFORMATION -------------------------------------------------------------------- 231. WATER CIRCUIT AND REFRIGERANT CIRCUIT --------------------------------------- 23

[a] KM-30A, KM-35A, KM-50A ---------------------------------------------------------------- 23[b] KM-75A ----------------------------------------------------------------------------------------- 24

2. WIRING DIAGRAM ------------------------------------------------------------------------------ 25[a] KM-30A, KM-35A ----------------------------------------------------------------------------- 25[b] KM-50A, KM-75A ----------------------------------------------------------------------------- 25

3. TIMING CHART ----------------------------------------------------------------------------------- 26

IV. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 271. NO ICE PRODUCTION ------------------------------------------------------------------------- 272. EVAPORATOR IS FROZEN UP -------------------------------------------------------------- 293. LOW ICE PRODUCTION ----------------------------------------------------------------------- 304. ABNORMAL ICE ---------------------------------------------------------------------------------- 305. OTHERS -------------------------------------------------------------------------------------------- 31

V. REMOVAL AND REPLACEMENT -------------------------------------------------------------- 321. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 32

[a] SERVICE INFORMATION ----------------------------------------------------------------- 32[b] REFRIGERANT RECOVERY ------------------------------------------------------------- 33[c] EVACUATION AND RECHARGE -------------------------------------------------------- 33

2. BRAZING ------------------------------------------------------------------------------------------- 34

ii

3. COMPRESSOR ----------------------------------------------------------------------------------- 354. DRIER ----------------------------------------------------------------------------------------------- 365. HOT GAS VALVE --------------------------------------------------------------------------------- 376. EXPANSION VALVE - KM-75A ONLY ------------------------------------------------------- 397. FAN MOTOR --------------------------------------------------------------------------------------- 418. PUMP MOTOR ------------------------------------------------------------------------------------ 429. WATER VALVE ------------------------------------------------------------------------------------ 43

10. DRAIN VALVE ------------------------------------------------------------------------------------- 4411. FLOAT SWITCH ---------------------------------------------------------------------------------- 45

[a] KM-30A, KM-35A, KM-50A ---------------------------------------------------------------- 45[b] KM-75A ----------------------------------------------------------------------------------------- 46

12. BIN CONTROL SWITCH ----------------------------------------------------------------------- 4713. THERMISTOR ------------------------------------------------------------------------------------ 5014. CONTROL BOX ---------------------------------------------------------------------------------- 51

[a] POWER SWITCH ---------------------------------------------------------------------------- 52[b] FUSE -------------------------------------------------------------------------------------------- 52[c] FUSE HOLDER ------------------------------------------------------------------------------- 52[d] CONTROL BOARD -------------------------------------------------------------------------- 52[e] POWER RELAY ------------------------------------------------------------------------------ 52[f] COMPRESSOR CAPACITOR - KM-50A, KM-75A ONLY -------------------------- 53[g] CONTROL BOARD TRANSFORMER -------------------------------------------------- 53

15. WATER TANK ------------------------------------------------------------------------------------- 5316. CUBE GUIDE ------------------------------------------------------------------------------------- 5517. SEPARATOR -------------------------------------------------------------------------------------- 5618. SPRAY TUBE, WATER SUPPLY PIPE, SPRAY GUIDE ------------------------------- 5619. DOOR ----------------------------------------------------------------------------------------------- 57

VI. CLEANING AND MAINTENANCE INSTRUCTIONS -------------------------------------- 581. CLEANING ----------------------------------------------------------------------------------------- 58

[a] CLEANING PROCEDURE ----------------------------------------------------------------- 58[b] SANITIZING PROCEDURE --------------------------------------------------------------- 60

2. MAINTENANCE ---------------------------------------------------------------------------------- 61[a] EXTERIOR PANELS ------------------------------------------------------------------------ 61[b] STORAGE BIN AND SCOOP ------------------------------------------------------------- 61[c] AIR FILTER ------------------------------------------------------------------------------------ 61[d] CONDENSER --------------------------------------------------------------------------------- 61

3. PREPARING THE ICEMAKER FOR LONG STORAGE -------------------------------- 61

1

I. SPECIFICATIONS

1. DIMENSIONS/SPECIFICATIONS

[a] KM-30A, KM-35A

2

[b] KM-35A (Auxiliary code: V-1 or later, European model only)

3

[c] KM-50A

4

[d] KM-50A (Auxiliary code: V-1 or later, European model only)

5

[e] KM-75A

6

[f] KM-75A (Auxiliary code: V-1 or later, European model only)

7

TopPanel Separator SprayTube

Evaporator

Door WaterSupply Tube FrontPanel Tank Louver

ControlBox

ControlSwitch

Condenser

HotGasValve AirFilter FanMotor Front View

Thermistor

WaterValve RearPanel

PumpMotor PipeCover

PowerSupply Cord

DrainValve

Drier Compressor Rear View RearCover

FloatSwitch

With Tank Removed BinControlSwitch

II. GENERAL INFORMATION

1. CONSTRUCTION

[a] KM-30A, KM-35A, KM-50A

8

[b] KM-75A

TopPanel Separator SprayTube

Evaporator

Door WaterSupply Tube FrontPanel Tank Louver

ControlBox

Control Switch

Condenser

HotGasValve AirFilter FanMotor Compressor Front View

Thermistor

WaterValve RearPanel

PumpMotor PipeCover

PowerSupply Cord

DrainValve

Drier RearCover Rear View

FloatSwitch

With Tank Removed BinControlSwitch

9

[c] ICEMAKING COMPARTMENT

WaterValve

SprayTube WaterSupplyPipe Evaporator

PumpMotor

Separator

CubeGuide

FloatSwitch

WaterTank

10

2. CONTROL BOARD

*AHOSHIZAKIexclusivesolid-statecontrolisemployedinKM-30A,KM-35A,KM-50AandKM-75ACrescentCubers.

*Allmodelsarepretestedandfactory-adjusted.

CAUTION

1.Fragile,handleverycarefully.

2.A control board contains integrated circuits,whichare susceptible tofailureduetostaticdischarge.Togetstaticfree,itisespeciallyimportanttotouchthemetalpartoftheunitwhenhandlingorreplacingtheboard.

3.Donot touch theelectronic deviceson theboardor thebackof theboardtopreventdamagetotheboard.Handletheboardbytheedgesonly.

4.Donotchangewiringandconnections.

5.Donot repair theelectronic devicesor partson theboard in the field.Alwaysreplacethewholeboardassemblywhenitgoesbad.

6.Donotshortout thepowersupplytotest forvoltage.Also,nevershortoutormodifytheTerminals.

11

[a] SEQUENCE (see “III. 3. TIMING CHART” for details)

1st cycle

1. UnitenergizedandControlSwitchto“ICE”position.Watersupplycyclestartsafter5seconds.

2. Afterwatersupplycyclestarts,FloatSwitchpositionischeckedeveryminute.Whenitisinupper(closed)position,defrostcyclestarts.

3. Thermistorreads9°C.DefrostTimerstartscounting.

4. At30secondsbeforetheendofdefrostcycle,WaterValvestopswatersupplyandPumpMotorstartstorunwateronEvaporatorsurface.

IMPORTANTWaterValveopeningislimitedto6minutesafter2.

6. At5minutesafterthermistortemperaturereaches2°Cinfreezecycle.ReadytocompletefreezecyclewhenFloatSwitchcircuitopens.

IMPORTANTBoardneveracceptsfreezecompletionsignalwithinthefirst5minutesafterthermistortemperaturereaches2°C.

5. DefrostTimerstopscounting.Defrostcycleiscompletedandfreezecyclestarts.

IMPORTANT1. Boardneveracceptsdefrostcompletion

signalwithinthefirst2minutesindefrostcycle.

2. Defrostcycletimeislimitedto20minutesevenifDefrostTimerdoesnotstopcounting.

StopTopreventslushing,PumpMotorstops(see“III.3.TIMINGCHART).

12

2nd cycle and after

1. FloatSwitchopensandsignalstocompletefreezecycle.


IMPORTANTFreezecycletimeislimitedtothetimesetbyFreezeBackupTimeronControlBoard(see“[d]CONTROLSANDADJUSTMENTS”)evenifFloatSwitchdoesnotopen.


IMPORTANTWaterValveopeningislimitedto6minutes.








13

1. FloatSwitchopensandsignalstocompletefreezecycle.


IMPORTANTFreezecycletimeislimitedtothetimesetbyFreezeBackupTimeronControlBoard(see“[d]CONTROLSANDADJUSTMENTS”)evenifFloatSwitchdoesnotopen.


IMPORTANTWaterValveopeningislimitedto6minutes.






2nd cycle and after (Drain Valve open)

Note:TheDrainValveisfactory-adjustedto open every 10 cycles. Thisfrequency is adjustable accordingto thewater quality.See “[d] 4)DrainCounter”forfurtherdetails.

6. Afterthefreezecyclecompletes,DrainValveopensfor20secondstodrainoutWaterTank.WhenDrainValvecloses,WaterValveopensandunitresumesnormalcycle.

D

RA

INVA

LVE

20sec



14

[b] CONTROL FEATURES

1) Maximum Water Supply Period - 6 minutes

Inletwater valveopening, in thedefrost cycle, is limited by thedefrost timer.Thewatervalvecannot remainopen longer than themaximumperiod.Thewatervalvecancloseinlessthansixminutesifthedefrostcycleiscompleted.

2) Defrost Backup Timer

Thedefrost backup timer shuts down the icemaker if, for two cycles in a row, thedefrostcycletakesmorethan20minutestocomplete.Thecontrolboardwillsignalthisproblemusing2beepsevery3seconds.Theresetbuttononthecontrolboardmustbepressedwithpowerontoresetthesafety.

3) Freeze Backup Timer

The freezebackup timer shutsdown the icemaker if, for two cycles in a row, thefreezecycletakeslongerthanthetimespecifiedtocomplete.Thecontrolboardwillsignalthisproblemusing3beepsevery3seconds.Thetimeisfactorysetusingdipswitches9&10.The safetywill be resetwhen the control switch is turnedoff andbackon.

4) High Temperature Safety

The temperatureof thesuction line in the refrigerationcircuit is limitedby thehightemperaturesafety.Thisprotectstheunitfromexcessivelyhightemperatures.Iftheevaporatortemperaturerisesabove53°C±4°C,thethermistoroperatesthesafety.Thisshutsdownthecircuitandtheicemakerautomaticallystops.

Thecontrolboardwillsignal thisproblemusing1beepevery3seconds.Theresetbuttononthecontrolboardmustbepressedwithpowerontoresetthesafety.

5) Low Water Safety

Thecontrolboardchecksthepositionofthefloatswitchattheendoftheinitialoneminutewaterfillcycleandattheendofeachdefrostcycle.

If the float switch is in theupposition (electrical circuit closed), the control boardchangestothenextcycle.Ifthefloatswitchisinthedownposition(electricalcircuitopen),thecontrolboardchangestoadditionaloneminutewaterfillcyclesuntilwaterentersthesumpandthefloatswitchcloses.Whenthefloatswitchcloses,thecontrolboardchangestothenextcycle.Theunitwillnotstartwithoutadequatewaterinthesump.Thisservesasalowwatersafetytoprotectthewaterpump.

6) High Voltage and Low Voltage Cut-outs

Themaximumandminimumallowablesupplyvoltagesofthisicemakerarelimitedbythehighvoltageandlowvoltagecut-outs.

15

Ifmiswiring (especially on single phase3wiremodels) causesexcessive voltage(294Vac±5%ormore) on the control board, thehigh voltage cut-out shuts downthecircuitin3secondsandtheicemakerautomaticallystops.Thecontrolboardwillsignalthisproblemusing7beepsevery3seconds.

The icemakeralsoautomaticallystops incasesof insufficientvoltage(184Vac±5%orless).Thecontrolboardwillsignalthisproblemusing6beepsevery3seconds.

When theproper supply voltage is resumed, the icemaker automatically startsrunningagain.

7) LED Lights

The control board includesLED indicator lights andanoutput test feature.The"POWEROK"LED indicates control voltageandwill remainonunlessa controlvoltageproblemoccurs.The“POWEROK”LEDflashescontinuouslywhenthebinisfull.LEDs4through8energizeandsequencefrominitialstartupaslistedinthetablebelow.

SequenceStep LED EnergizedComponentsFirstWaterFillCycle 8 WatervalveDefrostCycle 5,6,8 Watervalve,hotgasvalve,compressorLast30secondsofdefrost,watervalvede-energizesandpumpmotorenergizes(LEDs5,6,and7areon)FreezeCycle 5,7 Compressor,pumpmotor,fanmotorDrain 5,6,4 Compressor,hotgasvalve,drainvalve

16

"H" Control Board

ConnectorK7 Transformer

ConnectorK3MagneticContactor

ConnectorK4Open

POWEROKLED(Lightswhenpowerissuppliedtotheboard.Flasheswhenbincontrolisactivated.)

ConnectorK5Pins#1FanMotor#2HotGasValve#3PumpMotor#4WaterValve#5Open#6DrainValve

ConnectorK6Open

ConnectorK1Pins#1,3FloatSwitch#2Open#4,5BinControl#6,7Thermistor#8,9Open

ConnectorK2Open

AlarmBuzzer DipSwitch AlarmResetButton

RelayLEDs(5)(indicatewhichrelaysareenergizedaslistedbelow)

LED5(X1Relay)Compressor

LED6(X2Relay)HotGasValveFanMotor(FanMotoroffwhenLEDon)

LED8(X4Relay)WaterValve

LED4(X6Relay)DrainValve

LED7(X3Relay)PumpMotor

ConnectorK8Open

OutputTestButton(usedtotestrelaysonboard)

ControlBoardAuxiliaryCode V0orEarlier V1orLaterFactoryPartNumber P00013-03 P01771-01ServicePartNumber P00013-02 P01771-02Type HKM2006V003

[c] CONTROL BOARD LAYOUT

17

[d] CONTROLS AND ADJUSTMENTS

1) Dip Switch

TheDipSwitchesontheControlBoardarefactory-adjustedtothefollowingpositions:

DipSwitchNo. 1 2 3 4 5 6 7 8 9 10KM-30AKM-35AKM-50AKM-75A

OFF OFF ON ON ON ON OFF ON ON ON

CAUTION

DonotchangethesettingsoftheDipSwitchNos.3,4,7,8,9and10,ortheunitwillnotoperateproperly.

If theS2DipSwitch ismountedon theControlBoard,all shouldbe left in the “OFF”position.

SwitchNos.1and2: UsedforadjustmentoftheDefrostTimer. TheDefrostTimerstartscountingwhentheThermistorreadsacertaintemperatureat

theEvaporatoroutlet.

SwitchNos.3and4: UsedforadjustmentoftheDrainTimerandtheminimumdefrosttime. Onceeverytenfreezecycles,theDrainValveopenstodraintheWaterTankforthe

timedeterminedbytheDrainTimer.Theseswitchesalsodeterminethetimetodelaycompletionofadefrostcycle,i.e.theminimumdefrosttime.

Donotchangethissetting,ortheunitwillnotoperateproperlyorproducehighqualityice.

SwitchNos.5and6: UsedforadjustmentoftheDrainCounter. TheDrainValveopenstodrain theWaterTankat the frequencydeterminedby the

DrainCounter.Onceeverytenfreezecycles,theDrainValvedrainstheWaterTanktocleaninsidethetankandpreventcloudyiceproductionbyconcentratedicemakingwater.This functionensuresproper operationeven in hardwater conditions.Thefrequencyof this drain cycle canbe changed to every cycle, every two cycles, oreveryfivecycles.

SwitchNos.7and8 UsedforadjustmentoftheWaterSaver. TheWaterSaverclosestheWaterValvetosavewaterwhenthePumpMotorstarts

tosupplywatertotheEvaporator30secondsbeforetheendofdefrostcycle.Donotchangethissetting.

18

SwitchNos.9and10 UsedforadjustmentoftheFreezeBackupTimer. Thefreezecyclebackuptimeissetto120minutes.Donotchangethissetting.

2) Defrost Control

A thermistor (semiconductor) is used for theDefrostControlSensor.The resistancevariesdependingon the suction line temperatures.TheThermistor detects thetemperatureof theEvaporator outlet to start theDefrostTimer.Noadjustment isrequired. If necessary, check for resistancebetweenThermistor leads, and visuallychecktheThermistormounting,locatedonthesuctionlinenexttotheEvaporatoroutlet.

Temperature(°F) Temperature(°C) Resistance(kΩ)0 -18 14.40110 -12 10.61332 0 6.00050 10 3.87170 21 2.47490 32 1.633

Fig. 1

TheControlBoardislocatedinsidetheControlBox.

OutputTestButton

DipSwitch

FreezeTimer(9&10)

WaterSaverTimer(7&8)

DrainFrequencyControl(5&6)

DrainTimer(3&4)

DefrostTimer(1&2)

19

ChecktheThermistorforresistancebyusingthefollowingprocedures.

(i) DisconnecttheConnectorK1ontheboard.

(ii) RemovetheThermistor.See“V.13.THERMISTOR”.

(iii) ImmersetheThermistorsensorportioninaglasscontainingiceandwaterfor2or3minutes.

(iv) CheckforresistancebetweentheThermistorleads.Normalreadingiswithin3.5to7kilohms.ReplacetheThermistorifitexceedsthenormalreading.

3) Defrost Timer

Noadjustment is requiredunder normal use, as theDefrostTimer is adjusted to thesuitableposition.However,ifnecessarywhenalltheiceformedontheEvaporatordoesnot fall into theBin in thedefrostcycle,adjust theDefrostTimer to longerpositionbysettingtheDipSwitch(Nos.1&2)ontheControlBoard.

DipSwitchSetting Time(seconds)No.1 No.2

OFF OFF 60 (factoryadjustment)ON OFF 90OFF ON 120ON ON 180

4) Drain Counter

TheDrainCounter is factory-adjusted to drain theWaterTankevery 10 cycles.Noadjustmentisgenerallyrequired.Ifmorefrequentdraincycleisnecessaryduetowaterquality,theDrainCountercanbereadjustedasfollows:

DipSwitchSetting FrequencyNo.5 No.6OFF OFF everycycleON OFF every2cyclesOFF ON every5cyclesON ON every10cycles (factoryadjustment)

5) Bin Control Switch

AmechanicalBinControlSwitchisemployedandnotaffectedbyambienttemperature.WhentheBinSwitchPlateispressedbytheweightoficefor15seconds,theunitwillstopicemakingoperation.Then,iftheBinSwitchPlateisreleasedfor90seconds,theunitwillautomaticallystartthedefrostcycletoresumeicemakingoperation.

20

[e] A

LAR

MS

Iftheunitcannotoperateproperlyfora

certaincause,theControlB

oardwillsoundabuzzertoinformtheuserandstoptheunit.Each

buzzingsequencerepresentsanerrorcondition.Therearefivedifferentalarmsasshownbelow.

Alarm

Error

Condition

Reset

Whileinerrorcondition

Error

recorded

atpow

er

OFF

Auto

Manual

LED

Buzzer

Load

1High

evaporator

temperror

OverheatThermistor

detectstempabove53°

Cfor1sec

PressResetSwitch

whileOverheat

Thermistordetects

tempbelow51°C

Pow

er

Lampon

1beep/3sec

Allloads

off

Yes

2Defrostcycle

time-outerro

r

Twoconsecutive

defrostcyclesexceed

20min

PressResetSwitch

Pow

er

Lampon

2beeps/3sec

Allloads

off

Yes

3Freezecycle

time-outerro

rTw

oconsecutivefreeze

cyclesexceed120min

TurnControlSwitch

offandbackon

Pow

er

Lampon

3beeps/3sec

Allloads

off

No

6Lowvoltage

error

Supplyvoltagefalls

below184Vfor5sec

Supplyvoltage

exceeds194V

for5sec

Pow

er

Lampoff

6beeps/3sec

Allloads

off

No

7Highvoltage

error

Supplyvoltageexceeds

294V

for3sec

Supplyvoltage

fallsbelow

270V

for3sec

Pow

er

Lampoff

7beeps/3sec

Allloads

off

No

ThebuzzingsoundforeachalarmstopswhenthePow

erSwitchisturnedoff.W

henthePow

erSwitchisturnedbackon:

Alarms1&2:T

hebuzzingsoundwillstartagain.Pressth

eResetSwitchonth

eContro

lBoard.T

hebuzzingsoundwillstopandthe

alarmwillbereset.

Alarm3:

Thebuzzingsoundwillremainoff.

Alarms6&7:T

healarmwillberesetonlywhenthepropervoltageissupplied.Afterthecauseofthealarmislocated,presstheReset

Switch.

21

[f] CHECKING THE CONTROL BOARD

Before replacingaControlBoard that doesnot showa visible defect and that yoususpectisbad,alwaysconductthefollowingcheckprocedure.Thisprocedurewillhelpyouverifyyourdiagnosis.

1)Check theDipSwitchsettings toassure that#3,4,7,8,9,&10are in the factorydefaultposition.Switches1,2,5,&6arecleaningadjustmentsandthesettingsareflexible.

2)MovetheControlSwitch to the“ICE”positionandcheck forpropercontrolvoltage.If thePowerOKLEDison, thecontrolvoltage isgood. If theLEDisoff,checktheControlTransformercircuit.Ifnovoltageispresent,checkthepowersupplycircuit.

3)Toperforma relay sequence test, turnon thepower switchwhile pressing the"OUTPUTTEST"button.Thecorrectlightingsequenceshouldbe5,6,7,8,4.Somecomponents (e.g., the compressor)will cycle during test.EachLEDcomeson for5seconds.LED5 isonwhileLED6 ison.Followingtheoutput testsequence, theicemakerwillresumenormaloperationbeginningwiththeinitialcycle.

Ifthecomponentscycleinadifferentsequence,theControlBoardisbadandshouldbe replaced.See “V. 14. [d]CONTROLBOARD”. If the components cycled in thecorrectsequence,proceedtothenextstep.

4)Move theControlSwitch to the “ICE”position.When theunit enters the freezecycle, allow it torunfor5minutesafterthethermistortemperaturereaches 2°C in the f reeze cyc le and thendisconnect the3-pinFloatSwitchConnector(graywire).TheConnector isnotshown,but it islocated in thegeneralareaof thecircle inFig.2.AftertheFloatSwitchisdisconnected,thedefrostcycle should start. If thedefrost cycledoesnotstart,replacetheboard.See“V.14.[d]CONTROLBOARD”.

Note: Theboardneveracceptsthefreezecompletionsignal (openFloatSwitch)within the first5minutesafter the thermistor temperaturereaches2°Cinthefreezecycle.

Fig. 2

22

ControlSwitch

FrontViewwithLouverRemoved

3. SWITCHES

Control Switch

TheControlSwitchislocatedattheleftfrontoftheunit.RemovetheAirFiltertoaccesstheControlSwitch.Thisswitch isusedtoplacethemachineintooneof threemodes:“OFF”(centerposition),“ICE”(rightposition),and“WASH”(leftposition).

1) “OFF”

Inthe“OFF”position,nopowerissuppliedtotheunit.However,toavoidanypossibleriskofelectricalshock,disconnectthepowerbeforeservicing.

2) “ICE”

Thispositionappliespower to theunitcausing theautomatic icemakingprocess tobegin.Referto“2.[d]SEQUENCE”forfurtherdetails.

3) “WASH”

When theControlSwitch is placed in the “WASH”position, power is supplied tothePumpMotor andCleaningWaterValve.This allows cleaningand/or sanitizingsolutions (see “VI.CLEANINGANDMAINTENANCE INSTRUCTIONS”) tocirculatethroughout thewater systemanddown the insideandoutsideof theEvaporatorplates.

Fig. 3

23

PumpMotor

WaterTank

Compressor

WaterCircuit

RefrigerationCircuit

III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

[a] KM-30A, KM-35A, KM-50A

DrainValve

DrainOutlet

HotGasValve

Accumulator

Insulation

Drier

CapillaryTube

Evaporator

FanCondenser

SprayTubeWaterValve

WaterInlet

FloatSwitch

Thermistor

Insulation

24

[b] KM-75A

PumpMotor

WaterTank

Compressor

WaterCircuit

RefrigerationCircuit

DrainValve

DrainOutlet

HotGasValve

Drier

ExpansionValve

Evaporator

Fan

Condenser

SprayTube

WaterValve

WaterInlet

FloatSwitch

Thermistor

25

2. WIRING DIAGRAM

[a] KM-30A, KM-35A

[b] KM-50A, KM-75A

26

3. T

IMIN

G C

HA

RT

30sec

10sec

30sec

10sec

30sec

10sec

30sec

30sec

10sec

30sec

30sec

30sec

30sec

30sec

30sec

10sec

30sec

10sec

30sec

10sec

30sec

30sec

10sec

20sec

20sec

ON

OFFON

ON

OFF ON

OFF ON

RELA

Y:X

3(PM)

RELA

Y:X

4(W

V)

OFFON

OFF

OFF ON

CONTROLBOARDFLOATSWITCH

ON

OFF

BINCONTR

OL

SWITCH

ON

OFF

RELA

Y:X

6(DV)

RELA

Y:X

1(COMP)

RELA

Y:X

2(HV/FM)

WATE

RVALV

EON

OFF

DRAINVALV

EON

OFF

Program

Ver3.1

(AuxiliaryCode:V-

1)

HOTGASVALV

EON

OFF

POWERSWITCH

Program

Ver3.2

orlater

(AuxiliaryCode:

V-2orlater)

FANMOTO

RON

OFF ON

PUMPMOTOR

Program

Ver2.5

orearlier

(AuxiliaryCode:

V-0orearlier)

ON

OFF

THERMISTO

R

COMPRESSOR

ON

OFF

FREEZE

CYCLE

OFF1°C

OFF 9°C

5°C

HARVESTCYCLE

(AFT

ERBINFULL)

BINFULL

HARVESTCYCLE

FREEZE

CYCLE

HARVESTCYCLE

(INCLU

DINGDRAIN)

FREEZE

CYCLE

HARVESTCYCLE

FREEZE

CYCLE

HARVESTCYCLE

(INITIAL)

PARTNAME

HARVESTCYCLE

Thermistorsenses9°Cafterm

orethan

8min30secinharvestcycle(V

er3.1

orlater)

H

ARVESTCYCLE

Thermistorsenses9°C

after6minto8min30sec

inharvestcycle(V

er3.1or

later)

6min

3min

30sec

6min

60sec

Max6min

5sec

Max6min

Max6min

Max6min

15sec

90sec

Max6min

10secOFF

,50secON

10secOFF

,50secON

10secOFF

,50secON

10°C

10°C

10°C

10secOFF

,50secON

10°C

Max6min

Max6min

27

IV. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY 1. OFF position. 1. Move to ON position. 2. Loose connections. 2. Tighten. 3. Bad contacts. 3. Check for continuity and

replace. 4. Voltage too high. 4. Check and get

recommended voltage.

a) Power Supply

5. Unplugged. 5. Plug in. b) Fuse (inside fused

disconnect, if any)1. Blown out. 1. Check for short circuit and

replace. 1. OFF position. 1. Move to ICE position. c) Control Switch 2. Bad contacts. 2. Check for continuity and

replace. 1. Tripped with bin filled

with ice. 1. Remove ice. d) Bin Control Switch

2. Defective reed switch. 2. Check for continuity and replace.

e) Transformer 1. Thermal fuse blown out or coil winding opened.

1. Replace.

f) Wiring to Control Board

1. Loose connections or open.

1. Check for continuity and replace.

g) Thermistor 1. Leads shorted or open and High Temperature Safety operates. If open, unit will start but have long defrost cycle.

1. See “II. 2. [d] CONTROLS AND ADJUSTMENTS, 2) Defrost Control”.

h) Hot Gas Solenoid Valve

1. Continues to open in freeze cycle and High Temperature Safety operates.

1. Check for power off in freeze cycle and replace.

i) Water Supply Line 1. Water supply off and water supply cycle does not finish.

1. Check and get recommended pressure. Check for water supply.

1. Mesh filter or orifice gets clogged and water supply cycle does not finish.

1. Clean. Replace if necessary.

2. Coil winding opened. 2. Replace.

j) Water Solenoid

3. Wiring to Water Valve. 3. Check for loose connection or open, and replace.

[1] The icemaker will not start.

k) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING THE CONTROL BOARD”.

1. Connector disconnected.

1. Place in position. [2] Water continues to be supplied, and the icemaker will not start.

a) Float Switch

2. Leads opened or defective switch.

2. Check and replace.

28

PROBLEM POSSIBLE CAUSE REMEDY 3. Float does not move

freely. 3. Clean or replace. [2] (Continued)

b) Control Board 1. Defective. 1. Replace. 1. WASH position. 1. Move to ICE position. a) Control Switch 2. Bad contacts. 2. Check and replace. 1. Bad contacts. 1. Check for continuity and

replace. 2. Voltage too low. 2. Increase voltage.

b) Overload Protector

3. Refrigerant overcharged or undercharged.

3. Recharge.

1. Bad contacts. 1. Check and replace. c) Starter 2. Coil winding opened. 2. Replace.

d) Start Capacitor 1. Defective. 1. Replace. 1. Bad contacts. 1. Check for continuity and

replace. e) Power Relay

2. Coil winding opened. 2. Replace. 1. Wiring to Compressor. 1. Check for loose

connection or open, and replace.

2. Defective. 2. Replace.

f) Compressor

3. Protector tripped. 3. Reduce temperature and verify cause.

g) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING THE CONTROL BOARD”.

[3] Compressor will not start or operates intermittently.

h) Condenser, Air Filter

1. Clogged with dirt and dust.

1. Clean and unclog.

a) Water Solenoid Valve

1. Diaphragm does not close.

1. Check for water leaks with icemaker off. Replace if necessary.

[4] Water continues to be supplied in freeze cycle. b) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING

THE CONTROL BOARD”.a) Water Supply Line 1. Water pressure too low

and water level in Water Tank too low.

1. Check and get recommended pressure.

b) Water Solenoid Valve

1. Dirty mesh filter or orifice and water level in Water Tank too low.

1. Clean.

1. Water leaks. 1. Check connections for water leaks, and replace.

c) Water System

2. Clogged. 2. Clean. 1. Motor winding opened. 1. Replace. 2. Bearing worn out. 2. Replace. 3. Wiring to Pump Motor. 3. Check for loose


4. Defective Capacitor. 4. Replace.

[5] No water comes from Spray Tubes. Water Pump will not start, or freeze cycle time is too short.

d) Pump Motor

5. Defective or bound impeller.

5. Replace and clean.

29

PROBLEM POSSIBLE CAUSE REMEDY [5] (Continued) e) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING

THE CONTROL BOARD”.1. Motor winding opened. 1. Replace. 2. Bearing worn out. 2. Replace. 3. Wiring to Fan Motor. 3. Check for loose


a) Fan Motor

4. Fan blade bound (locked Fan Motor).


[6] Fan Motor will not start, or is not operating.

b) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING THE CONTROL BOARD”.

1. Undercharged. 1. Check for leaks and recharge.

a) Refrigerant

2. Air or moisture trapped. 2. Replace Drier, and recharge.

b) Compressor 1. Defective valve. 1. Replace.

[7] All components run but no ice is produced.

c) Hot Gas Solenoid Valve

1. Continues to open in freeze cycle.


2. EVAPORATOR IS FROZEN UP

PROBLEM POSSIBLE CAUSE REMEDY 1. Leads shorted or

defective switch. 1. Check and replace. a) Float Switch

2. Float does not move freely.

2. Clean or replace.

b) Water Solenoid Valve

1. Diaphragm does not close.

1. Check for water leaks with icemaker off. Replace if necessary.

[1] Freeze cycle time is too long.

c) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING THE CONTROL BOARD”.

a) Evaporator 1. Scaled up. 1. Clean. b) Water Supply Line 1. Water pressure too low. 1. Check and get

recommended pressure. 1. Dirty mesh filter or

orifice. 1. Clean. c) Water Solenoid

Valve 2. Diaphragm does not

close. 2. Check for water leaks

with icemaker off. Replace if necessary.

d) Ambient and/or water temperature

1. Too cool. 1. Increase temperature.

e) Thermistor 1. Out of position or loose attachment.

1. See “V. 13. THERMISTOR”.

[2] All ice formed on Evaporator does not fall into bin in defrost cycle.

f) Control Board 1. Defrost Timer is set too short.

1. Adjust longer, referring to “II. 2. [e] CONTROLS AND ADJUSTMENTS, 3) Defrost Timer”.

30

PROBLEM POSSIBLE CAUSE REMEDY [2] (Continued) 2. Defective. 2. See “II. 2. [f] CHECKING

THE CONTROL BOARD”.1. Clogged. 1. Clean. a) Spray Tubes 2. Out of position. 2. Place in position.

b) Water System 1. Dirty. 1. Clean. c) Refrigerant 1. Undercharged. 1. Check for leaks and

recharge. 1. Bulb out of position or

loose attachment. 1. Place in position. d) Expansion Valve

(KM-75 only) 2. Defective. 2. Replace. 1. Coil winding opened. 1. Replace. 2. Plunger does not move. 2. Replace.

e) Hot Gas Solenoid Valve

3. Wiring to Hot Gas Valve.

3. Check for loose connection or open, and replace.

f) Water Supply Line 1. Too small; requires 9.5 mm OD line dedicated per machine.

1. Increase water supply line size.

[3] Others

g) Water Filter 1. Flow rate too small. 1. Replace with filter that has larger flow rate.

3. LOW ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY a) See chart 1 - [3] and check dirty Air Filter or Condenser, ambient or water

temperature, water pressure, and refrigerant charge. [1] Freeze cycle

time is long. b) See chart 2 - [1] and check Float Switch, Water Solenoid Valve, and Control

Board. [2] Defrost cycle

time is long. a) See chart 2 - [2] and check Control Board, Thermistor, Evaporator, ambient

and/or water temperature, water supply line, and Water Solenoid Valve.

4. ABNORMAL ICE

PROBLEM POSSIBLE CAUSE REMEDY a) Cube Guide,

Water Tank 1. Out of position.

Circulated water falls into bin.

1. Check that Cube Guide is properly installed on Water Tank and tank is fixed securely with snaps.

[1] Small cubes

b) See chart 1 - [5] and check water supply line, Water Solenoid Valve, water system, Pump Motor, and Control Board.

a) See chart 2 - [1] and - [3] and check Float Switch, Water Solenoid Valve, Control Board, Spray Tubes, water system, refrigerant charge and Expansion Valve.

b) Spray Guide 1. Dirty. 1. Clean.

[2] Cloudy or irregular cubes

c) Water Quality 1. High hardness or contains impurities.

1. Install a water filter or softener.

31

5. OTHERS

PROBLEM POSSIBLE CAUSE REMEDY 1. Completely

disconnected and dropped inside bin.

1. Place in position.

2. Detector broken. 2. Replace. 3. Detector out of position. 3. Place in position. 4. Defective reed switch. 4. Check for continuity and

replace. 5. Reed switch out of

position. 5. Place in position.

a) Bin Control Switch

6. Magnet disconnected from Detector.

6. Place in position.

[1] Icemaker will not stop when bin is filled with ice.

b) Control Board 1. Defective. 1. See “II. 2. [f] CHECKING THE CONTROL BOARD”.

a) Pump Motor 1. Bearings worn out. 1. Replace. 1. Bearings worn out. 1. Replace. 2. Fan blade deformed. 2. Replace fan blade.

b) Fan Motor

3. Fan blade does not move freely.

3. Replace.

1. Bearings worn out, or cylinder valve broken.

1. Replace. c) Compressor

2. Mounting pad out of position or loose hold-down bolt.

2. Reinstall.

[2] Abnormal noise

d) Refrigerant Lines 1. Rub or touch lines or other surfaces.

1. Reposition.

[3] Ice in Storage Bin often melts.

a) Bin Drain 1. Plugged. 1. Clean.

32

V. REMOVAL AND REPLACEMENT

1. SERVICE FOR REFRIGERANT LINES

[a] SERVICE INFORMATION

1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R134a]

Thecompressormustnotbeopenedmorethan30minutesinreplacementorservice.Donotmixlubricantsofdifferentcompressorsevenifbotharechargedwiththesamerefrigerant,exceptwhentheyusethesamelubricant.

2) Treatment for Refrigerant Leak [R134a]

Ifarefrigerant leakoccurs inthelowsideofanicemaker,airmaybedrawnin.Evenif the lowsidepressure is higher than theatmospheric pressure in normal operation,a continuous refrigerant leakwill eventually lower the low sidepressurebelow theatmosphericpressureandwillcauseairsuction.Aircontainsalargeamountofmoisture,andesteroileasilyabsorbsalotofmoisture.IfanicemakerchargedwithR134ahaspossiblydrawn inair, thedriermustbe replaced.Besure touseadrierdesigned forR134a.

3) Handling of Handy Flux [R134a]

Repairoftherefrigerantcircuitrequiresbrazing.Itisnoproblemtousethesamehandyflux that hasbeenused for the current refrigerants.However, its entrance into therefrigerantcircuitshouldbeavoidedasmuchaspossible.

4) Oil for Processing of Copper Tubing [R134a]

Whenprocessingthecoppertubingforservice,wipeoffoil,ifanyused,byusingalcoholorthelike.Donotusetoomuchoilorletitintothetubing,aswaxcontainedintheoilwillclogthecapillarytubing.

5) Service Parts for R134a

SomepartsusedforrefrigerantsotherthanR134aaresimilartothoseforR134a.Butnever useanyparts unless theyare specified forR134abecause their enduranceagainst the refrigeranthasnotbeenevaluated.Also, forR134a,donotuseanypartsthathavebeenused forother refrigerants.Otherwise,waxandchlorine remainingonthepartsmayadverselyaffectR134a.

6) Replacement Copper Tubing [R134a]

Thecopper tubescurrently inusearesuitable forR134a.Butdonotuse them ifoilyinside.Theresidualoilincoppertubesshouldbeaslittleaspossible.(Lowresidualoiltypecoppertubesareusedintheshippedunits.)

33

7) Evacuation, Vacuum Pump and Refrigerant Charge [R134a]

Never allow theoil in the vacuumpump to flowbackward.The vacuum level andvacuumpumpmaybe the sameas those for the current refrigerants.However, therubber hoseandgaugemanifold to beused for evacuationand refrigerant chargeshouldbeexclusivelyforR134a.

8) Refrigerant Leak Check

Refrigerant leaks canbedetectedby charging theunitwitha little refrigerant, raisingthepressurewithnitrogenandusinganelectronicdetector.Donotuseairoroxygeninsteadofnitrogenfor thispurpose,orrise inpressureaswellas in temperaturemaycauseR134a to suddenly reactwithoxygenandexplode.Be sure tousenitrogen topreventexplosion.

[b] REFRIGERANT RECOVERY

NorefrigerantAccessValveisprovidedintheunit.InstallaproperAccessValveonthelow-side line(ex.CompressorProcessPipe).Recover therefrigerant fromtheAccessValve, and store it in a proper container.Donot discharge the refrigerant into theatmosphere.

[c] EVACUATION AND RECHARGE

1)AttachChargingHoses,aServiceManifoldandaVacuumPumptothesystem.

2)TurnontheVacuumPump.

3)Allow theVacuumPump topulldown toa760mmHgvacuum.Evacuatingperioddependsonthepumpcapacity.

4)ClosetheLow-sideValveontheServiceManifold.

5)Disconnect theVacuumPump, andattachaRefrigerantChargingCylinder.Remember to loosen the connection, andpurge theair from theHose.See theNameplatefortherequiredrefrigerantcharge.

6)Open theLow-sideValve.Donot invert theChargingCylinder.A liquidchargewilldamagetheCompressor.

7)Turnontheicemakerwhenchargingspeedgetsslow.TurnofftheicemakerwhentheLow-sideGauge showsapproximately 0 kg/cm2.Donot run the icemaker atvacuumpressures.Close theLow-sideValvewhen theChargingCylinder getsempty.

34

8)Repeatsteps4)through7),ifnecessary,untiltherequiredamountofrefrigeranthasenteredthesystem.

9)Close theRefrigerantAccessValve, anddisconnect theHoses,ServiceManifold,etc.

10)CaptheAccessValvetopreventpossibleleak.

Fig. 4

CapAccessValve

Depressed

OPEN

2. BRAZING

DANGER

1.RefrigerantR134a itself is not explosiveor poisonous.However,whenexposed to high temperatures (open flames),R134a canbedecomposed to formhydrofluoric acidand carbonyl fluoridebothofwhicharehazardous.

2.Alwaysrecovertherefrigerantandstoreitinapropercontainer.Donotdischargetherefrigerantintotheatmosphere.

3.DonotusesilveralloyorcopperalloycontainingArsenic.

4.Donot useR134aasamixturewith pressurizedair for leak testing.Refrigerant leaks canbedetectedby charging theunitwith a littlerefrigerant, raising thepressurewith nitrogenandusinganelectronicleakdetector.

Note: All brazing connections inside thebin are clear coated.Sandpaper thebrazingconnectionsbeforeunbrazing the components.Useagoodabrasive cloth toremovethecoating.

35

3. COMPRESSOR

WARNING

TheCompressorTerminalCovermust be refitted in its correct position.Otherwise,operationunderhightemperatureandhighhumidityconditionsmaycauseelectricshock,fire,orcorrosiontoshortentheservicelife.

IMPORTANT

Always install a newDrier every time the sealed refrigeration system isopened.DonotreplacetheDrieruntilafterallotherrepairorreplacementhasbeenmade.

1)Unplugtheicemakerordisconnectthepowersource.

2)RemovetheLouverandRearCover.

3)Recovertherefrigerantandstoreitinapropercontainer,ifrequiredbyanapplicablelaw(see“1.[b]REFRIGERANTRECOVERY”).

4)Remove theTerminalCover on theCompressor, anddisconnectSolderlessTerminals.

5)DisconnecttheDischargeandSuctionPipesusingbrazingequipment.

6)RemovetheHold-downBolts,WashersandRubberGrommets.

7)SlideandremovetheCompressor.UnpackthenewCompressorpackage.

8)AttachtheRubberGrommetsofthepreviousCompressor.

9)CleantheSuctionandDischargePipeswithanabrasivecloth/paper.

10)PlacetheCompressorinposition,andsecureitusingtheBoltsandWashers.

11)RemovePlugsfromtheCompressorSuctionandDischargePipes.

12)BrazeorsoldertheAccess,SuctionandDischargelines(Donotchangethisorder),withnitrogengasflowingatapressureof0.2-0.3bar.

13)InstallthenewDrier(see“4.DRIER”).

14)Checkforleaksusingnitrogengas(10bar)andsoapbubbles.

15)Evacuatethesystemandcharge itwithrefrigerant(see“1. [c]EVACUATIONANDRECHARGE”).

36

16)Connect theSolderlessTerminals and replace theTerminalCover in its correctposition.

17)RefittheLouverandRearCoverintheircorrectpositions.

18)Plugintheicemakerorconnectthepowersource.

Note: HoshizakirecommendsthatCompressorstartingelectricsarealwaysreplacedatthesametimeastheCompressor.

4. DRIER

IMPORTANT



2)RemovetheRearCover.


4)RemovetheDrierHolder,ifany,andpulltheDriertowardyouforeasyservice.

5)RemovetheDrierusingbrazingequipment.

6)Brazeor solder thenewDrier,with thearrowon theDrier in thedirection of therefrigerant flow.Usenitrogengasat a pressure of 0.2 - 0.3 barwhenbrazingtubings.BrazeinanAccessValveusingateeifnecessary.



9)RefittheRearCoverinitscorrectposition.


Note:AlwaysuseaDrierofthecorrectcapacityandrefrigeranttype.

37

5. HOT GAS VALVE

CAUTION

Toensureoptimumperformance,useacoppertubeofthesamediameterandlengthforreplacementofthehotgascircuit.

IMPORTANT



2)RemovetheLouverandRearCover.


4)DisconnecttheHotGasValveleads.

5)RemovethescrewandtheSolenoidCoil.

6)RemovethevalveandDrierusingbrazingequipment.

Fig. 5

HotGasValve

38

7)BrazethenewHotGasValvewithnitrogengasflowingatapressureof0.2-0.3bar.

WARNING

Alwaysprotectthevalvebodybyusingadampclothtopreventthevalvefromoverheating.Donotbrazewiththevalvebodyexceeding135°C.

8)InstallthenewDrier(see“4.DRIER”).



11)AttachtheSolenoidCoiltothevalvebody,andsecureitwiththescrew.

12)Connecttheleadwires.

13)Refitthepanelsintheircorrectpositions.


39

6. EXPANSION VALVE - KM-75A ONLY

IMPORTANT

Thewater intherefrigerationcircuitmayexceedthecapacityof theDrierand freeze in theExpansionValve.Always installanewDrierevery timethe sealed refrigeration system is opened.Donot replace theDrier untilafterallotherrepairorreplacementhasbeenmade.


2)RemovetheTopPanel,RearPanelandRearCover.


4)RemovetheExpansionValveusingbrazingequipment.ProtecttheEvaporatorandpipesfromexcessiveheatwithdampclothsorsimilar.

5)Remove the InsulationHose fromtheExpansionValveSensor (Bulb)and removetheBulb.

6)RemovetheDrierusingbrazingequipment.

7)Braze in thenewExpansionValve.Protect thebodyof the valve fromexcessiveheat,andusenitrogenatapressureof0.2-0.3barwhenbrazing.

8)BrazeorsolderthenewDrier(see“4.DRIER”).



11)Attach theBulb to thesuction line inposition.Besure tosecure itusingawireorclampandreplacetheinsulation.

12)Replacethepanelsintheircorrectpositions.


WARNING

Alwaysprotectthevalvebodybyusingadampclothtopreventthevalvefromoverheating.Donotbrazewiththevalvebodyexceeding115°C.

40

Fig. 6

RemoveExpansionValveCoverfirst

CuttiestomakeBulbremovable

TopRearViewwithTopandRearPanelsRemoved

BulbInsulationHose

ExpansionValve

RemovebandfromBulbwithascrewdriver

Wrapthispartwithadampclothtopreventoverheating

Bulb

ExpansionValveisbrazedatthesetwopoints.Whilebrazing,removeIn-sulationHosesfrompipesandkeepbrazingequipmentawayfromotherpartstopreventburning.

41

7. FAN MOTOR


2)RemovetheLouver.

3)DisconnecttheConnectoroftheFanMotorlead.

4)RemovethetwoscrewssecuringtheFanMotorBracketandpullouttheFanMotorinthearrowdirection.Topreventdeformation,donothittheFanontheCondenserorotherparts.

5)InstallthenewFanMotorinthereverseorderoftheremovalprocedure.

6)RefittheLouverinitscorrectposition.


Fig. 7

Condenser

FanMotor

FanMotorBracket

Screw

42

8. PUMP MOTOR


2)RemovetheTopPanelandunscrewtheRearPanel.

3)DisconnecttheConnectorofthePumpMotorlead.

4)RemovetheWaterTank(see“15.WATERTANK”).

5)Remove the ties connecting thePumpMotor dischargeoutlet andpull off theSiliconeHose.

Fig. 8

6)RemovethescrewsecuringthePumpMotor.ShifttheCasetothecentertoreleaseitfromtheStopper,andliftoffthePumpMotor.

Tie

SiliconeHose

7)Installthenewmotorinthereverseorderoftheremovalprocedure.

8)Plugintheicemakerorconnectthepowersource,andcheckforleaks.


Fig. 9Stopper

Screw

Slidetocenter

Liftoff

43

9. WATER VALVE


2)Closethewatersupplytap.


4)DisconnecttheTabTerminals.

5)PinchandlowertheHoseClamp.

6)Disconnect theRubberHose from theWaterValve.Put a towel under theWaterValvetoreceivewatercomingout.

7)TurntheInletNut in thearrowdirectiontoremoveit fromtheWaterValve.DonotlosetheGasketinside.

8)Removethetwomountingscrews.

9)Installthenewvalveinthereverseorderoftheremovalprocedure.

10)TightentheInletNuttoatorqueof7.85N•m(±5%)topreventwaterleaks.

11)Openthewatersupplytap.


13)Checkforleaks.


Fig. 10

TabTerminal

HoseClamp

InletNut

MountingScrew

RubberHose

44

10. DRAIN VALVE


2)Closethewatersupplytap.

3)DraintheWaterTank(see“15.WATERTANK”).

4)Disconnectanyrigid(fixed)pipeforwatersupplyanddrainconnections.

5)UnscrewtheRearCover.PullouttheunitforeasyaccesstotheDrainValve.

6)DisconnecttheConnectors(orTabTerminals)oftheDrainValvelead.

7)PinchandshiftthetwoHoseClamps.

8)Disconnect theHoses from theDrainValve.Puta towelunder theDrainValve toreceiveanywatercomingoutandpreventitfromsplashingout.

9)Removethetwomountingscrews.

10)Installthenewvalveinthereverseorderoftheremovalprocedure.

11)Reconnectthewatersupplyanddrainconnections,ifdisconnectedinstep4).

12)Openthewatersupplytap.


14)Checkforleaks.


Fig. 11HoseClamp*Pinchandlower

MountingScrew

HoseClamp*Pinchandshifttoleft

45

11. FLOAT SWITCH

[a] KM-30A, KM-35A, KM-50A



3)Disconnect theConnectorof theFloatSwitch leadandremove the leadwire fromtheGrommetthroughtheslit.


5)RemovethescrewsecuringtheFloatSwitch.

6)InstallthenewFloatSwitchinthereverseorderoftheremovalprocedure.



Fig. 12

Slit

Grommet

MountingScrew

FloatSwitch* Attachtothreearrowedsurfaceswhenfixingwithscrew

46

Fig. 13

[b] KM-75A



3)DisconnecttheConnectoroftheFloatSwitchlead(gray).

4)TheFloatSwitchislocatedbehindthePumpMotor.Pinchthearrowedpart(1)andpullitdiagonallyforward(2)tounhooktheFloatSwitch.

5)RemovethescrewsecuringtheFloatSwitchtotheBracket.

6)AttachthenewFloatSwitchtotheRailoftheBracket.Securethemwiththescrewbyfittingtheroundendoftheslottothescrewhole.

PumpMotor

FloatSwitch

Hook(A)

Hook(B)

FloatSwitch

Bracket

Screw

Pinch

Pull

Fig. 14

Rail

Roundendofslot* Secureherewithscrew

Whenfittedproperly,topendsofBracketandFloatSwitchbecomeflushwitheachother

Screw

47

7)PuttheFloatSwitchdownintothemountingholeandhookitinpositionasshown.Toensureproperoperation,besuretofittheHook(A)underthemountinghole.

8)Refittheremovedpartsinthereverseorderoftheremovalprocedure.


12. BIN CONTROL SWITCH



3)Disconnect theConnector of theBinControlSwitch lead (black) coveredwith asiliconehoseandremovetheleadwirefromtheGrommet.

4)RemovetheWaterTank(see“15.WATERTANK”).TheBinControlSwitchislocatedasshownbelowwhenviewedfromthefront.

Fig. 15

MountingHole

Fig. 16

Separator BinControlSwitch

5)Pulldownand remove the leadwire from the retaineron the rightsideof theBinControlSwitch.

6)HoldbothsidesoftheBinControlSwitchandpullittowardyou.

48

7)TheBinControlSwitch(KM-30A/35A)pulledoutoftheStorageBinhastheinternalstructureasshownbelow.

Fig. 17

RetainerEvaporator

PumpMotor

Holdhereandpulltowardyou

Stopper(A)[bothsides]

SlideRail[bothsides]

Pull

Fig. 18

ReedSwitch LeadHook

BinSwitchCase BinSwitchPlate ReedSwitchCover

Stopper(B)[bothsides]*FitinStopper(A)

49

8)ToremovetheBinSwitchPlate,slightlywarpbothsidesandpull theShaft towardyou.

Fig. 19

TopView

Slightlywarp

Pulltowardyou

9)Refit theremovedparts in thereverseorderof theremovalprocedure.Besure toputtheleadwirebackintheRetainerontheBracket.


50

13. THERMISTOR



3)DisconnecttheConnectoroftheThermistorlead(orange).

4)RemovetheTies,Insulation,ThermistorHolder,andThermistorinthisorder.

5)RemovetheoldsealantfromtheThermistorHolderandSuctionPipe.

6)WipeoffanymoistureorcondensationfromtheSuctionPipesurfaces.

7)Pressa tubeof thesealantKE4560RTV,manufacturedbyShin-EtsuSilicones, totherecessoftheThermistorHolder.Slowlysqueezethesealantoutofthetubeandspreaditsmoothlyintherecess.Donotuseanysealantotherthantheabove.

8)Attach thenewThermistor in positionon theSuctionPipeandpressdown theThermistorHolder over theThermistor.Be careful not to damage theThermistorlead.Cover thepartswith the Insulationandsecure themwith theTies.Keep theThermistorinsidetheThermistorHolder.AftertheThermistorHolderisfitted,donotpulltheThermistorleadtomovetheThermistor.

9)Refittheremovedpartsinthereverseorderoftheremovalprocedure.


Fig. 20

ThermistorLead Tie

Insulation ThermistorHolder Fitrightontopofpipe

AfterThermistorHolderisfitted,donotpullThermistorlead

Fillinshadedarea

Filluptoslightlyabovetopofrecess

Donotletinairandmakeahollowinrecess

51

14. CONTROL BOX


2)RemovetheLouver.

3)TilttheTabsinwardatthesametimeonbothsidesoftheControlBoxandpulltheControlBoxtowardyou.TiltingonlyoneTabwillnotwork.

4)TorefittheControlBox,pushitinhorizontally.

Fig. 21

Tab

ControlBox

PowerRelay

Transformer

ControlBoard

Control Box

Capacitor(KM-50/75only)

PowerSwitch

FuseFuseHolder

Tab

PushButton

PositioningLug

52

Note: AfterreplacingthecomponentsinsidetheControlBox,connectandtiethewiresproperlyintheircorrectposition.EspeciallymakesurethattheHarnessdoesnotpressthePushButtonsontheControlBoard.

[a] POWER SWITCH

1)DisconnecttheTabTerminalsandremovetheNutsecuringthePowerSwitch.

2)InstallthenewSwitchinthereverseorderoftheremovalprocedure.

3)Topreventmiswiring, check the terminal numbers and leadwire colorswith theWiringLabel.

[b] FUSE

1)Useaphillipsheadscrewdriver to remove theFuseHolderCapand takeout theFuse.

2)InstallthenewFuseinthereverseorderoftheremovalprocedure.

[c] FUSE HOLDER

1)DisconnecttheTabTerminalandremovetheNutsecuringtheFuseHolder.

2)InstallthenewFuseHolderinthereverseorderoftheremovalprocedure.

[d] CONTROL BOARD

1)DisconnectalltheConnectors.

2)PulltheTabtoreleasetheControlBoard.

3)LiftofftheControlBoard.

4)TorefittheControlBoard,fititsfourcornerholesonthepositioninglugsinsidetheControlBoxandsecuretheControlBoardwiththeTab.

5)WhenreconnectingtheConnectors,donotpushthemtoohard.TheControlBoardmaybedamaged.

[e] POWER RELAY

1)Disconnect theTabTerminals, remove themounting screw,and lift off thePower

53

Relayfromthefitatthebottom.

2)InstallthenewRelayinthereverseorderoftheremovalprocedure.

3)Topreventmiswiring, check the terminal numbers and leadwire colorswith theWiringLabel.

[f] COMPRESSOR CAPACITOR - KM-50A, KM-75A ONLY

1)DisconnecttheTabTerminalsandcuttheTie.

2)InstallthenewCapacitorinthereverseorderoftheremovalprocedure.UseacabletietosecuretheCapacitortightly.

[g] CONTROL BOARD TRANSFORMER

1)Disconnect theConnectors andClosedEndConnectors connecting theControlBoard.(TheTiesecuringtheharnessmayberemoved.Butbecarefulnottobreaktheleadwires.)

2)RemovethemountingscrewandliftofftheTransformerfromthefitatthebottom.

3)InstallthenewTransformerinthereverseorderoftheremovalprocedure.

15. WATER TANK

1)Unplug the icemaker or disconnect thepower source.Removeall ice from theStorageBin.

2)Drain out theWaterTankbypullingoff theOverflowPipe from theWaterTankbottomandtheSiliconeHosefromtheStorageBinbottom.

Fig. 22

CubeGuide

SiliconeHose(Connect/disconnectarrowedpart)

StorageBin

WaterTank

OverflowPipe(Disconnectfromtankbottom)

54

3)Pinchandpushdown theSnapsonboth sidesof theBracket to unhooktheWaterTankfromthesquareholes,andpullitabout1”towardyou.

4)When theSnapsareunhooked fromthe squareholes, the rear part of theWaterTank(dottedcirclebelow)isalsounhooked.Hold theWaterTankwithbothhands.

Fig. 23

WaterTank

Snap

Fig. 24

PumpMotor

FloatSwitch

5)TilttherightsideoftheWaterTankandpullittowardyou.DonothitthePumpMotororFloatSwitch.SlightlytwisttheleftsideoftheWaterTankinwardandpullittowardyou.

Fig. 25RightSide

LeftSide

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6)Slide the left sideof theWaterTank toreleaseitfromtheBracketRail, liftdowntheentireWaterTank,andpull it towardyououtoftheStorageBin.Donothittheothercomponents.

7)RefittheWaterTankinthereverseorderof theremovalprocedure(left, right, top,rear).

8)Plug in the icemaker or connect thepowersource.

Fig. 26

BracketRail

16. CUBE GUIDE


2)LiftofftheCubeGuideoutoftheWaterTank.

3)TorefittheCubeGuide,fittheNotchesonbothsidestotheStoppersintheWaterTank.

4)Theunit isprovidedwith twoor threeCubeGuides (quantityvariesdependingonmodel).BesuretolocatetheVerticalFlangesonbothsides.

Fig. 27

CubeGuide

VerticalFlange Notch

Stopper

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17. SEPARATOR


2)RemovethescrewsattherearandtakeofftheTopPanel.

3)Holdboth sidesof theSeparator from the top.Bend theFrontSeparator into aU-shapeand remove it from theShaft of theEvaporatorBracket.Bend theRearSeparatorintoaninvertedU-shapeandliftitofftheShaftoftheEvaporatorBracket.

4)Refit theSeparator in the reverseorderof the removalprocedure.Check that theSeparatorisfitcorrectlyontheShaftandcanswinglikeapendulum.


Fig. 28

18. SPRAY TUBE, WATER SUPPLY PIPE, SPRAY GUIDE

1)Unplugtheicemakerordisconnectthepowersource.RemovetheTopPanel.

2)PushtheTabsonbothsidestoreleasetheSprayTube.

3)RemovetheendoftheSprayTubefromtheBracket.

4)PinchandlowertheHoseClampanddisconnecttheHose.TheSprayTubeiseasilycleanablebyremovingtheblackrubbercapontheend.

SprayGuide

SprayTube

FrontSeparatorWaterSupplyTube

RearSeparator

EvaporatorBracket

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5)TheWaterSupplyPipe is located rightunder theSprayTube.Remove theWaterSupplyPipefromtheEvaporator,pinchandshift theHoseClamp,anddisconnecttheHose.

6)TheSprayGuideislocatedundertheWaterSupplyPipe.PullofftheSprayGuidefromtheEvaporatorPlate.

7)Refit the removedparts in the reverseorderof the removal procedure.Check forwaterleaks.

IMPORTANT

FittheSprayGuidesecurelyandtightlyontheEvaporatorfin.Otherwise,cloudyorirregularicecubesorperformancereductionmaybecaused.


19. DOOR

1)RemovetheTopPanel.

2)Move theDoor tofit theDoorShaft in the inletof theDoorChannel.Slideup theDoortoreleaseitfromtheDoorChannel.

3)RefittheDoorinthereverseorderoftheremovalprocedure.DonotforgettofittheCollarontheDoorShaft,ortheDoorwillnotopenorclosesmoothly.

Fig. 29

DoorChannel

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VI. CLEANING AND MAINTENANCE INSTRUCTIONS

IMPORTANT

Ensureall components, fasteners and screwsare securely in placeafteranymaintenanceorcleaningisdonetotheequipment.

1. CLEANING

WARNING

1.Hoshizaki recommends cleaning this unit at least oncea year.Morefrequent cleaning, however,maybe required in someexistingwaterconditions.

2.Topreventinjurytoindividualsanddamagetotheicemaker,donotuseammoniatypecleaners.

3.Alwayswear liquid-proof gloves to prevent the cleaningand sanitizingsolutionsfromcomingintocontactwithskin.

4.For safety andmaximumeffectiveness, use cleaningand sanitizingsolutionsimmediatelyafterdilution.

[a] CLEANING PROCEDURE

1)Dilute 148ml of recommended cleanerHoshizaki “ScaleAway” or “LIME-A-WAY”(EconomicsLaboratory,Inc.)with3.8lit.ofwater.

2)RemovetheAirFilter.RemoveallicefromtheEvaporatorandtheStorageBin.

Note:ToremovecubesontheEvaporator,movetheControlSwitchontheControlBox to the “OFF” positionandmove it back to the “ICE” positionafter 3minutes.Thedefrost cycle starts and the cubeswill be removed from theEvaporator.

3)MovetheControlSwitchtothe“OFF”position.OpentheDoor.

4)DisconnecttheSiliconeHosetodrainthewater.SeeFig.22.ReconnecttheSiliconeHosebackinitscorrectpositionafterallofthewaterhasdrained.

5)Pour the cleaning solution into theWaterTank.Move theControlSwitch to the“WASH”position.ClosetheDoor.

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6)After30minutes,movetheControlSwitchtothe“OFF”position.

7)Sameasstep4.

8)MovetheControlSwitchtothe“ICE”positiontofilltheWaterTankwithwater.

9)After3minutes,movetheControlSwitchtothe“WASH”position.

10)After5minutes,movetheControlSwitchtothe“OFF”position.

11)Sameasstep4.

12)Repeatsteps8through11threemoretimestorinsethoroughly.

13)DisconnecttheSiliconeHoseandOverflowPipe.RemovetheWaterTank.See“V.15.WATERTANK”fordetails.

14)PulltheCubeGuides(quantityvariesdependingonmodel)upwardtoremovethemfromtheWaterTank.Theyaresnappedinplace.SeeFig.30.Referto“V.16.CUBEGUIDE”fordetails.

Fig. 30

CubeGuide

*Th i s i l l u s t r a t i o n s hows KM-30A/35A.The followingnumberofCubeGuidesareprovided:

KM-30A/35A 2pcs KM-50A 3pcs KM-75A 3pcs

Snap

WaterTank

BinControlSwitch

*TheBinControlSwitch is accessible byremoving theWaterTank.Pull the switchtowardsyouforeasymaintenance.

*ThisisthefrontviewwiththeDooropenedandtheWaterTankremoved.

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15)Sameasstep1.

16)WashtheBinControlSwitch,WaterTank,FloatSwitch,CubeGuide,SiliconeHoseandOverflowPipebyusinganylonscouringpad,brushesandthecleaningsolution.Inadditiontotheremovedparts,alsowashthebinlinerandBracket(L)(R)withthesolution.

17)Discardthecleaningsolutionandrinsethepartsthoroughlywithwater.

[b] SANITIZING PROCEDURE - Following Cleaning Procedure

1)Diluteapproximately15mlor1tbsofa5.25%sodiumhypochloritesolution(chlorinebleach)with 3.8 lit. ofwarmwater.Usinga chlorine test strip or othermethod,confirmthatyouhaveaconcentrationofabout200ppm.

2)Soak the removedparts fromstep16above in a clean container containing thesanitizingsolution.Afterallowingthepartstosoakfor10minutes,washthemwiththesolution.Alsowashthebinliner,Bracket(L)(R)withthesolution.

3)Discardthesanitizingsolutionandrinsethepartsthoroughlywithwater.

4)Replace the removedparts in their correctpositions in the reverseorderofwhichtheywereremoved.

5)Sameasstep1.

6)PourthesanitizingsolutionintotheWaterTank,andallowthesanitizertositfor10minutes.

7)MovetheControlSwitchtothe“WASH”position.ClosetheDoor.

8)After15minutes,movetheControlSwitchtothe“OFF”position.OpentheDoor.

9)DisconnecttheSiliconeHosetodrainthewater.ReconnecttheSiliconeHosebackinitscorrectpositionafterallofthewaterhasdrained.

10)Repeat steps5 through9one time.Repeat steps8 through11 in theCleaningProcedurethreetimestorinsethoroughly.

11)FlushtheStorageBinwithwater.

12)Move theControlSwitch to the “ICE”position, and start theautomatic icemakingprocess.

13)ClosetheDoor.ReplacetheAirFilterinitscorrectposition.

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2. MAINTENANCE

[a] EXTERIOR PANELS

Topreventcorrosion,wipetheexterioroccasionallywithacleanandsoftcloth.Useadampclothcontaininganeutralcleanertowipeoffalloilordirtbuildup.

[b] STORAGE BIN AND SCOOP

*Washyourhandsbeforeremovingice.Usetheplasticscoopprovided(Accessory).

*TheStorageBinisforiceuseonly.Donotstoreanythingelseinthebin.

*Keepthescoopclean.Cleanitbyusinganeutralcleanerandrinsethoroughly.

*Cleanthebinlinerbyusinganeutralcleaner.Rinsethoroughlyaftercleaning.

[c] AIR FILTER

TheplasticmeshAirFilterremovesdirtordustfromtheair,andkeepstheCondenserfromgetting clogged.As the filter gets clogged, the icemaker’s performancewill bereduced.Check thefilterat least twiceamonth.When it isclogged,usewarmwaterandaneutralcleanertowashthefilter.

[d] CONDENSER

Check theCondenseronceayear,andclean if requiredbyusingabrushorvacuumcleaner.More frequent cleaningmaybe requireddependingon the locationof theicemaker.

3. PREPARING THE ICEMAKER FOR LONG STORAGE

IMPORTANT

Whenshuttingoff the icemaker for anextended time, drainout allwaterfromthewaterlinesandremovetheicefromtheStorageBin.TheStorageBinshouldbecleanedanddried.Drain the icemakerusingairor carbondioxide to prevent damage to thewater supply linesat sub-freezingtemperatures.Shutofftheicemakeruntiltheproperambienttemperatureisresumed.

When the icemaker is not used for twoor threedays, it is sufficient to onlymove

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theControlSwitch to the “OFF” position, unless the icemakerwill beat sub-freezingtemperatures.

[a] Remove the water from the potable water supply line:

1)RemovetheAirFilterifithasnotalreadybeenremoved.

2)MovetheControlSwitchontheControlBoxtothe“OFF”position.

3)Unplugtheicemakerordisconnectthepowersupply.

4)Closethewatersupplytap,andremovetheInletHose.SeeFig.31.

5)RemoveallicefromtheStorageBin,andcleantheBin.

[b] Drain the potable Water Tank:

1)Turnoffthepowersupplyatthebreakerbox.

2)MovetheControlSwitchontheControlBoxtothe“OFF”position.

3)OpentheDoor.DisconnecttheSiliconeHosetodrainthewater.SeeFig.21.

4)Reconnect theSiliconeHoseback in itscorrectpositionafterallof thewaterhasdrained.

5)RemoveallicefromtheStorageBinandcleantheStorageBin.

6)ClosetheDoor.

7)PlacetheAirFilterinitscorrectposition.

WaterSupplyTap

Fig. 31

InletHose

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