Service Manual Stackable Crescent Cuber Models KMH-2100SWJ3, SRJ/3 hoshizakiamerica.
WARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No installation or service should be undertaken until the technician has thoroughly read this Service Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 5 I.
III. Controls and Adjustments................................................................................................ 35 A. Control Board Layout................................................................................................... 36 B. LED Lights and Audible Alarm Safeties........................................................................ 37 C. Settings and Adjustments............................................................................................. 38 1.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the appliance or property. IMPORTANT Indicates important information about the use and care of the appliance.
WARNING, continued • The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. • Children should be properly supervised around the appliance. • Do not climb, stand, or hang on the appliance or allow children or animals to do so.
I. Construction and Water/Refrigeration Circuit Diagram A. KMH Construction 1.
2.
B. Bin Control 1a. Single Thermostatic Bin Control Bin Control Bulb Holder F Bin Control Bulb Holder G Bin Control Bulb Holder E Spacer Bin Control Bulb Holder C Silicone Hose Bin Control Extension Bracket Bin Control Bulb Holder Z Bracket Used for Hoshizaki B-1300, B-1500, B-1650, and Non-Hoshizaki Ice Stoarage Bin 1b.
Water Circuit Pump-Out Water Pump Check Valve Spray Tubes Evaporator Freeze/Harvest Pump Timer Refrigeration Circuit Water Tank Spray Tubes Inlet Water Valve Drain Float Switch Condenser Compressor Hot Gas Valve Check Valves Water Supply Drain/Return High-Pressure Switch Strainer Discharge Line Service Valve Suction Line Drier Water Regulating Valve Thermostatic Expansion Valves Service Valve Liquid Line Valve Heat Exchanger Thermistor Cleaning Valve Water Supply C.
Water Circuit Pump-Out Water Pump Check Valve Spray Tubes Evaporator Freeze/Harvest Pump Timer Refrigeration Circuit Water Tank Spray Tubes Inlet Water Valve Drain Fan Liquid Line Valve Receiver Drier Headmaster (C.P.R.
Comp energized FMR energized PM energized LLV energized HGV de-energized FS closed 5-min. minimum freeze timer in control Comp energized FMR energized HGV energized PM de-energizes for 2 sec., then reverses for 10/20 sec. LLV de-energized When freeze time differential exceeded, freeze-time correction cycle starts. See "II.A.3. Freeze-Time Correction Chart." Anti-Slush Thermistor temperature reaches 36°F (2.2°C) (5.8 kΩ). PM de-energized for 10 sec.
Legend: BC–bin control 2. Icemaker Off All components de-energized. To 1. 1-Minute Fill Cycle 3. Ice Level Lowered No ice touching BC bulb. Icemaker starts at "1. 1-Minute Fill Cycle." BC closed BC open All components de-energized NOTE: Green "BC CLOSED" LED on continuously when K4 jumper is in place. 1. Bin Full Within 10 sec. after ice contacts BC bulb, icemaker shuts down. Ice contacts BC bulb BC Operation Shutdown and Restart Shutdown Flow Chart 2.
254 309 349 380 406 427 446 462 3 4 5 6 7 8 9 10 Note: When 1st freeze-time correction cycle is initiated, CB "POWER OK" LED starts blinking. On 2nd freeze-time correction cycle, if CB "POWER OK" LED has been reset, CB "POWER OK" LED starts blinking. If CB "POWER OK" had not been reset after 1st freeze-time correction cycle CB "POWER OK" LED continues to blink. After 3rd freeze‑time correction cycle in 36 hours, CB yellow "EXT HARVEST" LED starts blinking.
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Control switch in "OFF" position does not de‑energize all loads Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
1. Operation Diagnosis 1) Turn off the power supply, then access the control box. Move ice away from BC bulb. 2) Check that 115VAC 10A fuse is good. 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5‑sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check CB K4 red jumper connection. Note: • CB red "POWER OK" LED remains on unless the 10.
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, FMR, HGV, X10, and X12 relays 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 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). WV and X11 relay are energized during harvest for a maximum of 6 min.
5c) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.G. Thermistor Check." If 1-min. fill cycle starts after harvest timer terminates, check that FS is clean and operating properly, see "II.F. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle.
d) PM Diagnosis: Confirm water is flowing over evaporator from PM and not WV. If PM de-energizes once freeze begins, check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized, check for 115VAC at control switch #5 (W/R) to neutral (W). If 115VAC is present at CB K1 #4 (R) and not at control switch #5 (W/R), check control switch continuity between #5 (W/R) and #4 (R). Replace as needed.
7) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the first pump-out is determined by S4 dip switch 5. See the table below. Control Board Settings S4 Dip Switch Setting Pump-Out Frequency 1st Pump-Out OFF Every 10 cycles After 11th freeze cycle ON Every cycle After 2nd freeze cycle No. 5 Comp and FMR continue, HGV energizes. If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV and X11 relay energize, energizing X10 relay.
8) Normal Harvest Cycle – Same as the initial harvest cycle. Return to step 5a) above. Note: Appliance continues to cycle until BC is satisfied, power is switched off or freeze‑time correction cycle is initiated. The appliance always restarts at the 1-min. fill cycle. 2. Shutdown Diagnosis 1) See "II.E. Bin Control Check." 3. Freeze-Time Correction Cycle Diagnosis 1) See "II.C. Freeze-Time Correction Cycle.
C. Freeze-Time Correction Cycle (90 min.) Freeze-Time Correction function is enabled when S4 Dip Switch 7 is in the "ON" position and initiates when the minimum and maximum freeze times have exceeded differential parameters. Freeze-time correction timer and count starts at the beginning of the 2nd freeze cycle after startup from power off condition.
2) Freeze-Time Correction Sequence: First occurrence within 36 hr., minimum and maximum freeze times have exceeded differential parameters. CB "POWER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Second occurrence within 36 hr., minimum and maximum freeze times have exceeded differential parameters. If not reset, CB "POWER OK" LED continues blinking. If reset from first occurrence, CB "POWER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Third occurrence within 36 hr.
D. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB while CB is beeping. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the icemaker starts at the 1-minute fill cycle. For audible alarm information, see "III.B.
E. Bin Control Check BC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb, regardless of the cycle at activation. NOTICE When the ambient temperature is below 45°F (7°C), BC opens and shuts down the appliance even if the ice storage bin is empty. When BC is set in the prohibited range, the appliance operates continuously even if the ice storage bin is filled with ice. Setting in the prohibited range may result in severe damage to the appliance.
1a. Single Thermostatic Bin Control Layout Bin Control Bulb Holder F Bin Control Bulb Holder G Bin Control Bulb Holder E Spacer Bin Control Bulb Holder C Silicone Hose Bin Control Extension Bracket Bin Control Bulb Holder Z Bracket Used for Hoshizaki B-1300, B-1500, B-1650, and Non-Hoshizaki Ice Stoarage Bin Fig. 1 1b.
F. Float Switch Check and Cleaning FS is used to determine that there is sufficient water in the water tank after the 1‑min. fill cycle and after each harvest cycle. FS is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle. No adjustment is required. 1. Float Switch Check To check FS, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position.
2. Float Switch Cleaning Depending on local water conditions, scale may build up on FS. Scale on the switch can cause the float to stick. In this case, FS should be cleaned. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the insulation panel, then remove the drain plug located on the lower front part of the ice chute. See Fig. 3. Allow the water tank to drain. 4) Replace the drain plug in its correct position.
G. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel. Move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor from the refrigerant tubing. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min. 6) Disconnect the thermistor connector from CB K3 connector and check the resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ.
I. Diagnostic Tables 1. No Ice Production No Ice Production - Possible Cause 1. Power Supply a) Off, blown fuse, or tripped breaker. b) Not within specifications. 2. Main Transformer (if applicable) a) Voltage tap switch not set to proper voltage. 3. Fuse (Control Box) a) Blown. 4. Thermostatic Bin Control See "II.D. Bin Control Check" a) Tripped with bin filled with ice. b) Coil winding open or shorted. b) Ambient temperature too cool. c) Set too warm. d) Bulb out of position.
No Ice Production - Possible Cause 15. Pump Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor. d) Mechanical seal worn out. 16 Thermostatic Expansion Valve a) Bulb loose. 17. Liquid Line Valve a) Closed in freeze cycle. b) Operating erratically. b) Open in harvest cycle. 18. Fan Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor. 19. Water System a) Water leaks causing short freeze time. 2.
Low Ice Production - Possible Cause 3. Float Switch a) Float does not move freely. 4. Splash Guard a) Missing or defective. 5. Check Valve a) Dirty. b) Defective. b) Defective. 6. Control Board a) Defective. 1. Evaporator a) Scaled up, dirty. Long Freeze Cycle 2. Float Switch a) Scaled up, dirty. See "II.F. Float Switch Check and b) Float sticking. Cleaning" c) Defective switch. 3. Inlet Water Valve a) Leaking by. 4. Hot Gas Valve a) Erratic or open. 5. Condenser a) Clogged. 6.
Freeze-Up - Possible Cause 6. Float Switch a) Dirty, sticking. See "II.F. Float Switch Check and b) Defective. Cleaning" 7. Refrigerant Charge a) Low. 8. Control Board See "II.D. Control Board Check" and "III.D. Settings and Adjustments" a) Harvest timer (S4 dip switch 1 & 2) set too short. 9. Bin Control See "II.E. Bin Control Check" a) Actuator does not move or defective. b) Harvest pump time (harvest assist) (S4 dip switch 7) not in factory default position. c) Defective. 10. Thermistor See "II.G.
J. Freeze-Up Check List Freeze-Up Check List Please Complete When Diagnosing a Freeze-Up, Refrigerant Leak, or Low Charge Technical Support Fax #: 770-487-3360 Make Copies And Use As Needed Model #___________________________ Serial # ____________________Install Date____________Freeze-Up Date___________ List model and manufacture of bin or dispenser__________________________. Date appliance was last cleaned:__________.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM and KMH series appliances. • All models are pretested and factory adjusted. • For a control board check procedure, see "II.D. Control Board Check." NOTICE • Fragile, handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the icemaker when handling or replacing the control board.
A. Control Board Layout • Bin Control Switch Closed LED (green) • "ALARM RESET" Button • S4 Dip Switch • "OUTPUT TEST" Button (used to test relays on control board) • K3 (white) Connector Thermistor (harvest control, antislush control, and high temperature safety) • Bin Control Switch Open LED (yellow) • Alarm Buzzer • K4 (red) Connector Thermostatic Bin Control Jumper (4a4883G01) • S5 Dip Switch • Ext.
B. LED Lights and Audible Alarm Safeties Beep occurs and red "POWER OK" LED turns on when control switch is moved to "ICE" position. Sequence Green LEDs 1 through 4 turn on and sequence from initial startup as listed in the table below. Order of green LEDs from the outer edge of control board is 1, 4, 3, 2. Sequence Step Energized Components LED Time LEDs are On Min. Max.
C. Settings and Adjustments NOTICE Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact your Hoshizaki Service Center. 1. Default Dip Switch Settings The dip switches are factory-adjusted to the following positions: S4 Dip Switch S4 Dip Switch No.
2. Harvest Time (S4 dip switch 1 & 2) The harvest timer starts counting when the thermistor reaches 48°F (9°C) at the evaporator outlet and the control board reads 3.9 kΩ from the thermistor. The harvest timer is factory set, and generally no adjustment is required. However, a setting longer than the factory setting may be advised in cases where the drain provided at harvest needs to be prolonged for extra cleaning.
4. Pump-Out Frequency Control (S4 dip switch 5) The pump-out frequency control is factory set to drain the water tank every 10 cycles. 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 can be set to have a pump‑out occur every cycle, or every 10 cycles. The first pump-out is dependent on S4 dip switch 5. See the table below.
6. Harvest Pump Time (Harvest Assist)/Freeze-Time Correction (S4 dip switch 7) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the appliance. a) Harvest Pump Time (Harvest Assist) Depending on S4 dip switch 7 setting, the pump motor either stays off or is energized during the last seconds of the harvest cycle. When the pump motor is energized (S4 dip switch 7 on), water circulates over the evaporator.
8. Freeze Timer (S4 dip switch 9 & 10) NOTICE Adjust to proper specification, or the icemaker may not operate correctly. The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of the freeze timer, the control board initiates the harvest cycle or pump-out cycle. After 2 consecutive freeze timer terminations, the control board shuts down the icemaker. In this case, see "II.G.3. Low Ice Production" for possible solutions.
11. Minimum Harvest Time (S5 dip switch 4) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside the factory default setting may result in damage to the appliance. S5 Dip Switch Setting No. 4 Minimum Harvest Timer OFF 120 sec. ON 70 sec. 12. Anti-Slush (S5 dip switch 5) This dip switch setting provides anti-slush control during the freeze cycle. When the evaporator temperature reaches 36°F (2.2°C) the control board reads a 5.
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the control switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF" position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. • Do not use silver alloy or copper alloy containing arsenic. 1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used. 6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
B. Component Service Information NOTICE When replacing a component listed below, see the notes to help ensure proper operation. Component Notes Compressor 1 phase: Install a new start capacitor, run capacitor, and start relay. 3 phase: Install a new magnetic contactor. Thermostatic Expansion Valves • Attach the thermostatic expansion valve bulb to the suction line in the same location as the previous bulb. • The bulb should be between the 10 and 2 o'clock positions on the tube.
C. Water Regulating Valve Adjustment (water-cooled models) The water regulating valve is factory set, and generally no adjustment is required. However, when necessary, adjust the water regulator using the following procedure. 1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure gauge to the high-side line of the system. 2) 5 min. after a freeze cycle starts, confirm that the thermometer reads 104°F to 115°F (40°C to 46°C).
V. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch or service switch with damp hands • Before servicing: Move the control switch to the "OFF" position and turn off the power supply.
VI. Preparing the Appliance for Periods of Non-Use NOTICE • When storing the appliance for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. • To prevent damage to the water pump, do not operate the appliance with the control switch in the "WASH" position when the water tank is empty. When the appliance is not used for two or three days under normal conditions, it is sufficient to move the control switch to the "OFF" 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, top, and right side panels. 2) Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve. 3) Open the condenser water supply line drain valve. If connected to a closed loop system, also open the condenser return line drain valve.
VII. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
VIII. Technical Information We reserve the right to make changes in specifications and design without prior notice. A. Specification and Performance Data Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 1. KMH-2100SWJ3 Specification Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) WATER COOLED CONDENSER gal./24HR (gal./100 lbs.
2. KMH-2100SRJ Specification Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) ICE PRODUCTION PER CYCLE BIN CONTROL SYSTEM REFRIGERANT CHARGE Performance Data Sheet APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 3 gal./day m /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min.
3. KMH-2100SRJ3 Specification Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) ICE PRODUCTION PER CYCLE BIN CONTROL SYSTEM REFRIGERANT CHARGE Performance Data Sheet APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day m3/day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min.
284±22 PSIG Cut-in 327±22 PSIG 412±22 0 PSIG 384± 0 PSIG Cut-out 22 Air and Remote Model * Water-Cooled Model * High-Pressure Switch B. Wiring Diagrams 1.
384±22 0 PSIG 284±22 PSIG Cut-out Cut-in * Water-Cooled Model 327±22 PSIG 412±22 0 PSIG Remote Model * High-Pressure Switch 2.
