Service Manual Modular Crescent Cuber Serenity Series Models KMS-1122MLJ with SRK-12J/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 service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
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.
IV. Refrigeration Circuit and Component Service Information.............................................. 44 A. Refrigeration Circuit Service Information..................................................................... 44 B. Component Service Information................................................................................... 47 V. Maintenance..................................................................................................................... 48 VI.
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 For KMS • Risk of electric shock. Control switch in "OFF" position does not de-energize all loads. • Power supply and ground connection are supplied from the SRK remote condensing unit via the wire harness provided. Do not connect the wire harness leads to an external power source. • Wire harness routing (conduit) and disconnect (if required) must meet national, state, and local electrical code requirements.
I. Construction and Water/Refrigeration Circuit Diagrams A. Construction 1.
2.
Drain Float Switch Evaporator Water Tank Spray Tube Thermistor Liquid Line Valve Check Valves Strainer Hot Gas Valve Heat Exchanger Drier Drain Valve Cleaning Valve Thermostatic Expansion Valves Pump Motor Inlet Water Valve Water Supply KMS-1122MLJ Shut Off Valves Accumulator Suction Line Discharge Line Compressor Check Valve Receiver Headmaster Fans Condenser SRK-12J/3 Discharge Line Thermostat Strainer Liquid Line Valve Strainer High-Pressure Switch Hot Gas Valve B.
Comp energized FMRs energized HGVs energized WV energized FS closed Thermistor in control FS check Comp energized FMRs energized HGVs energized PM de-energizes for 2 sec., then restarts for 10/20 sec. LLVs 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.
Within 10 sec. after ice contacts BC bulb, icemaker shuts down. 1. Bin Full Ice contacts BC bulb BC Operation Shutdown and Restart BC open All components de-energized All components de-energized. No ice touching BC bulb. Icemaker starts at "1. 1-Minute Fill Cycle." 3. Ice Level Lowered To 1. 1-Minute Fill Cycle BC closed NOTE: control board green "BC CLOSED" LED on continuously when the K4 jumper is in place. 2. Icemaker Off 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. Use extreme caution and exercise safe electrical practices. • Risk of electric shock. Control switch (KMS) in "OFF" position does not de‑energize all loads. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
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 CB green "BC CLOSED" LED turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check CB K4 red jumper. Move ice away from BC bulb. Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is interrupted (K2 connector). • Check CB using the steps in "II.D. Control Board Check.
4) 1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGVs, and FMRs energized), continue to step 5a. If FS is open, WV remains energized until FS closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: Check that water enters the water tank.
5b) Harvest Pump Timer – LEDs 1, 3, and 2 are on. 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). When WV de-energizes, LED 4 turns off, X11 relay de-energizes and LED 3 turns on. PM energizes. Comp, FMRs, HGVs, and X10 relay continue. Diagnosis: Place a thermometer on the suction line next to the thermistor. Has it warmed to 48°F (9°C) or warmer? Confirm thermistor status. See "II.
a) Freeze Cycle Diagnosis: Confirm Comp, FMRs, and PM continue. Confirm that LLVs energize. Next, confirm HGVs and X10 relay de-energize. During the first 5 min. of freeze, confirm evaporator is cooling. If not, confirm WV de-energized (not leaking by), HGVs de-energized (not bypassing), LLVs energizes, TXV and HM operate correctly, Comp is efficient, and refrigerant charge is correct. See "VIII.A. Specification and Performance Data Sheets.
g) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with FS removed but would previously not switch out of freeze with FS connected (long freeze - 3 beep alarm), see "II.F. Float Switch Check and Cleaning.
b) CB Diagnosis: Confirm LLVs de-energize. If LLVs are energized with LEDs 1, 3, and 2 on, replace CB. If PM does not stop and restart and DV does not energize, check that CB LEDs 1, 3, and 2 are on. If not, replace CB. If LEDs 1, 3, and 2 are on and X12 relay is not energized, check for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present at CB K1 #5 (DBU) and X12 relay is not energized, continue to "c) X12 Relay Diagnosis:" below.
2. Shutdown Diagnosis When the appliance is running, hold ice in contact with the thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. BC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations. Diagnosis: See "II.E. Bin Control Check." CB red K4 connector must have the jumper in place. When the jumper is in place, the green "BC CLOSED" LED remains on.
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 difference between the minimum and maximum recorded freeze times is equal to or greater than values shown in the table below. Freeze time is recorded and freeze cycles are counted starting at the 2nd freeze cycle after startup from a 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.
4) To verify voltage output from CB to the components, slide the CB K1 connector out far enough to allow multimeter lead contact. With the icemaker in the cycle to be tested, check output voltage from the corresponding pin on CB K1 connector to a neutral (W). If output voltage is not found and the appropriate LED is on, replace CB. 5) Check CB control connectors K3, K4, and K5 for correct VDC per table below. Note: Pin #1 is DC ground (GND) on each connector.
E. Bin Control Check To check BC, follow the steps below. NOTICE When the ambient temperature is below 45°F (7°C), BC switch 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. BC is factory set, and generally no adjustment is required.
F. Float Switch Check and Cleaning FS is used to confirm sufficient water in the water tank after the 1‑min. fill cycle and after each harvest cycle. FS is also used to terminate 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. 3) Place the control switch in the "SERVICE" position. Then place the service switch in the "DRAIN" position.
19) Move the control switch to the "ICE" position. 20) Replace the front panel in its correct position. 21) Turn on the power supply to start the automatic icemaking process. Legend: CB–control board; FS–float switch 2. Float Switch Cleaning Depending on local water conditions, scale may build up on FS. Scale can cause FS to stick. In this case, FS should be cleaned. 1) Turn off the power supply. 2) Remove the front panel. 3) Place the control switch in the "SERVICE" position.
G. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor. 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 white K3 connector and check resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ.
H. Switches Two control switches are used to control operation. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. 1. Control Switch The control switch has three positions: "OFF" for power off, "ICE" for icemaking, and "SERVICE" to activate the service switch. WARNING! Moving control switch to "OFF" position does not de-energize all components. 2.
I. Diagnostic Tables Before consulting the diagnostic tables, check for correct installation, proper voltage per nameplate, and adequate water pressure (10 to 113 PSIG). Check control board using the steps in "II.D. Control Board Check." 1. No Ice Production No Ice Production - Possible Cause 1. Power Supply a) Off, blown fuse, or tripped breaker. 2. Main Transformer (3 phase SRK) (208-230VAC/115VAC) a) Voltage tap switch not set to proper voltage. 3.
No Ice Production - Possible Cause 13. Inlet Water Valve a) Screen or orifice clogged. b) Coil winding open. c) Water valve open in freeze cycle. 14. Float Switch a) Float does not move freely. See "II.F. Float Switch Check and b) Defective. Cleaning" 15. Compressor a) Magnetic contactor contacts bad or coil winding open. b) Start capacitor or run capacitor defective (1 phase SRK). c) Start relay contacts bad or coil winding open (1 phase SRK). d) Internal protector open. e) Compressor defective. 16.
2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. The freeze-up checklist can be found in the Hoshizaki Technician's Pocket Guide or contact your local distributor for a copy of the freeze-up checklist. Freeze-Up - Possible Cause Harvest Cycle 1. Evaporator a) Scaled up. b) Damaged. 2. Cube Guides a) Out of position. 3. Spray Tubes and/or Spray Guides a) Dirty. 4. Water Supply a) Low water pressure. b) Damaged. b) Out of position.
Freeze-Up - Possible Cause 8. Thermostatic Expansion Valve a) Bulb loose or defective. 9. Headmaster a) Defective. 10. Liquid Line Valves (KMS & SRK) a) Restricted. 3. Low Ice Production Low Ice Production - Possible Cause Long Harvest Cycle 1. Evaporator a) Scaled up. 2. Spray Tubes, Spray Guides, and a) Dirty. Splash Guard b) Out of position. 3. Refrigerant Charge a) Low. 4. Water Supply a) Low water pressure. b) External water filters clogged. c) Insufficient water line size.
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______________Fail 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 the KMS-1122MLJ series. • All models are pretested and factory adjusted. • For a control board check procedure, see "II.C. 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 appliance when handling or replacing the control board.
A. Control Board Layout "J" Control Board • Bin Control Switch Closed LED (green) • "ALARM RESET" Button • S4 Dip Switch • K3 (white) Connector Thermistor (harvest control and high temperature safety) • Bin Control Switch Open LED (yellow) • Alarm Buzzer • K4 (red) Connector K4 Jumper • Ext. Harvest LED (yellow) (blinks when 3rd occurrence of freeze time correction initiates within 36 hr.) • S5 Dip Switch • K5 (black) Connector Float Switch (water level) • POWER OK LED (red) (lights when 10.
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 Hoshizaki Technical Support at 1-800-233-1940. 1. Default Dip Switch Settings The dip switches are factory-adjusted to the following positions: S4 Dip Switch Dip Switch No. KMS-1122MLJ 1 2 3 4 5 OFF OFF OFF OFF ON 6 ON 7 8 9 10 ON OFF OFF OFF S5 Dip Switch (Do Not Adjust) Dip Switch No.
2. Harvest Timer (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.I.3. Low Ice Production" for possible solutions.
10. Refill Counter (S5 dip switch 2 and 3) The refill counter determines the number of refills. The KMS‑1122MLH does not refill during the freeze cycle. NOTICE Do not adjust. These must be left in the factory default position or the icemaker will not operate correctly. S5 Dip Switch Setting Refill Counter No. 2 No. 3 OFF OFF 0 OFF ON 1 refill ON OFF 9 refills ON ON 10 refills 11. Minimum Harvest Time (S5 dip switch 4) NOTICE Factory set for proper operation. Do not adjust.
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. • Before servicing the KMS or SRK: Move the KMS control switch to the "OFF" position and turn off the power supply to the SRK condensing unit. Place the KMS disconnect (if applicable) in the "OFF" position.
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.
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends on pump capacity. 4) Close the low-side valve and high-side valve on the gauge manifold. 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 nameplate on the condensing unit or the rating label inside the icemaker.
B. Component Service Information NOTICE When replacing a component listed below, see the notes to help ensure proper operation. Component Notes Compressor 1 Phase SRK: Install a new start capacitor, run capacitor, and start relay. 3 Phase SRK: 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.
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.
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 "SERVICE" 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.
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 Sheets Pressure data is recorded at 5 min. into freezing cycle. The data not in boldshould be used for reference only. 1. KMS-1122MLJ with SRK-12J Specification Sheet AC SUPPLY VOLTAGE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
2. KMS-1122MLJ with SRK-12J3 Specification Sheet AC SUPPLY VOLTAGE 115VAC Supplied by SRK-12J3 via Factory Supplied Wire Harness 90/70°F 70/50°F ELECTRIC & WATER CONSUM 1850 (4.05) 1730 (3.60) ELECTRIC W (kWH/100 lb 176 (16.0) 338 (29.3) WATER gal./24HR (gal./100 ICE PRODUCTION PER CYCL 18.6 lbs. (8.4 kg) 880pcs. BIN CONTROL SYSTEM Thermostatic REFRIGERANT CHARGE TOTAL R404A, 16 lb. 5 oz. (7400g) ICEMAKER, 0 lb. 7.1 oz. (200g) CONDENSER, 15 lb. 14 oz.
3.
4. SRK-12J3 Specifications Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE EXTERIOR DIMENSIONS (WxDxH) DIMENSIONS INCLUDING LEGS (WxDxH) EXTERIOR FINISH WEIGHT CONNECTIONS - ELECTRIC - REFRIGERATION CIRCUIT COMPRESSOR CONDENSER COMPRESSOR PROTECTION FAN MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE OPERATING CONDITIONS ACCESSORIES -SUPPLIED -REQUIRED 208-230/60/3 (115VAC Supplied to KMS via Factory Wire Harness) 10.
V V P P BK BK W GR GR Neutral W HGV LLV Contactor Fuse 10A BR BR Wire Color Code: BK-black BR-brown GR-green P-pink V-violet W-white GND SRK Condensing Unit (field connected) Legend: CB-control board GND-ground HGV-hot gas valve LLV-liquid line valve GND V CB BR Fuse 10A BR GR V P P HGV KMS Icemaker Unit (factory connected) Wire Harness Connections LLV BK BK W Neutral W B. Wiring Diagrams 1.
426±22 0 PSIG 341±22 PSIG Cut-in ** Discharge Line Thermostat Cut-in 239°F±9°F (115°C±5°C) Cut-out 266°F±9°F (130°C± 5°C) * Cut-out *High-Pressure Switch ** Auxiliary Code H-1 and Later Auxiliary Code H-0 2.
426± 0 PSIG 341±22 PSIG Cut-out Cut-in 22 *High-Pressure Switch Cut-in 239°F±9°F (115°C±5°C) Cut-out 266°F±9°F (130°C± 5°C) ** Discharge Line Thermostat ** Auxiliary Code H-1 and Later Auxiliary Code H-0 3.
