Service Manual Modular Crescent Cuber Serenity Series Model KMS-2000MLJ Including Condensing Unit Models SRK-20J/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.
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 Diagram A. Construction 1.
2. Condensing Unit Top Panel Main Transformer (Three Phase Only) Condenser Right Side Panel Control Box Suction Line Shutoff Valve Liquid Line Shutoff Valve Fan Motors Liquid Line Shutoff Valve 2 High-Pressure Switch Compressor Crankcase Heater Junction Box Louver Panel Front Panel Discharge Line Thermostat Liquid Line Valve Strainers Left Side Upper Panel Right Left Side Upper Panel Hot Gas Valves Headmaster (C.P. R.
Water Tank Evaporator Pump Motor Spray Tube Drain 9 Drain Valve Float Switch Check Valves Receiver Headmaster (C.P. R.
F/S open 10 Legend: BC-bin control Comp-compressor DV-drain valve FMRs-fan motors-remote F/S-float switch HGVs-hot gas valves (KMS and SRK) LLVs-liquid line valves (KMS and SRK) PM-pump motor WV-inlet water valve FS closed 5-min. minimum freeze timer in control Comp continues FMRs continue PM continues LLVs energized HGVs de-energized Anti-Slush Thermistor temperature drops to 36°F (2.2°C) (5.8 kΩ or more). PM de‑energizes for 10 sec.
BC Operation Shutdown and Restart 11 Legend: BC–bin control BC open (BC actuator paddle engaged) Green "BC CLOSED" LED off Yellow "BC OPEN" LED on All components de-energized. 2. Icemaker Off BC closed (BC actuator paddle disengaged) Green "BC CLOSED" LED on Yellow "BC OPEN" LED off To 1. 1-Minute Fill Cycle Icemaker starts at "1. 1-Minute Fill Cycle." 3. Ice Level Lowered Control board retains freeze-time correction count data between bin control restarts. Yellow "BC OPEN" LED continues.
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.
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.
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, FMRs, HGVs, and X10 relay 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.
c) WV and HGVs Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB. If 115VAC is not present, replace WV (bypassing). If HGVs (KMS and SRK) did not de‑energize at the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC is present 50 sec. after PM energizes, replace CB. If 115VAC is not present, replace HGV(s) (bypassing).
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 Control Board OFF Every 10 cycles After 11th freeze cycle ON Every cycle After 2nd freeze cycle No. 5 Comp and FMRs continue, HGVs energize. Note: 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.
d) PM Diagnosis: Check for 115VAC at X12 relay #6 (DBU) to neutral (W). If 115VAC is not present, see "b) CB Diagnosis" above. Next, check for 115VAC at X12 relay #4 (W/R) to neutral (W). If 115VAC is not present, confirm X12 relay is energized. If X12 relay is de-energized, see "c) X12 Relay Diagnosis:" above. If X12 relay is energized and 115VAC is present at X12 relay #6 (DBU) and not at X12 relay #4 (W/R), replace X12 relay.
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.
Third occurrence within 36 hr. minimum and maximum freeze times have exceeded differential parameters. CB yellow "EXT HARVEST" LED starts blinking. Also, If not reset, CB "POWER OK" LED continues blinking. If reset, CB "POWER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Total freeze-time correction cycle last for 90 min. At the end of 80 min., the final step initiates and final Harvest Pump Time (Harvest Assist) with WV (10‑min.) starts.
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 1. Bin Control Check This appliance uses a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required. To check BC, 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 base cover and clear any ice away from BC. 5) Disconnect BC connector from CB K4 connector. 6) Check for continuity across the wires of BC connector.
2. Bin Control Cleaning Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick. In this case, BC should be cleaned. WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the ppliance is serviced. Make sure that none have fallen into the dispenser unit/storage bin. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position.
F. Float Switch Check and Cleaning F/S is used to determine that there is sufficient water in the water tank after the 1‑minute fill cycle and after each harvest cycle. F/S 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 F/S, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel. 3) Place the control switch in the "SERVICE" position.
20) Reconnect F/S connector to CB K5 (black) connector, then replace the control box cover, right side, and top panels in their correct positions. 21) Move the control switch to the "ICE" position. 22) Replace the front panel in its correct position. 23) Turn on the power supply to start the automatic icemaking process. Legend: CB–control board; F/S–float switch 2. Float Switch Cleaning Depending on local water conditions, scale may build up on F/S. Scale can cause F/S to stick.
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 top and right side panels, then 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 minutes. 6) Disconnect the thermistor connector from CB K3 (white) connector and check resistance between thermistor leads.
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 - continued 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. Hot Gas Valves (KMS & SRK) a) Closed in harvest cycle. b) Open in freeze cycle. 17.
2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. See "II.J. Freeze Up Check List," the Hoshizaki America 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. b) Damaged. 3. Spray Tubes and/or Spray Guides or Splash Curtain a) Dirty. 4. Water Supply a) Low water pressure.
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 and/or Spray Guides or Splash Curtain a) Dirty. 3. Refrigerant Charge a) Low. 4. Water Supply a) Low water pressure. b) Out of position. 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-2000MLJ series. • 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 "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 Bin Control • S5 Dip Switch • Ext. Harvest LED (yellow) (blinks when 3rd occurence of freeze time correction initiates within 36 hr.) • 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 CB "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-2000MLJ 1 2 3 4 5 6 7 8 9 10 OFF OFF OFF OFF OFF OFF 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.
7. Factory Use (S4 dip switch 8) Factory set for proper operation. Do not adjust. This must be left in the factory default position. 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.
10. Refill Counter (S5 dip switch 2 and 3) NOTICE Do not adjust. These must be left in the factory default position or the icemaker will not operate correctly. S5 Dip Switch Setting No. 2 No. 3 Refill Counter 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. Adjustment outside the factory default setting may result in damage to the appliance. S5 Dip Switch Setting No.
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.
2. Remove the water from the water tank: 17) Remove the insulation panel and front frame. 18) Disconnect the hoses connected to the water tank. Allow the tank and hoses to drain completely. See Fig. 6. 19) Remove all ice from the dispenser unit/storage bin and clean the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning. 20) Reconnect the hoses to the water tank. 21) Replace all removed parts and panels in their correct positions.
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 bold should be used for reference only. 1.
2.
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4.
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.
W/BK COM C1 W/BK W 57 W WIRE COLOR CODE BK -BLACK BR -BROWN DBU -DARK BLUE GR -GREEN GY -GRAY O -ORANGE P -PINK R -RED V -VIOLET W -WHITE Y -YELLOW W/BR -WHITE/BROWN W/R -WHITE/RED W/BK -WHITE/BLACK W W BK L1 W BR C2 NC (BK) V GY W W W W WASH VALVE V V WASH 3 W W V GY GY VALVE DRAIN 1 CIRC R GY DRAIN BR BR W W (BR) FAN (BK) BK CAP. 10MFD BR (W) V R O GY CAP.
MAIN W W W W C1 WIRE COLOR CODE BK -BLACK BR -BROWN DBU -DARK BLUE GR -GREEN GY -GRAY O -ORANGE P -PINK R -RED V -VIOLET W -WHITE Y -YELLOW W/BR -WHITE/BROWN W/R -WHITE/RED W/BK -WHITE/BLACK TRANSFORMER W BR BK 208V 0V BR V C2 NC BK (BK) GY GY BR 58 W W W W BK WASH VALVE W W V WASH 3 (BK) BK DRAIN 1 GY CIRC W W W GY GY DRAIN VALVE BR BR BR CAP.
