Hoshizaki Hoshizaki America, Inc. Stackable Crescent Cuber Models KM-1301SAH-E KM-1301SWH-E KM-1301SRH-E “A Superior Degree of Reliability” SERVICE MANUAL www.hoshizaki.
IMPORTANT Only qualified service technicians should install, service, and maintain the icemaker. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the equipment in accordance with this manual may adversely affect safety, performance, component life, and warranty coverage. Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker.
IMPORTANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety. Please retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information....................................................................................
III. Technical Information....................................................................................................... 25 A. Water Circuit and Refrigeration Circuit......................................................................... 25 1. KM-1301SAH-E (air-cooled).................................................................................... 25 2. KM-1301SWH-E (water-cooled).............................................................................. 26 3.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. CAUTION Indicates a situation which could result in damage to the unit. IMPORTANT Indicates important information about the use and care of the unit.
I. Specifications A. Icemaker 1. KM-1301SAH-E (air-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lb./day ( kg/day ) Reference without *marks FOR THE EUROPEAN MARKET ICE CAPACITY lb./day (kg/day) SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lb.) WATER gal./24HR (gal./100 lb.
2. KM-1301SWH-E (water-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lb./day ( kg/day ) Reference without *marks FOR THE EUROPEAN MARKET ICE CAPACITY lb./day (kg/day) SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lb.) WATER gal./24HR (gal./100 lb.) WATER COOLED CONDENSER gal./24HR (gal./100 lb.
3. KM-1301SRH-E (remote air-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lb./day ( kg/day ) Reference without *marks FOR THE EUROPEAN MARKET ICE CAPACITY lb./day (kg/day) SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lb.) WATER gal./24HR (gal./100 lb.
B. Condenser Unit 1. URC-14FE Units: mm [in.] TOP VIEW 935 [36-13/16] 850 [33-15/32] 700 [27-9/16] AIR FLOW 370 [14-9/16] 435 [17-1/8] 460 [18-1/8] 398 [15-11/16] 380 [14-15/16] 357 [14-1/16] AIR FLOW 960 [37-13/16] 68 [2-11/16] 380 [14-15/16] 557.8 [21-15/16] FRONT VIEW 907.
SPECIFICATIONS MODEL: URC-14FE AC SUPPLY VOLTAGE 115/50/1 (Connection to Icemaker) FAN MOTOR 115 V EXTERIOR DIMENSIONS (WxDxH) 35-11/16"×15-11/16"×21-15/16" (907.2×398×557.8 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 37-13/16"×18-1/8"×36-15/16" (960×460×937.8 mm) EXTERIOR FINISH Galvanized Steel WEIGHT Net 80 lb. ( 36 kg ) CONNECTIONS - ELECTRIC Permanent - Connection - REFRIGERANT Total 2.6FLA 130W Shipping 87 lb.
II. General Information A. Construction 1.
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B. Sequence of Operation IMPORTANT KM-1301SAH-E utilizes a thermostatic bin control. For KM-1301SAH-E operation, the K4 jumper (4A4883G01) must be in place on the control board RED K4 connector or the unit will not operate. 1. Sequence Cycles and Shutdown The steps in the sequence are as outlined below. When power is supplied, CB red "POWER OK" LED and green "BC CLOSED" LED come on. If red "POWER OK" LED is off on KM-1301SAH-E, clear ice away from the thermostatic bin control bulb in the storage bin area.
c) Freeze Cycle LED 1 is on. Comp and FMR remain energized, PM energizes or remains energized depending on harvest pump timer (S4 dip switch 7) setting. FM and LLV energize. HGV and X1 relay (auxiliary code T-0, U-0), X10 relay (auxiliary code U-1 and later) de‑energize. For the first 5 minutes, CB will not accept a signal from F/S. This minimum 5-minute freeze time is short cycle protection for Comp. At the end of 5 minutes, F/S assumes control.
(2) Mechanical Bin Control (KM-1301SWH-E, KM-1301SRH-E) When mechanical BC is activated (BC open), the yellow "BC OPEN" LED comes on. The unit then shuts down as outlined in the table below. Cycle at Shutdown Mechanical Bin Control Activation Fill Cycle 15 seconds after activation. Harvest Cycle At the end of the harvest cycle, or up to 15 seconds into the freeze cycle if activated at the end of the harvest cycle.
Within 10 sec. after ice contacts thermostatic bulb, unit shuts down. 1. Bin Full F/S open F/S check BC-open All components de-energized All components de-energized. 2. Icemaker Off Yellow "BC OPEN" LED continues. All components de‑energized All components de-energized. To 1 above Ice level lowered. No ice pressing against BC actuator paddle. Icemaker starts at "1. 1-Minute Fill Cycle." 3.
C. Control Board • A Hoshizaki exclusive solid-state control board is employed in Hoshizaki Stackable Crescent Cubers. • All models are pretested and factory set. CAUTION 1. The control board is fragile; handle very carefully. 2. 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 unit before handling or replacing the control board. 3.
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a) LED Lights and Audible Alarm Safeties At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below. Note that the order of the LEDs from the outer edge of the control board is 1, 4, 3, 2.
2. Controls and Adjustments CAUTION 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. a) Default Dip Switch Settings The dip switches are factory set to the following positions: S4 Dip Switch S4 Dip Switch No.
c) Pump-Out Timer (S4 dip switch 3 & 4) CAUTION Do not adjust S4 dip switch 3 off and S4 dip switch 4 on for this model. Otherwise, pump motor does not rotate in the pump-out direction. When a pump-out is called for, the pump motor stops after the preceding freeze cycle. The pump motor restarts 2 seconds later in the reverse direction, taking water from the bottom of the tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain.
e) Harvest Pump Timer (S4 dip switch 7) CAUTION Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the icemaker. Depending on the harvest pump timer setting, the pump motor energizes and runs the last 0 or 50 seconds of harvest. When the pump is on, water circulates over the evaporator.
h) Float Switch Control (S5 dip switch 1) CAUTION Do not adjust. This must be left in the factory default position or the unit will not operate correctly. Factory set. S5 dip switch 1 allows for single or double float switch applications. The KM‑1301SAH-E, KM1301SWH-E, and KM-1301SRH-E use a single float switch. i) Refill Counter (S5 dip switch 2 through 5) CAUTION Do not adjust. These must be left in the factory default position or the unit will not operate correctly. Factory set.
Water Circuit Pump-Out Water Pump Check Valve Inlet Water Valve Spray Tubes Evaporator Freeze/Harvest Pump Timer Refrigeration Circuit Water Tank Spray Tubes Drain Compressor Service Valve Drier Discharge Line Suction Line Expansion Valves Service Valve Heat Exchanger Liquid Line Valve Fan Condenser Thermistor Float Switch Water Supply Strainer Hot Gas Valve High-Pressure Switch Check Valves III. Technical Information A. Water Circuit and Refrigeration Circuit 1.
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 Liquid Line Valve Condenser Compressor Hot Gas Valve Check Valves Cond. Water Inlet Cond. Water Outlet High-Pressure Switch Strainer Discharge Line Service Valve Suction Line Drier Water Regulating Valve Expansion Valves Service Valve Heat Exchanger Thermistor Float Switch Water Supply 2.
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 Receiver Tank Liquid Line Valve Drier Headmaster (C.P.R.
412±21 0 PSIG 327±21 PSIG Cut-out Cut-in Transformer Output 10.5V at 115V a) KM-1301SAH-E (air-cooled) * High-Pressure Switch * Auxiliary Code T-0, U-0 B. Wiring Diagrams 1.
* 412±210 PSIG 327±21 PSIG Cut-out Cut-in * High-Pressure Switch Auxiliary Code U-1 and V-0 Auxiliary Code U-1 and Later Transformer Output 10.5V at 115V 2.
384±21 0 PSIG 284±21 PSIG Cut-out Cut-in * High-Pressure Switch * Transformer Output 10.
412±210 PSIG 327±21 PSIG Cut-out Cut-in * High-Pressure Switch * Transformer Output 10.
C. Performance Data 1. KM-1301SAH-E (air-cooled) 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. HEAD PRESSURE PSIG kg/cm2G SUCTION PRESSURE PSIG kg/cm2G AMBIENT TEMP. (ºF/ºC) 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 50/10 1114 1089 505 494 1082 1048 491 475 WATER TEMP.
2. KM-1301SWH-E (water-cooled) 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. HEAD PRESSURE PSIG kg/cm2G SUCTION PRESSURE PSIG kg/cm2G AMBIENT TEMP. (ºF/ºC) 70/21 80/27 50/10 90/32 100/38 70/21 80/27 90/32 1330 1310 603 594 1304 1281 591 581 WATER TEMP.
3. KM-1301SRH-E (remote air-cooled) 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. HEAD PRESSURE PSIG kg/cm 2G SUCTION PRESSURE PSIG kg/cm 2G AMBIENT TEMP. (ºF/ºC) 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 50/10 1270 1241 576 563 1233 1211 559 549 WATER TEMP.
IV. Service Diagnosis WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices. 3. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. 4. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the storage bin.
4) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X2 relay (auxiliary code T‑0, U-0), X11 relay (auxiliary code U-1 and later) remain energized, HGV, X1 relay (auxiliary code T-0, U-0), X10 relay (auxiliary code U-1 and later), Comp, and FMR 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 a 3.
an inoperative Comp, or an inoperative HM. If the unit switches out of freeze with F/S connector removed, but would previously not switch out of freeze with F/S connected (long freeze - 3 beep alarm), F/S may be sticking. To check and clean F/S, see "IV.D. Float Switch Check and Cleaning." If the unit remains in freeze longer than 15 seconds after disconnecting black F/S connector, replace CB. Note: Normal freeze cycle will last 20 to 40 minutes depending on model and conditions.
8) Shutdown a) Thermostatic Bin Control: KM-1301SAH-E When the unit is running hold ice in contact with the thermostatic bulb, the thermostatic BC switch opens within 10 seconds, shutting down the unit (CB red "POWER OK" LED is off). The bin control is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations. Diagnosis: See "IV.C.1. Thermostatic Bin Control Check.
B. Control Board Check Before replacing a control board 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 the control board is in alarm (beeping), press the "ALARM RESET" button on the control board while the control board is beeping. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the unit starts at the 1-minute fill cycle.
C. Bin Control Check 1. Thermostatic Bin Control Check: KM-1301SAH-E To check the thermostatic bin control, follow the steps below. CAUTION When the ambient temperature is below 45°F (7°C), the thermostatic bin control switch opens and shuts down the icemaker even if the ice storage bin is empty. When the thermostat is set in the prohibited range, the icemaker operates continuously even if the ice storage bin is filled with ice. Setting in the prohibited range may result in severe damage to the icemaker.
7) Press the actuator paddle, check for continuity across the wires of the red connector. When the actuator paddle is engaged, the mechanical bin control switch is open. If closed, check that the actuator paddle is not restricted. Clean if necessary. See "IV.C.2.b) Mechanical Bin Control Cleaning." If the mechanical bin control switch still reads closed, replace the mechanical bin control.
b) Mechanical Bin Control Cleaning Scale may build up on the mechanical bin control. Scale can cause the actuator paddle and magnet to stick. In this case, the mechanical bin control should be cleaned. WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the storage bin. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position.
D. Float Switch Check and Cleaning The float switch is used to determine that there is sufficient water in the tank after the 1‑minute fill cycle and after each harvest cycle. The float switch 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 the float switch, follow the steps below. 1) Turn off the power supply.
2. Float Switch Cleaning Depending on local water conditions, scale may build up on the float switch. Scale on the switch can cause the float to stick. In this case, the float switch 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.
E. 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 minutes. 6) Disconnect the white thermistor connector from the control board WHITE K3 connector and check the resistance between thermistor leads. Normal reading is within 4.
G. Diagnostic Charts Before consulting the diagnostic charts, check for correct installation, proper voltage per unit nameplate, and adequate water supply. Check CB using the steps in "IV.B. Control Board Check." Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, & 10 and S5 dip switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, & 6 are cleaning adjustments and the settings are flexible. For factory default settings, see "II.C.3.
No Ice Production - Possible Cause 14. Float Switch See "IV.D. Float Switch Check and Cleaning." a) Float does not move freely. 15. Compressor a) Compressor relay/magnetic contactor contacts bad or coil winding open. b) Defective. b) Start capacitor or run capacitor defective. c) Internal overload protector open. d) Starter contacts bad or coil winding open. e) Protector tripped. f) Compressor defective. 16. Pump Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor.
2. Freeze Up Defrost and clean the unit prior to diagnosing freeze up. See "VI.A. Cleaning and Sanitizing Instructions." Freeze Up - Possible Cause Harvest Cycle 1. Evaporator a) Scaled up. 2. Separators a) Out of position. 3. Cube Guide a) Out of position. 4. Spray Tubes and/or Spray Guides a) Dirty. b) Damaged. b) Out of position. 5. Refrigerant Charge a) Low. 6. Ambient Temperature a) Too cool. 7. Water Supply a) Low water pressure. b) External water filters clogged.
Freeze Up - Possible Cause Freeze Cycle 1. Evaporator a) Scaled up. b) Damaged. 2. Separators a) Out of position. 3. Spray Tubes and/or Spray Guides a) Dirty. 4. Refrigerant charge. a) Low. 5. Check Valve a) Defective. b) Out of position. 6. Control Board a) Freeze timer set incorrectly. See "IV.B. Control Board Check." b) Defective. 7. Inlet Water Valve a) Leaking by. 8. Float Switch See "IV.D. Float Switch Check and Cleaning." a) Float does not move freely. 9. Pump Motor a) RPM too slow.
3. Low Ice Production Low Ice Production - Possible Cause Long Harvest Cycle 1. Evaporator a) Scaled up. 2. Spray Tubes and/or Spray Guides 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. Minimum 3/8" nominal ID (10 mm nominal OD) d) Too cold. 5. Control Board a) Thermistor connection loose (K3). See "IV.B. Control Board Check." b) Defective. 6. Thermistor See "IV.E.
V. Replacement of Components WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently. 3. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced.
2. Brazing WARNING 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). 2. 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. 3. Do not use silver alloy or copper alloy containing arsenic. 4. Use an electronic leak detector or soap bubbles to check for leaks.
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 air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled model, see the rating label inside the icemaker.
B. Important Notes for Component Replacement CAUTION When replacing a component listed below, see the notes to help ensure proper operation. Component Compressor Notes Install a new start capacitor, run capacitor, and start relay. Expansion Valve • Attach the 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 position on the tube. • Secure the bulb with the clamp and holder, then insulate it.
VI. Cleaning and Maintenance This icemaker must be cleaned and maintained in accordance with the documentation and labels provided with the icemaker. Consult with your local distributor about cleaning and maintenance service. To obtain the name and phone number of your local distributor, contact your nearest Hoshizaki Service office (listed in the Instruction Manual and at www.hoshizaki.com). WARNING 1. Except as specified below, only qualified service technicians should attempt to service this icemaker.
5) Remove the drain plug located on the lower front part of the ice chute. See Fig. 6. Allow the water tank to drain. 6) Replace the drain plug in its correct position. Be careful not to cross thread it. 7) In bad or severe water conditions, clean the float switch assembly as described below. Otherwise, continue to step 8. a. Disconnect the vent tube and the flush tube from the top of the float switch, then remove the float switch assembly. Remove the rubber boot from the bottom of the assembly. b.
15) Move the control switch to the "ICE" position. 16) Replace the front panel in its correct position. 17) Turn on the power supply to fill the water tank with water. 18) Turn off the power supply after 3 minutes. 19) Remove the front panel. 20) Move the control switch to the "WASH" position. 21) Replace the front panel in its correct position. 22) Turn on the power supply to rinse off the cleaning solution. 23) Turn off the power supply after 5 minutes. 24) Remove the front panel and the insulation panel.
B. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the icemaker's environment, and local sanitation regulations. WARNING 1. Except as specified below, only qualified service technicians should attempt to service this icemaker. 2. Move the power switch to the "OFF" position and disconnect power before servicing. 1.
3) Close the icemaker water supply line shut-off valve, then open the icemaker water supply line drain valve. 4) Allow the line to drain by gravity. 5) Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve. 6) Move the control switch to the "ICE" position. 7) Replace the front panel in its correct position, then turn on the power supply. 8) Blow the icemaker water supply line out using the compressed air or carbon dioxide supply.
