Hoshizaki American, Inc. KM-515MAH User manual

1

Hoshizaki

“A Superior Degree

of Reliability”

www.hoshizaki.com

Models

KM-515MAH

KM-515MWH

KM-515MRH

Modular Crescent Cuber

Hoshizaki America, Inc.

SERVICE MANUAL

™

Number: 73157

Issued: 2-1-2008

2

IMPORTANT

Only qualiﬁed service technicians should attempt to install, service, or maintain

this 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, and warranty coverage.

HOSHIZAKI provides this manual primarily to assist qualiﬁed service technicians in the

service and maintenance of the icemaker.

Should the reader have any questions or concerns which have not been satisfactorily

addressed, please call, write, or send an e-mail message to the HOSHIZAKI Technical

Support Department for assistance.

HOSHIZAKI AMERICA, INC.

618 Highway 74 South

Peachtree City, GA 30269

Attn: HOSHIZAKI Technical Support Department

Phone: 1-800-233-1940 Technical Service

(770) 487-2331

Fax: 1-800-843-1056

(770) 487-3360

E-mail: techsuppor[email protected]

Web Site: www.hoshizaki.com

NOTE: To expedite assistance, all correspondence/communication MUST include the

following information:

• Model Number ________________________

• Serial Number ________________________

• Complete and detailed explanation of the problem.

3

CONTENTS

I. Speciﬁcations ...................................................................................................................... 5

A. Icemaker ....................................................................................................................... 5

1. KM-515MAH (air-cooled) ......................................................................................... 5

2. KM-515MWH (water-cooled) ................................................................................... 6

3. KM-515MRH (remote air-cooled) ............................................................................ 7

B. Condenser Unit ............................................................................................................. 8

1. URC-5F ................................................................................................................... 8

II. General Information ......................................................................................................... 10

A. Construction ................................................................................................................ 10

1. KM-515MAH (air-cooled) ....................................................................................... 10

2. KM-515MWH (water-cooled) ................................................................................. 11

3. KM-515MRH (remote air-cooled) .......................................................................... 12

B. Sequence of Operation ............................................................................................... 13

1. One Minute Fill Cycle ............................................................................................ 13

2. Initial Harvest Cycle .............................................................................................. 13

3. Freeze Cycle ......................................................................................................... 13

4. Pump-Out Cycle ................................................................................................... 13

5. Normal Harvest Cycle .......................................................................................... 14

C. Control Board .............................................................................................................. 16

1. Control Board Layout ............................................................................................. 17

2. Features ................................................................................................................ 18

a) Maximum Water Supply Period – Six minutes .................................................... 18

b) Harvest Backup Timer and Freeze Timer ........................................................... 18

c) High Temperature Safety .................................................................................... 18

d) Low Water Safety ............................................................................................... 18

e) High Voltage and Low Voltage Cut-outs ............................................................. 18

f) LED Lights and Audible Alarm Safeties ............................................................... 19

3. Controls and Adjustments ..................................................................................... 20

a) Default S4 Dip Switch Settings ........................................................................... 20

b) Harvest Timer (S4 dip switch 1 & 2) ................................................................... 20

c) Pump-Out Timer (S4 dip switch 3 & 4) ............................................................... 21

d) Pump-Out Frequency Control (S4 dip switch 5 & 6) ........................................... 22

e) Factory Use (S4 Dip Switch 7 & 8) ..................................................................... 22

f) Freeze Timer (S4 dip switch 9 & 10).................................................................... 22

4. Control Board Check Procedure ............................................................................ 23

5. Control Board Replacement .................................................................................. 23

D. Harvest Control – Thermistor ...................................................................................... 24

E. Bin Control .................................................................................................................. 24

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.

4

III. Technical Information ...................................................................................................... 25

A. Water Circuit and Refrigeration Circuit ........................................................................ 25

1. KM-515MAH (air-cooled) ....................................................................................... 25

2. KM-515MWH (water-cooled) ................................................................................. 26

3. KM-515MRH (remote air-cooled) .......................................................................... 27

B. Wiring Diagrams .......................................................................................................... 28

1. KM-515MAH (air-cooled) and KM-515MWH (water-cooled) ................................. 28

2. KM-515MRH (remote air-cooled) .......................................................................... 29

C. Performance Data ....................................................................................................... 30

1. KM-515MAH (air-cooled) ....................................................................................... 30

2. KM-515MWH (water-cooled) ................................................................................. 31

3. KM-515MRH (remote air-cooled) ..........................................................................

32

IV. Service Diagnosis ........................................................................................................... 33

A. 10-Minute KM Diagnostic Procedure .........................................................................

33

B. Diagnostic Charts ........................................................................................................ 35

1. No Ice Production .................................................................................................. 35

2. Evaporator is Frozen Up ........................................................................................ 38

3. Low Ice Production ................................................................................................ 40

4. Abnormal Ice ......................................................................................................... 40

5. Other ...................................................................................................................... 41

V. Removal and Replacement of Components .................................................................... 42

A. Service for Refrigerant Lines ...................................................................................... 42

1. Refrigerant Recovery ............................................................................................. 42

2. Brazing ..................................................................................................................

42

3. Evacuation and Recharge (R-404A) ...................................................................... 43

B. Removal and Replacement of Compressor ................................................................ 44

C. Removal and Replacement of Expansion Valve ......................................................... 45

D. Removal and Replacement of Hot Gas Valve or Line Valve ....................................... 46

E. Removal and Replacement of Evaporator .................................................................. 47

F. Removal and Replacement of Water Regulating Valve -Water-Cooled Model Only .... 47

G. Adjustment of Water Regulating Valve - Water-Cooled Model Only ........................... 48

H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)

- Remote Air-Cooled Model Only .............................................................................. 49

I. Removal and Replacement of Thermistor .................................................................... 50

J. Removal and Replacement of Fan Motor .................................................................... 51

K. Removal and Replacement of Inlet Water Valve ......................................................... 51

L. Removal and Replacement of Pump Motor ................................................................. 52

VI. Cleaning and Maintenance ............................................................................................ 53

A. Cleaning and Sanitizing Instructions ........................................................................... 53

1. Cleaning Procedure ...............................................................................................

54

2. Sanitizing Procedure - Following Cleaning Procedure .......................................... 55

B. Maintenance ................................................................................................................ 56

C. Preparing the Icemaker for Long Storage ................................................................... 56

5

I. Speciﬁcations

A. Icemaker

1. KM-515MAH (air-cooled)

Note: We reserve the right to make changes in speciﬁcations and design without prior

notice.

AC SUPPLY VOLTAGE 115/60/1

AMPERAGE 11.7 A ( 5 Min. Freeze AT 104°F / WT 80°F)

MINIMUM CIRCUIT AMPACITY 20 A

MAXIMUM FUSE SIZE 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)

PER 24 HR. Temp.(°F) 50 70 90

lbs./day ( kg/day ) 70 *501 (227) 482 (218) 447 (203)

Reference without *marks 80 486 (221) 456 (207) 416 (189)

90 482 (218) *435 (197) 396 (180)

100 472 (214) 426 (193) 361 (164)

SHAPE OF ICE Crescent Cube

ICE PRODUCTION PER CYCLE 10.2 lbs. (4.6 kg) 480pcs.

APPROXIMATE STORAGE CAPACITY N/A

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F

ELECTRIC W (kWH/100 lbs.) 1090(6.0) 980(4.7)

WATER gal./24HR (gal./100 lbs.) 99(22.8) 188(37.6)

EXTERIOR DIMENSIONS (WxDxH) 22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm)

EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)

WEIGHT Net 151 lbs. (68 kg), Shipping 175 lbs. (79 kg)

CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" OD Tube

CUBE CONTROL SYSTEM Float Switch

HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer

ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe

COOLING WATER CONTROL N/A

BIN CONTROL SYSTEM Thermostat

COMPRESSOR Hermetic, Model RST55C1E-CAA-202

CONDENSER Air-Cooled , Fin and tube type

EVAPORATOR Vertical type, Stainless Steel and Copper

REFRIGERANT CONTROL Thermostatic Expansion Valve

REFRIGERANT CHARGE R404A, 1 lb. 7.3 oz. (660g)

DESIGN PRESSURE High 467PSIG, Low 206PSIG

P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )

COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )

REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch

LOW WATER PROTECTION Float Switch

ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Dispenser or Ice Storage Bin

OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

ENG.F-011.1.0205

6

2. KM-515MWH (water-cooled)

Note: We reserve the right to make changes in speciﬁcations and design without prior

notice.

AC SUPPLY VOLTAGE 115/60/1

AMPERAGE 9.6 A ( 5 Min. Freeze AT 104°F / WT 80°F)

MINIMUM CIRCUIT AMPACITY 20 A

MAXIMUM FUSE SIZE 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)

PER 24 HR. Temp.(°F) 50 70 90

lbs./day ( kg/day ) 70 *500 (227) 493 (223) 465 (211)

Reference without *marks 80 494 (224) 483 (219) 445 (202)

90 493 (223) *475 (215) 441 (200)

100 481 (218) 467 (212) 409 (186)

SHAPE OF ICE Crescent Cube

ICE PRODUCTION PER CYCLE 10.3 lbs. (4.7 kg) 480pcs.

APPROXIMATE STORAGE CAPACITY N/A

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F

ELECTRIC W (kWH/100 lbs.) 950(4.8) 940(4.5)

WATER gal./24HR (gal./100 lbs.) 102(21.5) 163(32.5)

WATER COOLED CONDENSER 546(115) 352(70)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH) 22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm)

EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)

WEIGHT Net 151 lbs. (68 kg), Shipping 175 lbs. (79 kg)

CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT Cond. Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT Cond. Outlet 3/8" FPT

3/8" OD Tube

CUBE CONTROL SYSTEM Float Switch

HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer

ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe

COOLING WATER CONTROL Pressure Regulator

BIN CONTROL SYSTEM Thermostat

COMPRESSOR Hermetic, Model RST55C1E-CAA-202

CONDENSER Water-cooled, Tube in tube type

EVAPORATOR Vertical type, Stainless Steel and Copper

REFRIGERANT CONTROL Thermostatic Expansion Valve

REFRIGERANT CHARGE R404A, 0 lb. 14.8 oz. (420g)

DESIGN PRESSURE High 427PSIG, Low 206PSIG

P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )

COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )

REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch

LOW WATER PROTECTION Float Switch

ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Dispenser or Ice Storage Bin

OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

ENG.F-011.1.0205

7

3. KM-515MRH (remote air-cooled)

Note: We reserve the right to make changes in speciﬁcations and design without prior

notice.

AC SUPPLY VOLTAGE 115/60/1

AMPERAGE 11.3A ( 5 Min. Freeze AT 104°F / WT 80°F)

MINIMUM CIRCUIT AMPACITY 20 A

MAXIMUM FUSE SIZE 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)

PER 24 HR. Temp.(°F) 50 70 90

lbs./day ( kg/day ) 70 *491 (223) 480 (218) 443 (201)

Reference without *marks 80 482 (219) 465 (211) 417 (189)

90 480 (218) *452 (205) 408 (185)

100 465 (211) 442 (200) 368 (167)

SHAPE OF ICE Crescent Cube

ICE PRODUCTION PER CYCLE 10.3 lbs. (4.7 kg) 480pcs.

APPROXIMATE STORAGE CAPACITY N/A

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F

ELECTRIC W (kWH/100 lbs.) 1090(5.8) 1000(4.9)

WATER gal./24HR (gal./100 lbs.) 94(20.8) 198(40.4)

EXTERIOR DIMENSIONS (WxDxH) 22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm)

EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)

WEIGHT Net 151 lbs. (68 kg), Shipping 175 lbs. (79 kg)

CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" OD Tube

CUBE CONTROL SYSTEM Float Switch

HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer

ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe

COOLING WATER CONTROL N/A

BIN CONTROL SYSTEM Thermostat

COMPRESSOR Hermetic, Model RST55C1E-CAA-202

CONDENSER Air-Cooled Remote, Condenser Unit URC-5F

EVAPORATOR Vertical type, Stainless Steel and Copper

REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-5F

REFRIGERANT CHARGE R404A, 4 lbs. 4.8 oz. (1950g)

(Icemaker 2 lbs. 6.8 oz. Cond. Unit 1 lbs. 14 oz.)

DESIGN PRESSURE High 467PSIG, Low 206PSIG

P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )

COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )

REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch

LOW WATER PROTECTION Float Switch

ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Dispenser or Ice Storage Bin, Remote Condenser Unit

OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

ENG.F-011.1.0205

8

B. Condenser Unit

1. URC-5F

24"

(610 mm)

23-1/32"

(585 mm)

19-11/16"

(500 mm)

18-1/8"

(460 mm)

20-15/32"

(520 mm)

21-15/16"

(557 mm)

7/8" DIA. HOLE

(23 mm DIA.)

6-5/16"

(160 mm)

2-15/16"

(75 mm)

18-1/8"

(460 mm)

6/16" × 3/4" (10×20 mm)

4×2 (SLOTTED HOLES)

17-1/8"

(435 mm)

14-9/16"

(370 mm)

14-1/8"

(358 mm)

14-15/16"

(380 mm)

15-11/16"

(398 mm)

17-7/8"

(454 mm)

2-1/2"

(63 mm)

14-15/16"

(380 mm)

Unit: inches (mm)

9

Speciﬁcations

MODEL: URC-5F

Note: We reserve the right to make changes in speciﬁcations and design without prior

notice.

SPECIFICATION NO. 06A022

ISSUED: 10/12/2006

ITEM: HOSHIZAKI REMOTE CONDENSER UNIT

MODEL URC-5F

BEGINNING SERIAL NO. ________________

ENDING SERIAL NO. ___________________

AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker)

FAN MOTOR 115 V Total 1.3FLA 65W

EXTERIOR DIMENSIONS (WxDxH) 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 454 mm)

DIMENSIONS INCLUDING LEGS (WxDxH) 24" x 18-1/8" x 32-13/16" (610 x 460 x 834 mm)

EXTERIOR FINISH Galvanized Steel

WEIGHT Net 61 lbs. ( 28 kg ) Shipping 68 lbs. ( 31 kg )

CONNECTIONS - ELECTRIC Permanent - Connection

- REFRIGERANT Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)

Liquid Line 5/8"-18 UNF Fitting (#6 AEROQUIP)

CONDENSER Air-cooled, Fin and tube type

FAN MOTOR PROTECTION Thermal Protection

REFRIGERANT CONTROL Condensing Pressure Regulator

REFRIGERANT CHARGE R-404A 1 lb. 14 oz. (850g)

DESIGN PRESSURE High 467 PSIG

OPERATING CONDITIONS VOLTAGE RANGE 104 ~ 127 V

AMBIENT TEMP. -20 ~ 122 °F

ACCESSORIES -SUPPLIED Leg 2 pcs

Hex. Head Bolt w/Washer 8 x 16 8 pcs

Hex. Nut 8 8 pcs

DRAWING NO. (DIMENSION) 441211

We reserve the right to make changes in specifications and design without prior notice.

10

II. General Information

A. Construction

1. KM-515MAH (air-cooled)

Bin Control Thermostat

Control Switch

Expansion Valve

Compressor

Float Switch

Water Pump

Control Box

Drier

Fan Motor Condenser

Hot Gas Valve

Condenser

Water Supply Pipe

Liquid Line Valve

Spray Tubes

11

2. KM-515MWH (water-cooled)

Water Supply Pipe

Water Regulator

Hot Gas Valve

Drier

Control Box

Water Pump

Float Switch

Compressor

Expansion Valve

Control Switch

Bin Control

Thermostat

Spray Tubes

Liquid Line Valve

Condenser

12

3. KM-515MRH (remote air-cooled)

Water Supply Pipe

Junction Box

Hot Gas Valve

Drier

Control Box

Water Pump

Float Switch

Compressor

Expansion Valve

Control Switch

Bin Control

Thermostat

Spray Tubes

Liquid Line Valve

Reciever Tank

13

B. Sequence of Operation

The steps in the sequence are as outlined below. When power is supplied, the red

"POWER OK" LED on the control board comes on. A 5-second delay occurs at startup.

Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2.

1. One Minute Fill Cycle

LED 4 is on. WV opens and the ﬁll period begins. After 1 minute, the board checks for

a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV will remain energized

through additional 1 minute cycles until water enters the sump and F/S closes. This

serves as a low water safety to protect the water pump.

2. Initial Harvest Cycle

LEDs 1, 4, and 2 are on. WV remains open, Comp, FMR, HGV energize. The control

board monitors the warming of the evaporator via the thermistor located on the suction

line. When the thermistor reaches 48°F (9°C), the control board reads a 3.9 kΩ signal

from the thermistor and turns harvest termination over to the adjustable harvest timer

which is factory set for normal conditions. The timer has settings of 60, 90, 120, and

180 seconds (S4 dip switch 1 & 2). For details, see "II.C.3.b) Harvest Timer." When the

harvest timer completes its countdown, the harvest cycle is complete and the freeze

cycle starts. The minimum total time allowed by the control board for a complete harvest

cycle is 2 minutes. WV is energized during harvest for a maximum of 6 minutes or the

length of harvest, whichever is shorter. At the end of harvest, the control board checks

the position of F/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute

ﬁll if it is open.

3. Freeze Cycle

LED 1 is on. Comp and FMR continue to run, PM and FMS energize, LLV opens, HGV

and WV close, and the freeze cycle starts. For the ﬁrst 5 minutes the control board

will not accept a signal from F/S. This 5 minute minimum freeze acts as a short cycle

protection. At the end of 5 minutes, F/S assumes control. As ice builds on the evaporator

the water level in the sump lowers. The freeze continues until F/S opens and terminates

ice production.

4. Pump-Out Cycle

LEDs 1, 3, and 2 are on. Comp and FMR continue to run, HGV opens, LLV closes, and

FMS de-energizes. PM stops for 2 seconds and reverses, taking water from the bottom

of the sump and forcing pressure against the check valve seat allowing water to go

through the check valve and down the drain. At the same time, water ﬂows through the

small tube to power ﬂush the F/S. When the pump-out timer (S4 dip switch 3 & 4) stops

counting, the pump out is complete. The pump-out frequency control (S4 dip switch

5 & 6) is factory-adjusted to drain the water tank every cycle, and no adjustment should

be made.

14

5. Normal Harvest Cycle

LEDs 1, 4, and 2 are on. Comp, FMR, and HGV remain energized. PM stops and WV

energizes. The control board monitors the warming of the evaporator via the thermistor

located on the suction line. When the thermistor reaches 48°F (9°C), the control board

reads a 3.9 kΩ signal from the thermistor and turns harvest termination over to the

pump-out timer's harvest timer which is factory set for normal conditions. For details,

see "II.C.3.c) Pump-Out Timer." When the pump-out timer's harvest timer completes

its countdown, the harvest cycle is complete and the freeze cycle starts. The minimum

total time allowed by the control board for a complete harvest cycle is 2 minutes. WV is

energized during harvest for a maximum of 6 minutes or the length of harvest, whichever

is shorter. At the end of harvest, the control board checks the position of F/S and

proceeds to the freeze cycle if it is closed or calls for a 1-minute ﬁll if it is open.

Legend: Comp–compressor; FMR–remote fan motor; FMS–self-contained fan motor;

F/S–ﬂoat switch; HGV–hot gas valve; LLV–liquid line valve; PM–pump motor;

WV–inlet water valve

15

Components Energized when the Control Switch is in the "WASH" Position

The "WASH" position on the control switch is used when cleaning and sanitizing the unit. When in the

"WASH" position, power is supplied to the pump motor. With the cleaning valve closed, the cleaner and

sanitizer ﬂow over the outside of the evaporator plate assembly. With the cleaning valve open, the cleaner

and sanitizer ﬂow over both the outside and the inside of the evaporator plate assembly.

Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not re-start

when the control switch is placed in the "ICE" position.

Legend:

Comp-compressor

FMR-remote fan motor

FMS-self-contained fan motor

F/S-ﬂoat switch

HGV-hot gas valve

PM-pump motor

WV-inlet water valve

KM-515MAH, KM-515MWH, KM-515MRH Sequence Flow Chart and Component Operation

1. One Minute

Fill Cycle

2. Harvest Cycle 3. Freeze Cycle

4. Pump-Out

Cycle

Cycle Steps

WV Energized

F/S open

F/S closed

Comp energized

HGV energized

FMR energized

WV continues

Thermistor temp

reaches 48°F (9°C)

(3.9 kΩ or less)

Harvest timer starts

F/S open

Comp continues

FMR continues

HGV de-energized

WV de-energized

PM energized

FMS energized

F/S closed

Freeze cycle

operation turned

over to F/S

Pump motor stops

for 2 sec. and then

reverses for 10/20 sec.

each cycle.

Comp continues

FMR continues

HGV energized

FMS de-energized

F/S Check

• Maximum inlet water valve time: 6 minutes

• Maximum harvest time: 20 minutes

Thermistor in

control

1 to 3 minute timer

in control

• Minimum freeze time: 5 minutes

• Maximum freeze time: freeze timer setting

5 minute timer

in control

F/S in

control

Initial startup always

begins here

"E" board will have

5 second delay

If F/S is open, compressor stops and cycle returns to 1 minute ﬁll

16

C. Control Board

• A HOSHIZAKI exclusive solid-state control is employed in KM-515MAH, KM-515MWH,

and KM-515MRH Modular Crescent Cubers.

• All models are pretested and factory-adjusted.

CAUTION

1. 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 board.

3. Do not touch the electronic devices on the board or the back of the board to

prevent damage to the board.

4. Do not change wiring and connections. Do not misconnect K3, K4, and K5,

because the same connector is used for the thermistor and ﬂoat switch. K4 is

not connected.

5. Always replace the whole board assembly if it goes bad.

6. Do not short out power supply to test for voltage.

17

Control Board

Part Number 2A1410-01 (factory); 2A1410-02 (service)

Type HOS-001A (Control Products - 10 Pin)

Control Products "E" Control Board

1. Control Board Layout

Output Test Switch

(used to test relays on board)

Connector K3

Harvest Control

(thermistor)

Connector K4

Open

(not connected)

Microprocessor

(board revision level

indicated by last 2

digits on label)

Connector K5

Float Switch

Part Number

Connector K1

Pins #1 through #10

#1, 9 Magnetic Contactor

#2 Hot Gas Valve

#3 Line Valve

Self-Contained Fan Motor (FMS)

#4 Pump Motor (icemaking)

#5 Pump Motor (drain)

#6 Water Valve

#7, 10 Power (line, bin control)

#8 Open

Switch for "C" board

and "ALPINE" board

(service boards only)

Alarm Reset Switch

Backup Freeze

Timer LED

S4 Dip Switch

Backup Harvest

Timer LED

Alarm Buzzer

Power LED

(lights when

power is supplied

to the board)

Relay LEDs (4)

(indicate which

relays are energized

as listed below)

LED 2

Hot Gas Valve (HGV)

Self-Contained Fan

Motor (FMS) (FMS

off when LED on)

LED 3

Pump Motor (PM)

(on at pump out only)

LED 4

Water Valve (WV)

LED 1

Compressor (Comp)

Remote Fan Motor

(FMR)

Transformer

Connector

18

2. Features

a) Maximum Water Supply Period – Six minutes

The inlet water valve will be open during harvest for six minutes or the length of harvest

whichever is shorter.

b) Harvest Backup Timer and Freeze Timer

The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest

cycle takes more than 20 minutes to complete. The control board will signal this problem

using 2 beeps every 3 seconds.

The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle

takes longer than the time speciﬁed to complete. The control board will signal this

problem using 3 beeps every 3 seconds. The time is factory set using S4 dip switch 9 &

10.

The "ALARM RESET" button on the control board must be pressed with power on to

reset either of these safeties.

c) High Temperature Safety

The temperature of the suction line in the refrigeration circuit is limited by the high

temperature safety. This protects the unit from excessively high temperatures. If the

evaporator temperature rises above 127 ± 7°F (53 ± 4°C), the control board reads a

.804kΩsignalfromthethermistor and operates the safety. This shuts down the circuit

and the icemaker automatically stops.

The control board will signal this problem using 1 beep every 3 seconds. The "ALARM

RESET" button on the control board must be pressed with power on to reset the safety.

d) Low Water Safety

The control board checks the position of the ﬂoat switch at the end of the initial one

minute water ﬁll cycle and at the end of each harvest cycle.

If the ﬂoat switch is in the up position (electrical circuit closed), the control board

changes to the ice making cycle. If the ﬂoat switch is in the down position (electrical

circuit open), the control board changes to additional one minute water ﬁll cycles until

water enters the sump and the ﬂoat switch closes. When the ﬂoat switch closes, the

control board changes to the ice making cycle. The unit will not start without adequate

water in the sump. This serves as a low water safety to protect the pump motor from

mechanical seal failure.

For water-cooled model, if the water is shut off, the unit is protected by the high pressure

switch.

e) High Voltage and Low Voltage Cut-outs

The maximum and minimum allowable supply voltages of this icemaker are limited by the

high voltage and low voltage cut-outs.

If miswiring (especially on single phase 3 wire models) causes excessive voltage

(147Vac ±5% or more) on the control board, the high voltage cut-out shuts down the

circuit in 3 seconds and the icemaker automatically stops. The control board will signal

this problem using 7 beeps every 3 seconds.

The icemaker also automatically stops in cases of insufﬁcient voltage (92Vac ±5% or

less). The control board will signal this problem using 6 beeps every 3 seconds.

When the proper supply voltage is resumed, the icemaker automatically starts running

again.

19

f) LED Lights and Audible Alarm Safeties

The red LED indicates proper control voltage and will remain on unless a control voltage

problem occurs. At startup, a 5 second delay occurs while the board conducts an internal

timer check. A beep occurs when the power is turned off.

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 board is 1, 4, 3,

2. For more information, see "II.B. Sequence of Operation."

Sequence Step LED

Energized

Components

Time LEDs are On

Min. Max. Avg.

1 Minute Fill Cycle

4 WV 60 seconds

Harvest Cycle 1, 4, and 2 WV, HGV,

Comp, FMR

2 minutes 20 minutes 3 to 5 minutes

Freeze Cycle 1 Comp, PM,

FMR/FMS,

LLV

5 minutes freeze timer

setting

30 to 35 minutes

Pump-Out Cycle 1, 4*, 3, and

2

Comp, HGV,

PM, FMR,

WV*

10 seconds 20 seconds *pump-out timer

setting

The built in safeties shut down the unit and have alarms as listed below.

No. of Beeps

(every 3 sec.)

Type of Alarm Notes

1 High Evaporator Temp.

(temperature > 127°F)

(53°C)

Check for harvest problem (stuck HGV or

relay), hot water entering unit, stuck HM, or

shorted thermistor.

2 Harvest Backup Timer

(harvest > 20 min. for two

cycles in a row)

Orange LED marked H TIMER lights up.

Check for open thermistor, HGV not opening,

TXV leaking by, low charge, or inefﬁcient

comp.

3 Freeze Timer

(freeze > speciﬁed setting

for two cycles in a row)

Timer is factory set using

S4 dip switch 9 & 10

Yellow LED marked F TIMER lights up. Check

for F/S stuck closed (up), WV leaking by, HGV

leaking by, PM not pumping, TXV not feeding

properly, low charge, HM not bypassing, or

inefﬁcient comp.

To reset the above safeties, press the "ALARM RESET" button with the power supply on.

6 Low Voltage

(92Vac ±5% or less)

Red LED will turn off if voltage protection

operates.

The control voltage safeties automatically

reset when voltage is corrected.

7 High Voltage

(147Vac ±5% or more)

Legend: Comp–compressor; FMR–remote fan motor; FMS–self-contained fan motor;

F/S–ﬂoat switch; HGV–hot gas valve; HM–headmaster (C.P.R.); LLV–liquid

line valve; PM–pump motor; TXV–thermostatic expansion valve; WV–inlet

water valve

20

3. 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 S4 Dip Switch Settings

The dip switches are factory-adjusted to the following positions:

Dip Switch No. 1 2 3 4 5 6 7 8 9 10

KM-515MAH

OFF OFF OFF OFF OFF OFF OFF OFF ON OFF

KM-515MWH OFF OFF OFF OFF OFF OFF OFF OFF ON OFF

KM-515MRH

OFF OFF OFF OFF OFF OFF OFF OFF ON OFF

Freeze Timer (9 & 10)

Pump-Out Frequency Control (5 & 6)

Do Not Adjust

Pump-Out Timer (3 & 4)

Harvest Timer (1 & 2)

Normally off (7 & 8)

b) Harvest Timer (S4 dip switch 1 & 2)

The harvest timer is only active during the initial harvest cycle. Every cycle thereafter the

pump-out timer's harvest timer (S4 dip switch 3 & 4, T2) acts in place of the harvest timer

on KM-515M_H models, as the pump out occurs every cycle. See "II.C.3.c) Pump Out

Timer (S4 dip switch 3 & 4)."

Dip Switch Setting Time

(seconds)

No. 1 No. 2

OFF OFF 60

ON OFF 90

OFF ON 120

ON ON 180

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Hoshizaki American, Inc. KM-515MAH, KM-515MRH, KM-515MWH User manual

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