SELF CONTAINED CRESCENT CUBER KM 250BWF R404Aguide
User Manual: SELF-CONTAINED CRESCENT CUBER KM-250BWF
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TECH - SPEC’S Technician’s Pocket Guide # 80045 This technicians pocket guide covers all models using R-404A refrigerant. For additional technical information, full parts and service manuals are available for review and download on the Tech Support page of the Hoshizaki web site. See “www.hoshizaki.com” for manuals, TechTips and additional technical information on Hoshizaki products. See Tech-Spec’s # 80024 purple pocket guide for older models using R-12/502. See Tech-Spec’s # 80021 green pocket guide for newer models using R-22. These guides can be downloaded from the Hoshizaki web site or purchased through your local Hoshizaki Distributor. 1 2/20/03 TABLE OF CONTENTS ....................................................................... PAGE Model Identification Code ........................................ 5 Nameplate .................................................................. 6 Warranty Information, Registration, Coverage ....... 7 KM Installation - General .......................................... 8 Plumbing Requirements (All) ............................. 8 Condensate Drain ............................................. 9 Water Flow Rates (All) ..................................... 9 Electrical Connections ...................................... 10 Optional Transformer Application .................... 11 Remote Applications Condenser Application Chart R-404A ............. 12 Remote Lines R-404A ...................................... 12 Installation Diagram .......................................... 13 Lineset Installation ............................................ 14 Refrigerant System Information System Charge R-404A ................................... 15 Cuber Charge Chart R-404A ........................... 16 Condenser Charge Chart ................................. 17 Refrigerant Oil .................................................. 17 Flaker/DCM Charge Chart R-404A ................... 18 Heat Load for AC & Cooling Tower R-404A .... 18 Component Technical Data “E” Board Setting Guide ................................... 19 Control Board Settings for R-404A ................. 20 “E” Control Board Functions ............................ 21 “E” Board Label ................................................ 22 Manual Reset Safeties ..................................... 23 Automatic Voltage Protection ........................... 23 Compressor Data R-404A ................................ 24 Head Pressure Controls R-404A ..................... 26 Remote Head Pressure Control ....................... 27 High Pressure Switch Chart ............................ 28 Bin Control (Thermostatic) ............................... 28 Mechanical Control ........................................... 29 Capacitive Control ............................................ 30 F/DCM Control ................................................... 31 KM Sequence of Operation ................................... 32 Sequence Flow Chart ...................................... 34 KM 10 Minute Check Out ................................. 35 Reservoir Flush System ................................... 37 Pumpout Check Valve ...................................... 37 KML Pumpout .................................................... 37 KM Control Switch ........................................... 37 Control Board Fuse .......................................... 38 Component Checks Float Switch ..................................................... 40 Thermistor ........................................................ 41 2 12/01/02 12/20/03 2/20/03 Component Checks PAGE Control Board ................................................... 42 Thermostatic Bin Control .................................. 44 Mechanical Bin ................................................. 44 Capacitive Bin Control ...................................... 45 F/DCM Bin Control ............................................ 46 KM Control Transformer ................................... 47 KM Pump Assembly .......................................... 48 Inlet Water Valve .............................................. 50 Diagnosing Water Problems ................................. 52 Freeze Up Check List ....................................... 55 Preventative Maintenance ................................ 57 Cleaning/Sanitizing Procedure ......................... 58 KM Production Check ....................................... 59 Cuber Water/Refg Circuit Reference Chart .......... 60 Performance Data KM-150BAF ............................. 73 KM-150BAF-E ................................................... 74 KM-250B_F ....................................................... 75 KM-280M_F/H ................................................... 76 KM-280M_F-E, KM-280MAH ............................ 77 KML250M_H ..................................................... 78 KML-350M_F/H ................................................. 79 KM-350MWH Serial M3~ ................................... 80 KML-450M_F/H ................................................. 81 KML-450MWH Serial M2~ ................................. 82 KM-500M_F/H ................................................... 83 KM-500MWH Serial M30961D~ ........................ 84 KM-500MAF-E/H-E ........................................... 85 KML-600M_F/H ................................................. 86 KM-630M_F/H ................................................... 87 KM-630MWH Serial M2 ..................................... 88 KM-630M_F-E, KM-630MAH-E ......................... 89 KM-900M_F/H ................................................... 90 KM-900MWH Serial M3~ ................................... 91 KM-900MRF3/H3 ............................................... 92 KM-1300S_F/H ................................................. 93 KM-1300S_F3/H3 ............................................. 94 KM-1300NRF/H ................................................. 95 KM-1300M_F/H ................................................. 96 KM-1300S_F-E ................................................. 97 KM-1600MRF/H ................................................. 98 KM-1600MRF3/H3 ............................................ 99 KM-1600SRF/H ................................................ 100 KM-1600SRF3/H3 ............................................ 101 KM-1800SAH ................................................... 102 KM-1800SAH3 ................................................. 103 KM-2000S_F3 .................................................. 104 KM2400SRF3 ................................................... 105 3 12/01/02 12/20/03 2/20/03 PAGE KM Wiring Diagram 10-Pin Connector ............................................ 106 Reference Chart R-404A ............................... 107 Flaker/DCM Installation - General ....................................... 141 Internal Auger Design ...................................... 142 Component Technical Data Control Transformer ........................................ 143 Gear Motor Protection & Checkout ................. 143 Auger Bearings & Inspection .......................... 146 Auger inspection & Bearing Replacement ...... 147 Flaker Safety’s ........................................................ 148 Dual Float Switch ............................................ 149 Flaker Water FIll System .................................. 151 Flaker Timer Board .......................................... 152 Flaker Sequence of Operation ........................ 153 Flaker Sequence Flow Chart .......................... 154 Flaker Periodic Flush ....................................... 155 DCM Sequence of Operation .......................... 155 F/DCM Production Check ................................. 155 Flush /Low Water Safety Flow Chart ............ 156 F/DCM Water/Refg Circuit Referance Chart.. ....... 157 Performance Data Flaker/DCM F-300BAF ........................................................ 167 F-450MAF/H, MAF-C/H-C ................................ 168 F-500BAF, BAF-C ........................................... 169 F-800M_F/H ..................................................... 170 F-800M_F-C/H-C .............................................. 171 F-1000M_F ...................................................... 172 F-1000M_F-C ................................................... 173 F-1000MLF/MLF-C ........................................... 174 F-1000MAF-22 ................................................ 175 F-1000M_F-50 ................................................. 176 F-1001M_H ...................................................... 177 F-1001M_H-C .................................................. 178 F-1001MLH/MLH-C .......................................... 179 F-2000M_F/H ................................................... 180 F-2000M_F-C/H-C ........................................... 181 F-2000MRF3/H3, MRF3-C/H3-C ...................... 182 F-2000MLF/H, MLF-C/H-C ............................... 183 DCM-240BAF ................................................... 184 DCM-270BAH .................................................. 185 DCM-500BAF/H ............................................... 186 DCM-750B_F/H ................................................ 187 F/DCM Wiring Diagram Reference Chart ........... 188 4 12/01/02 12/20/03 2/20/03 HOSHIZAKI MODEL NUMBER IDENTIFICATION CODE KM 1300 S A F -E UNIT TYPE KML KM FDCM DB BDM - Low Profile Crescent Cuber Crescent Cuber Flaker Dispenser Cubelet Maker Dispenser Bin Bin Countertop Dispenser PRODUCTION Approximate production/24 Hours @70°F Air/50°F Water UNIT STYLE MSB- Modular Stackable Self contained with bin CONDENSER STYLE AWR- Air cooled Water cooled Remote air cooled GENERATION Model designation F= R404A refrigerant unit H= R404A and rounded front SPECIAL MODEL DESIGNATION CCubelet EEuropean 5050 HZ. The model number, serial number, electrical specifications and refrigerant data are found on the unit name plate. (See name plate) 5 12/01/02 12/20/03 2/20/03 NAMEPLATE HOSHIZAKI ICE MAKER MODEL NUMBER SERIAL NUMBER AC SUPPLY VOLTAGE COMPRESSOR FAN MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY DESIGN PRESSURE REFRIGERANT MOTOR-COMPRESSOR THERMALLY PROTECTED HOSHIZAKI AMERICA, INC. Peachtree City, GA LISTED ICE MAKER WITHOUT STORAGE MEANS 946Z NSF ® C COMPONENT v See the Nameplate for electrical and refrigeration specifications. This Nameplate is located on the upper right hand side of rear panel. Since this Nameplate is located on the rear panel of the icemaker, it cannot be read when the back of the icemaker is against a wall or against another piece of kitchen equipment. Therefore, the necessary electrical and refrigeration information is also on the rating label, which can be easily seen by removing only the front panel of the icemaker. We reserve the right to make changes in specifications and design without prior notice. 6 12/01/02 12/20/03 2/20/03 WARRANTY INFORMATION REGISTRATIONTwo warranty registration cards are supplied with the equipment. They must be completed and sent in to initiate warranty. The warranty begins on the date of installation if registration procedures are followed. If registration is not completed, the warranty date will be the date of sale or date of shipment from the factory, respectively. WARRANTY COVERAGEThe warranty will cover defects in material or workmanship under normal and proper use and maintenance service as specified by Hoshizaki. Coverage for parts and labor is limited to the repair or replacement of parts or assemblies that in Hoshizaki's opinion are defective. COVERAGE CHARTITEM PRODUCT PARTS LABOR Total Unit KM Cuber F/DCM B/DB/DM Bev. Valves 3 Years 1 Year 2 Years 1 Year 3 Years 1 Year 2 Years 1 Year Compressor & AirCooled Condenser KM Cuber F/DCM 5 Years 5 Years 3 Years 2 Years Evaporator Plate KM Cuber 5 Years 5 Years Evaporator, Auger Gear Motor Assy. F/DCM 2 Years 2 Years Effective January 1, 1991 See Warranty Statement supplied with the unit for details. Warranty valid in United States, Canada, Mexico, Puerto Rico, and U. S. Virgin Islands. Contact factory for warranty in other countries, territories, or possessions. 7 12/01/02 12/20/03 2/20/03 KM INSTALLATION GENERAL The ice machine is not intended for outdoor use. OPERATING CONDITIONS - ALL MODELS ITEM Voltage Range MODEL RANGE 115V units 104 - 127V. 208-230 V units 187 - 264 V. 220-240 or 230V 198 - 254V. Ambient Temperature All 45 - 100 Deg. F. Remote Condenser -20 - 122 Deg. F. Water Supply Temperature All 45 - 90 Deg. F. Water Supply Pressure All 10 -113 PSIG Allow 6" clearance at rear, sides, and top for proper air circulation and ease of maintenance or service. 20" top clearance for F/DCM. PLUMBING REQUIREMENTS - Water Supply: On KM units the water supply line size is critical due to the water assisted harvest and the use of a ported inlet water valve solenoid. MODEL KM-150 - KM-900 KM-1300 - KM-2400 All F/DCM Line Size 3/8" OD 1/2" OD 3/8" OD Fitting Size 1/2 FPT 1/2 FPT 1/2 FPT *Water cooled condenser units require two separate supplies sized as per list above. Drain: Fitting Size Line Size MODEL All Bins 3/4" OD 3/4 FPT All KM/KML’s 3/4" OD 3/4 FPT Flakers 3/4" OD 3/4 FPT* DCM 3/4" OD 3/4 FPT* *Some models have 2 drain outlets. Water Cooled Condenser outlet: KM-150BWF, KM-250BWF, KM-1600SWH, KM-1600SWH3, KM-2000SWH3 have 1/2” FPT outlet. All other KM models, All KML, All Flaker, All DCM have 3/8” FPT outlet. 8 12/01/02 12/20/03 2/20/03 Hoshizaki recommends that the ice machine drain and bin drain be piped separately to the drain connection point allowing 1/4" per foot fall. CONDENSATE DRAIN The condensate drain is generally connected to the ice machine drain for simplicity. It can be piped separately to the drain exit if desired. A 6" vent tee is recommended as per drawing: Condensate Drain Reservoir Drain FLOW RATES The minimum flow rate requirements for Hoshizaki ice maker units are as follows: KM-150/250/280/AII Flakers KM-500 KM-630/900/AII DCM's KM-1300/1600 KM-2000/2400 1.05 GPM 1.58 GPM 2.11 GPM 3.96 GPM 4.23 GPM Use this information when sizing a filter system for the ice machine application. NOTE: A good rule of thumb is to utilize a 3 GPM flow rate filter for KM-150 through 900 and a 5 GPM flow rate filter for KM-1300 or larger. 9 12/01/02 12/20/03 2/20/03 ELECTRICAL CONNECTIONS 115 VOLT/1 PHASE 115V. (2 wire w/gnd) 115V. Neutral Brown White GND 208-230 VOLT/1PHASE 208-230V/1 Phase units require a dedicated neutral due to the use of 115V components. 115V. 208-230V. Neutral (3 wire 115V. w/gnd) Brown White Black GND The dedicated neutral requires an insulated conductor which runs directly to the panel. If high leg is present connect to black wire. A transformer can be used to provide 115v control circuit. 208-230 VOLT/3 PHASE 208-230V. 3 phase (3 wire w/gnd) 115V. 115V. 115V. Black Red Brown GND REMOTE CONDENSER CONNECTIONS Fan Control Circuit From Unit 115V. Brown Neutral White GND 10 12/01/02 12/20/03 2/20/03 Note: All Electrical connections must be made in accordance with all national and local electrical codes. Transformer Application All 208-230V models include a 115V transformer with a 208/230V selector switch. Be sure to select the position that best matches the incoming voltage prior to supplying power to the unit. (Voltage from the center tap to case ground will be 67.5V due to the transformer circuit.) 208/230V models include 115V controls. They require a 115 / 208-230V circuit which has 4 wires including L1, L2, dedicated neutral, and ground. If a dedicated neutral is not available or the previous unit used a 3 wire circuit, (L1,L2, & gnd.) a step-down transformer can be used at the unit to provide power to the 115V components. This will save on installation time and cost if a dedicated neutral is not present. Transformer # 4A0817-01 or equivalent can be used for KM models. Transformer # 446240-01 or equivalent can be used for F-1000 models. The transformer should be mounted inside the compressor compartment and wired using the following generic diagram. GND. L1 L2 230V 208V Θ L1 BK N W L2 BN UNIT 11 12/01/02 12/20/03 2/20/03 REMOTE APPLICATIONS CONDENSER CHART CONDENSER MODEL MODEL NUMBERS URC-6F URC-7F URC-12F URC-20F KM-500/630MRF, F-1000MRF KML-600MRF KM-900/1300MRF, KM-1300SRF KM-1600MRF, KM-1600/2000SRF, F-2000MRF URC-24F KM-2400SRF Note: F condensers will be used on either F or H series units as listed above. When installing a remote application the unit/condenser combination must match with the above chart. A non-OEM multi-pass condenser can be used with prior written factory approval. REMOTE LINESHoshizaki has 3 precharged line set lengths. 20 foot, 35 foot, and 55 foot sets are available. The line sets are available in different line sizes for different models. LINE SET IDENTIFICATION CODE R404 - 35 6 10 Refrigerant Length In Feet Liquid Line Size in 16th’s Discharge Line Size in 16th’s LINE SET APPLICATIONS MODELS KML-600, KM-500/630, F-1000 KM-900/1300 KM-1600/2000/2400 F-2000 LINE SET LL (SIZE) DL R404-__46-2 R404-__68-2 R404-__610 R404-__610 1/4" OD 3/8" OD 3/8" OD 1/2" OD 3/8" OD 5/8" OD 3/8" OD 5/8" OD 12 12/01/02 12/20/03 2/20/03 13 12/01/02 2/20/03 LINE SET INSTALLATION A universal line set adapter kit, part number OS-QUICK, is available if you need to field engineer your line set. Both lines should be insulated separately the entire length of run. The refrigerant charge for a new unit is distributed between the unit head and the URC condenser. The line set has a minimal holding charge of 15 to 30 psig refrigerant vapor. If you need to field engineer your line set or shorten/ lengthen a precharged line set you can do so by following these steps: 1. Using the OS-QUICK kit, braze the line set connections. (If you shorten or lengthen a precharged line set, recover the holding charge, cut or lengthen and braze the connections.) 2. Pressurize the lines and leak check all braze joints. 3. Evacuate the lines through the service ports on the Aeroquip quick connect fittings. 4. Charge both lines with 15 to 30 psig R-404A vapor. To make Aeroquip connection to the unit head and condenser: 1. Lubricate the threads and O-ring with clean refrigerant oil. 2. Tighten the female connector until it bottoms out. Note: Always use a back up wrench when tightening these fittings. 3. Then turn an additional 1/4 turn to assure a good brass to brass seal. Leak check the joints with soap bubbles or an electronic leak detector. 14 12/01/02 12/20/03 2/20/03 SYSTEM CHARGE - R-404A The ice machine head and URC condenser are shipped with enough refrigerant charge for up to 66 feet of line set length. The maximum line set length is 100 equivalent feet from the head to the condenser. For applications longer than 66 ft. up to the maximum 100 ft. Length, additional refrigerant must be added. For units utilizing 1/4" L.L. and 3/8" D.L., the line size should be increased to 3/8"L.L. and 1/2"D.L. for the entire length of the run. Add 16.5 ounces plus 0.4 oz. per foot over 66 feet. For units utilizing 3/8"L.L., add 0,4 oz. per foot over 66 feet. NOTE: (1) Recommended line sizes are same as listed in the line set application chart. (2) Older models utilize R-502 refrigerant or R-22 refrigerant. Always check the unit nameplate for the correct refrigerant type. Do not connect components using different type refrigerants! (3) If refrigerant is added due to extended line set length, mark the correct total charge on the unit nameplate for future reference. (4) When routing and installing remote lines, always use standard refrigerant piping practices. (5) Hoshizaki recommends eliminating any excess loops in a pre-charged line set application before making the unit connections. This will eliminate oil traps and possible crimps in the excess tubing. (6) A service loop should be included behind the unit as shown in the illustration on page 13 to allow the unit to be moved away from the wall if needed. CRITICAL CHARGE AMOUNT The total system charge is critical for proper operation according to Hoshizaki specification. Always weigh in the proper charge per the following charge chart. (Remote units show standard charge good for up to 66 feet.) Unit charge information is also found on the unit Name Plate. FOR FACTORY SUPPORT CONTACT HOSHIZAKI TECHNICAL SUPPORT AT: 1 -800-233-1940 E-Mail: techsupport@hoshizaki.com 15 12/01/02 12/20/03 2/20/03 HOSHIZAKI CUBER REFRIGERANT R-404A CHARGE CHART NOTE: This Chart represents both F and H series models. MODEL KM-150 TOTAL CHARGE BAF 10.6 oz. BAF-E 11.1 oz. BWF 12.7 oz. BWF-E 11.6 oz. KM-250 BAF 12.7 oz. BWF 11 oz. KM-280 MAF / MWF & -E 12 oz. KML-250 MAH 1 lb. 2 oz. MWH 14.1 oz. KML-350 MAF 1 lb. 2 oz. MWF 13.6 oz. KML-450 MAF 1 lb. 5 oz. MWF 15 oz. KM-500 MAF 1 lb. 10 oz. MAF-E 1 lb. 10 oz. MWF 13.4 oz. MWF-E 13.2 oz. MRF 3 lb. 15 oz. KML-600 MAF 2 lb. 4 oz. MAF-E 1 lb. 6 oz. MWF &-E 1 lb. 5 oz. MRF 10 lb. 6 oz. KM-630 MAF 1 lb. 7.6 oz. MWF 1 lb. 3 oz. MRF 4 lb. 4 oz. KM-900 MAF 3 lb. 7 oz. MWF 1 lb. 7 oz. MRF1/3 9 lb. 14 oz. KM-1300 SAF1/3 & -E 3 lb. 14 oz. SWF1/3 & -E 2 lb. 2 oz. SRF1/3 & -E 11 lb. 7 oz. KM-1300 MAF 4lb. MWF 2lb. 3 oz. MRF 9lb. 15 oz. KM-1300 NRF 11 lb. 7 oz. KM-1600 MRF1/3 14 lb. 12 oz. KM-1600 SWF1/3 3 lb. 1 oz. SRF1/3 14 lb. 12 oz. KM-1800 SAH1/3 4 lb. 7 oz. KM-2000 SWF3 3 lb. 7 oz. SRF3 16 lb. 2 oz. KM-2400 SRF3 24 lb. REFRIGERANT R-404A “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ NOTE: To convert to grams multiply oz. X 28.35. 16 12/01/02 12/20/03 2/20/03 R-404A URC REMOTE CONDENSERS (Condenser charge is included in total charge.) MODEL FACTORY CHARGE REFRIGERANT URC-6F 1 Lb. 14 Oz. R-404A URC-7F 2 Lbs. 5 Oz. “ URC-12F 4 Lbs. 7 Oz. “ URC-20F 7 Lbs. 11 Oz “ URC-24F 11 Lbs “ Note: F series condensers are used for both F and H series remote units. REFRIGERANT OIL All R-404A models use Polyol Ester (POE-EAL) oil. POE oil absorbs moisture easily. Extra care must be taken to reduce the possibility of moisture entering the system during service. If moisture contamination is suspected, the oil should be changed and the liquid line drier must be replaced. Changing the oil requires removal of the compressor so that the oil can be drained and replaced with the correct amount. See compressor data chart for oil amount. Replacement compressors are shipped with POE oil. HOSHIZAKI FLAKERS/DCM’S REFRIGERANT R-404A CHARGE CHART NOTE: This Chart represents both F and H series models. MODEL F-300 F-450 BAF MAF MWF F-500 BAF F-800 MAF MWF F-1000 MAF MWF MRF F-1001 MAF MWF MRF F-2000 MWF MRF DCM-240 BAF DCM-500 BAF BWF DCM-750 BAF BWF TOTAL CHARGE REFRIGERANT 10.5 oz. 1 lb. 12 1 lb. 1 lb. 1 lb. 4 lb. 1 lb. 4 lb. 2 lb. 14 lb. 10 13 12 15 1 12 15 1 oz. oz. oz. oz. oz. oz. oz. oz. oz. 9 oz. 15.5 oz 1 lb. 4.1 oz. 13.4 oz. 1 lb. 1.7 oz. 1 lb. 1.7 oz. 17 R-404A “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ “ 12/01/02 12/20/03 2/20/03 HEAT LOAD FOR R-404A MODELS The heat of rejection information listed below by model number should be used for sizing air conditioning equipment or water-cooled cooling tower applications. CUBERS: AIR WATER-COOLED MODEL COOLED KM-150B KM-150B -E KM-250BAF KML-250M KML-350M KM-280M & -E KML-450M KM-500M KM-500M -E KML-600M KM-630M -E KM-900M KM-1300S/M KM-1300S3 KM-1300S -E KM-1600SWF KM-1600SWF3 KM-1800SAH KM-1800SAH3 KM-2000SWF3 3100 3400 5064 5560 6550 8159 7480 8206 7371 11580 10375 14800 19800 18130 20400 ——24720 24150 —- (CONDENSER ONLY) 2800 2900 5707 5000 5370 6773 6180 6663 6876 12635 12635 14400 17150 15450 17925 18000 17560 ——22700 HEAT LOAD - R-404A FLAKERS/DCM’S MODEL AIR WATER-COOLED COOLED (CONDENSER ONLY) F-300B 3178 —F-450M 5090 —F-500B 4683 —F-800M 7500 6270 F-1000M 9050 7110 F-1000M/50 9000 7000 F-1001M 9050 7110 F-2000M —15530 DCM-240B DCM-270B DCM-500B DCM-750B 3800 3532 6300 8314 ——5575 5130 Figures shown are at 90° F air temp. 70° F water temp. Allow for a pressure diffenential of 7 psi across the water cooled condenser. 18 12/01/02 12/20/03 2/20/03 “E” Control Board Adjustment Chart The early “E” boards have 8 dip switches. The latest “E” boards have 10 dip switches. “E” BOARD DIP SWITCH SETTING GUIDE ADJUSTMENTS DEFROST COMPLETION TIMER PUMP OUT TIME DIP # 1 Switch Code 1=ON 0=OFF 0 1 0 1 2 0 0 seconds 60 90 3 0 1 1 1 120 180 0 1 4 0 0 1 1 Length of pump out seconds 10 10 10 20 Min Defrost Time seconds 150 180 120 180 Inlet Water Valve status OFF OFF ON OFF 5 0 1 PERIODIC 0 1 1 1 PUMP OUT FREQUENCY BIN CONTROL 6 0 0 cycles 1/1 1/2 7 1/5 1/10 OFF for thermostatic contol SWITCH ON for mechanical control TEST 8 MAX. FREEZE 9 1 1 0 0 10 1 0 1 0 75/50hz 70 60/60hz 50 60 ALWAYS OFF Default TIME (Improved E board only.) minutes NOTE: 1. TO IMPROVE BUILT-IN CLEANING Adjust switches 1&2 to provide for longer flush and switches 5&6 to every cycle pump-out 1/1. Do not adjust 1&2 on KM150/250 in high ambient area. 2. DO NOT ADJUST 3, 4, 7, 8, 9 &10 from factory setting. 3. DO NOT MAKE CONNECTION to the red K-4 terminal unless a special bin control / red connector is provided. 4. Dip-switches 9&10 are on improved “E” board only. If original board has 8 dip-swithes, use default setting of OFF/OFF for 9 & 10. If original board has 10 dip-switches, match original “E” board settings. 19 12/01/02 12/20/03 2/20/03 SETTING CHART FOR R-404A (F/H) MODELS FACTORY DIP SWITCH CODE 1=ON 0=OFF SWITCH SETTINGS: MODEL: 1 2 3 4 5 6 7 8 9 10 KM-150 BA/W/A-E/W-E 0 1 0 1 0 0 0 0 0 0 0 0 0 1 1 1 0 0 1 0 KML-250M A KM-280MA 1 0 0 1 1 1 0 0 0 0 KM-280MA-E 1 0 0 0 0 0 0 0 1 0 KML-250MW, KML350/450/600MA/W 0 0 0 1 1 1 0 0 0 1 KM-280/500MW-E 0 0 0 0 0 0 0 0 0 0 KM-280MWF, 0 0 0 1 1 1 0 0 0 0 KML-350MAF/MWF 0 0 0 1 1 1 0 0 0 1 KM-500MAF, KM630MAF/MRF 0 0 0 0 1 1 0 0 1 0 KM-250B, KM-500MWF/MRF, KM-630MWF 0 0 0 0 1 1 0 0 0 0 KM-500MAF-E, KM-630MAF-E/MWF-E 0 0 0 0 0 0 0 0 1 0 KML-600MRF 1 0 0 0 1 1 0 0 0 1 KM-1300S_F/SWF3, KM-2000SWF3/SRF3 0 0 1 1 1 1 0 0 0 0 KM-1300SAF-E/SRF-E 0 0 1 1 0 0 0 0 1 0 KM-1300SWF-E 0 0 1 1 0 0 0 0 0 0 KM-1300MAF/MRF 0 0 1 0 1 1 0 0 0 0 KM-1300NRF 0 0 1 1 1 1 1 0 0 0 KM-900M_F/MRF3, KM-1300MWF, KM-1600MRF/MRF3 0 0 1 0 1 1 0 0 0 1 KM-1600SRF/SRF3 1 0 1 1 1 1 0 0 0 0 KM-1600SWF3 0 0 1 1 1 1 0 0 0 1 KM-1800SAH 0 0 1 1 1 1 0 0 1 0 KM-2400SRF3 0 0 1 0 0 0 0 0 0 1 Note: The above chart reflects the factory dip-switch settings for models using R-404A refrigerant. Adjustments may be made to switches 1, 2, 5, & 6 to improve the built-in cleaning ability as per the DIP SWITCH SETTING GUIDE. If you replace the control board, match the cleaning settings with the original board. Switches 3, 4, 7, 8, 9, & 10 must remain in the factory position. 20 12/01/02 12/20/03 2/20/03 “E” Control Board Functions An instruction label explaining the “E” board features is included somewhere on the unit. You should find it either on the control box cover, on the inside of the front panel, or under the top panel. A stick on label is also included with the service replacement board. If you are replacing an “E” board, be sure to place the new label over the original label. This will advise anyone performing future service that the original board has been replaced and explain the application switch as outlined below. { The #2A1410-02 universal replacement board has an application switch between relays X3 & X4 that is not included on the original factory board supplied with the unit. This application switch allows this replacement board to be used on older C and Alpine control board models. The application switch has 2 positions (C & ALP). On R-404A models, this switch must be in the ALP position. If the switch is left in the C position, the compressor contactor will energize as soon as power is supplied to the unit whether the power switch is ON or OFF. There are 4 green LED’s which light in sequence throughout the unit operation. It is important to note that the green LED’s are not numbered consecutively. LED1 is located at the edge of the board beside the K-2 transformer connection. The numbering sequence from the outside edge of the board is 1, 4, 3, and 2. The green LED’s are also used for a built-in output test which can be conducted to diagnose a bad board. The label explains the output test procedure. The correct lighting sequence for the output test is as follows. When the control switch is switched ON with the output test switch S-3 ON, after a 5 second delay, LED2 lights. 5 seconds later LED2 goes out and LED3 lights. 5 seconds later LED3 goes out and LED4 lights. 5 seconds later LED4 goes out and LED1 lights. 5 seconds later LED1 goes out and LED4 lights to begin the normal sequence of operation. If the LED’s follow this sequence, the board is OK. If any other lighting sequence occurs, the board is bad. A copy of the “E” board label is included on the next page. Review the board label thoroughly to understand the “E” board functions. 21 12/01/02 12/20/03 2/20/03 ATTENTION ! THIS UNIT HAS A CONTROL PRODUCTS IMPROVED “E” CONTROL BOARD INSTALLED. HOSHIZAKI PART NUMBER 2A1410-01. The improved “E” board includes 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 short beep occurs when the power switch is turned “ON” or “OFF”. The green LED’s 1~4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows: Sequence Step LED’s on: Length:Min. Max. 1 Minute Fill Cycle LED 4 Harvest Cycle LED 1, 4, & 2 2 min. 20 min. Freeze Cycle LED 1 5 min. 60 min. Reverse Pump Out LED 1, 3, & 2 10 sec. 20 sec. Avg. 60 sec. 3-5 min. 30-35 min. Factory set. {With light on, LED 1 = Comp/RFM; LED 2 = HGV; LED 3 = PM; LED 4 = WV} Note: LED’s are not numbered consecutively. They are # 1,4,3,2 from board edge. The built in safeties shut down the unit and have alarms as follows: 1 beep every 3 sec. = High Evaporator Temperature >127° F. Check for defrost problem (stuck HGV or relay), hot water entering unit, stuck headmaster, or shorted thermistor. 2 beeps every 3 sec. = Defrost Back Up Timer. Defrost >20 minutes. Orange LED marked “H Timer” energizes. Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient compressor. 3 beeps every 3 sec. = Freeze Back Up Timer. Freeze > Specified Setting Yellow LED marked “F Timer” energizes. Check for F/S stuck closed (up), WV leaking by, HGV leaking by, PM not pumping, TXV not feeding properly, low charge, or inefficient comp. Dip switches 9 & 10 allow for factory adjustment of this back up timer feature. Note: 2 & 3 beep alarms represent 2 consecutive occurrences. Additional alarms for mechanical bin switch: 4 beeps every 3 sec. = Short Circuit between the K4 connection on the control board and the bin control. Check connections and replace wire harness if necessary. 5 beeps every 3 sec. = Open Circuit between the K4 connection on the control board and the bin control. Check connections and replace wire harness if necessary. Note: Units with mechanical bin switch installed, dip switch No.7 must be in the “ON” position. If thermostatic control is used No. 7 must be “OFF”. To manually reset the above safeties, depress white alarm reset button with the power supply “ON”. 6 beeps every 3 sec. = Low Voltage. Control voltage < 92 Vac ±5%. The red LED will de-energize if voltage protection operates. 7 beeps every 3 sec. = High Voltage. Control voltage > 147 Vac ±5%. The red LED will de-energize if voltage protection operates. Note: The voltage safety automatically resets when voltage is corrected. The Output Test switch “S3” provides a relay sequence test. With power OFF, place S3 on and switch power to ICE. The correct lighting sequence should be none, 2, 3, 4, 1, & 4, in 5 second intervals, then normal sequence. Components will cycle during test. S3 should remain in the “OFF” position for normal operation. The dip switches should be adjusted per the adjustment chart published in the Tech Specs book. No. 8 must remain in the “OFF” position. 22 12/01/02 12/20/03 2/20/03 MANUAL RESET SAFETIES: The Alpine control board has one manual reset safety. It is the 127°F high evaporator temperature safety. There is no indication that the Alpine board is off on this safety. You will only notice that the unit will restart in the 1 minute fill cycle when the power switch is shut OFF and Back ON. This is the only way to reset this safety. If this occurs check for a hot gas circuit or valve problem, a headmaster stuck in bypass, hot water entering the unit, or a shorted thermistor. In case of a shorted thermistor, the unit will not restart. You will hear a relay click after approximately 2 seconds and the unit will remain off. The “E” control board can have up to 5 manual reset safeties. They are outlined in the control board function label. These safeties shut the unit down and assist the service technician in diagnosing the problem. The safeties include audible and visual alarms as follows: 1 Beep = 127ºF (52.8ºC) high evaporator temp. safety. 2 Beeps & orange LED = 2 consecutive 20 minute harvest cycles. 3 Beeps & yellow LED = 2 consecutive maximum freeze cycles. 4 Beeps = Short circuit on mechanical bin control circuit. 5 Beeps = Open circuit on mechanical bin control circuit. To reset either safety, press the white reset button on the control board with the power ON. Next, proceed to check the items outlined on the function label. The items listed on the function label represent the most common reasons that the safety would function. There may be other remote possibilities however, the items listed should be checked first. VOLTAGE PROTECTION: Built-in voltage protection for the “E” board will automatically shut the unit down and beep if either a high or low voltage problem occurs as follows: 6 Beeps = Low voltage condition. 7 Beeps = High voltage condition. The high and low voltage protections are the only board alarms that will automatically restart the unit when the voltage returns to normal. If constant voltage fluctuation occurs, additional external voltage protection will be required. 23 12/20/03 12/01/02 2/20/03 24 12/01/02 12/20/03 2/20/03 MANUFACTURER # Copeland / JS25C1E-IAA-252 Copeland / ASE24C3E-1AA-252 Danfoss / SA10CL Copeland / ASE32C3E-CAA-202 Tecumseh / AKA9438ZXA Tecumseh / AKA9438ZXC Copeland / RS43C1E-CAA-219 Copeland / RS55C2E-CAA Tecumseh / AKA9455ZXA Tecumseh / AKA9455ZXC Copeland / CS10K6E-PFV Copeland / RS64C1E-CAV Copeland / RS64C1E-IAZ-219 Copeland / CS14K6E-PFV Copeland / CS14K6E-TF5 Copeland / CS14K6E-PFJ Copeland / CS20K6E-PFV * Remote units use –02 compressor which has crankcase heater. -E = European model / 50 hz. Resistance is measured with Wheatstone bridge under Controlled ambient conditions. PART # KM-150B, DCM-240B, F-300B 4A1177-01 DCM-270B 4A2272-01 KM-150B -E 4A1845-01 KML-250M 4A2456-01 KM-280M 4A1812-01 KM-280M -E 4A1924-01 KM-250B_F, KML-350M 4A2300-01 KML-450M, 4A1843-01 KM-500M 4A1820-01 KM-500M -E 4A1925-01 KML-600M 4A1539-01 KM-630M 4A1683-01 KM-630M -E 4A1839-01 KM-900M, KM-1300S/M 4A1412-01 KM-900M/3, KM-1300S/3 4A1484-01 KM-1300S -E 4A1749-01 KM-1600M/S, F-2000M 4A1420-01 MODEL (Ohms) RWR SWR 6.010 0.902 7.3 1.2 11.8 6.7 7.3 1.2 4.22 0.590 2.746 7.149 4.08 O.59 3.906 – 4.494 0.614 – 0.706 5.95 0.690 7.149 2.746 2.883 – 3.317 1.079 1.241 7.366 – 8.474 1.442 – 1.659 6.512 – 7.492 1.692 – 1.947 2.474 – 2.846 1.004 – 1.156 Line to line 1.496 – 1.722 2.455 – 2.836 1.302 – 1.498 2.204 – 2.536 0.605 – 1.498 (Ohms) OIL TYPE POE EAL ICI 224B RL 32DR ICI 224B POE EAL “ “ “ “ “ “ “ “ “ “ “ “ LRA = Lock Rotor Amperage SWR = Start Winding Resistance RWR = Run Winding Resistance RLA = Running Load Amperage (see performance data) LRA 37 39 13 33.6 59 26.3 51 60 50 26.3 56 37 33 61 55 58 96 COMPRESSOR DATA fl. oz. / cc. 20 / 568 15 / 426 20 / 568 12 / 341 18 / 512 18 / 511 24 / 682 24 / 682 18 / 511 18 / 512 45 / 1279 24 / 682 24 / 682 45 / 1279 45 / 1279 45 / 1279 45 / 1279 CHARGE 25 12/01/02 12/20/03 2/20/03 4A1462-01 4A1272-01 4A1387-01 4A1843-01 4A1322-01 434209-01 4A1581-01 DCM-230FE-UK DCM-500B,F-450M, F-500B DCM-750B (Early models) F-800M (Late models) F-1000M, F-1001M F-1000M-22 (Special R-22) F-1000M-50 Danfoss / SC12DL Copeland / RS43C1E-CAA-219 Copeland / RS55C1E-PAA Copeland / RS55C2E-CAA Copeland / RS70-C1E-PFV Copeland / REK3-0125-PFV Copeland / RS80-C1E-CAZ MANUFACTURER # Copeland / CS14K6E-PFV Copeland / CS20K6E-TF5 Copeland / CS18K6E-PFV-237 Copeland / CS18K6E-TF5-237 Copeland / CS20K6E-TF5 Maneurop / MTZ-56-HL3T 34 31 31 19 51 60 LRA 61 75 82 65.5 75 125 * Remote units use –02 compressor which has crankcase heater. -E = European model / 50 hz. -C = Cubelet model is same as standard Flaker Resistance is measured with wheatstone bridge under Controlled ambient conditions. PART # 4A1412-02 4A1419-01 4A2334-01 4A2330-01 4A1419-01 4A2043-01 MODEL KM-1300NRF KM-1600M3/S3, KM-1800SAH KM-1800SAH3 KM-2000S3,F-2000M3 KM-2400SRF3 COMPRESSOR DATA 3.17 0.59 0.512 - 0.560 0.614 - 0.706 1.823 - 2.097 0.387 - 0.445 1.990 - 2.290 POE EAL POE EAL POE EAL POE EAL POE EAL POE EAL POE EAL 24 / 682 24 / 682 45 / 1279 21 / 600 24 / 682 24 / 682 CHARGE OIL TYPE Fl. oz. / cc. POE EAL 45 / 1279 POE EAL 45 / 1279 POE EAL 45 / 1279 POE EAL 45 / 1279 POE EAL 45 / 1279 POE EAL 78 / 2216 LRA = Lock Rotor Amperage SWR = Start Winding Resistance RWR = Run Winding Resistance RLA = Running Load Amperage (see performance data) 14.6 4.08 4.464 - 5.136 3.906 - 4.494 4.584 - 5.232 4.68 - 5.38 8.175 - 9.405 (Ohms) (Ohms) SWR RWR 2.474~2.846 1.004~1.156 Line to line 0.984 – 1.132 2.623~3.017 0.688~0.792 Line to line 1.168 - 1.344 Line to line 0.984 – 1.132 Line to line 0.62 “ HEAD PRESSURE CONTROLS WATER-COOLED An adjustable (Pressure Modulated) water-regulating valve is installed on the water-cooled condenser outlet. A # V46 Johnson Controls Penn valve is used. A label on the valve housing identifies the Penn valve. PENN VALVE Adjust: CW - for lower pressure and outlet water temperature with higher water flow. CCW – for higher pressure and outlet water pressure with lower water flow. CONDENSER OUTLET WATER TEMPERATURE RANGE. Model All KM All DCM All F Range 104 ~ 115 ºF 100 ~ 104 ºF 100 ~ 104 ºF High side pressure 270 psig. 260 psig. 260 psig. In some cases, if the water-cooled unit has been in operation for a long period of time, adjusting the water- regulating valve does not allow proper pressures. In this case the water-cooled condenser is likely scaled and requires cleaning. An acid based condenser cleaner should be circulated through the coil using an acid pump, until the inner tube is free of scale. Once the scale is removed, the water-regulating valve should be adjusted to maintain the range and pressure listed above. 26 12/01/02 12/20/03 2/20/03 REMOTE HEAD PRESSURE CONTROL All remote condenser units utilize a condensing pressure regulating (CPR/Headmaster) valve to maintain head pressure in low ambient conditions. You will find a Sporland LAC-4 210 psig. valve mounted in the condenser of all R-404A remote units with the exception of the KM-2400SRF3. The KM2400SRF3 model uses a Sporland LAC-5 210 psig valve which is mounted in the unit head. D R The symptoms of a bad headmaster are similar to an undercharged unit. To diagnose a bad headmaster, add additional refrigerant in 2 lb. increments and watch the pressures. If the pressures begin to look normal, the unit was undercharged. In this case, leak check the system to find the leak and use normal refrigeration practices to recover, repair, evacuate and recharge the unit. If not, a bad headmaster is a possibility. Check to see if the valve is stuck open by conducting temperature checks at the outlet of the headmaster. Replace the headmaster as necessary. Use safe refrigeration practices when removing the valve and protect the valve from overheating. HIGH PRESSURE SAFETY SWITCH An automatic reset high pressure safety switch is utilized on all Hoshizaki “F” series ice makers. The pressure switch part numbers and settings are as follows: 27 12/01/02 12/20/03 2/20/03 Pressure switch chart for R-404A models: Models part number cut out (psig.) 400 ±10 DCM-240B 3A0740-01 All KM & DCM water-cooled, All F models 433441-05 384 ± 21.3 DCM-500/750BAF All KM air & remote, 433441-07 412 ± 21. cut in (psig.) 270 ±10 284± 21.3 327 ± 21.3 BIN CONTROL KM BIN CONTROLS: KM/KML cubers will use one of three types of bin controls. The type of bin control will vary depending on the unit style, or model and serial number. 1. THERMOSTATIC BIN CONTROL: The thermostatic bin control is the primary control that supplies 115 volts to all major components in the unit except the compressor. When this control is closed, 115V is supplied to the control transformer and to the K1 control board connector which switches 115 volts to the components as the sequence dictates. A thermostatic capillary bulb is mounted in the ice drop zone area or on a drop down bracket which extends into the bin cavity. The Thermostatic control is normally closed. (It opens on temperature drop and closes on temperature rise.) When ice touches the thermostatic bulb, the bulb pressure opens the bin control switch to shut the unit down. The thermostatic bin control will shut the unit down at any point in the sequence of operation if ice contacts the control bulb. The shut down time will depend on the control adjustment. This adjustment is factory set however it should always be checked at start-up to assure proper operation. High altitude areas require adjustment. When ice is moved away from the bulb, the unit will always restart in the 1minute fill cycle. Note: The unit will not operate in either ICE or WASH unless the thermostatic bin control switch is closed. Larger M models and S models include a drop down bulb bracket. This bracket should be secured to the unit base and the control plug connection must be made before the unit will operate. A bin control extension bracket is included with all S models. Be sure to install the extension 28 12/01/02 12/20/03 2/20/03 bracket. When installing, make sure the bracket points downward so that the cubes will easily fall away from the bin control bulb. ___ When replacing a thermostatic bin control, check the operation by holding ice against the thermostatic bulb with the control switch in the wash position. The pump should stop within 6 to 10 seconds. Adjustment up to 30~45 seconds could be acceptable depending on the application. Adjust the control “CCW” for a faster shut down. Note: Control board dip switch number 7 must be OFF for this control to operate the unit. A thermostatic bin control may be used on KML models and is required for some dispenser application. 2.MECHANICAL BIN CONTROL: KML and some M models use a mechanical bin control. This control includes a proximity switch and actuator paddle assembly. The mechanical bin control assembly mounts in the ice drop zone area and will shut the unit dowm within 3 seconds when ice pushes the actuator paddle to the full right position, away from the proximity switch. Shut down will only occur during the first 5 minutes of the freeze cycle when the paddle is moved away from the proximity switch. If the paddle is moved away from the proximity switch and held at any other time during the sequence, the unit will continue to run until the next freeze cycle occurs. This feature allows for a full batch of ice every cycle so that there are no small cubes in the bin. A resistor wireing harness connects the mechanical bin control to the red K4 connector on the control board. As the proximity switch opens and closes, the resistance value will change to either start up or shut down the unit. 29 12/01/02 12/20/03 2/20/03 a) When the control paddle is hanging in the normal position, the resistance at the red K4 connector will be 7.9 K ohms and the unit will start. BIN EMPTY Priximity switch closed. Mechanical control in the normal position supplies 7.9 K ohms at red K4 connector to start unit. b) When the unit is held to the right, the resistance at the K4 red connector will be 15.8 K ohms and the unit will shut down within 3 seconds during the first 5 minutes of the freeze cycle or at the beginning of the next freeze cycle at any other time in the sequence of operation. BIN FULL Proximity switch open. Mechanical bin control in the full right position supplies 15.8 K ohms at connector red K4 to shut unit down. Note: Control board dip switch number 7 must be ON for this control to operate the unit. 3. CAPACATIVE PROXIMITY SWITCH: KM-1300NRF This control is used only on the KM-1300NRF model which was designed tor 42 inch beverage dispenser applications. You will find it only on this specific model. The control works by sencing mass (in this case, ice) within 1/2 to 1 30 12/01/02 12/20/03 2/20/03 inch of the sensor. It also connects to the K4 red connector on the control board and has the same operating sequence as the mechanicam bin control. The capacitive proximity control has 4 components including a sensor, bin control relay, 24VDC power supply and resistor harness. This resistor harness is slightly different from the harness used for the mechanical control. It will supply either 15.8 K ohms or 5.6 K ohms to the red K4 connector to control the unit. As the sensor switches, the resistance value will change to either start up or shut down the unit through the control board K4 connector. a) When no ice is present within 1/2~1 inch of the sensor end, the resistance at the K4 connector will be 5.6 K ohms and the unit will start. This is the bin empty signal. b) When ice is present within 1/2~1 inch of the sensor, the resistance at the K4 connector will be 15.8 K ohms and the unit will shut down within the first 5 minutes of the freeze cycle. This is the bin full signal. Note: Control board dip switch number 7 must be ON for this control to operate the unit. F/DCM Bin Control Flaker / DCM units use a mechanical bin control. A paddle pivots on a hinge pin to operate either a micro- switch or magnetic proximity switch. For proper operation, make sure that the paddle swings freely. The F-450MAF-C cubelet unit uses an Infrared eye control since it is designed for dispenser applications. This control has a seperate DC power supply and an infrared sensor which is mounted to the base of the ice chute. CAPACITORS See wiring diagram reference chart for capacitor ratings. Check capacitors with an ohm meter for a short or open circuit. A capacitor checker can be used to check the capacitance however, it is a good common practice to change a run capacator any time a PSC motor is replaced. Always check the run capacitor if a PSC motor will not start, is running slow, overamping, or overheating. 31 12/01/02 12/20/03 2/20/03 HOSHIZAKI KM CUBER SEQUENCE OF OPERATION THE STEPS IN THE SEQUENCE ARE AS FOLLOWS: NOTE: When power is supplied to the “E” Control board, a 5 second delay occurs at start-up. 1. 1 Minute Fill Cycle The unit always starts in the 1 minute fill cycle. When power is applied to the unit the water valve is energized and the fill period begins. After 1 minute the board checks for a closed float switch. If the float switch is closed the harvest cycle begins. If not, the unit will not start without adequate water in the sump. This serves as a low water safety shut off. The water valve will remain energized through additional 1 minute cycles until water enters the sump and the float switch closes. 2. 1st Harvest Cycle The compressor starts, hot gas valve opens, water valve remains open and harvest begins. As the evaporator warms, the thermistor located on the suction line checks for a 48° F. temperature. When 48° F. is reached, the harvest is turned over to the adjustable control board defrost timer which is factory set for normal conditions. This adjustment can vary the defrost timer from 1 to 3 minutes. 3. Freeze Cycle After the timer terminates the harvest cycle, the hot gas and water valves close, and the ice production cycle starts. For the first 5 minutes the controller board will not accept a signal from the float switch. This 5 minute minimum freeze acts as a short c y c l e protection. At the end of 5 minutes the float switch assumes control. As ice builds on the evaporator the water level in the sump lowers. Thefreeze continues until the float switch opens and terminates ice production. 32 12/01/02 12/20/03 2/20/03 4. Harvest Pump Out When the float switch opens and signals the completion of the freeze cycle, the harvest cycle begins. The hot gas valve opens and the compressor continues to run. The drain timer starts counting the 10/20 second pump out. The water pump 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 float switch. When the drain timer stops counting, the pump out is complete. Pump out always occurs on the 2nd harvest after startup. The Alpine control board allows for adjustment for pump out to occur every cycle, or every 2nd, 5th or 10th cycle from this point. 5. Normal Harvest Cycle The water valve opens to allow water to assist the harvest. As the evaporator warms, the thermistor reaches 48° F. The control board receives the thermistor signal and starts the defrost timer. The watervalve is open during harvest (defrost) for a maximum of 6 minutes or the length of harvest, whichever is shorter. When the defrost timer completes its count down, the defrost cycle is complete and the next freeze cycle starts. The unit continues to cycle through 3 , 4 and 5 sequence until the bin control senses ice and shuts the unit down. 33 12/01/02 12/20/03 2/20/03 34 12/01/02 12/20/03 2/20/03 KM CHECK OUT PROCEDURE The following is a detailed explanation of the KM 10 Minute Check Out procedure. The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70°F or warmer air and 50°F or warmer water temperatures. Before conducting a 10 minute checkout, check for correct installation, proper voltage per unit nameplate and adequate water supply. As you go through the procedure, check to assure the components energize and de-energize correctly. If not, those components and controls are suspect. 10 MINUTE CHECK OUT PROCEDURE 1. Turn power OFF - gain access to unit control box. 2. Turn power ON – place control switch in ice position. Note: A 5 second delay occurs for units with “E” control board. A) 1 Minute Fill Cycle begins – WV energized. After 1 minute, control board checks FS. If FS is closed…unit cycles to Harvest. Continue to (B). If FS is open, unit repeats 1 minute fill cycle until water enters and FS closes (low water safety protection during initial start up and at the end of each harvest) Diagnosis: If WV does not open, check for no supply voltage at WV terminals, bad coil, or plugged screen or external filter (no water flow). If unit fails to start harvest, check for open FS or bad 1 minute timer in board. B) Initial Harvest Cycle – WV remains energized, CC energizes to start C, HGV, & (FM on RS model) energize. Evaporator warms…thermistor senses 48°F…turns operation of harvest to control board defrost completion timer. Timer completes counting (1 ~3 minutes)…Unit cycles to freeze. Diagnosis: Check if C is running, HGV is open, WV still open. Avg. harvest cycle at factory setting is 2 ~ 3 minutes. How long does initial harvest last? 1.5 minutes after initial harvest begins, touch C discharge line. Is it hot? If not check refrigerant pressures and C operation. If it is hot, touch inlet line to the evaporator. Is it hot? If it is hot and unit is 35 12/01/02 12/20/03 2/20/03 not starting freeze cycle, check defrost completion timer adjustment, thermistor for open circuit, discharge line temperature, C efficiency, and if HGV is fully open. C) Freeze cycle – C remains energized, PM, (LV on RS model), and FM energize…WV & HGV de-energize. Unit is held in freeze by 5 minute short cycle protection timer. After 5 minutes freeze cycle operation to transferred to FS for freeze termination. During first 5 minutes of freeze, confirm that evaporator temperature drops. After 7 minutes in freeze, remove black FS lead from K5 connector…Unit should immediately switch to pump out cycle. Diagnosis: If evaporator is not cold, check for HGV still open, TXV not opening properly, WV continuing to fill reservoir, improper unit pres sures, and inoperative C. If unit remains in freeze with FS removed replace board. * Normal freeze cycle will last 20 ~ 40 minutes depending on model and conditions. Cycle times and pressures should follow performance data provided in Tech –Specs. D) Pump Out Cycle – (10/20 second pump out) C remains energized, HGV energizes, FM deenergizes, PM stops for 2 seconds and starts in reverse rotation for 10/20 seconds.( This removes contaminants from the water reservoir through check valve and down the drain and allows for power flush of FS.) Check clear tubing at check valve housing or unit drain for water flow. Diagnosis: If PM does not reverse, check PM circuit and capacitor. If water does not pump out, remove housing and check/clean valve assembly. E) Normal Harvest Cycle –same as Initial Harvest Cycle – Return to B)…* Unit continues to cycle through B)…C)…& D) (Setting can be adjusted to skip D until every 2, 5, of 10 cycles)…until bin control is satisfied or power is switched OFF. • Unit always restarts at A). Legend: C – Compressor FS – Float Switch PM – Pump Motor CC – Contactor Coil HGV – Hot Gas Valve RS – Remote System 36 FM – Condenser Fan Motor LV – Line Valve WV – Inlet Water Valve 12/01/02 12/20/03 2/20/03 RESERVOIR FLUSH SYSTEM A displacement device ( cap or assembly ) is positioned over the top of the overflow stand pipe. This device allows sediment to be pulled from the bottom of the reservoir and flush down the drain when overflow occurs. Water should always overflow the stand pipe for a short period towards the end of harvest to allow this flushing action. To extend this flushing action, adjust dip switches 1 & 2 for longer harvest. If overflow does not occur, you likely have restricted water flow into the unit. Check the inlet water valve screen, incoming water line size, or the external filter system. The displacement device must be in position for proper operation. If not, water goes down the drain during freeze and short cycling occurs. PUMP-OUT CHECK VALVE A mechanical spring & seat check valve is located in the pump-out housing. If this check valve sticks open, water flows down the drain during freeze and a 5 minute freeze cycle occurs. In this case, check for a displaced seat, trash or a weak spring. Replace the spring if it is weak. When reinstalling the check valve, the seat always faces the pump supply. KML PUMP OUT The Standard KM series has a dual winding pump motor that reverses direction during the pump-out cycle. The reverse rotation pumps sediment down the drain. The KML models have a single winding pump motor that does not reverse. Instead of a pump-out check valve and reversing pump, a drain solenoid and the pump motor are energized by a relay so that sediment is pumped out. KM CONTROL SWITCH The standard KM models have a three position control switch. The switch positions are “ICE-OFF-WASH”. Also, a manual cleaning valve includes a micro-switch which opens the control transformer circuit to the control board during the cleaning process. This cleaning valve must be in the horizontal position to make ice. The KML models have 2 switches. The control switch positions are “ICE- OFF-SERVICE”. With the control switch in the SERVICE position, the SERVICE switch is energized. 37 12/01/02 12/20/03 2/20/03 The service switch also has three positions, “DRAINCIRCULATE-WASH”. With the control switch in SERVICE and the service switch in DRAIN, the pump starts and drain valve solenoid opens to automatically drain the reservoir. In the CIRCULATE position, the pump motor circulates cleaner to the outside of the evaporator. In WASH, the cleaning solenoid energizes and the pump circulates cleaner to the inside and outside of the evaporator. CONTROL BOARD FUSE Beginning in May 2002 Hoshizaki began including a 10 Amp control fuse on KM models. This new feature was added to specific models as they were produced. The fuse is located in a fuse holder that is mounted on the control box and connected in the circuit supplying 115V to the control board 10-pin connector through pins 10 & 7. The purpose of this fuse is to protect the control board from damage in case of a short circuit in one of the components. This fuse will also offer some protection against external wiring problems, voltage spikes, and surges. If the fuse is blown, you should isolate each individual component and check for shorts and grounded conditions. It is important that any external wiring connections, including the remote condenser circuit be checked before replacing this fuse. If the problem is not corrected, the fuse will blow again. In general, you should check the component that connects to the pin that has a burnt trace on the back side of the board first. The fuse is a Bussman AGC 10 Amp 250VAC slow blow fuse, Hoshizaki part # 4A0893-07 and should only be replaced with one of identical size and type. A replacement fuse is taped to the control box. Should you want to add this feature to an existing KM unit in the field, you can order fuse holder # 4A0892-01, fuse label # 4A2817-01 and fuse # 4A0893-07, through your local distributor. You should also make a note on the wiring diagram indicating the fuse addition, fuse size and type. On the following page, you will find a typical wiring diagram showing where the fuse is wired in the circuit and the label that is included on the control box. 38 12/01/02 12/20/03 2/20/03 39 12/01/02 2/20/03 4A2817-01 If fuse blows, look for shorted component before replacing. CONTROL FUSE (10A) (Fuse Label) COMPONENT CHECKS: 1.FLOAT SWITCH: Check out the float switch with an ohm meter. When the float is up, the switch is closed. When the float is down, the switch is open. STICKING FLOAT SWITCH: It is important to remember that the float switch is in the water circuit and is susceptible to scale buildup. This can cause the float to stick either up or down. If the float switch is sticking, it should be cleaned thoroughly with ice machine cleaner and checked for proper operation. If the float switch is defective, it should be replaced however, a dirty float switch is not considered a warranty item. The symptoms of a sticking float are: UP/CLOSED: 60 minute freeze cycle, larger cubes, and pump cavitates prior to harvest. After 2 consecutive maximum freeze cycles, the unit will shut down on a 3 beep safety. To reset this alarm, press the Alarm Reset but ton on the board with power ON. DOWN/OPEN: Unit shuts down on low water safety and water runs continuously. Heavy scale can be difficult to remove from the float. The float is available as a replacement part as well as the float pin. If the housing is defective, replace the complete float switch assembly. Replacement Float # 4A0886F02 Replacement pin # 4A1141-01 40 12/01/02 12/20/03 2/20/03 UNIVERSAL REPLACEMENT FLOAT SWITCH: There are two styles of KM float switches. One has no hole in the outside pipe and one has a hole in the outside pipe. Float switch number 4A0886-02 can be used as a universal replacement on any KM unit. Simply seal off the small hole in the outside tube with silicone or a seal cap from 3/8” refrigeration tubing if it is not needed. CONNECTOR BOOT: The float switch boot will sometimes collect scale deposits since it is in a low area of the water circuit. The boot should be cleaned thoroughly during scheduled maintenance. Due to age and high amounts of chlorine in the local water supply, it can also deteriorate and may cup upward in the middle holding the float up . In this case, the boot should be replaced. Order part number 426799-01 as universal replacement part and cut the tube to length as needed. Universal float boot # 426799-01 (Cut tube to length) 2. THERMISTOR: Check out the thermistor mounting and check resistance versus temperature per this chart: THERMISTOR TEMPERATURE / RESISTANCE SENSOR TEMP (F°) RESISTANCE (K OHMS) 0 10 32 50 70 90 14.4 10.6 6.0 3.9 2.5 1.6 The symptoms of a bad thermistor are: OPEN: 20 minute harvest cycle. The unit will shut down on a 2 beep safety after 2 consecutive 20 minute harvest cycles. SHORTED: Unit locks out on manual reset high temperature 1 beep safety in this case. High Temperature Safety: If evaporator reaches 127°F the thermistor signal (500 ohms) shuts down the unit on this manual reset. A 1 beep alarm will occur. To reset this alarm, press the Alarm Reset button on the board with power ON. Then check the items listed on the control board label for a 1 beep alarm. 41 12/01/02 12/20/03 2/20/03 Note: The Thermistor must be mounted using a heat sink compound to assure good heat transfer and accurate sensing. Use Hoshizaki Part Number 4AO68301 or equivalent. (Radio Shack #276-1372 or GE Electronics #10-8108, ect.) 3. CONTROL BOARD: The electronic control board maintains the sequence of operation. There are 3 input connections to the board. 1. The Float switch connects to the control board through the black K5 connector. 2. The thermistor connects to the control board through the white K3 connector. 3. If a mechanical bin control is used, it will connect to the K4 Red connector. ( In this case, dip switch #7 must be set to the ON position.) The control transformer supplies 10.5 VAC control voltage to the K2 connection. The control board will not operate unless control voltage is present at K2. Proper control voltage is indicated by the Power OK red LED ON. The final connector on the control board is the K1 10-pin connector. This connector supplies 115 VAC into the control board switchin components or relay contacts and powers the individual components during the sequence of operation. The control board also has 10 dip switches that allow for board adjustments. These switches are set from the factory for proper operation and maximum efficiency. See control board adjustment chart for factory settings and adjustments. BOARD CHECKOUT: Before replacing a control board that does not show a visable defect and that you suspect is bad, always conduct the follow checkout procedure. This procedure will help you verify your diagnosis. 1. Check the dip switch settings to assure that #3,4, 7, 8, 9, & 10 are in the factory setting. Output test switch S3 should also be OFF. Switches 1, 2, 4, & 5 are cleaning adjustments and the settings are flexible. 42 12/01/02 12/20/03 2/20/03 2. Turn the control switch to ICE and check for proper control voltage. If the Red LED is ON, the control voltage is good. If the Red LED is OFF, check the control transformer circuit. See checking control transformer. 3. Next, check the 115 volt input at the 10-pin connector. Check the brown wire at pin #10 to a white neutral wire for 115 volts. (Always choose a white neutral wire to establish a good neutral connection when checking voltages.) A jumper also feeds 115 volts into pin # 7. If no voltage is present, check the 115 volt supply circuit. 4. Check the board sequence using the S3 output test. a) Turn the control switch to OFF and switch S3 ON. b) Turn the Control switch to ICE and watch the lighting sequence of the 4 green LED’s numbered 1, 4, 3, 2 from the board edge. The Red LED should light in about 3 seconds. About 3 seconds later, LED 2 should light. 5 seconds later, Led 2 will go out and LED 3 will light. 5 seconds later, Led 3 will go out and LED 4 will light. 5 seconds later, Led 4 will go out and LED 1 will light. 5 seconds later, Led 1 will go out and LED 4 will light. This sequence completes the output test and the unit is now in the 1 minute fill cycle. Note: If the LED’s light in a different sequence or the 5second interval does not occur as explained, the control board is bad and should be replaced. If the test sequence is correct, turn the control switch OFF and switch S3 OFF. The S3 switch must remain in the OFF position during normal operation. The components will cycle during this test. 5. You have checked the board sequence and now need to check the output to each component through the K1 10-pin connector for 115 volts. Follow the wiring color code on the wiring diagram or use the generic drawing in the wiring diagram section to check each component for 115 volts through out the sequence and check from each pin to a white wire. Note: Checking from pin to case ground can give a false reading in some instances. Always choose a white neutral wire to establish a good neutral connection when checking voltages. 43 12/01/02 12/20/03 2/20/03 4. BIN CONTROL: Checkout for the bin control will vary depending on the model and control that is used. a) THERMOSTATIC BIN CONTROL: The thermostatic bulb is mounted in the ice drop area to sense the ice buildup. To adjust the bin control, hold ice against the bulb while the unit is operating. You will find it easier to place the control switch to the wash position to check the bin control operation. It is easy to hear the pump motor stop when the bin control opens. The unit should shut down within a 10 second window when the control is adjusted properly. If this does not occur, adjust the thermostatic control by turning the screwdriver slot. Adjusting towards warmer will allow the unit to shut down quicker. This adjustment should be checked at installation, when diagnosing a bin control problem, or if a replacement bin control is installed. KM 150 / 250 / 280 / 500 / 630 /900 units have a bin control mounted in the ice drop zone area. KM-1300M / S and larger units have a drop down bracket that must be dropped down, secured, and plugged in at installation. The ice must contact the bulb to operate the bin control. Some bin applications require an extension bracket or relocation of the bulb mounting to allow for proper shut down. Check this positioning if the control is adjusted properly and ice continues to back up into the evaporator section. Assure that the extension bracket is installed. The symptoms of a bad thermostatic control are: STUCK CLOSED: The unit continues to operate when the bin is full. This allows ice to back up in the evaporator compartment and generally causes a freeze up condition. This will also occur if the bin control is adjusted too cold or fully “CW”. Check the adjustment and bulb location before you diagnose a stuck bin control. STUCK OPEN: The unit will not start in the ice position. An easy method to check for an open bin control is to flip the control switch to WASH. If the pump starts, the bin control is closed. b) MECHANICAL BIN CONTROL: The mechanical bin control uses a moving actuator paddle to open and 44 12/01/02 12/20/03 2/20/03 closes a magnetic proximity switch. The control is connected to the red K5 connector on the control board through a resistor harness. As the proximity switch opens or closes, the resistance will change to signal the control board to start up or shut down. The control board will only respond to this change in resistance during the first 5 minutes of each freeze cycle. Note: Dip switch # 7 must be in the ON position for this control. When dip switch # 7 is ON, the following 2 safeties will occur if the mechanical control fails: 4 Beeps = Short circuit on K5 bin control circuit. 5 Beeps = Open circuit on K5 bin control circuit. To reset either safety, press the white reset button on the control board with the power ON. CHECKOUT: To check this control with the unit running, you must be in the first 5 minutes of the freeze cycle. Turn the control switch to OFF and back to ICE. Allow the unit to cycle through the 1 minute fill cycle and the initial harvest cycle. Once the freeze cycle begins (LED 1 ON and when you hear the pump motor start you will know that the freeze cycle has begun), push the control paddle to the full right position and the unit should shut down within 3 seconds. Another method to check this control is to unplug the wiring harness from the K5 Red connector and check the resistance at the end of the harness with an ohmmeter as the proximity switch opens and closes. 1) When the control paddle is hanging in the normal position, (Bin Empty) the resistance at the red K4 connector will be 7.9 K ohms. 2) When the control paddle is held to the full right position, (Bin Full) the resistance at the red K4 connector will be 15.8 K ohms. c) CAPACITIVE PROXMITY SWITCH: This control is used on the KM-1300NRF model only. It operates with the same sequence as the mechanical control and has the same safeties. The difference is that this control has a separate 24VDC power supply and operates through a bin control relay. 45 12/01/02 12/20/03 2/20/03 CHECKOUT: To check the operation of this control follow the same check out procedure as with the mechanical control. Instead of moving a paddle, you will place your hand within 1/2~1 inch of the sensor end. With the control switch in ICE, you should hear the bin control relay switch when you move your hand away from the sensor end and back again. Check the resistance supplied at the Red K4 connector as you move your hand back and forth at the sensor end. Unplug the harness and use an ohmmeter to check the resistance. As the sensor switches, the resistance value will change as follows: a) When your hand is away from the sensor end, the resistance at the K4 connector will be 5.6 K ohms. This is the bin empty signal. b) When your hand is within 1/2~1 inch of the sensor, the resistance at the K4 connector will be 15.5 K ohms. This is the bin full signal. If the relay does not switch or the resistance does not change, check the control wiring, relay operation, and the control power supply for 115 VAC input / 24 VAC output. Note: Remember that dip switch # 7 must be ON and the control will have these safeties. 4 Beeps = Short circuit on K5 bin control circuit. 5 Beeps = Open circuit on K5 bin control circuit. F/DCM BIN CONTROL: DCM bin controls may be a mechanical flapper with a magnetic proximity switch or a micro-switch assembly. Since these controls have moving parts, make sure that all parts move freely. Sticking can occur if scale builds up at the pivot points. All flakers except the F-450MAF-C use the mechanical/proximity switch control. If the bin control fails, the spout will fill with ice causing higher gear motor current and the gear motor protect fuse will blow. The F-450MAF-C has an infrared eye bin control. A separate power supply provides 24 VDC to the infrared eye. This power supply is mounted in a separate control box along with the bin control relay. The IR sensor is mounted on the outside of the chute base in a molded indentation. Two mounting holes mount the sensor to the chute base. 46 12/01/02 12/20/03 2/20/03 The sensor has two LED lamps that light to show that power is supplied. Since the voltage is DC, the sensor is polarity sensitive. The sensor has four wires. The orange wire is capped off and not used. The black wire connects to the coil of relay X7. The brown wire is the positive lead and connects to terminal J2-1 on the power supply. The blue wire is the negative lead and connects to terminal J22. If these wires are crossed, the sensor will not shut the unit down. The result will be that the spout will fill with ice causing higher gear motor current and the gear motor protect fuse will blow. In this case, the bin control is the first component to check. The sensor has two adjustments that are factory set. The first adjustment sets the operation mode of the sensor. It must be in the D position. The second adjust the operating distance of the infrared beam at approximately 4”. It should be set so that the white dot on the dial is at 12 o’clock (top dead center). These settings should not be altered. 5. KM CONTROL TRANSFORMER: The KM control transformer supplies 10.5 VAC to the control board through the K2 connector. This 115V/10.5V stepdown transformer is a heavy duty component with an internal thermal overload. The primary winding of this transformer will handle higher voltage without damage because the thermal overload will open to protect the winding in the case of improper supply voltage. The control board monitors the output voltage of this control transformer and provides automatic reset high and low voltage protection. The red LED on the control board will not light if no control voltage is supplied. The 115V transformer primary circuit is supplied through the thermostatic bin control, control switch, high pressure switch, and low pressure switch if included. If either of these switches are open, there is not control voltage at the K2 connector and the unit will not operate. The transformer secondary circuit includes the cleaning valve interlock switch. If this switch is open, no control voltage is supplied to the K2 connector so the unit will not operate. Always check the cleaning valve position and interlock switch if the red LED is off. Because of the voltage protection, if the control transformer fails, it is important to use the correct OEM part. 47 12/01/02 12/20/03 2/20/03 6. KM PUMP MOTOR ASSEMBLY: The KM pump assembly has a dual winding PSC motor with an internal overload. The motor has a cast housing and sealed stainless steel roller bearings. No lubrication is required for these roller bearings. If the pump motor fails, always repalce the pump motor capacitor. If other failures occur, the front end of the pump assembly is rebuildable. The mechanical seal is the most common failure part and can be replaced. Following, are the assembly breakdown’s for two generic pump assemblies. Use these drawings as a guide to reassemble a pump assembly that you are rebuilding. PUMP ASSEMBLY BREAKDOWN: SMALLER STYLE KM’s 1 Motor 6 Pump Gasket 2 Retainer 7 Impeller 3 Mechanical Seal 8 Pin 4 “O” Ring 9 Pump Gasket 5 Plate 48 12/20/03 12/01/02 2/20/03 LARGER STYLE KM’s 1 Motor 2 Pump Flange 3 Bracket 4 Mechanical Seal 5 Packing 6 Impeller 7 Pin 8 Pump Housing 49 12/01/02 12/20/03 2/20/03 7. INLET WATER VALVE: Hoshizaki uses inlet water valve solenoid to fill the reservoir for ice making. This constant duty solenoid valve is very reliable however, in areas of hard water and high levels of chlorine, the diaphragm is susceptible to failure. Water quality is constantly changing and local municipalities are now adding higher levels of chlorine, chloramine, and chlorine dioxides to the water. These agents can damage rubber parts and effect the diaphragm life. The diaphragm is made of rubber and ABS and has a bleed port on the inside ABS piece. This port allows the pressure to balance on the top and bottom of the diaphragm so that the valve will open and close properly with the spring pressure. If the rubber becomes dry and brittle or the bleed port is plugged with trash or debris, the valve will leak by. In this case the valve can be disassembled for cleaning and the diaphragm and inlet screen can be cleaned or replaced. It is important to remember that the warranty covers repair of defects and not cleaning. Should the valve be scaled or dirty, it should be cleaned and bill to the customer. Below you will find an exploded view of the valve assembly and instructions for reassembly of the valve. When replacing the diaphragm and re-assembling the valvereplacing the diaphragm, it is important that the plunger is in the correct position. This plunger has a white plastic seal on one end and is metal on the other end. The white seal end of the plunger must be in contact with the diaphragm in order for the valve to work correctly. 50 12/01/02 12/20/03 2/20/03 Because of the different flow rates, it is important to use the correct OEM water valve when servicing a Hoshizaki ice maker. Use the following chart to identify the correct valve, diaphragm or inlet screen. CKD VALVES Replacement screen for all CKD valves # SP9200010 Part # Vender # Diaphragm # Model #’s 3U0111-01 J248-030 SP8802237 KM-1200/1300/1600 3U0111-02 J248-032 “ KM-630/632/800/900 3U0111-03 J248-033 “ KM-450/452/500 KML-600 3U0111-04 J248-072 “ KM-250B_B KML-350/400/450 3U0150-01 J248-647 “ KM-280, KML-200 3U0145-01 J248-126 “ KM-250B_C/E/F/H 3U0152-01 J248-662 “ KM-150BAF 3U0133-01 J248-096 “ KM-250M_E/F 3U0136-01 J248-106 “ KM-1800/2000/2400 3U0085-01 J246-379 0000-0264 KM-451/1201 3U0070-02 J246-354 “ KM-601/631 3U0065-01 J246-086 “ F-251/250/441/450 F-650/1101/1001, F-1000M_B, F-2000M-E F-1000M_E >>Serial code F-0 DCM-231/230/240, DCM-451/450/701/700 EATON VALVE Replacement screen # SA0019 Part # Vender # Diaphragm # Model #’s 4A0865-01 K-63310-01 SA0020 F-650/800, F-1000M_E F-1001, F-2000M_F DCM-270/500/750, DCM-450 Serial code F-1>>> 8. Check other components using a good quality multimeter normal electrical diagnostic procedures. 51 12/01/02 12/20/03 2/20/03 Diagnosing water problems. Many common water related problems will cause cubes to look unnatural. Looking at the ice in the bin will point you towards the problem area. Study these shapes and causes to help you diagnose water related problems. 1. Normal cube, No problem. Average cube size 1/2” thick x 1 1/8” wide x 1 1/2” high. 2. Larger than normal cube with heavy saddled edges. Note: Normal cube may have slight saddled edge. If the float switch sticks in the up position, (closed ) the unit will have a consistent 60 minute freeze cycle. This will result in heavy saddled edges and may cause pump cavitation and ice to stick on the evaporator or ice possible bridging. A FREEZE UP MAY OCCUR IF ICE STICKS DUE TO THE LARGER EDGES. 52 12/01/02 12/20/03 2/20/03 3. Bridging or ice strips a) Bridging that occurs on all ribs of all evaporator plates is the result of excessive water in the reservoir. This is caused by the inlet water valve leaking by. Check for a plugged bleed port in the water valve diaphragm or a defective water valve. b) May be the result of # 2. c) Bridging can occur on a few ribs if some of the holes in the water distribution tubes are plugged. An inspection of the ice build up on the evaporator will show some ribs with no ice and others with strips. Clean the water distribution system. d) Bridging on 1 or 2 plates of a multiple evaporator unit can result from water distribution problems or a refrigeration system problem. Eliminate water problems first then check TXV, hot gas valve, charge, etc.... BRIDGING WILL GENERALLY CAUSE A FREEZE UP. 53 12/01/02 12/20/03 2/20/03 4. Melt away of back of cube a) This can occur if the evaporator plate is scaled up. De-scaling is required. b) Insufficient water flow during harvest can also cause the flat side of the cube to melt away. Check for a plugged inlet water valve screen, plugged external filter, low water pressure, or a small water line size. EITHER OR BOTH OF THESE ITEMS CAN CAUSE THIS SYMPTOM. 5. Small cube (Size will depend on how much water is in the reservoir.) a) b) c) 6. Can be caused by a low volume of water at the beginning of freeze. Check for adequate water flow during harvest. See item 4 b) If the pump out check valve is stuck open or has a weak spring, the water left in the reservoir will be pumped out during the first five minutes of freeze. This results in a short cycle and slivers of ice or small cubes. Any loss of water, whether by leak, water trail, or loose stand pipe can cause this problem. Freeze ups can be caused by 2, 3, or 4 above in any combination. The major cause however is a dirty (scaled up ) water system or evaporator. A thorough cleaning will eliminate most freeze ups. The second most common reason for freeze up is low water flow. Always check the evaporator, and water flow first, then go to other checks when diagnosing freeze ups. 54 12/01/02 12/20/03 2/20/03 PLEASE COMPLETE WHEN DIAGNOSING A FREEZEUP, REFRIGERANT LEAK, OR LOW CHARGE. MODEL#_________________SERIAL#_________________ INSL DATE ______________FAIL DATE____________ Single Stacked 1. Single unit or stacked equipment? [ ] [ ] YES NO 2. Condition of float switch - Dirty float? [ ] [ ] Are contacts opening? [ ] [ ] 3. Is water pump always running during freeze? [ ] [ ] 4. Is thermistor properly mounted? [ ] [ ] 5. Is the TXV bulb tight and insulated? [ ] [ ] 6. Does water sump fill to overflow in 60 –90 secs. or less when empty? [ ] [ ] 7. Is the water line size 1/2”?If not ______” [ ] [ ] 8. Is water flow 3 GPM for KM-150~KM-900?[ ] [ ] 9. Only one water line per unit? If not _____ [ ] [ ] 10. Is water flow 5GPM for KM-1300 ~ KM-2400? [ ] [ ] 11. Will bin control cycle OFF within 6-10 seconds when in contact with ice? [ ] [ ] 12. Have you checked that the bin control capillary is not touching a heated source?[ ] [ ] 13. Are the evaporator separators positioned properly? [ ] [ ] 14. Is the cube guide positioned correctly? [ ] [ ] 15. Date evaporators were last cleaned _____________ 16. Does the unit have any water filtration? [ ] [ ] If so, please list the following: Brand filter_________________________________ Filter model________________________________ Water filter pressure gauge reading _________psig Date filter last replaced ______________________ 55 12/01/02 12/20/03 2/20/03 _______________________ 17. Date screen on water solenoid was last cleaned ________ Does water valve close completely when de-energized? [ ] [ ] 18. What is the water pressure? _________ psig Temperature? ________°F 19. Please list the control board dip switch settings. 1 _______ 2 _______ 3 _______ 4 _______ 5 _______ 6 _______ 7 _______ 8 _______ 20. Is cube size consistent from inlet to YES NO outlet of evaporator? (full freeze pattern) [ ] [ ] 21. Is ice still dropping when unit cycles into the freeze mode? [ ] [ ] 22. After defrosting, was the unit leak checked? [ ] [ ] Were any leaks found? [ ] [ ] If so, where? (Be specific) ____________________________________________ 23. Was any refrigerant added to the unit? [ [ [ ] If so, how much? ___________________________________________ 24. What is the head pressure? Freeze ___________ Harvest _____________ 25. What is the suction pressure? Freeze ____________Harvest _____________ 26. What is length of Freeze cycle______________ Harvest cycle? _______________ 27. Ambient temperature? _______________ ° F 28. Water-cooled condenser outlet water temp._________°F 29. Is the hot gas valve opening? [ ] [ ] 30. List model and manufacturer of bin ________________________________________ 31. If non-Hoshizaki bin, what modifications have been made to bin control mounting? [ ] [ ] 32. Has extension bracket been added to the bin control bracket? [ ] [ ] 33. Check ice drop weight. ________________________ 56 12/01/02 12/20/03 2/20/03 PREVENTATIVE MAINTENENCE: Perventative Maintenance is the key to long equipment life and maximum efficiency. Hoshizaki recommends preforming the following maintenance steps at least annually. The PM frequency will depend on the local water quality and operating conditions. PREVENTATIVE MAINTENANCE STEPS: 1. Clean the removable air filter. Hoshizaki air-cooled units include a front accessible, cleanable air filter. This filter collects dirt, dust, and grease can be cleaned with warm soapy water. Hoshizaki recommends cleaning the air filter twice a month or more as conditions dictate. 2. Service the external water filter system (if equipped) and check and clean inlet water valve screen. 3. Clean and sanitize the water system and bin. A cleaning label with detailed instructions is usually located on the inside of the front panel. 4. Check bearings for wear annually on Flaker/DCM. Pull the auger and inspect evaporator, auger, and bearing surfaces for wear. More frequently bearing inspections may be needed in areas with poor water quality. 5. Visually inspect the unit for loose wires, oil spots, water drips, etc. 6. Clean & wipe exterior with a soft cloth and neutral cleaner. STAINLESS STEEL CLEANING: Water quality is constantly changing and local municipalities are now adding higher levels of chlorine, chloramine, and sometimes, chlorine dioxides to reduce bacteria in the water. Stainless steel is a durable metal however it can be suseptable to corrosion from exposure to chlorine gas. As ice forms on a cuber evaporator, chlorine outgases and the chlorine gas settles in the lowest point in the bin. This gas sticks to wet surfaces and around the mouth of the bin and forms hydrochloric acid. If this acid remains on the stainless steel, rust colored corrosion occurs. With enough exposure, the corrosion can pit and damage the stainless. If rust colored corrosion is found, it should be cleaned throughly with a non-abrasive cleaner and protected with a stainless steel polish. Heavy corrosion will require some effort to remove and may require the use of a cleaning agent like “Brasso” or non-abrasive powdered cleaner like “Zud” or “Bon Ami”. Care should be taken so as not to scratch the stainless during the cleaning process. 57 12/01/02 12/20/03 2/20/03 CLEANING/SANITIZING PROCEDURE A label which details the step by step cleaning/sanitizing procedure is located on the inside front panel of the ice machine. These instructions are also provided in the Instruction Manual shipped with each unit. Follow these instructions to conduct a thorough cleaning and sanitizing of the water system. Annual cleanings are recommended. More frequent cleanings may be required in bad water areas. INLET WATER VALVE The inlet water valve includes an 80 mesh screen to protect the water system from debris. Always check and clear this screen during the cleaning procedure. CLEANERS: Hoshizaki recommends "Hoshizaki Scale Away' or "LimeA-Way" (by Economics Laboratory, Inc.) however any FDA approved ice machine cleaner is acceptable. If you carry a nickel safe cleaner, the acidic solution is weaker than normal cleaners to protect plated surfaces. You may need to use a heavier mixture of nickel safe to cut heavier scale deposits. RECOMMENDED CLEANING SOLUTION MIXTURE MODEL CLEANER WATER KM-150 DCM-240 KM-250B KML-250/450 KM-280/500/630/900 KML-600 KM-1300/1600 KM-2000/2400 All Flakers & DCM-500/750 5 Fl. Oz. 6 Fl. Oz. 7 Fl. Oz. 10.5 Fl. Oz. 1 Gal. 1 Gal. 1.3 Gal. 2.0 Gal. 16 Fl. Oz. 27 Fl. Oz. 38Fl. Oz. 3.0 Gal. 5.0 Gal. 7.0 Gal. 9.6 Fl. Oz. 1.6 Gal. The system should be sanitized using a solution of water and 5.25% sodium hypochlorite (chlorine bleach). Any commercial sanitizer recommended for ice machine application is acceptable. 58 12/01/02 12/20/03 2/20/03 RECOMMENDED SANITIZING SOLUTION MIXTURE MODEL SANITIZER WATER KM-150 KM-250B DCM-500/750 KML-250/450 KM-280/500/630/900, KML-600,DCM-240 KM-1300/1600 KM-2000/2400 All Flakers .5 Fl. Oz. .65 Fl. Oz. .82 Fl. Oz. 1 Fl. Oz. 1 Gal. 1.3 Gal. 1.6 Gal. 2.0 Gal. 1.5 Fl. Oz. 3.5 Fl. Oz. 3.7 Fl. Oz. 2.5 Fl. Oz. 3.0 Gal. 5.0 Gal. 7.0 Gal. 5.0 Gal. KM PRODUCTION CHECK The steps for a cuber production check are as follows: 1. Time a complete cycle from the beginning of one freeze cycle to the beginning of the next freeze cycle. 2. Catch all of the ice from this freeze cycle and weigh the total batch. 3. Divide the total minutes in a 24 hour day (1440 minutes) by the complete cycle time in minutes to obtain the number of cycles per day. 4. Multiply the number of cycles per day by the cycle batch weight for the cuber production per 24 hours. (1440 • Total Cycle Time) x Ice Batch Weight= 24 Hour Production Once you calculate the production, check the incoming water temperature, and ambient condensing temperature at the cuber and cross reference to performance data included in this manual to see if the calculation falls within 10% of the specification. For the most accurate production check, a normal freeze cycle should be checked. If the evaporator compartment has been opened for service or if the unit has been cut off for a long period of time, the first freeze cycle will be longer than normal. Timing this cycle can result in an inaccurate production check. To avoid this, start the unit and allow it to operate for 10 minutes in the freeze cycle, unplug the float switch lead and cause the unit to cycle into harvest mode. Replug the float switch and start timing as soon as the next freeze begins. Also remember that the evaporator compartment must be closed during the production check. Removing the front cover to check the ice buildup during a production check will allow heat into the evaporator and will affect the total cycle time and actual production. 59 12/01/02 12/20/03 2/20/03 WATER AND REFRIGERATION CIRCUIT DRAWING REFERENCE CHART MODEL PAGE KM-150BAF/F-E ......................................................... 61 KM-280MAF/H, MWF/H .............................................. 62 KM-280MAF/H-E, MWF/H-E ....................................... 62 KML-250MAH, MWH .................................................. 63 KML-350MAF/H, MWF/H ............................................ 63 KML-450MAF/H, MWF/H ............................................ 63 KML-600MAF/H, MWF/H ............................................ 63 KML-600MRF/H .......................................................... 64 KM-500MAF/H, MWF/H .............................................. 65 KM-500MRF/H ............................................................ 66 KM-630MAF/H,F/H-E, MWF/H, F/H-E ........................ 65 KM-630MRF/H ............................................................ 66 KM-900MAF/H, MWF/H .............................................. 65 KM-900MRF/H ............................................................ 66 KM-1300SAF/H,F/H-E, SWF/H, F/H-E ....................... 67 KM-1300SRF/H .......................................................... 68 KM-1300MAF/H, MWF/H ............................................ 69 KM-1300NRF .............................................................. 68 KM-1600MRF/H .......................................................... 70 KM-1600SWF/H ......................................................... 67 KM-1600SRF/H .......................................................... 68 KM-1800SAH ............................................................. 71 KM-2000SWF/H, SRF/H ............................................. 71 KM-2400SRF/H .......................................................... 72 NOTE: Some drawings have been combined to represent more than one model. 60 12/01/02 12/20/03 2/20/03 KM-150BAF, BWF KM-150BAF-E, BWF-E 61 12/01/02 12/20/03 2/20/03 KM-280MAF/H, KM-280MWF/H KM-280MAF/H-E, KM-280MWF/H-E 62 12/01/02 12/20/03 2/20/03 KML-250MAF/H, KML-250MWF/H KML-350MAF/H, KML-350MWF/H KML-450MAF/H, KML-450MWF/H KML-600MAF/H, KML-600MWF/H 63 12/01/02 12/20/03 2/20/03 KML-600MRF/H 64 12/01/02 12/20/03 2/20/03 KM-500MAF/H, KM-500MWF/H KM-500MAF/H-E, KM-500MWF/H-E KM-630MAF/H, KM-630MWF/H KM-630MAF/H-E, KM-630MWF/H-E KM-900MAF/H, KM-900MWF/H 65 12/01/02 12/20/03 2/20/03 KM-500 MRF/H KM-630 MRF/H KM-900 MRF/H 66 12/01/02 12/20/03 2/20/03 KM-1300SAF/H, SAF/H-E KM-1300SWF/H, SWF/H-E KM-1600SWF/H 67 12/01/02 12/20/03 2/20/03 KM-1300 NRF KM-1300SRF/H KM-1600SRF/H 68 12/01/02 12/20/03 2/20/03 KM-1300MAF/H, MWF/H 69 12/01/02 12/20/03 2/20/03 KM-1600MRF/H 70 12/01/02 12/20/03 2/20/03 KM-1800SAH, SAH3 KM-2000SWF/H, KM-2000SRF/H 71 12/01/02 12/20/03 2/20/03 KM-2400 SRF/H 72 12/01/02 12/20/03 2/20/03 73 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Air 150 137 124 70 / 21 141 129 122 Water Cycle Time Freeze 25 25 26 26 28 29 3.5 3.3 Cycle Time 3 3 Harvest 3 3 50 / 9 215 278 Pressure 70 / 21 230 279 High Side 90 / 32 230 282 50 / 9 35 48 Pressure 70 / 21 37 48 Suction 90 / 32 38 49 NOTE: Total Cycle Time = Freeze + Harvest. cycle. Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water Temp (F°) MODEL: KM-150B_F Total Amperage (Compressor RLA): BAF 8A (6A) Water Consumption for water cooled Condenser: Air 30 32 35 3 3 3 245 250 265 36 38 38 135 122 108 Water 128 99 93 49 49 51 26 31 33 3 3 3 279 280 284 Air 100 97 95 48 38 48 37 49 38 49 38 50 39 50 38 Pressure data is recorded 5 minutes into the freeze 35 34 40 3 3 3 260 254 275 26 29 32 3 3 3 278 279 284 Water 130 100 96 100 / 38 27 31 36 3 3 2.8 280 281 288 Air 124 114 100 Water 134 113 112 90 / 32 38 39 43 3 3 3 305 315 310 80 / 27 Supply Voltage: 115-120/60/1 BWF: 7.5A (6A) Ice Production per cycle: 2.6 Lbs, 130 pcs. 90/70 (32/21) 326 Gal/24 hr. 70/50 (21/9) 134 Gal/24 hr: R-404A PERFORMANCE DATA 74 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 25 22 28 24 33 26 3 3.2 Cycle Time 3 3 Harvest 3 3 260 / 18.3 50 / 9 280 / 19.7 Pressure 281 / 19.7 70 / 21 281 / 19.8 High Side psig / kg/cm2G 303 / 21.3 90 / 32 284 / 20.0 50 / 9 45 / 3.2 45 / 3.2 Pressure 70 / 21 46 / 3.2 46 / 3.2 Suction psig / kg/cm2G 90 / 32 47 / 3.3 48 / 3.4 NOTE: Total Cycle Time = Freeze + Harvest. Cycle Time Freeze 27 32 37 3 3 3 276 / 19.4 308 / 21.6 326 / 23.0 46 / 3.2 47 / 3.3 48 / 3.4 29 36 46 3 3 2.5 282 / 19.9 335 / 23.2 370 / 26.0 125 / 57 98 / 44 76 / 34 141 / 64 119 / 54 108 / 49 24 28 30 3 3 3 281 / 19.8 285 / 20.0 288 / 20.2 Air Water 281 / 19.8 283 / 19.9 286 / 20.1 46 / 3.2 46 / 3.2 46 / 3.2 46 / 3.2 47 / 3.3 47 / 3.4 48 / 3.4 47 / 3.4 49 / 3.5 50 / 3.5 50 / 3.5 49 / 3.4 Pressure data is recorded 5 minutes into the freeze cycle. 23 26 29 3 3 3 127 / 58 101 / 46 88 / 40 Air 46 / 3.2 48 / 3.4 52 / 3.7 25 29 33 3 3 2.7 282 / 19.8 286 / 20.1 290 / 20.4 139 / 63 116 / 53 97 / 44 Water Supply Voltage: 220-240/50/1 Ice Production per cycle: 2.6 Lbs, 130 pcs. 90/70 (32/21) 243 Gal/24 hr. 100 / 38 90 / 32 28 35 41 3 3 2.5 281 / 19.7 330 / 23.2 351 / 24.7 R-404A PERFORMANCE DATA MODEL: KM-150B_F- E Total Amperage (Compressor RLA): BAF-E 5A (3.8A) BWF-E: 5.5A (3.8A) Water Consumption for water cooled Condenser: 70/50 (21/9) 132 Gal/24 hr: 70 / 21 80 / 27 Ambient Temp (F°) Water Kg=lbs. Air Water Air Water Temp (F°) x .454 143 / 65 Production 50 / 9 138 / 63 130 / 59 150 / 68 129 / 59 24 hours 70 / 21 127 / 58 113 / 51 141 / 64 118 / 54 (lbs./kg.) 90 / 32 114 / 52 101 / 46 129 / 59 75 12/01/02 12/20/03 2/20/03 PERFORMANCE DATA Water 222 211 199 236 222 197 70 / 21 Air Cycle Time Freeze 21 22 22 23 26 24 3.3 4.5 Cycle Time 2.9 4.1 Harvest 2.8 3.8 50 / 9 261 260 Pressure 70 / 21 279 266 High Side 90 / 32 301 270 50 / 9 43 47 Pressure 70 / 21 44 47 Suction 90 / 32 46 48 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Kg=lbs. Temp (F°) x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 22 24 29 3.0 2.4 2.3 275 303 324 44 45 47 226 204 176 Air 22 26 30 2.9 2.0 2.0 279 323 345 22 24 26 4.2 3.6 3.5 264 274 275 23 25 27 4.1 3.1 3.0 266 280 283 211 185 173 Water 90 / 32 23 27 34 2.6 2.0 2.0 283 328 365 215 183 136 Air 48 48 50 23 25 29 3.6 3.1 2.8 270 281 285 210 182 163 Water 100 / 38 47 44 47 44 48 46 48 46 49 50 49 48 Pressure data is recorded 5 minutes into the freeze cycle. 222 189 161 Air 214 197 186 Water 80 / 27 Supply Voltage: 115/60/1 MODEL: KM-250BM_F Total Amperage (Compressor RLA): Air: 10.6A (9.2A) Water: 9.5A (8.5A) Ice Production per cycle: 3.98Lbs, 200 pcs. 90/70 422.5 Gal/24 hr. Water Consumption for water cooled Condenser: 70/50 (21/9) 321 Gal/24 hr: 76 12/01/02 12/20/03 2/20/03 PERFORMANCE DATA Water 252 240 226 269 245 219 70 / 21 Air Cycle Time Freeze 22 22 25 24 30 25 3.0 3.5 Cycle Time 2.7 3.2 Harvest 2.6 3.0 50 / 9 236 279 Pressure 70 / 21 259 279 High Side 90 / 32 285 283 50 / 9 45 46 Pressure 70 / 21 50 48 Suction 90 / 32 54 52 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Kg=lbs. Temp (F°) x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 24 28 34 2.8 2.3 2.4 254 290 312 49 56 60 251 214 192 Air 25 31 37 2.7 2.0 2.0 259 316 339 23 25 27 3.3 2.8 2.8 279 280 286 24 26 28 3.2 2.6 2.4 279 280 285 240 212 197 Water 90 / 32 26 32 42 2.5 2.0 2.0 262 321 361 242 182 141 Air 49 54 61 24 27 30 3.2 2.5 2.4 281 281 290 238 209 184 Water 100 / 38 4.7 Lbs, 240 pcs. 90/70 396 Gal/24 hr. 48 50 48 50 51 62 53 61 55 69 57 65 Pressure data is recorded 5 minutes into the freeze cycle. 245 188 164 Air Supply Voltage: 115/60/1 Ice Production per cycle: 243 225 211 Water 80 / 27 MODEL: KM-280M_F & H Total Amperage (Compressor RLA): Air: 11.6A (10.2A) Water: 10A (9.2A) Water Consumption for water cooled Condenser: 70/50 (21/9) 418 Gal/24 hr: 77 12/01/02 12/20/03 2/20/03 Water 230 / 104 219 / 99 201 / 91 258 / 117 231 / 105 204 / 93 70 / 21 Air Cycle Time Freeze 20 22 23 23 30 25 3.1 3.2 Cycle Time 3.1 3.1 Harvest 3.0 3.1 245 17.2 50 / 9 275 / 19.3 Pressure 267 / 18.8 70 / 21 279 / 19.6 High Side psig / kg/cm2G 290 / 20.4 90 / 32 289 / 20.3 50 / 9 55 / 3.9 50 / 3.5 Pressure 70 / 21 58 / 4.1 53 / 3.7 Suction psig / kg/cm2G 90 / 32 61 / 4.3 57 / 4.0 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Kg=lbs. Temp (F°) x .454 Production 50 / 9 24 hours 70 / 21 (lbs./kg.) 90 / 32 22 28 35 3.1 3.0 2.5 262 / 18.4 296 / 20.8 315 / 22.1 57 / 4.0 62 / 4.3 64 / 4.5 23 25 28 3.1 2.9 2.9 279 / 29.6 290 / 20.4 300 / 21.1 25 33 45 3.0 2.9 2.9 269 / 18.9 325 / 22.8 360 / 25.3 54 / 3.8 61 / 4.3 68 / 4.8 24 26 30 3.1 2.9 2.9 282 / 19.8 292 / 20.6 30 / 21.8 215 / 97 188 / 85 156 / 71 Water 100 / 38 229 / 104 160 / 73 120 / 54 Air 278 / 19.6 285 / 20.1 296 / 20.8 52 / 3.7 58 / 4.1 53 / 3.7 58 / 4.1 57 / 4.0 66 / 4.6 60 / 4.2 65 / 4.6 61 / 4.3 70 / 4.9 64 / 4.5 68 / 4.8 Pressure data is recorded 5 minutes into the freeze cycle. 23 31 39 3.1 2.9 2.9 267 / 18.8 320 / 22.5 341 / 24.0 23 24 27 3.2 3.0 3.0 219 / 99 192 / 87 173 / 79 Water 90 / 32 231 / 105 166 / 75 142 / 64 Air 222 / 100 204 / 93 185 / 84 Water 80 / 27 237 / 108 196 / 89 175 / 79 Air PERFORMANCE DATA Supply Voltage: 220-240/50/1 MODEL: KM-280M_F-E & KM-280MAH-E 4.7 Lbs, 240 pcs. Total Amperage (Compressor RLA): MAF-E / H-E 5.1A (4.3A) MWF-E: 5A (3.8A) Ice Production per cycle: 90/70 (32/21) 290 Gal/24 hr. Water Consumption for water cooled Condenser: 70/50 (21/9) 163 Gal/24 hr: 78 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 307 284 267 Air 70 / 21 314 304 290 Water Cycle Time Freeze 27 28 29 29 32 31 4.7 4.1 Cycle Time 4.0 3.6 Harvest 3.7 3.3 247 50 / 9 280 Pressure 266 70 / 21 280 High Side 293 90 / 32 284 50 / 9 58 61 Pressure 70 / 21 59 61 Suction 90 / 32 60 63 NOTE: Total Cycle Time = Freeze + Harvest. cycle. Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water Temp (F°) MODEL: KML-250M_H Total Amperage (Compressor RLA): Air 8.2A (7A) Water Consumption for water cooled Condenser: 29 32 35 4.1 3.0 3.1 261 290 319 59 61 62 289 253 245 Air 29 31 33 3.6 2.5 2.2 280 280 285 255 224 204 Air 301 276 252 Water 100 / 38 62 62 65 29 35 38 4.0 2.2 2.1 266 311 340 29 30 32 3.7 3.0 2.8 280 280 286 304 279 265 Water 61 61 61 59 62 62 62 62 63 64 64 63 Pressure data is recorded 5 minutes into the freeze 284 227 215 306 290 277 90 / 32 29 31 35 3.4 2.4 2.0 282 284 290 Air Water Supply Voltage: 115/60/1 Ice Production per cycle: 6.6 Lbs, 360 pcs. 90/70 511 Gal/24 hr. 33 36 41 3.2 2.2 2.0 295 318 366 80 / 27 Water 7.5A (6.5A) 70/50 398 Gal/24 hr: PERFORMANCE DATA 79 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 383 364 329 Air 70 / 21 358 349 324 Water Cycle Time Freeze 25 28 27 29 30 31 4.0 2.8 Cycle Time 3.4 2.6 Harvest 3.2 2.5 240 50 / 9 280 Pressure 261 70 / 21 280 High Side 285 90 / 32 284 50 / 9 48 57 Pressure 70 / 21 50 58 Suction 90 / 32 53 45 NOTE: Total Cycle Time = Freeze + Harvest. Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water Temp (F°) 26 29 33 3.6 2.6 2.8 256 288 310 50 53 56 368 338 300 Air Air 364 317 279 27 31 35 3.4 2.0 2.0 261 310 333 Water 351 336 305 29 30 33 2.6 2.3 2.3 280 280 286 90 / 32 28 32 38 2.6 2.0 2.0 284 315 355 354 308 245 Air 58 59 60 30 32 37 2.6 2.0 2.0 282 284 290 340 319 271 Water 100 / 38 51 58 56 59 62 60 into the freeze cycle. 29 31 34 2.6 2.0 2.0 280 280 290 349 326 297 Water Supply Voltage: 115/60/1 Ice Production per cycle: 7.3 Lbs, 360 pcs. 90/70 469 Gal/24 hr. 57 50 58 55 59 59 Pressure data is recorded 5 minutes 80 / 27 R-404A PERFORMANCE DATA MODEL: KML-350M_F & H *MWH with SN up to M20060C Total Amperage (Compressor RLA): Air 11A (9A) Water 10.5A (9A) Water Consumption for water cooled Condenser: 70/50 240 Gal/24 hr: 80 12/01/02 12/20/03 2/20/03 280 280 284 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 25 26 27 3.1 2.8 2.7 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure Suction 54 55 56 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze 55 56 57 280 280 287 25 26 29 2.9 2.4 2.4 55 57 58 280 280 290 55 57 59 282 284 291 26 27 31 2.4 2.0 2.0 341 320 291 345 324 207 26 27 29 2.8 2.0 2.0 Water Water Supply Voltage: 115/60/1 Ice Production per cycle: 7.3 lbs. 360 pcs. 90/70 489 Gal/24 hr. 90 / 32 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. R-404A PERFORMANCE DATA MODEL: KML-350MWH With SN M30061E and after Total Amperage (Compressor): 10A (9A) Water Consumption for water cooled Condenser: 70/50 (21/9) 397 Gal/24 hr: 70 / 21 80 / 27 Ambient Temp (F°) Water temp Kg=lbs. Water Water F°C° x .454 354 347 50 / 9 Production 345 334 70 / 21 24 hours 330 326 90 / 32 (lbs.) 81 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 432 400 381 Air 70 / 21 447 430 406 Water Cycle Time Freeze 20 19 22 24 23 28 3.0 2.8 Cycle Time 2.7 2.6 Harvest 2.6 2.5 250 50 / 9 280 Pressure 276 70 / 21 280 High Side 293 90 / 32 286 50 / 9 42 40 Pressure 70 / 21 46 42 Suction 90 / 32 49 45 NOTE: Total Cycle Time = Freeze + Harvest. Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water Temp (F°) 21 24 25 2.8 2.3 2.4 270 311 316 45 52 52 408 359 353 Air Air 400 324 313 22 26 27 2.7 2.0 2.0 276 340 350 Water 434 408 384 23 31 32 2.6 2.3 2.3 280 280 289 90 / 32 23 26 28 2.6 2.0 2.0 284 342 360 390 321 302 Air 43 46 54 24 37 41 2.6 2.0 2.0 283 284 295 425 384 342 Water 100 / 38 46 41 56 45 59 50 into the freeze cycle. 24 36 39 2.6 2.0 2.0 280 280 290 430 390 365 Water Supply Voltage: 115/60/1 Ice Production per cycle: 6.6 Lbs, 360 pcs. 90/70 694 Gal/24 hr. 41 46 43 56 48 58 Pressure data is recorded 5 minutes 80 / 27 PERFORMANCE DATA 76D MODEL: KML-450M_F & H *MWH with SN up to M10530 Total Amperage (Compressor RLA): Air 13.3A (11.6A) Water 12A (10.6A) 70/50 398 Gal/24 hr: Water Consumption for water cooled Condenser: 82 12/01/02 12/20/03 2/20/03 280 280 286 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 20 21 22 3.5 3.1 2.9 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure Suction 47 48 52 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze 47 48 55 280 280 289 20 21 23 3.2 2.5 2.6 48 49 55 280 280 290 50 50 60 283 284 295 21 22 25 3.2 2.0 2.0 417 402 354 426 409 380 21 22 24 3.1 2.0 2.0 Water Water Supply Voltage: 115/60/1 Ice Production per cycle: 6.6 lbs. 360 pcs. 90/70 728 Gal/24 hr. 90 / 32 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. R-404A PERFORMANCE DATA MODEL: KML-450MWH With SN M20531D and after Total Amperage (Compressor): 12A (10.6A) Water Consumption for water cooled Condenser: 70/50 (21/9) 547 Gal/24 hr: 70 / 21 80 / 27 Ambient Temp (F°) Water temp Kg=lbs. Water Water F°C° x .454 433 428 50 / 9 Production 426 417 70 / 21 24 hours 402 385 90 / 32 (lbs.) 83 12/01/02 12/20/03 2/20/03 29 33 38 3.3 2.0 2.0 499 462 411 27 29 33 3.1 2.5 2.5 241 264 284 Air 468 393 353 Remote 30 33 35 3.5 2.5 2.3 448 411 385 Water 90 / 32 266 315 350 52 59 62 cycle 30 35 43 3.3 2.0 2.0 493 436 387 27 31 34 3.0 2.1 2.0 245 280 300 Air 461 384 314 Remote 249 285 319 50 56 60 54 57 59 480 425 342 28 32 38 3.0 2.0 2.0 Remote 284 284 298 31 33 37 3.5 2.4 2.1 442 405 361 Water 100 / 38 Supply Voltage: 115/60/1 Ice Production per cycle: 9.5 Lbs, 480 pcs. 90 / 70 (32/21) 723 Gal/24 hr. 281 263 282 310 290 331 52 50 54 54 47 59 56 57 56 53 61 58 58 57 55 Pressure data is recorded 5 minutes into the freeze 280 281 291 259 289 308 51 56 57 244 280 50 / 9 230 263 281 70 / 21 245 285 287 90 / 32 265 49 50 / 9 53 47 Pressure 52 70 / 21 54 50 Suction 54 90 / 32 55 52 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side 30 32 34 3.6 2.9 2.8 30 32 34 3.5 2.6 2.5 26 27 31 3.4 3.0 2.8 29 30 32 3.9 3.5 3.2 27 29 33 3.9 3.3 3.1 517 493 449 451 428 401 Remote Water 463 448 423 80 / 27 Air Water Air 499 468 428 70 / 21 451 428 401 Ambient Temp (F° / C°) Water Kg=lbs. Temp (F°) x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 50 / 9 Cycle Time 70 / 21 Freeze 90 / 32 50 / 9 Cycle Time 70 / 21 Harvest 90 / 32 PERFORMANCE DATA MODEL: KM-500M_F & H *MWH with SN up to M30961D Total Amperage (Compressor RLA): Air: 15A (11A) Water: 12A (10.5A) Remote: 16A (11A) Water Consumption for MWE Condenser: 70 / 50 (21/9) 380 Gal/24 hr: 84 12/01/02 12/20/03 2/20/03 280 281 288 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 27 28 30 3.9 3.3 3.2 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure Suction 50 52 54 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze 51 54 56 281 283 293 27 28 31 3.5 2.6 2.8 52 56 58 281 285 293 52 56 60 286 285 301 28 30 34 2.8 2.0 2.0 458 439 375 471 448 410 28 29 32 3.3 2.0 2.0 Water Water Supply Voltage: 115/60/1 Production per cycle: 9.5 lbs. 480 pcs. 90/70 832 Gal/24 hr. 90 / 32 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. R-404A PERFORMANCE DATA MODEL: KM-500MWH With SN M30961D and after Ice Total Amperage (Compressor): 12A (10.5A) Water Consumption for water cooled Condenser: 70/50 (21/9) 661 Gal/24 hr: 70 / 21 80 / 27 Ambient Temp (F°) Water temp Kg=lbs. Water Water F°C° x .454 480 473 50 / 9 Production 471 458 70 / 21 24 hours 439 417 90 / 32 (lbs.) 85 12/01/02 12/20/03 2/20/03 50/9 70/21 90/32 50/9 70/21 90/32 50/9 70/21 90/32 Air 454 / 206 402 / 182 360 / 163 31 36 41 3 3 3 480 / 218 446 / 202 403 / 183 29 32 37 3 3 3 Pressure High Side 446 / 202 365 / 166 321 / 146 32 39 44 3 2.9 2.9 Air 90 / 32 33 40 50 3 2.8 2.8 438 / 199 355 / 161 281 / 127 Air 100 / 38 Supply Voltage: 220-240/50/1 9.5 Lbs, 480 pcs. Ice Production per cycle: 273 / 19.2 268 / 18.8 263 / 18.5 316 / 22.2 310 / 21.8 291 / 20.4 360 / 25.3 336 / 23.6 316 / 22.3 53 / 3.7 53 / 3.7 52 / 3.7 59 / 4.1 59 / 4.2 56 / 3.9 61 / 4.3 62 /4.4 57 / 4.0 Pressure data is recorded 5 minutes into the freeze cycle. 80 / 27 Air PERFORMANCE DATA 70 / 21 50/9 250 / 17.6 70/21 268 / 18.8 90/32 293 / 20.6 50/9 50 / 3.5 Pressure 70/21 53 / 3.7 Suction 90/32 55 / 3.8 NOTE: Total Cycle Time = Freeze + Harvest. Cycle Time Harvest Cycle Time Freeze Production 24 hours (lbs.) Ambient Temp F°/C° Water Kg=lbs. Temp (F°) x .454 MODEL: KM-500MAF-E / H-E Total Amperage (Compressor RLA): 5.5A (4A) 86 12/01/02 12/20/03 2/20/03 PERFORMANCE DATA 20 21 24 3.5 3.1 2.9 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 266 298 332 40 45 51 Pressure High Side Cycle Time Harvest Cycle Time Freeze 575 513 455 22 24 27 2.9 2.0 2.0 616 577 540 20 21 23 3.3 2.8 2.6 229 247 274 Air Remote 90 / 32 22 23 25 3.5 2.5 2.2 547 488 481 Water 20 21 23 3.2 2.5 2.2 232 260 286 610 550 512 Remote 272 280 278 320 287 354 41 35 36 36 34 48 42 38 37 39 54 49 46 46 46 Pressure data is recorded 5 minutes into the freeze 272 275 285 21 22 24 3.6 2.9 2.8 553 515 513 605 551 492 250 270 50 / 9 220 271 272 70 / 21 232 302 280 90 / 32 255 38 50 / 9 35 32 Pressure 41 70 / 21 36 35 Suction 47 90 / 32 42 41 NOTE: Total Cycle Time = Freeze + Harvest. 635 610 574 80 / 27 Water Air 21 23 26 3.2 2.5 2.6 21 22 23 3.9 3.5 3.2 572 547 534 631 596 542 50 / 9 70 / 21 90 / 32 Remote 20 20 21 3.5 3.2 2.9 Production 24 hours (lbs.) 70 / 21 Water Air Ambient Temp (F° / C°) Water Kg=lbs. Temp (F°) x .454 310 328 385 43 49 60 cycle 24 25 30 2.5 2.0 2.0 540 499 401 Air 239 266 310 37 44 55 39 40 53 602 541 478 21 21 25 3.2 2.4 2.0 Remote 275 280 295 22 23 26 3.5 2.4 2.0 535 486 475 Water 100 / 38 Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) MODEL: KML-600M_F / H Total Amperage (Compressor RLA.): Air 11A (9.5A), Water 9A ( 8.3 A), Remote: 11. 9A (9.8 A) Production per cycle: 10lbs. 480 pcs. Water consumption for water cooled cond: 70/50 (21/ 9) 458 Gal/24 hr. 90/70 (32/21) 844 Gal/24 hr. 87 12/01/02 12/20/03 2/20/03 619 596 563 31 33 37 4.1 3.6 3.3 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure High Side Cycle Time Harvest Cycle Time Freeze 238 251 281 43 42 47 602 566 533 33 39 43 3.6 2.4 2.2 571 512 466 33 37 41 4.0 3.0 2.9 Air 573 499 457 Remote 32 36 39 3.7 2.5 2.2 596 541 507 Water 90 / 32 34 39 47 3.7 2.4 2.0 562 470 422 34 40 44 3.8 2.4 2.2 267 320 349 249 266 313 44 43 50 cycle Air 564 489 418 Remote 280 240 262 280 260 267 290 288 296 43 44 44 44 44 42 47 47 46 46 46 49 49 47 47 Pressure data is recorded 5 minutes into the freeze 280 280 292 32 34 37 3.8 3.0 2.9 Water Air 80 / 27 580 532 491 232 280 50 / 9 245 240 280 70 / 21 267 263 288 90 / 32 296 43 50 / 9 43 43 Pressure 43 70 / 21 44 44 Suction 46 90 / 32 46 46 NOTE: Total Cycle Time = Freeze + Harvest. 600 562 514 Remote 33 36 40 3.7 2.9 2.8 31 32 35 4.2 3.7 3.3 Water Air 630 573 531 50 / 9 70 / 21 90 / 32 70 / 21 31 34 38 4.4 3.8 3.5 Production 24 hours (lbs.) Ambient Temp (F° / C°) Water Kg=lbs. Temp (F°) x .454 272 327 375 44 47 50 44 47 50 554 459 378 35 41 48 3.9 2.4 2.0 Remote 284 282 300 33 37 41 3.7 2.4 2.0 589 533 476 Water 100 / 38 PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) MODEL: KM-630M_F & H *MWH with SN up to M10961D Production per cycle: 14.3 lbs. 720 pcs. Total Amperage (Compressor RLA.): Air: 7.5A (6A), Water: 6.5A (6A), Remote: 9.5A (6A) 90/70 (32/21) 844 Gal/24 hr. Water consumption for water cooled cond: 70/50 (21/ 9) 458 Gal/24 hr. 88 12/01/02 12/20/03 2/20/03 Pressure Suction 47 47 48 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 47 48 49 33 36 41 3.4 2.3 2.0 282 285 295 32 35 38 3.4 2.3 2.1 280 280 288 48 48 50 590 537 473 599 546 508 52 56 58 Water Water Supply Voltage: 208-230/60/3 Production per cycle: 14.3 lbs. 720 pcs. 90/70 745 Gal/24 hr. 90 / 32 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. R-404A PERFORMANCE DATA MODEL: KM-630MWH With SN M20301E and after Ice Total Amperage (Compressor): 6.5A (6A) Water Consumption for water cooled Condenser: 70/50 (21/9) 653 Gal/24 hr: 70 / 21 80 / 27 Ambient Temp (F°) Water temp Kg=lbs. Water Water F°C° x .454 621 604 50 / 9 Production 599 570 70 / 21 24 hours 563 532 90 / 32 (lbs.) 32 31 50 / 9 Cycle Time 34 32 70 / 21 Freeze 37 35 90 / 32 50 / 9 3.5 3.8 Cycle Time 70 / 21 2.8 3.4 Harvest 90 / 32 2.7 3.1 50 / 9 280 280 Pressure 70 / 21 280 280 High Side 90 / 32 288 286 89 12/01/02 12/20/03 2/20/03 Water 541 / 245 520 / 236 483 / 219 624 / 283 576 / 261 420 / 236 70 / 21 Air Cycle Time Freeze 32 37 35 38 42 42 3 3.4 Cycle Time 3 3.3 Harvest 3 3.2 270 50 / 9 280 Pressure 291 70 / 21 280 High Side psig / kg/cm2G 309 90 / 32 284 50 / 9 50 48 Pressure 70 / 21 51 48 Suction psig / kg/cm2G 90 / 32 52 49 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Kg=lbs. Temp (F°) x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 35 40 47 3 3 3 286 318 330 50 51 53 38 42 46 3.3 2.9 2.9 280 280 285 37 45 57 3 2.8 2.8 391 344 370 49 49 51 40 43 50 3.3 2.9 2.9 282 282 290 510 / 231 460 / 209 393 / 178 Water 100 / 38 568 / 258 447 / 203 357 / 162 Air 48 51 48 51 49 52 49 52 50 55 50 54 Pressure data is recorded 5 minutes into the freeze cycle. 35 44 51 3 2.9 2.9 291 340 356 38 40 45 3.3 3.1 3.1 280 280 286 Water 520 / 236 469 / 213 429 / 195 90 / 32 576 / 261 460 / 209 406 / 184 Air Supply Voltage: 220-240/50/ 1 Ice Production per cycle: 14.3 lbs. 720 pcs. 90/70 (32/21) 586 Gal/24 hr. 525 / 238 492 / 223 452 / 195 Water 80 / 27 587 / 266 513 / 233 463 / 210 Air PERFORMANCE DATA MODEL: KM-630M_F-E & KM-630MAH-E Total Amperage (Compressor RLA): MAF-E / H-E 8.7A (7.1A) MWF-E 6.5A (5.9A) 70/50 (21/ 9) 368 Gal/24 hr. Water consumption for water cooled condenser: 90 12/01/02 12/20/03 2/20/03 853 836 787 21 22 23 3.5 3.2 2.9 278 280 290 37 38 41 21 22 25 4.5 3.9 3.5 245 267 296 33 36 40 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 220 233 255 32 34 37 21 22 24 4.5 3.9 3.5 835 817 786 Remote NOTE: Total Cycle Time = Freeze + Harvest. Pressure Suction Pressure High Side Water Air 838 804 759 Water Kg=lbs. Temp (F°) x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 50 / 9 Cycle Time 70 / 21 Freeze 90 / 32 50 / 9 Cycle Time 70 / 21 Harvest 90 / 32 21 22 25 3.3 2.8 2.6 22 24 27 4.1 3.1 3.0 230 251 274 34 37 40 267 320 349 36 42 46 34 40 43 280 285 298 38 42 45 272 327 375 37 43 50 23 27 31 3.9 2.4 2.0 22 24 26 3.9 2.5 2.2 233 265 288 22 23 25 3.2 2.5 2.2 22 26 29 4.0 2.5 2.2 817 772 739 22 23 25 4.1 3.1 3.0 Air 795 710 634 Remote 836 794 736 821 792 758 Water Air 804 721 676 Remote Pressure data is recorded 5 minutes into the freeze cycle 38 40 43 280 283 297 840 813 750 262 296 324 35 39 43 Water Air 812 659 715 39 43 47 285 288 310 22 23 27 3.2 2.4 2.0 818 780 683 Water 35 41 45 239 270 310 808 764 708 22 24 28 22 24 28 Remote PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) MODEL: KM-900M_F & H With SN M20500D and after Production per cycle: 14.3 lbs. 720 pcs. Total Amperage (Compressor RLA.): Air: 11.7A (10.2A), Water: 10.3A (9.7A), Remote: 12A (10A) 90/70 (32/21) 1024 Gal/24 hr. Water consumption for water cooled cond: 70/50 (21/ 9) 580 Gal/24 hr. 100 / 38 90 / 32 70 / 21 80 / 27 Ambient Temp (F° / C°) 91 12/01/02 12/20/03 2/20/03 280 280 288 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 21 22 23 3.9 3.5 3.2 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure Suction 36 38 39 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze 38 41 41 280 280 292 21 22 25 3.6 2.9 2.8 38 43 44 284 284 300 22 23 27 3..5 2.4 2.0 Pressure data is recorded 5 minutes into the freeze cycle. 38 43 44 280 280 290 22 23 25 3.5 2.4 2.2 R-404A PERFORMANCE DATA Supply Voltage: 208-230/60/3 MODEL: KM-900MWH With SN M30501E and after Ice Production per cycle: 14.3 lbs. 720 pcs. Total Amperage (Compressor): 10.3A (9.7A) 90/70 1185 Gal/24 hr. Water Consumption for water cooled Condenser: 70/50 (21/9) 909 Gal/24 hr: 90 / 32 100 / 38 70 / 21 80 / 27 Ambient Temp (F°) Water temp Kg=lbs. Water Water Water Water F°C° x .454 846 814 833 830 50 / 9 Production 830 778 808 790 70 / 21 24 hours 787 694 754 740 90 / 32 (lbs.) 92 12/01/02 12/20/03 2/20/03 225 235 254 30 32 35 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 32 35 38 233 249 270 22 23 26 4.1 3.1 3.0 22` 23 24 4.5 3.9 3.5 33 39 44 241 265 300 23 24 28 4.0 2.4 2.0 811 777 694 Remote 100 Pressure data is recorded 5 minutes into the freeze cycle. 32 38 41 235 260 281 23 24 26 3.9 2.5 2.2 826 789 739 Remote 830 806 753 Remote Remote 842 826 784 90 Supply Voltage: 208-230/60/3 Ice Production per cycle:14.3 lbs. 720 pcs. 80 PERFORMANCE DATA 70 NOTE: Total Cycle Time = Freeze + Harvest. Pressure Suction Pressure High Side Ambient Temp (F°) Water Temp Kg=lbs. °F/°C x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 50 / 9 Cycle Time 70 / 21 Freeze 90 / 32 50 / 9 Cycle Time 70 / 21 Harvest 90 / 32 MODEL: KM-900MRF3 / H3 Total Amperage (Compressor): 10A (7A) 93 12/01/02 12/20/03 2/20/03 1252 1233 1176 32 32 35 4.3 4 3 275 278 288 47 48 49 30 32 36 4.5 4 4 255 273 296 45 47 49 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 220 232 247 45 46 49 29 30 33 5 4 4 1296 1248 1173 Remote NOTE: Total Cycle Time = Freeze + Harvest. Pressure Suction Pressure High Side Cycle Time Harvest Cycle Time Freeze Production 24 hours (lbs.) 1283 1238 1135 50 / 9 70 / 21 90 / 32 70 / 21 Water Air Ambient Temp (F° / C°) Kg=lbs. Water Temp °F/°C x .454 268 296 318 46 49 51 32 37 41 4 2.2 2 30 31 35 4 3 3 273 315 338 47 51 53 1238 1129 1011 1260 1185 1105 229 247 262 46 48 51 Air Remote 90 / 32 47 50 53 48 49 50 278 285 297 277 320 360 47 51 55 33 38 44 4 2 2 1203 1101 902 1248 1133 1053 30 32 36 4 2.2 2 232 260 276 Air Remote 32 33.6 36 4 2.25 2 1233 1188 1119 Water Pressure data is recorded 5 minutes into the freeze cycle 47 48 49 277 282 295 32 33 36 4 3 3 1238 1209 1134 1249 1178 1053 32 35 39 4 3 3 Water Air 80 / 27 48 49 51 282 288 308 33 34 39 4 2 2 1211 1172 1056 Water 100 / 38 47 51 55 235 264 290 1230 1114 980 31 33 40 4 2 2 Remote PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) MODEL: KM-1300S_F & H Total Amperage (Compressor RLA.): SAF 12.6A (10.2A), SWF 10.2A (9.7A), SRF 12.8A (10A) Production per cycle: 30.1 lbs.1440 pcs. Water consumption for water cooled cond: 70/50 (21/ 9) 964 Gal/24 hr. 90/70 (32/21) 1521 Gal/24 hr. 94 12/01/02 12/20/03 2/20/03 30.2 31 33 4.2 4 3 270 274 284 48 49 50 30 32 36 4 3 3 255 274 296 47 48 50 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 230 242 259 50 51 53 30 31 33 4.8 4 4 1308 1282 1203 1301 1273 1205 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Remote Water 70 / 21 NOTE: Total Cycle Time = Freeze + Harvest. Pressure Suction Pressure High Side Cycle Time Harvest Cycle Time Freeze Ambient Temp (F° / C°) Kg=lbs. Water Temp Air °F/°C x .454 1320 50 / 9 Production 1257 70 / 21 24 hours 1153 90 / 32 (lbs.) 270 299 318 48 50 52 30 32 35 4 3 3 274 320 341 48 52 54 32 37.4 41 4 2.1 2 1288 1247 1145 239 257 275 51 52 55 Air 1257 1105 993 Remote 51 53 56 49 51 52 274 285 295 277 325 360 49 52 55 33 38 44.75 4 2 2 1282 1218 1125 31 33 36 4 2.2 2 242 270 288 Air 1230 1079 890 Remote 31 32.75 35 4 2.2 2 1273 1204 1126 Water 90 / 32 49 51 53 277 287 305 32 33 36.5 4 2 2 1250 1186 1055 Water 100 / 38 52 54 58 246 274 305 1252 1196 1039 31 34 39 4 2 2 Remote Supply Voltage: 208-230/60/3 Production per cycle: 30.1 lbs.1440 pcs. 90/70 1372 Gal/24 hr. Pressure data is recorded 5 minutes into the freeze cycle 49 50 51 273 280 291 31 32 34 4 3 3 1279 1235 1152 32 35 39 4 3 3 Water Air 1272 1174 1060 80 / 27 PERFORMANCE DATA MODEL: KM-1300S_F3 & H3 Total Amperage (Compressor RLA.): SAF3 8.4A (6.1A), SWF3 7.3A (5.8A), SRF3 9.8A (7A) Water consumption for water cooled cond: 70/50 885 Gal/24 hr. 95 12/01/02 12/20/03 2/20/03 Pressure Suction 230 242 261 50 / 9 70 / 21 90 / 32 49 50 53 239 257 278 100 / 38 50 51 55 247 275 310 33 36 41 4.2 2.4 2.0 1196 1149 986 Remote Pressure data is recorded 5 minutes into the freeze cycle. 50 51 53 242 270 291 32 35 38 4.3 2.5 2.2 32 34 37 4.4 3.3 3.2 31 32 35 5.0 4.3 3.8 1229 1172 1075 1234 1198 1091 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 90 / 32 Remote 1252 1229 1149 80 / 27 Remote 70 / 21 PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) Ice Production per cycle: 30.9 lbs. 1440 pcs. Remote 49 50 51 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Kg=lbs. Water Temp °F/°C x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) Ambient Temp (F°) MODEL: KM-1300NRF & H Total Amperage (Compressor): 18A (14A) 96 12/01/02 12/20/03 2/20/03 Pressure High Side Cycle Time Harvest Cycle Time Freeze 264 297 318 50 52 53 1259 1211 1126 49 50 51 Pressure 277 280 294 29 31 33 3.7 3 3 Water Air 30 35 39 1285 1209 1121 28 31 34 4 3.2 3 Air 1216 1040 943 Remote 30 32 34 3.6 2.6 2.4 278 285 297 1252 1177 1097 Water 90 / 32 272 326 365 50 54 56 cycle 31 36 43 3.3 2.5 2 1273 1155 1068 29 32 35 3.9 2.6 2.3 239 268 285 Air 1198 1017 853 Remote 4 2.6 2.3 269 236 321 255 344 271 50 48 49 48 53.2 50 50.4 49 55 52 52 51 data is recorded 5 minutes into the freeze 80 / 27 1233 1120 1026 247 275 50 / 9 227 269 277 70 / 21 239 293 287 90 / 32 256 49 50 / 9 49 47 Pressure 50 70 / 21 49 48 Suction 52 90 / 32 51 49 NOTE: Total Cycle Time = Freeze + Harvest. 29 30 32 4 3.6 3.3 1322 1273 1193 1283 1252 1182 29 33 37 4.2 3.3 2.5 28 30 33 4.5 4 3.6 Remote Water 70 / 21 27 29 31 4.4 3.9 3.5 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F° / C°) Kg=lbs. Water Temp Air °F/°C x .454 1289 50 / 9 Production 1216 70 / 21 24 hours 1120 90 / 32 (lbs.) 50 51 53 282 285 307 30 32 36 3.6 2.5 2.3 1229 1158 1046 Water 100 / 38 48 50 53 243 272 300 1252 1135 989 30 33 38 3 2.5 2 Remote PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) MODEL: KM-1300M_F & H Production per cycle: 28.6 Lbs, 1440 pcs. Total Amperage (Comp. RLA): Air: 12.6A (10.2A) Water: 10.2A (9.7A) Remote: 12.8A (10A) 90 / 70 (32/21) 723 Gal/24 hr. Water Consumption for MWE Condenser: 70 / 50 (21/9) 380 Gal/24 hr: 97 12/01/02 12/20/03 2/20/03 1145 1096 1004 30 31 34 5 5 4 280 281 292 52 53 55 1200 1106 988 26 29 35 5 4 4 240 268 287 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure High Side Pressure Suction 230 242 255 50 51 53 30 32 36 5 5 4 1129 1077 987 Remote 50 51 54 NOTE: Total Cycle Time = Freeze + Harvest. Cycle Time Harvest Cycle Time Freeze Production 24 hours (lbs.) Water 70 / 21 Air Ambient Temp (F° / C°) Kg=lbs. Water Temp °F/°C x .454 261 304 313 51 53 56 Air 1106 880 763 29 37 43 4 3.5 4 Remote 1089 1008 908 31 35 39 5 4 4 31 34 38 5 3.6 4 1096 977 875 Water 90 / 32 265 338 360 52 56 60 cycle 31 38 49 4 4 3.5 1077 950 853 32 37 41 5 3.5 4 242 270 283 Air 1086 853 655 Remote 54 56 60 286 288 310 32 35 42 5 4 3.6 1069 953 782 Water 100 / 38 51 53 57 244 273 295 1053 927 763 33 38 45 5 4 3.5 Remote Production per cycle: 30.1 lbs.1440 pcs. Supply Voltage: 220-240/50/1 281 268 239 285 335 257 298 348 269 53 53 51 51 50 55 54 55 52 51 58 57 58 55 54 Pressure data is recorded 5 minutes into the freeze 281 283 298 31 33 37 5 4 4 1107 1031 926 28 33 40 4 4 4 Water Air 1129 983 871 80 / 27 PERFORMANCE DATA MODEL: KM-1300S_F-E Total Amperage (Compressor RLA.): SAF-E 10.3A (8.6A), SWF-E 9.5A (7.7A), SRF-E 10A (9A) Water consumption for water cooled cond:70/50 964 Gal/24 hr. 90/70 1521 Gal/24 hr. 98 12/01/02 12/20/03 2/20/03 23 24 26 4.5 4.1 3.5 227 229 259 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 1486 1438 1347 50 / 9 70 / 21 90 / 32 Remote 70 / 21 Pressure Suction 40 42 44 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water Temp °F/°C MODEL: KM-1600MRF & H Total Amperage (Compressor): 21A (18.6A) 41 44 46 42 46 50 244 272 310 25 27 31 4.0 2.9 2.0 1411 1299 1128 Remote Pressure data is recorded 5 minutes into the freeze cycle. 42 46 48 239 267 289 24 27 29 4.1 3.0 2.5 24 26 28 4.2 3.5 3.0 236 254 277 1438 1323 1221 Remote 1450 1375 1270 Remote PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) Ice Production per cycle: 28.6 lbs. 1440 pcs. 90 / 32 100 / 38 80 / 27 99 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 225 237 260 50 / 9 70 / 21 90 / 32 Pressure Suction 37 40 42 234 252 279 38 43 47 244 271 315 25 27 31 4.0 2.9 2.0 1453 1311 1185 Remote Pressure data is recorded 5 minutes into the freeze cycle. 37 42 45 237 265 291 24 27 29 4.1 3.0 2.5 24 26 28 4.2 3.5 3.0 1524 1467 1392 23 24 26 4.5 4.1 3.5 1467 1328 1253 1480 1391 1319 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Remote 80 / 27 Remote Supply Voltage: 208-230/60/3 Ice Production per cycle:28.6 lbs. 1440 pcs. 90 / 32 100 / 38 Remote PERFORMANCE DATA 70 / 21 35 37 40 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Ambient Temp (F°) Water temp Kg=lbs. F°C° x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) MODEL: KM-1600MRF3 & H3 Total Amperage (Compressor): 13.8A (11.4A) 100 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 225 235 256 50 / 9 70 / 21 90 / 32 Pressure Suction 39 41 43 233 249 273 40 43 47 242 265 305 26 28 32 4.9 2.9 2.5 1383 1359 1207 Remote 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. 39 41 43 235 260 283 26 28 30 4.8 3.0 2.7 26 27 29 4.9 3.8 3.7 1430 1415 1343 25 26 28 5.5 4.8 4.3 1415 1380 1290 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Remote 1419 1396 1295 90 / 32 Remote 80 / 27 PERFORMANCE DATA upply Voltage: 208-230/60/1 (3 wire with neutral for 115V) Ice Production per cycle: 30.9 lbs. 1440 pcs. Remote 70 / 21 38 39 41 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Kg=lbs. Water Temp °F/°C x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) Ambient Temp (F°) MODEL: KM-1600SRF & H Total Amperage (Compressor): 18A (14A) 101 12/01/02 12/20/03 2/20/03 1500 1495 1451 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Water Water Temp °F/°C 1496 1489 1423 1430 1415 1343 Cycle Time Freeze 24 25 26 4.4 3.3 3.2 271 273 276 41 42 45 Water Remote 24 25 25 26 26 28 4.0 5.5 Cycle Time 4.3 4.8 Harvest 4.0 4.3 270 50 / 9 225 Pressure 271 70 / 21 235 High Side 274 90 / 32 256 50 / 9 40 38 Pressure 70 / 21 41 39 Suction 90 / 32 43 41 NOTE: Total Cycle Time = Freeze + Harvest. Kg=lbs. x .454 Production 24 hours (lbs.) 26 27 29 4.8 3.0 2.7 235 260 278 1426 1341 1274 Remote 25 26 28 4.0 2.4 2.0 272 276 280 1473 1470 1373 Water 38 41 42 38 40 43 44 39 44 46 48 43 Pressure data is recorded 5 minutes into the freeze cycle. 25 26 27 4.3 2.5 2.2 271 275 278 1495 1484 1426 1434 1380 1311 25 26 29 4.9 3.8 3.7 233 249 267 Water Remote 39 41 47 26 27 31 4.9 2.9 2.5 240 264 195 1409 1325 1213 Remote R-404A PERFORMANCE DATA Supply Voltage: 208-230/60/3 MODEL: KM-1600S_F3 / H3 Total Amperage (Compressor): SWF3 10.3A (9A), SRF3/H3 13.6A (9.5A) Ice Production per cycle: 30.9 lbs. 1440 pcs. Water consumption for SWF3 Condenser: 70 / 50 (21/9) 2563 Gal/24 hr. 90 / 70 (32/21) 2597 Gal/24 hr. 100 / 38 90 / 32 70 / 21 80 / 27 Ambient Temp (F°) 102 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 230 251 277 50 / 9 70 / 21 90 / 32 Pressure Suction 51 53 56 246 278 303 52 56 60 255 306 350 37 40 45 4.2 3.4 2.5 1579 1491 1326 Air 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. 51 55 58 251 300 326 33 39 42 5.3 3.5 3.0 33 36 39 5.4 4.3 3.9 31 33 36 6.0 5.3 4.6 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 1685 1514 1416 1702 1592 1496 1756 1685 1589 Air 90 / 32 Air 80 / 27 PERFORMANCE DATA Supply Voltage: 208-230/60/1 (3 wire with neutral for 115V) Ice Production per cycle: 42.9 lbs. 2160 pcs. Air 70 / 21 50 51 54 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Kg=lbs. Water Temp °F/°C x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) Ambient Temp (F°) MODEL: KM-1800SA H Total Amperage (Compressor): 18A (14.5A) 103 12/01/02 12/20/03 2/20/03 50 / 9 70 / 21 90 / 32 240 262 283 50 / 9 70 / 21 90 / 32 Pressure Suction 53 54 57 257 291 306 54 56 60 291 319 350 38 41 45 4.1 2.9 2.5 1579 1486 1344 Air 100 / 38 Pressure data is recorded 5 minutes into the freeze cycle. 53 55 58 262 315 333 34 40 43 5.1 3.0 2.7 34 37 40 5.3 4.0 3.9 32 34 37 6.0 5.1 4.6 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 1683 1506 1422 1701 1587 1507 1757 1683 1597 Air 90 / 32 Supply Voltage: 208-230/60/3 Ice Production per cycle: 42.9 lbs. 2160 pcs. Air 80 / 27 PERFORMANCE DATA Air 70 / 21 52 53 55 NOTE: Total Cycle Time = Freeze + Harvest. Pressure High Side Cycle Time Harvest Cycle Time Freeze Kg=lbs. Water Temp °F/°C x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) Ambient Temp (F°) MODEL: KM-1800SAH3 Total Amperage (Compressor): 11A (7.5A) 104 12/01/02 12/20/03 2/20/03 Remote 1865 1821 1746 1907 1899 1826 70 / 21 Water Cycle Time Freeze 29 30 30 31 31 33 4.5 5 Cycle Time 4.1 4 Harvest 3.7 4 265 50 / 9 233 Pressure 266 70 / 21 243 High Side 277 90 / 32 263 50 / 9 46 45 Pressure 70 / 21 47 46 Suction 90 / 32 48 47 NOTE: Total Cycle Time = Freeze + Harvest. 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Temp Kg=lbs. °F/°C x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 29 30 33 4.2 3.5 3.3 266 268 283 46 47 48 1901 1887 1781 Water 1832 1764 1679 90 / 32 31 34 36 4 3 2 243 268 290 1821 1716 1634 Remote 30 31 35 4.1 2.9 2.5 271 273 295 1863 1856 1698 Water 46 47 50 32 34 38 4 3 2 249 273 310 1801 1697 1558 Remote 100 / 38 Supply Voltage: 208-230/60/3 Ice Production per cycle: 46.3 lbs. 2160 pcs. 46 47 47 45 47 48 48 46 49 49 50 48 Pressure data is recorded 5 minutes into the freeze cycle. 30 31 33 4.1 3.0 2.7 266 270 283 1899 1878 1784 Remote 31 33 35 5 4 3 241 257 280 Water 80 / 27 PERFORMANCE DATA MODEL: KM-2000S_F3 & H3 Total Amperage (Compressor): Water: 10.1A (9A), Remote: 11.4A (9A) 105 12/01/02 12/20/03 2/20/03 23 24 26 5.6 5.0 4.7 250 259 279 50 50 50 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 NOTE: Total Cycle Time = Freeze + Harvest. Pressure Suction Pressure High Side Cycle Time Harvest Cycle Time Freeze MODEL: KM-2400SRF3 & H3 Total Amperage (Compressor): SRF3 19.7A (15A) 70 /21 Ambient Temp (F°) Water Temp Kg=lbs. Remote °F/°C x .454 50 / 9 2294 Production 70 / 21 2249 24 hours 90 / 32 2107 (lbs.) 50 50 51 257 270 295 50 50 51 266 285 325 25 27 31 3.0 3.4 3.2 2194 2101 1813 Remote Pressure data is recorded 5 minutes into the freeze cycle. 50 50 51 259 280 303 24 27 29 5.0 3.4 3.3 2249 2141 1970 24 26 28 5.1 4.1 4.1 Remote 2260 2190 2003 Supply Voltage: 208-230/60/3 Ice Production per cycle: 45 lbs. 2160 pcs. 90 / 32 100 / 38 Remote 80 / 27 PERFORMANCE DATA WIRING DIAGRAMS: The wiring diagrams provide on the following pages are generic in some cases because they can represent several models. Hoshizaki provides a specific wiring label on every unit for electrical diagnosis. See the following wiring diagram chart for your model and capacitor information. MECHANICAL BIN CONTROL DIAGRAM..............110 CAPACITIVE BIN CONTROL DIAGRAM ................111 10 - PIN CONNECTOR: This connector diagram shows the standard color code and component layouts. Use it as a guide for circuit diagnosis. 106 12/01/02 12/20/03 2/20/03 107 12/01/02 12/20/03 2/20/03 Mechanical Bin Control Capacitive Bin Control KM-150BAF, BWF KM-150BAF-E, BWF-E KM-250BAF, BWF KM-280MAF, MWF KM-280MAF-E, MWF-E KML-250MAF/H,MWF/H KML-350MAF/H, MWF/H KML-450MAF/H, MWF/H KM-500MAF/H, MWF/H KM-500MRF/H KM-500MAF-H/H-E KML-600MAF/H, MWF/H KML-600MRF/H Model A B A C D E F G H I J K K 110 111 112 113 112 114 115 116 117 118 119 120 121 122 122 Wiring Diagram Page 145~174 MFD 80 MFD 243~292 MFD 378~445 MFD 72~86 MFD 72~86 MFD 243~292 MFD 189~227 MFD 72~88 MFD 72~88 MFD 72~86 MFD 145~174 MFD 145~174 MFD Start Capacitor None None 15 MFD None 15 MFD 20 MFD 15 MFD 25 MFD 25 MFD 25 MFD 15 MFD 30 MFD 30 MFD Run Capacitor 2 MFD 2.MFD 5.5 MFD 5.5 MFD 5.5 MFD None None None 5.5 MFD 5.5 MFD 5.5 MFD None None Pump Capacitor KM Wiring Diagram Reference Chart for R-404A Models 5 MFD 5 MFD 5 MFD 10 MFD 2.5 MFD 5 MFD 10 MFD None None 5MFD 5 MFD 2.5 MFD Fan Capacitor 108 12/01/02 12/20/03 2/20/03 KM-630MAF/H, MWF/H KM-630MRF/H KM-630MAF-E/H-E, MWF-E/H-E KM-900MAF/H, MWF/H KM-900MRF/H KM-900MRF3/H3 KM-1300SAF/H, SWF/H, KM-1300MAF/H, MWF/H KM-1300SRF/H, MRF/H KM-1300SAF3/H3, SWF3/H3 KM-1300SRF3/H3 KM-1300SAF-E/H-E, SWF-E/H-E KM-1300SRF-E/H-E KM1600SWF/H, SRF/H, MRF/H KM-1600SWF3/H3, SRF3/H3 Model Page 123 124 125 126 127 128 129 129 130 131 132 133 134 135 136 L M N O P Q R R S T U V W X Y 88~108 MFD 88~108 MFD 88~108 MFD 145~174 MFD 145~174 MFD None 145~174 MFD 145~174 MFD 145~174 MFD None None 160 MFD 160 MFD 189~227 MFD None Start Capacitor 15 MFD 15 MFD None 35 MFD 35 MFD None 35 MFD 35 MFD 35 MFD None None 35 MFD 35 MFD 40 MFD None Run Capacitor KM Wiring Diagram Reference Chart Wiring Diagram 5.5 MFD 5.5 MFD 5.5 MFD 10 MFD 5.5 MFD 5.5 MFD 10 MFD 10 MFD 10 MFD 10 MFD 10 MFD 15 MFD 15 MFD 10 MFD 10 MFD Pump Capacitor 5 MFD 10 MFD 2.5 MFD 5 MFD 10 MFD 10.MFD 5 MFD 5 MFD 10 MFD 5 MFD 10 MFD 5 MFD 10 MFD 10 MFD 10 MFD Fan Capacitor 109 12/01/02 12/20/03 2/20/03 137 138 139 140 141 Z AA BB AA CC KM-1600MRF3/H3 KM-1800SAH3 KM-1800SAH3 KM-2000SWF3, SRF3 KM-2400SRF3 URC-6F URC-7F URC-12F URC-20F URC-24F URC-6F-E, 12F-E Page Model None 145~174 MFD None None None Start Capacitor None 35 MFD None None None Run Capacitor KM Wiring Diagram Reference Chart Wiring Diagram 10 MFD 10 MFD 10 MFD 10 MFD 15 MFD Pump Capacitor 10 MFD 10 MFD 10 MFD 10 MFD 15 MFD 10 MFD 10 MFD 2 - 5 MFD 2 - 5 MFD 10 MFD 15 MFD Fan Capacitor 110 12/01/02 12/20/03 2/20/03 MECHANICAL BIN CONTOL OPERATION: The mechanical bin control is included on some modelsproduced in 2002. The mechanical assembly is located in the ice drop zone area . When the actuator paddle is in the normal (Bin Empty) position, the bin control proximity switch will close. 1. When the switch contacts close, 7.6 K Ohms of resistance is supplied to the K4 board connector. When ice pushes the paddle to the full right position (Bin Full), the proximity switch opens as shown above. 2. Bin control proximity switch is shown in the Bin Full position and will supply 15.8 K Ohms to the K4 board connector. BIN EMPTY BIN FULL 111 12/01/02 12/20/03 2/20/03 24 VDC CAPACITIVE PROXIMITY BIN CONTROL: (Used on KM-1300NRF/H only) The capacitive bin control requires DC voltage to operate. It has a seperate 24VDC power supply and switches a control relay to supply resistance to the K4 connector. The relay contacts isolates the 24VDC from the control board which switches by resistance. 1. When the bin is empty, the resistance at K4 is 5.6 K Ohms. 2. When ice is within 1/2 to 1 inch of the sensor end, the resistance at K4 is 15.8 K Ohms to shut the unit down. 115 VAC A KM-150BAF, BWF, KM-250BAF, BWF Note: 1. Fuse was added to H model on late 2002 production. 2. See wiring diagram chart for KM-250B capacitor sizes. 112 12/01/02 12/20/03 2/20/03 B KM-150BAF-E, BWF-E Note: Fuse was added to H model on late 2002 production 113 12/01/02 12/20/03 2/20/03 C KM-280 MAF/H, MWF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 114 12/01/02 12/20/03 2/20/03 D KM-280 MAF-E/H-E, MWF-E/H-E Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 115 12/01/02 12/20/03 2/20/03 E KML-250MAH, MWH Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 116 12/01/02 12/20/03 2/20/03 F KML-350MAF/H, MWF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 117 12/01/02 12/20/03 2/20/03 G KML-450 MAF/H, MWF/H R Notes: 1. Some H series unit have mechanical bin control. 2. Fuse was added to H series in mid 2002. 3. This is a universal diagram, there is no KML-450 remote model. 118 12/01/02 12/20/03 2/20/03 H KM-500 MAF/H, MWF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 119 12/01/02 12/20/03 2/20/03 I KM-500 MRF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 120 12/01/02 12/20/03 2/20/03 J KM-500 MAF-E Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 121 12/01/02 12/20/03 2/20/03 K KML-600 MAF/H, MWF/H, MRF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 122 12/01/02 12/20/03 2/20/03 L KM-630 MAF/H, MWF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 123 12/01/02 12/20/03 2/20/03 M KM-630 MRF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 124 12/01/02 12/20/03 2/20/03 N KM-630 MAF-E/H-E, MWF-E/H-E Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 125 12/01/02 12/20/03 2/20/03 O KM-900 MAF/H, MWF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 126 12/01/02 12/20/03 2/20/03 P KM-900 MRF/H Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 127 12/01/02 12/20/03 2/20/03 Q KM-900 MRF 3/H 3 Notes: 1.Some H series unit have mechanical bin control. 2.Fuse was added to H series in mid 2002. 128 12/01/02 12/20/03 2/20/03 R KM-1300 SAF/H, SWF/H KM-1300 MAF/H, MWF/H Note: 1. Fuse was added to H models on mid 2002 production. 2. M Series model has 2 condenser fan motors. 129 12/01/02 12/20/03 2/20/03 S KM-1300 SRF/H, MRF/H Note: 1. Fuse was added to H models on mid 2002 production. 130 12/01/02 12/20/03 2/20/03 T KM-1300 SAF3/H3, SWF3/H3 Note: 1. Fuse was added to H models on mid 2002 production. 131 12/01/02 12/20/03 2/20/03 U KM-1300 SRF3/H3 Note: 1. Fuse was added to H models on mid 2002 production. 132 12/01/02 12/20/03 2/20/03 V KM-1300 SAF-E, SWF-E Note: 1. Fuse was added to H models on mid 2002 production. 133 12/01/02 12/20/03 2/20/03 W KM-1300 SRF-E 134 12/01/02 12/20/03 2/20/03 X KM-1300 NRF / H 135 12/01/02 12/20/03 2/20/03 Y KM-1600 SWF/H, SRF/H, MRF/H Note: 1. Fuse was added to H models on mid 2002 production. 136 12/01/02 12/20/03 2/20/03 Z KM-1600SWF3/H3, SRF3/H3 KM-1600MRF3/H3, KM-2000SWF3/H3, SRF3/H3 Note: 1. Fuse was added to H models on mid 2002 production. 137 12/01/02 12/20/03 2/20/03 AA KM-1800 SAH Note: 1. Fuse was added to H models on mid 2002 production. 138 12/01/02 12/20/03 2/20/03 BB KM-1800 SAH3 Note: 1. Fuse was added to H models on mid 2002 production. 139 12/01/02 12/20/03 2/20/03 CC KM-2400 SRF3/H3 Note: 1. Fuse was added to H models on mid 2002 production. 140 12/01/02 12/20/03 2/20/03 FLAKER/DCM INSTALLATION - GENERAL As always, you should follow the installation instructions that are provided in the instruction manual supplied with the unit. You will also find a yellow instruction sheet attached to the top of a new unit. This sheet highlights the installation steps. Three things are critical for a proper F/ DCM installation: 1. The water temperature should fall within the 45° F to 90° F range. Colder water can cause excess stress on the auger gear motor which may activate the gear motor overload. 2. A filter system is very important in poor water quality areas as high mineral content can cause premature bearing wear. 3. The unit should be level, front to back, side to side to assure proper evaporator water level and maximum production. CUBELET MODELS The DCM product produces Cubelet ice. Certain flaker models can also be converted to produce cubelet ice. This requires changing the extruding head and cutter at the top of the evaporator assembly. The F-450M, F-800M, and F2000M models are produced as cubelet models and are designated by a - C at the end of the model number. Converting a flaker to a cubelet maker reduces the overall production by around 8 %. The flaker gear motor is sized to handle the extra load of producing cubelet ice with only a slight increase in the running amperage. The evaporator outlet temperature and operating pressures will be similar to the standard flaker model. Use the temperature and pressure information provided on the standard flaker performance data provided as a bench mark when diagnosing a converted cubelet (- C) unit. 141 12/01/02 12/20/03 2/20/03 INTERNAL AUGER DESIGN Hoshizaki Flakers and DCM’s use an internal auger system to provide high quality crisp flakes and cubelet ice. The evaporator cylinder and auger are made of anti-magnetic stainless steel. This higher quality stainless steel elimnates pitting caused by harmful minerals in the water. This maintains a smooth surface to reduce ristriction to ice flow providing consistant production and quality. The picture below is a generic breakdown of the F/DCM evaporator assembly. The extruding head # 9 and cutter #12 can be exchanged so that this Flaker assembly will produce Cubelet style (chunklet) ice like the DCM application. The sleeve type alignment bearings are pressed into the housing # 4 and extruding head # 9. The mechanical seal # 6 and “O” ring # 5 seal the lower end of the evaporator system. 142 12/01/02 12/20/03 2/20/03 COMPONENT TECHNICAL DATA CONTROL TRANSFORMER Hoshizaki Flaker units include a 24 volt control transformer. This transformer has a 115 volt primary and 24 volt secondary and is protected by a 1Amp control fuse. (The DCM has a dual output secondary of 10.5/24V) The 24 volt secondary supplies power to the solid state timer board, relay coils, inlet water valve and flush timer circuit. The flush valve will be either 24 volts AC or DC, depending on the model. A rectifier is provide in the flush valve circuit to convert to DC. Without control voltage on pins 1 and 2, the timer board will not allow the unit to start. GEAR MOTOR PROTECTION The auger gear motor circuit includes two overload safeties. The primary safety is a manual reset, current type protector or slow blow fuse located in the control box. This is a time delay protection which operates if high amp draw occurs. The secondary safety is a thermal protector which is incorporated into the gear motor windings. The current type gear motor safety has been replaced with a slow blow fuse on most models. The Fuse provides more consistant protection in low voltage applications. GEAR MOTOR PROTECTION: MODEL PROTECTION F-300B & F-500B Current type protector Later production uses a 1.5 amp fuse. F-450M, F-800 1.5 Amp fuse F-1000M Current type protector Later production uses a 1.5 amp fuse. F-1000M_F-C 2 amp fuse. F-1001M_H 3 amp fuse. F-2000M_F Current type protector. F-2000M_H 10 amp fuse. Note: Some cases require a 2 amp fuse for the F-1000M. Gear motor failure can be expensive and it is very important to find the cause of the failure when it is replaced. There are several possibilities for the cause of gear motor failure. The following check list is designed to help you find the reason your failure occurred. 143 12/01/02 12/20/03 2/20/03 F-1000M GEAR MOTOR CHECKOUT NORMAL AMPERAGE: The amperage for the F-1000M gear motor should be 0.6~1.0 amps with no load and 1.0~1.4 amps when making ice. Answer the following questions to discover the possible cause for your failure: 1. Is Ambient Temperature above 45 degrees F. 2. Does the unit have the Wrong Extruding Head. Check the Extruder Type. Is it a Flaker or Cubelet style. (The cubelet style head will have smaller openings for the ice to extrude.) 3. Does the unit have the Wrong Cutter. The cutter should match the extruding head style. Flake or Cubelet. 4. Do you have a Damaged Extruder. Look for following imperfections. A. Dents B. Fins Bent C. Scale D. Other Resistance 5. Does the unit have the Correct Auger. Is the auger a dual flight auger? (Double Spirals) Check the parts breakdown for the correct auger style. 6. Check the Voltage Supply and circuit amperage. Is this unit on it’s own dedicated circuit? The supply voltage should be within +/- 10% of the rated voltage when the unit is making ice. 7. Check the Running Voltage at the gear motor. (While the unit is making Ice.) 8. Inspect bearings for wear. ( Use bearing gauge ) Are the Bearings OK? If the upper bearing is worn, both bearings should be replaced. 9. Check Evaporator Cylinder/ Barrel for signs of scoring. 10. Is there any condensation dripping onto the Gear Motor windings? If yes, find the source and take action to stop the moisture. 11. Is the galvanized shield mounted over the motor assembly? 12. Verify that you have the proper Gear Motor Capacitor. 13. Is the Gear Motor Locked. Check motor winding resistance. 2. WRONG GEAR MOTOR OVERLOAD / FUSE: Check fuse size. Has the original overload reset been replaced with the fuse kit? The M_F Flaker requires Bussman GMD 1.5A Fuse P/N 4A0893-04. The M_F-C Cubelet requires Bussman GMD 2.0A Fuse P/N 4A0893-05. This fuse is a slow blow type. Replacing it with a standard fuse will cause the fuse to blow again. 144 12/01/02 12/20/03 2/20/03 Although it is common practice to install a larger fuse during service diagnosis, you should not leave a larger fuse in the unit when you leave the site. This could cause a serious unit failure. 3. MISWIRING Is gear motor wired correctly and wire connections tight. Check the wiring diagram for the proper wiring. 4. BIN CONTROL SWITCH DOES NOT OPERATE Check the bin control operation. A bad or miswired bin control can cause ice to back up in the spout and chute and cause higher gear motor amperage. Is Bin Control wired correctly and are the wire connections tight. Make sure there are no metallic components interfering with the magnetic bin control. Verify top panel is non-magnetic. Assure that the proximity switch is mount properly. The switch must be secure and mounted level to the chute top. Does the Bin Control Paddle move freely and is it unobstructed? As you can see, there are many factors that can cause a gear motor to fail. A gear motor check list comes with a service replacement part. The check list can be used as a diagnostic tool. If the gear motor is under warranty, the checklist should be completed and submitted with the warranty claim. GEAR MOTOR STRESS When looking for the cause of a gear motor failure, you should consider anything that will add stress to the assembly. Stress on the gear motor will increase the gear motor amperage and torque. The most common causes for stress is scale on the auger surface and evaporator walls. Scale nsulates the evaporator walls and causes reduced heat transfer. As a result, the ice will be wet and mushy. This poor quality ice does not extrude well and tends to pack in the evaporator outlet. Heavy scale build up must be removed using an acid based cleaner which will loosen the scale. Follow the cleaning instructions provided on the cleaning label to preform a maintenance cleaning. If the unit has not been cleaned and maintained frequently, it may require you to pull the auger 145 12/01/02 12/20/03 2/20/03 and clean the cylinder wall with a Scotchbrite pad & cleaner. The extruding head surface may also have heavy scale and can be cleaned with Scotchbrite & cleaner as well. AUGER BEARINGS: Bearing Type: Sleeve/Alignment, Bearing Material: Poly/Carbon The bearings are pressed into the top extruding head and lower brass housing. A repress program is available through the local Hoshizaki Distributor for undamaged extruding heads and housings. The bearings should always be replaced as a set. Return the extruding head and housing to your distributor for an exchange set or to be returned for repressing. BEARING INSPECTIONS: Annual bearing inspections are recommended. More frequent inspections may be necessary in poor water quality areas. The steps for bearing inspections are as follows: (1 ) Gain access to the ice chute head by removing the top panel and spout connectors as necessary. (2) Remove the thumbnuts which hold the ice chute head in place and lift it up and off of the evaporator (take care to place the O-ring in a safe location until you replace the head.) (3) Remove the stainless steel bolt holding the cutter or breaker in place and lift off to access the extruding head and auger shaft. (4) Replace the bolt into the auger shaft and use it to push the auger back and forth from left to right to check for excessive movement. (5) Pull the auger towards you and try to insert a .02” round stock or pin gauge in between the back side of the auger shaft and bearing surface. Check several locations around the auger shaft. If the gauge will go in between the shaft and bearing, it is time to install new bearings. Both top and bottom bearings should be replaced if the top bearing is worn. If there is no excessive movement in the auger shaft and the gauge does not fit, the bearings are okay. Replace the cutter, O-ring, ice chute head and connectors. 146 12/01/02 12/20/03 2/20/03 AUGER INSPECTION / BEARING REPLACEMENT A visual inspection of the auger bearing shaft surface is also recommended annually in poor water areas. The steps for this inspection is as follows: Note: Clean the evaporator prior to removing the auger. This will loosen scale around the extruding head and allow for easier removal. (1) Follow steps 1 through 5 of the bearing inspection procedure above. (2) Remove the (metric) Allen head cap screws that secure the extruding head in place. (3) Thoroughly drain the water supply system. 4) Turn the cutter up-side down, replace the bolt and use the cutter to lift the auger out of the evaporator. If heavy scale is present the auger may be difficult to remove. In this case, you will find it helpful to clean the evaporator system following the instructions located on the Inside front panel, before you attempt to remove the auger. (5) With the auger removed, remove the cutter and slide the extruding head from the top of the auger. Visually inspect the bearing surface at the top and bottom of the auger. Also inspect the auger flight and mechanical seal for any damage. The extruding head contains the top bearing, the bottom bearing is pressed into the brass housing at the bottom of the evaporator. To remove the housing: (6) Remove the Allen screws that secure the evaporator to the housing. (7) Loosen the belly band screw and lift the evaporator up 147 12/20/03 12/01/02 2/20/03 and off of the housing. Holding the evaporator up, re-tighten the belly band. This will hold the evaporator up so that you can remove the housing. (8) Remove the bolts that secure the housing to the gear motor assembly and remove the brass housing. The mechanical seal ceramic disk and boot are pressed into the top of the housing. Remove these parts before you exchange the bearings. The extruding head and brass housing will be exchanged for a repressed set at your local distributor. When you replace the new parts, reverse the order above. Use a light coat of food grade lubricant around the bottom of the evaporator and on the o-ring portion of the housing to the seal o-ring and help keep it in place as you lower the evaporator. Inspect the mechanical seal thoroughly and reuse it, if it is in good shape. Flaker Safety’s Mechanical failures in an auger style ice machine can be time consuming and expensive repairs. Hoshizaki has incorporated several safety’s in our Flaker and DCM units which add protection against this type of failure. The following safety’s are included in all Hoshizaki F and DCM units: 1. Low water safety: Designed to protect against dry operation or possible freeze up in the evaporator due to low water flow. This safety utilizes the dual float switch and a 90 second timer to shut down the unit when water flow is interrupted. The unit will automatically restart when water flow is resumed. 2. Protect relay safety: This safety incorporates a relay in the gear motor circuit and will not allow the refrigeration system to operate unless the gear motor is running. If the gear motor fails during normal operation, the protect relay shuts down the compressor to protect against evaporator freeze-up. 3. Gear motor circuit safety’s: The gear motor has 2 additional safety’s which will operate if the gear motor is subjected to excessive load or improper voltage. A current type manual reset safety or slow blow fuse is located in the control box and will trip when the gear motor amperage exceeds normal amp draw. This acts as a primary safety for the gear motor. A secondary internal thermal overload 148 12/01/02 12/20/03 2/20/03 is included in the motor windings. Both will work in conjunction with the protect relay to shut the unit down. 4. Voltage protect relay: This relay will shut the unit off in case of a voltage surge and automatically restart the unit when the voltage is correct. 5. High pressure switch: All Hoshizaki ice machines include an automatic reset high pressure safety switch to shut down the unit in case of high head pressures. 6. Fuse protection: A lamp buss-type fuse is utilized in the control circuit. Smaller units like the DCM-240 and F-300 have a fuse in the incoming power circuit. 7. Short cycle protection timer: A 1 minute time delay is included in the start-up sequence to protect against short cycling the gear motor or compressor. 8. Compressor protection is provided either internally or by means of an external motor circuit protector. This is an automatic reset thermal type circuit breaker. 9. The F-2000 has a spout safety control to shut down the unit if the bin control fails for any reason. This is a manual reset safety and will notify the technician by means of a indicator light on the control box. To reset this safety, turn the control switch OFF and back ON. This re-sets the holding relay circuit and turns off the light. The gear motor current protector serves as a back-up for the bin control on other models. These safety’s protect the Flaker or DCM models from internal failures. DUAL FLOAT SWITCH Hoshizaki float switch, part number 435490-01 can be used as a universal replacement on any Hoshizaki Flaker or DCM model in the field. It now subs for all previous float switch numbers in our parts system. Since the float switch is mounted into the water reservoir, it is susceptible to scale build-up. The amount of scale build-up will depend on the local water quality. Scale on 149 12/01/02 12/20/03 2/20/03 the switch shaft can cause the floats to stick. This will effect the unit operation. In this case, the float switch should be cleaned and checked. The float switch is held in place on the top cover by a twist lock bracket. To remove it, twist the switch flange and lift. Soak the switch assembly in ice machine cleaner. While it is not necessary to do so, some technicians remove the floats from the shaft during cleaning. If you remove them, note that the blue float is on top. Also it is important to clearly mark the top of the floats so that they can be replaced correctly. (See drawing below). Installing the floats upside down will effect the timing of the float switch operation. Once clean, rinse and wipe the cleaner off and check the switch with a good quality ohm meter. This float switch has three wires (the black wire is common) and two separate switches. Check the top switch by ohming out the black and red wires. When the float is up the switch should be closed. Check the bottom switch by ohming out the black and blue wires in the same manner. If either switch fails, the assembly should be replaced. (bottom) 150 (top) 12/01/02 12/20/03 2/20/03 FLAKER WATER FILL SYSTEM The reservoir in a Hoshizaki auger type ice maker feeds water by gravity flow to the evaporator cylinder. The level of water in the reservoir is maintained by the operation of the dual float switch. The dual float switch assembly is made up of two reed switches inside of a sealed shaft. The reed switch contacts are operated by individual magnets attached inside of the two separate floats. As ice is made and extruded from the evaporator cylinder, the water level in the reservoir drops. When the level drops, the top float opens the top switch contacts (considered a latching circuit). Opening these contacts allows the bottom float switch control of the water control relay in the control circuit. As the water level continues to drop, the bottom float contacts open to de-energize the water control relay. De-energizing the water control relay closes a circuit to supply 24 volts to the inlet water valve solenoid. This allows water to fill the reservoir. It also opens a circuit to the timer board which starts a 90 second low water safety shutdown timer. When the water supply is available, the reservoir refills. As the reservoir level rises, these two switches swap jobs. The bottom float is now the latching circuit and thetop float re-energizes the water control relay. This will stop the safety timer and shut off the water flow. If no water is available, i.e. the filter is stopped up or the water supply is turned off, the unit cycles down and the water valve remains energized. When the water supply is restored, the reservoir fills and the top float switch reenergizes the water control relay to automatically restart the unit. This system provides a consistent water level in the reservoir and an automatic reset low water safety protection. Since the float switch is mounted into the water reservoir, it is susceptible to scale build-up. The amount of scale build-up will depend on the local water quality. Scale on the switch shaft can cause the floats to stick. This will effect the unit operation. In this case, the float switch should be cleaned and checked. 151 12/01/02 12/20/03 2/20/03 FLAKER TIMER BOARD The solid state timer board used in Hoshizaki Flakers is a simple electronic sequence timer. In order for the board to sequence, certain circuits must be closed. In order to diagnose a bad timer board, it is necessary to check these circuits to assure they are operating properly. If you are trouble-shooting a timer, the first thing you should check is the in coming control voltage. All Hoshizaki flakers have a 24 volt control transformer. The output of this transformer is protected by a 1 amp buss type fuse. Control voltage comes in the timer on pins 1 & 2. If you do not have 24 volts at pins 1 & 2, check the transformer and fuse. Now check for 24 volts across pins 7 & 8. If voltage is present, the timer board has cycled up which indicates there is not a problem in the timer board. The problem is in the gear motor relay circuit. remember that there is a time delay from the time you turn the unit on to the time it cycles up completely. this time will be from 1 ~ 2.5 minutes, depending on the model of flaker. In order for the flaker to start up, the reservoir must be full and both float switches must be closed. This closes the control circuit to pins 3 & 4. Do not confuse these pins with the line voltage terminals marked 3 & 4 on the compressor relay located on the board. You can check this circuit with a volt meter across the pins or by placing a jumper across them. If the unit cycles up with the jumper in place, the board is good and your problem is in the water relay control circuit. Next, you should check the bin control circuit at pins 5 & 6. Check for a closed circuit with a volt meter or place a jumper across them. If the unit cycles up with the jumper in place, the board is good and the bin control circuit is the problem. The last circuit check is across pins 10 & 11. These pins connect to the gear motor protect relay and will shut down the unit if the gear motor fails. Check for a closed circuit with a volt meter or place a jumper across them. If the unit cycles up with the jumper in place, the board is good and the gear motor protect circuit is suspect. 152 12/01/02 12/20/03 2/20/03 Flaker Sequence of Operation The Hoshizaki Flaker utilizes a solid state sequence timer board to switch the components on and off as needed. The sequence is as follows: With proper voltage and water supplied to the Flaker and the flush and ice switch is in the ice position, power is supplied to the inlet water valve. The unit will not start unless the reservoir is full and both floats on the dual float switch are closed (in the up position). The operation is then turned over to the bin control. If the bin control is closed and calling for ice, the gear motor and condenser fan motor are energized. One minute later, the compressor starts. As the refrigeration systems cools the water in the evaporator, ice will start to form within 2 to 5 minutes. This depends on the inlet water temperature and ambient conditions. Ice production will continue until the bin control is satisfied (opens). The shut down process is very simple. On the F-450, F-800, F-1000, and F-2000 units, the entire unit shuts down within 6 seconds after the bin control switch opens. On the F-300 and F-500, approximately 90 seconds after the bin control switch opens, the compressor stops, on minute later the gear motor and condenser fan motor stop. This sequence of operation is accomplished through a series of timers within the solid state timer board. FOR FACTORY SUPPORT CONTACT HOSHIZAKI TECHNICAL SUPPORT AT: 1 -800-233-1940 E-Mail: techsupport@hoshizaki.com 153 12/01/02 12/20/03 2/20/03 154 12/01/02 12/20/03 2/20/03 FLAKER PERIODIC FLUSH Beginning with the F-450M and larger flakers, a periodic flush cycle is included. A 12 hour timer will cycle the unit down and open the flush valve which allows the complete water system to drain. The unit will remain off for 20 minutes which allows any ice remaining in the evaporator to melt and flush the evaporator walls and mechanical seal out. The inlet water valve is not energized during this flush period. The unit will automatically restart after 20 minutes on the flush timer. The F-500 will flush when the bin control is open. DCM SEQUENCE OF OPERATION DCM sequence for the ice making unit is similar to the F500, with a delay of the compressor at start up and a delay of the gear motor at shut down. A periodic flush is also incorporated in the DCM units. All DCM models have periodic agitation in the bin to eliminate ice bridging. The DCM- 240 model uses a solid state relay to turn the gear motor for .2 seconds every 90 minutes. On DCM-500 and 750 models, the solid state timer board will start the agitation motor for .6 seconds every 12 seconds of accumulated dispensing time. FLAKER/DCM PRODUCTION CHECK Checking the production on a F/DCM is a simple process. To check the production you will need a bucket or pan to catch the ice and a set of scales to weigh the ice. After the unit has operated for 10 to 20 minutes, catch the ice production for 10 full minutes. Weigh the ice to establish the batch weight. Multiply the batch weight by 144 for the total production in 24 hours. Some prefer to catch the ice for 20 minutes and multiply the weight by 72 for a more realistic production check. It is true that a longer catch is more accurate, however, it doubles your test time and may only show a 1 to 2% difference in production. Performing a production check is an excellent way to prove proper F/ DCM operation. 155 12/01/02 12/20/03 2/20/03 156 12/01/02 12/20/03 2/20/03 WATER AND REFRIGERATION CIRCUIT DRAWING REFERENCE CHART FOR R-404A MODELS MODEL DRAWING PAGE F-300B ....................................... A .................... 158 F-450MAF/H, F-500BAF ............ B .................... 159 F-800MAF/H, MWF/H ................. C .................... 160 F-1000MAF, MWF ...................... C .................... 160 F-1001MAH, MWH ..................... C .................... 160 F-1000MRF, F-1001MRH ........... D .................... 161 F-1000MLF ................................. E .................... 162 F-2000MRF/H ............................. F .................... 163 F-2000MLF/H ............................. G .................. 164 DCM-240B, DCM-270 ................. H .................... 165 DCM-450B ................................... I .................... 166 DCM-700B ................................... I .................... 166 NOTE: Some drawings have been combined to represent more than one model. 157 12/01/02 12/20/03 2/20/03 A F-300 BAF 158 12/01/02 12/20/03 2/20/03 B F-450 MAF/H F-500 BAF 159 12/01/02 12/20/03 2/20/03 C F-800MAF/H, MWF/H F-1000 MAF, MWF F-1001MAH, MWH 160 12/01/02 12/20/03 2/20/03 D F-1000 MRF F-1001 MRH 161 12/01/02 12/20/03 2/20/03 E F-1000 MLF F1001 MLH 421 162 12/01/02 12/20/03 2/20/03 F F-2000 MRF F-2000 MRH 163 12/01/02 12/20/03 2/20/03 G F-2000 MLF F-2000 MLH 621 164 12/01/02 12/20/03 2/20/03 H DCM-240 BAF DCM-270 BAH 165 12/01/02 12/20/03 2/20/03 I DCM-500 BAF/H, BWF/H DCM-750 BAF/H, BWF/H 166 12/01/02 12/20/03 2/20/03 167 12/01/02 12/20/03 2/20/03 Pressure Suction 50/9 70/21 90/32 35 35 35 19 22 22 19 19 19 250 250 250 37 37 37 280 280 280 Air 267 256 246 Air Kg=lbs. WaterTemp (F°/C°) x .454 50/9 Production 70/21 24 hours 90/32 (lbs.) Evaporator 50/9 Outlet temp. 70/21 (°F) 90/32 50/9 Pressure 70/21 High Side 90/32 80 / 27 303 290 278 70 / 21 Ambient Temp F°/C° MODEL: F-300BAF Total Amperage (Compressor RLA): 9A (7.6A) R-404A PERFORMANCE DATA 39 39 39 236 232 218 22 22 22 311 311 311 Air 90 / 32 43 43 43 26 26 26 351 351 351 209 201 188 Air 100 / 38 Supply Voltage: 115/60/1 168 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Ambient Temp (F°/C°) Water Temp Kg=lbs. (F°/C°) x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 16 16 16 236 236 236 30 30 30 426 407 387 476 456 435 16 16 16 235 235 235 29 29 29 -C Air 70 / 21 Total Amperage (Compressor RLA): 11.25A (8.5A) MODEL: F-450MAF/H & MAF -C/H-C (cubelet) 16 16 16 272 272 272 33 33 33 416 397 379 Air 80 / 27 362 355 330 16 16 16 308 308 308 36 36 36 16 16 16 273 273 273 34 34 34 Air -C 368 350 333 R-404A PERFORMANCE DATA 90 / 32 -C 16 16 16 310 310 310 37 37 37 317 310 287 16 16 16 348 348 348 39 39 39 315 301 282 Air 16 16 16 351 351 351 41 41 41 273 260 244 -C Supply voltage: 115/60/1 100 / 38 169 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) 50 / 9 70 / 21 90 / 32 8 8 8 221 221 221 26 26 26 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Air 478 458 438 Water Temp (F°/C°) Ambient Temp (F°/C°) 9 9 9 225 225 225 27 27 27 431 315 398 Air -C 70 / 21 Total Amperage (Compressor RLA): 9.95A (7.9A) MODEL: F-500BAF & BAF -C (cubelet) Air 8 12 12 253 253 253 28 28 28 419 400 383 80 / 27 9 12 12 258 258 258 30 30 30 12 13 15 285 285 285 31 31 31 Air 366 359 335 Air -C 381 365 350 R-404A PERFORMANCE DATA 90 / 32 12 12 15 292 292 292 32 32 32 336 333 308 Air -C Air 15 15 15 327 327 327 34 34 34 320 306 287 100 / 38 15 15 15 332 332 332 35 35 35 295 283 263 Air-C Supply voltage: 115/60/1 170 12/01/02 12/20/03 2/20/03 720 695 680 800 765 735 270 287 287 39 41 41 265 267 266 37 37 37 17 18 18 223 239 255 35 37 38 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Pressure High Side Pressure Suction 19 21 20 710 680 655 Air 50 / 9 70 / 21 90 / 32 21 22 21 Water 70 / 21 Air Evaporator Outlet temp. (°F) WaterTemp Kg=lbs. °F/°C x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 Ambient Temp °F/°C 80 / 27 Water consumption for water cooled cond: 70/50 (21/9) 318 Gal/24 hr. 41 41 43 286 287 306 267 266 265 38 37 38 21 20 21 630 615 585 670 660 650 22 22 22 Air Water R-404A PERFORMANCE DATA MODEL: F-800M _F / H Total Amperage (Compressor RLA): MAF 11.95A (9.2A), MWF 10.2A (8.3A) 90 / 32 38 38 38 266 266 265 21 22 22 640 625 620 Water Supply voltage: 115/60/1 44 45 45 315 325 325 22 23 22 560 540 505 Air 100 / 38 39 39 39 267 269 268 23 23 22 605 595 555 Water 90/70 (32/21) 539 Gal/24 hr. 171 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Kg=lbs. Water temp °F/°C x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 Ambient Temp °F/°C 21 22 21 265 267 266 37 37 37 670 650 640 16 17 17 221 221 221 35 35 35 Water Air 760 730 700 70 / 21 Air 18 18 19 254 254 254 38 38 38 665 640 610 80 / 27 Water consumption for water cooled cond: 70/50 (21/9) 318 Gal/24 hr. 21 29 21 286 286 286 41 41 41 625 615 605 22 22 22 267 266 265 38 37 38 Air 585 575 535 Water R-404A PERFORMANCE DATA MODEL: F-800M _F-C / H-C (cubelet) Total Amperage (Compressor RLA): MAF-C 11.95A (9.2A), MWF-C 10.2A (8.3A) 90 / 32 21 23 22 266 266 265 38 38 38 590 590 570 Water Supply voltage: 115/60/1 22 23 23 325 325 325 45 45 45 510 490 455 Air 100 / 38 23 23 23 267 269 268 39 39 39 560 550 505 Water 90/70 (32/21) 553 Gal/24 hr. 172 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (F°) Kg=lbs. x .454 Production 24 hours (lbs.) 890 855 840 23 23 25 263 266 269 33 34 35 970 930 890 19 19 19 213 213 213 32 32 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 70 / 21 Water Air Water Temp F°/C° Ambient Temp (F° / C°) 33 33 33 23 24 25 221 221 221 930 895 865 Remote 35 35 35 33 34 35 23 23 25 263 266 269 820 805 785 855 820 785 19 23 23 244 244 244 Water Air 80 / 27 Air 755 740 695 23 23 25 274 274 274 38 38 38 Remote 835 805 780 25 26 26 239 239 239 35 35 35 33 34 35 23 23 25 263 266 269 770 755 735 Water 90 / 32 41 41 41 25 25 25 315 315 315 665 635 595 750 745 700 26 27 28 256 256 256 36 36 36 Air Remote 33 34 35 23 23 25 263 266 269 720 705 655 Water 100 / 38 39 39 39 675 650 605 28 28 28 295 296 295 Remote R-404A PERFORMANCE DATA MODEL: F- 1000M_F Supply Voltage: 208-230/60/1 ( 3 wire with neutral for for 115V) Total Amperage (Compressor RLA): MAF 6.85A (4.2A) MWF: 5.83A(4.2A), MRF: 8.9A (4.2A) 90 / 70 (32/21) 480 Gal/24 hr. Water Consumption for water cooled cond. 70 / 50 (21/9) 303 Gal/24 hr: 173 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (F°) Kg=lbs. x .454 Production 24 hours (lbs.) 790 760 750 23 23 25 263 266 269 33 34 35 860 820 790 18 18 18 209 209 209 32 32 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 70 / 21 Water Air Water Temp F°/C° Ambient Temp (F° / C°) 34 34 33 23 24 25 220 220 220 840 810 790 Remote 35 35 35 33 34 35 23 23 25 263 266 269 735 720 710 765 735 710 18 23 23 243 243 243 Water Air 80 / 27 Air 680 665 635 23 23 27 277 277 277 38 38 38 Remote 765 745 720 25 26 26 238 238 238 36 36 36 33 34 35 23 23 25 263 266 269 695 685 670 Water 90 / 32 41 41 41 27 27 27 217 317 217 610 585 550 700 695 660 26 25 28 256 256 256 37 37 37 Air Remote 33 34 35 23 23 25 263 266 269 660 645 600 Water 100 / 38 40 40 40 640 620 575 28 28 28 295 295 295 Remote R-404A PERFORMANCE DATA MODEL: F- 1000M _F -C (cubelet) Supply Voltage: 208-230/60/1 ( 3 wire with neutral for for 115V) Total Amperage (Compressor RLA): MAF -C 6.85A (4.2A), MWF: 5.83A (4.2A), MRF: 8.9A (4.2A) 90 / 70 (32/21) 492 Gal/24 hr. Water Consumption for water cooled cond. 70 / 50 (21/9) 303 Gal/24 hr. 174 12/01/02 12/20/03 2/20/03 R-404A PERFORMANCE DATA 50 / 9 70 / 21 90 / 32 21 21 21 106 106 106 26 26 26 1150 1035 1005 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Low side Water Temp °F/°C -C 21 21 21 106 106 106 26 26 26 1020 945 915 21 21 21 125 125 125 30 30 30 980 950 925 Low side 900 885 805 21 21 23 143 143 143 33 33 33 21 21 21 125 125 125 30 30 30 Low side -C 885 860 835 -C 21 21 23 143 143 143 33 33 33 805 795 760 23 23 23 166 166 166 35 35 35 830 805 690 Low side 100 / 38 23 23 23 166 166 166 35 35 35 735 710 640 -C Supply voltage: 115/60/1 Note: The data provided is calculated by using a refrigeration capacity of 5700 BTU/h with a high side pressure of 213 PSIG and suction pressure of 31.2 PSIG. The actual production and system operating pressures will vary depending on the specific R-404A rack system setup. Factory setting for the Evaporator Pressure Regulating Valve (EPR) is 32 PSIG. for evaporator temperature no less than 0 °F (-17.7°C). Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) This unit is designed for connection to a Rack System using R-404A refrigerant. The data below is calculated. 90 / 32 70 / 21 80 / 27 Ambient Temp °F/°C MODEL: F-1000MLF & MLF-C (cubelet) Total Amperage 1.63A 175 12/01/02 12/20/03 2/20/03 28 28 28 50/9 70/21 90/32 30 30 30 14 18 18 199 199 199 50/9 70/21 90/32 14 14 14 170 170 170 680 720 710 860 820 790 50/9 70/21 90/32 50/9 70/21 90/32 Air Air 80 / 27 Water Temp °F/°C 70 / 21 NOTE: R-22 refrigerant charge 1 lb. 7oz. (660g.). Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp F°/C° MODEL: F-1000MAF-22 (Special production using R-22 refrigerant) Total Amperage (Compressor RLA): MAF 7.25A (4.5A) 32 32 32 680 670 635 18 18 21 228 228 228 Air 90 / 32 R-22 “ SPECIAL MODEL” PERFORMANCE DATA 34 34 34 21 21 21 258 258 258 615 585 555 Air 100 / 38 Supply Voltage: 115/60/1 176 12/01/02 12/20/03 2/20/03 R-404A PERFORMANCE DATA Pressure Suction Pressure High Side Evaporator Outlet temp. °F /°C Production 24 hours (lbs.) 14 / -10 14 / -10 14 / -10 224 224 224 33 33 33 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Air 935 / 424 895 / 404 865 / 393 Water Temp °F /°C 16 / -9 16 / -9 16 / -9 260 260 261 35 37 39 860 / 390 855 / 388 840 / 383 Water 14 / -10 16 / -9 16 / -9 257 257 257 36 36 36 835 / 383 805 / 373 780 / 363 Air Air 750 / 353 750 / 353 737 / 334 16 / -9 16 / -9 17 / -9 289 289 289 39 39 39 Water 16 / -9 16 / -9 16 / -9 260 260 261 35 37 39 16 / -9 16 / -9 16 / -9 260 260 261 35 37 39 17 / -9 17 / -9 17 / -9 329 329 329 43 43 43 16 / -9 16 / -9 16 / -9 260 260 261 35 37 39 Water 777 / 352 768 / 348 690 / 313 Air 717 / 325 650 / 316 655 / 297 Water Supply Voltage: 220-240 50/ 1 90/70 (32/21) 503 Gal/24 hr. 100 / 38 770 / 365 840 / 381 735 / 357 90 / 32 820 / 379 805 / 374 785 / 370 MODEL: F-1000M_F-50 Total Amperage (Compressor RLA): MAF 6.8A (5.9A), MWF 6.3A (5.4A) Water consumption for water cooled cond: 70/50 (21/9) 326 Gal/24 hr. 70 / 21 80 / 27 Ambient Temp °F /°C 177 12/01/02 12/20/03 2/20/03 Pressure Suction 50 / 9 70 / 21 90 / 32 Water Temp Kg=lbs. F°/C° x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 50 / 9 Evaporator 70 / 21 Outlet temp. 90 / 32 (F°) 50 / 9 Pressure 70 / 21 High Side 90 / 32 Ambient Temp (F° / C°) Water 890 855 840 23 23 25 263 266 269 33 34 35 Air 970 930 890 19 19 19 213 213 213 32 32 32 70 / 21 33 33 33 23 24 25 221 221 221 930 895 865 Remote 23 23 25 263 266 269 19 23 23 244 244 244 33 34 35 820 805 785 835 805 780 35 35 35 Water Air 80 / 27 Air 755 740 695 23 23 25 274 274 274 38 38 38 Remote 835 805 780 25 26 26 239 239 239 35 35 35 33 34 35 23 23 25 263 266 269 770 755 735 Water 90 / 32 41 41 41 25 25 25 315 315 315 665 635 595 750 745 700 26 27 28 256 256 256 36 36 36 Air Remote 33 34 35 23 23 25 263 266 269 720 705 655 Water 100 / 38 39 39 39 675 650 605 28 28 28 295 296 295 Remote R-404A PERFORMANCE DATA MODEL: F- 1001M_H Supply Voltage: 208-230/60/1 ( 3 wire with neutral for for 115V) Total Amperage (Compressor RLA): MAH 6.85A (4.2A) MWH: 5.83A(4.2A), MRH: 8.9A (4.2A) 90 / 70 (32/21) 480 Gal/24 hr. Water Consumption for water cooled cond. 70 / 50 (21/9) 303 Gal/24 hr: 178 12/01/02 12/20/03 2/20/03 Pressure Suction 50 / 9 70 / 21 90 / 32 Water Temp Kg=lbs. F°/C° x .454 50 / 9 Production 70 / 21 24 hours 90 / 32 (lbs.) 50 / 9 Evaporator 70 / 21 Outlet temp. 90 / 32 (F°) 50 / 9 Pressure 70 / 21 High Side 90 / 32 Ambient Temp (F° / C°) Water 790 760 750 23 23 25 263 266 269 33 34 35 Air 860 820 790 18 18 18 209 209 209 32 32 32 70 / 21 34 34 33 23 24 25 220 220 220 840 810 790 Remote 23 23 25 263 266 269 18 23 23 243 243 243 33 34 35 735 720 710 35 35 35 Water Air 765 735 710 80 / 27 Air 680 665 635 23 23 27 277 277 277 38 38 38 Remote 765 745 720 25 26 26 238 238 238 36 36 36 33 34 35 23 23 25 263 266 269 695 685 670 Water 90 / 32 41 41 41 27 27 27 217 317 217 700 695 660 26 25 28 256 256 256 37 37 37 Air 610 585 550 Remote 33 34 35 23 23 25 263 266 269 660 645 600 Water 100 / 38 40 40 40 640 620 575 28 28 28 295 295 295 Remote R-404A PERFORMANCE DATA MODEL: F- 1001M _H -C (cubelet) Supply Voltage: 208-230/60/1 ( 3 wire with neutral for for 115V) Total Amperage (Compressor RLA): MAH -C 8.08A (4.2A), MWH-C: 5.83A (4.2A), MRH-C: 10.23A (4.2A) 90 / 70 (32/21) 492 Gal/24 hr. Water Consumption for water cooled cond. 70 / 50 (21/9) 303 Gal/24 hr. 179 12/01/02 12/20/03 2/20/03 R-404A PERFORMANCE DATA 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Water Temp °F/°C 21 21 21 106 106 106 26 26 26 Low side 21 21 21 106 106 106 26 26 26 -C 21 21 21 125 125 125 30 30 30 980 950 925 Low side 900 885 805 21 21 23 143 143 143 33 33 33 21 21 21 125 125 125 30 30 30 Low side -C 885 860 835 -C 21 21 23 143 143 143 33 33 33 805 795 760 23 23 23 166 166 166 35 35 35 830 805 690 Low side -C 23 23 23 166 166 166 35 35 35 735 710 640 Note: The data provided is calculated by using a refrigeration capacity of 5700 BTU/h with a high side pressure of 213 PSIG and suction pressure of 31.2 PSIG. The actual production and system operating pressures will vary depending on the specific R-404A rack system setup. Factory setting for the Evaporator Pressure Regulating Valve (EPR) is 32 PSIG. for evaporator temperature no less than 0 °F (-17.7°C). Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) 100 / 38 Supply voltage: 115/60/1 This unit is designed for connection to a Rack System using R-404A refrigerant. The data below is calculated. 90 / 32 70 / 21 80 / 27 Ambient Temp °F/°C MODEL: F-1001MLH & MLH-C (cubelet) Total Amperage: 3.03A 180 12/01/02 12/20/03 2/20/03 Pressure Suction 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Evaporator Outlet temp. (°F) Pressure High Side Water temp F°/C° 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Kg=lbs. x .454 Production 24 hours (lbs.) 25 25 25 12 12 12 221 221 221 1992 1930 1878 2030 1957 1916 11 11 11 262 263 265 26 27 28 Remote Water 70 / 21 11 11 11 262 263 265 26 27 28 1875 1836 1797 Water 80 / 27 11 11 11 262 263 265 26 27 28 1759 1730 1686 1827 1777 1729 12 12 12 230 230 230 26 26 26 Water Remote R-404A PERFORMANCE DATA MODEL: F-2000M_F/H Total Amperage (Compressor RLA): Water 16.9 (10.8A), Remote 19.4A (10.8A) Water consumption for water cooled cond: 70/50 (21/9) 735 Gal/24 hr. 90 / 32 12 12 14 238 238 238 26 26 26 1683 1676 1593 Remote 11 11 11 262 263 265 26 27 28 1651 1616 1500 Water 14 14 14 274 274 274 29 29 29 1550 1508 1393 Remote 100 / 38 90/70 (32/21) 1165 Gal/24 hr. Supply Voltage: 208-230/60/1 181 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Water Kg=lbs. temp F°/C° x .454 Production 50 / 9 24 hours 70 / 21 (lbs.) 90 / 32 Ambient Temp (F°) 26 26 26 12 12 12 220 220 220 1714 1662 1628 1790 1727 1698 10 10 12 262 263 266 27 27 28 Remote Water 70 / 21 10 10 12 262 263 266 27 27 28 1669 1641 1614 Water 10 10 12 262 263 266 27 27 28 1587 1560 1534 1595 1562 1530 12 14 14 227 227 227 26 26 26 Water Remote 80 / 27 R-404A PERFORMANCE DATA MODEL: F-2000M_F-C/H-C (cubelet) Total Amperage (Compressor RLA): Water 16.9 (10.8A), Remote 19.4A (10.8A) Water consumption for water cooled cond: 70/50 (21/9) 765 Gal/24 hr. 90 / 32 14 14 14 233 233 233 27 27 27 1498 1491 1437 Remote 10 10 12 262 263 266 27 27 28 1508 1483 1375 Water 14 14 14 266 266 266 29 29 29 1408 1379 1272 Remote 100 / 38 90/70 (32/21) 1190 Gal/24 hr. Supply Voltage: 208-230/60/1 182 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Production 24 hours (lbs.) 14 14 14 219 219 219 25 25 25 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 2011 1948 1897 Remote 50 / 9 70 / 21 90 / 32 Ambient Temp (F°) Water Kg=lbs. temp F°/C° x .454 70 / 21 25 25 25 -1 -1 -1 222 222 222 1725 1684 1648 -C 14 14 14 230 230 230 26 26 26 1845 1796 1748 Remote 80 / 27 14 14 16 241 241 241 27 27 27 1701 1693 1612 -1 0 0 225 225 225 25 25 25 Remote -C 90 / 32 1613 1579 1546 R-404A PERFORMANCE DATA MODEL: F-2000MRF/H3 & MRF3-C/H3-C (cubelet) Total Amperage (Compressor RLA): Remote 17.6A (9A) -C 0 0 3 228 228 228 26 26 26 1526 1513 1450 16 16 16 271 271 271 29 29 29 1569 1527 1411 Remote 100 / 38 3 3 3 262 262 262 29 29 29 1420 1390 1274 -C Supply Voltage: 208-230/60/3 183 12/01/02 12/20/03 2/20/03 R-404A PERFORMANCE DATA 12 12 12 190 256 297 16 21 22 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 2280 1955 1915 50 / 9 70 / 21 90 / 32 Remote 70 / 21 -C 16 21 22 12 12 12 190 256 297 1965 1680 1660 12 12 12 190 256 297 16 21 22 2010 1835 1795 Remote 80 / 27 -C 12 12 12 190 256 297 16 21 22 1755 1615 1585 12 12 14 190 256 297 16 21 22 1760 1730 1685 Remote 90 / 32 -C 12 12 14 190 256 297 16 21 22 1565 1540 1515 14 14 14 190 256 297 16 21 22 1650 1615 1370 Remote 100 / 38 14 14 14 190 256 297 16 21 22 1500 1475 1245 -C Supply Voltage: 115/60/1 Note: The data provided is calculated by using a refrigeration capacity of 11600 BTU/h with a high side pressure of 221 PSIG and suction pressure of 22 PSIG. The actual production and system operating pressures will vary depending on the specific R-404A rack system setup. Factory setting for the Evaporator Pressure Regulating Valve (EPR) is 22 PSIG for evaporator temperature no less than -14 °F (-25 °C). Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) Ambient Temp (F°) Water temp F°/C° MODEL: F-2000MLF/H & MLF-C/H-C (cubelet) Total Amperage: 6.14A This unit is designed for connection to a Rack System using R-404A refrigerant. The data below is calculated. 184 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) Kg=lbs. x .454 Production 24 hours (lbs.) 240 230 215 24.8 24.8 24.8 245 250 265 275 265 250 21.2 21.2 21.2 215 230 230 38.5 38.5 38.5 50/9 70/21 90/32 50/9 70/21 90/32 50/9 70/21 90/32 50/9 70/21 90/32 40.0 40.0 40.0 Air 80 / 27 Air 70 / 21 Water Temp °F/°C Ambient Temp F°/C° MODEL: DCM-240BAF Total Amperage (Compressor RLA): 8.5A (6.5A) R-404A PERFORMANCE DATA 43.5 43.5 43.5 215 210 200 24.8 24.8 24.8 260 254 275 Air 90 / 32 46.3 46.3 46.3 25.7 25.7 25.7 305 315 310 190 190 175 Air 100 / 38 Supply Voltage: 115/60/1 185 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) 20 23 23 251 251 251 20 20 20 217 217 217 37 37 37 50/9 70/21 90/32 50/9 70/21 90/32 50/9 70/21 90/32 40 40 40 248 238 228 282 271 259 80 / 27 Air 70 / 21 Air Water Temp Kg=lbs. °F/°C x .454 50/9 Production 70/21 24 hours 90/32 (lbs.) Ambient Temp F°/C° MODEL: DCM-270BAH Total Amperage (Compressor RLA): 8.5A (6.5A) R-404A PERFORMANCE DATA 43 43 43 219 215 201 23 23 24 285 285 285 Air 90 / 32 46 46 46 23 22 21 327 327 327 192 184 172 Air 100 / 38 Supply Voltage: 115/60/1 186 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F) 23 26 26 264 264 264 23 23 23 230 230 230 33 33 33 50/9 70/21 90/32 50/9 70/21 90/32 50/9 70/21 90/32 35 35 35 461 438 416 535 510 485 80 / 27 Air 70 / 21 Air Water Temp Kg=lbs. °F/°C x .454 50/9 Production 70/21 24 hours 90/32 (lbs.) Ambient Temp F°/C° MODEL: DCM-500BAF/H Total Amperage (Compressor RLA): 11.2A (7.9A) R-404A PERFORMANCE DATA 37 37 37 396 385 358 26 26 28 297 297 297 Air 90 / 32 43 43 43 28 28 28 335 335 335 340 323 304 Air 100 / 38 Supply Voltage: 115/60/1 187 12/01/02 12/20/03 2/20/03 Pressure Suction Pressure High Side Evaporator Outlet temp. (°F ) Kg=lbs. x .454 Production 24 hours (lbs.) 50 / 9 70 / 21 90 / 32 30 30 30 249 249 249 44 44 44 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 50 / 9 70 / 21 90 / 32 Air 803 770 726 Water Temp °F /°C 30 30 30 255 255 255 44 44 44 879 851 830 Water 30 32 32 280 280 280 47 47 47 684 645 608 Air MODEL: DCM-750B_ F/H Total Amperage (Compressor RLA): BAF 16.4 (11A), BWF 14.5A (10A) Water consumption for water cooled cond: 70/50 (21/9) 421 Gal/24 hr. 70 / 21 80 / 27 Ambient Temp °F /°C Air 573 567 509 32 32 33 310 310 310 49 49 49 Water 809 789 770 30 30 30 256 256 256 45 45 45 R-404A PERFORMANCE DATA 90 / 32 30 30 32 256 256 256 45 45 45 751 746 714 Water 33 33 33 346 346 346 52 52 52 480 452 423 Air 32 32 32 614 614 614 47 47 47 697 679 628 Water Supply Voltage: 115/60/1 90/70 (32/21) 624 Gal/24 hr. 100 / 38 188 12/01/02 12/20/03 2/20/03 Page 189 190 191/192 193 194/195 196 197 198 199 200 201 202 203 204 205 Wiring Diagram (A) (B) (C)/(D) (E) (F)/(G) (H) (I) (J) (K) (L) (M) (N) (O) (P) (Q) Model Number DCM-240BAF DCM-270BAH DCM-500BAF, BWF DCM-500BAH, BWH DCM-750BAF, BWF DCM-750BAH. BWH F-300BAF F-450MAF/H F-450MAF-C/H-C F-500BAF F-800MAF/H, MWF/H F-1000MAF, MWF, MRF F-1000MAF-22 F-1000MAF-50 F-1000MLF 145~174 MFD 145~174 MFD 243~292 MFD 243~292 MFD 88~108 MFD 189~227 MFD 145~174 MFD 243~292 MFD 243~292 MFD 270~324 MFD 124~149 MFD 108~130 MFD 108~130 MFD 64~77 MFD 145~174 MFD Start Capacitor None None 15 MFD 15 MFD 15 MFD 25 MFD None 15 MFD 15 MFD 15 MFD 25 MFD 25 MFD 25 MFD 20 MFD 30 MFD Run Capacitor None None 5 MFD 5 MFD 5 MFD 5 MFD None 5 MFD 5 MFD 5 MFD 5 MFD 5 MFD 5 MFD 2.5 MFD 10 MFD Fan Capacitor DCM/Flaker Wiring Diagram Reference Chart for R-404A Models 10 MFD 10 MFD 12 MFD 12 MFD 24 MFD 24 MFD 10 MFD 12 MFD 12 MFD 12 MFD 12 MFD 12 MFD 12 MFD 12 MFD 12 MFD Gear Motor Capacitor 189 12/01/02 12/20/03 2/20/03 URC-6F,F URC-6F-E URC-20F F-1001M_H F-1001MLH F-2000MRF/H, MWF/H F-2000MRF3/H3 F-2000MLF/H Model Number Page 206 207 208 209 210 Wiring Diagram (R) (S) (T) (U) (V) 108~130 MFD None 189~227 MFD None None Start Capacitor 25 MFD None 40 MFD None None Run Capacitor 10 MFD 10 MFD 10 MFD 5 MFD None 10 MFD 10 MFD 10 MFD Fan Capacitor DCM/Flaker Wiring Diagram Reference Chart for R-404A Models 24 MFD 24 MFD 65 MFD 65 MFD 65 MFD Gear Motor Capacitor (A) DCM-240 BAF 190 12/01/02 12/20/03 2/20/03 (B) DCM-270 BAH 191 12/01/02 12/20/03 2/20/03 (C) DCM-500 BAF, BWF Serial numbers H0 & J0 192 12/01/02 12/20/03 2/20/03 (D) DCM-500 BAF, BWF Serial numbers J1 & after. 193 12/01/02 12/20/03 2/20/03 (E) DCM-500 BAH, BWH 194 12/01/02 12/20/03 2/20/03 (F) DCM-750 BAF, BWF Serial numbers H0 & J0 195 12/01/02 12/20/03 2/20/03 (G) DCM-750 BAF, BWF Serial numbers J1 & after. 196 12/01/02 12/20/03 2/20/03 (H) DCM-750 BAH, BWH 197 12/01/02 12/20/03 2/20/03 (I) F-300 BAF 198 12/01/02 12/20/03 2/20/03 (J) F-450 MAF/H 199 12/01/02 12/20/03 2/20/03 (K) F-450 MAF-C/H-C Note: Later Production will have proximity switch bin control like F-450MAF. 200 12/01/02 12/20/03 2/20/03 (L) F-500 BAF 201 12/20/03 12/01/02 2/20/03 (M) F-800 MAF/H, MWF/H Note: Capacitors vary with compressor number #RS55C1E Start - 124~149 MFD Run - 25 MFD #RS55C2E Start - 243~292 MFD Run - 15 MFD 202 12/01/02 12/20/03 2/20/03 (N) F-1000 MAF, MWF, MRF 203 12/01/02 12/20/03 2/20/03 (O) F-1000 MAF-22 204 12/01/02 12/20/03 2/20/03 (P) F-1000 MAF-50 205 12/01/02 12/20/03 2/20/03 (Q) F-1000 MLF 206 12/01/02 12/20/03 2/20/03 (R) F-1001 MAH, MWH, MRH 207 12/01/02 12/20/03 2/20/03 (S) F-1001 MLH 208 12/01/02 12/20/03 2/20/03 (T) F-2000 MRF/H, MWF/H 209 12/01/02 12/20/03 2/20/03 (U) F-2000 MRF3/H3 210 12/01/02 12/20/03 2/20/03 (V) F-2000 MLF/H 211 12/01/02 12/20/03 2/20/03 NOTES 212 12/01/02 12/20/03 2/20/03 NOTES 213 12/01/02 12/20/03 2/20/03 NOTES 214 12/01/02 12/20/03 2/20/03
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