spec’s technician’s pocket guide - hoshizaki america, inc. · 5 11-01-02 hoshizaki model number...

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This technicians pocket guide covers all mod-els using R-22 refrigerant. For additional tech-nical information, full parts and service manu-als are available for review and download onthe Tech Support page of the Hoshizaki website.

See “www.hoshizaki.com” for manuals, Tech-Tips and additional technical information onHoshizaki products.

See Tech-Spec’s # 80024 purple pocket guidefor older models using R-12/502.

TECH - SPEC’STechnician’s Pocket Guide

# 80021

See Tech-Spec’s # 80045 orange pocket guidefor newer models using R-404A.

These guides can be downloaded from theHoshizaki web site or purchased through yourlocal Hoshizaki Distributor.

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TABLE OF CONTENTS

....................................................................... PAGEModel Identification Code ............................................. 5

Nameplate ..................................................................... 6

Warranty Information, Registration, Coverage ............ 7

KM Installation - General .............................................. 8Plumbing Requirements (All) ............................. 8Condensate Drain ............................................. 9Water Flow Rates (All) ..................................... 9Electrical Connections ...................................... 10Optional Transformer Application .................... 11

Remote ApplicationsCondenser Application Chart ........................... 12Remote Lines .................................................... 12Installation Diagram .......................................... 13Lineset Installation ............................................ 14

Refrigerant System InformationSystem Charge R-22 ........................................ 15Cuber Charge Chart R-22 ................................ 16Flaker/DCM Charge Chart R-22 ........................ 17Heat Load for AC & Cooling Tower R-22 ........ 17

Component Technical DataAlpine Board Setting Guide .............................. 18“E” Board Setting Guide ................................... 19 Control Board Settings .................................... 20 “E” Control Board Functions ........................... 21“E” Board Label ................................................ 23Manual Reset Safties ....................................... 24Automatic Voltage Protection ........................... 24Compressor Data ............................................. 25Head Pressure Controls ................................... 26Remote Head Pressure Control ....................... 27Liquid Line Valve .............................................. 28Bypass Cooling ................................................ 28High Pressure Switch (All) .............................. 29Thermo-Disc ..................................................... 29Bin Control ........................................................ 29Capacitors ........................................................ 30

KM Sequence of Operation ......................................... 31Sequence Flow Chart ...................................... 33KM 10 Minute Check Out ................................. 34

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Component ChecksFloat Switch ..................................................... 37Thermistor ........................................................ 37Bin Control ........................................................ 38Control Board ................................................... 39

Diagnosing Water Problems ........................................ 40Freeze Up Check List ....................................... 43Cleaning/Sanitizing Procedure ......................... 45KM Production Check ....................................... 46

Cuber Water/Refg Circuit Referance Chart R-22 ....... 47

KM Performance Data for R-22KML-200M_E .................................................... 60KM-250B_E ....................................................... 61KM-250M_E ...................................................... 62KM-280M_E ...................................................... 63KML-400M_E .................................................... 64KM-500M_E ...................................................... 65KM-630M_E ...................................................... 66KM-630MAE50 .................................................. 67KM-800M_E ...................................................... 68KM-1200M_E .................................................... 69KM-1200S_E ..................................................... 70KM-1200S_E50 ................................................. 71KM-1600MRE .................................................... 72KM-1600MRE3 .................................................. 73KM-1600S_E ..................................................... 74KM-1600S_E3 ................................................... 75KM-2000S_E3 ................................................... 76KM-2400SRB3 .................................................. 77

KM Wiring Diagram Reference Chart .......................... 78

Flaker/DCMInstallation - General ........................................ 96Cubelet Models ................................................. 96

Component Technical DataGear Motor Safeties, Auger Bearings ............. 97Bearing Inspection ........................................... 97Auger Bearing Replacement ............................ 98

Reservoir Flush System .............................................. 36Pumpout Check Valve ...................................... 36KML Pumpout .................................................... 36KM Control Switch ........................................... 36

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Flaker OperationFlaker Safety’s ................................................. 99Dual Float Switch ............................................ 100Flaker Water FIll System .................................. 102Flaker Timer Board .......................................... 103Flaker Sequence of Operation ........................ 104Flaker Sequence Flow Chart .......................... 105Flaker Periodic Flush ....................................... 106DCM Sequence of Operation .......................... 106F/DCM Production Check ................................. 106Flush /Low Water Safety Flow Chart ............ 107

F/DCM Water/Refg Circuit Referance Chart .............. 108

Flaker/DCM Performance Data for R-22F-250BAE ........................................................ 117F-450BAE ........................................................ 118F-650M_E ........................................................ 119F-1000M_E ...................................................... 120F-1000M_E/50 ................................................. 121F-2000M_E ...................................................... 122F-2000MRE3 .................................................... 123F-2000MLE ...................................................... 124DCM-240BAE ................................................... 125DCM-450B_E ................................................... 126DCM-700B_E ................................................... 127

F/DCM Wiring Diagram Reference Chart R-22 ........... 130

Notes: ......................................................................... 140

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HOSHIZAKI MODEL NUMBERIDENTIFICATION CODE

KM 1200 M A E

UNIT TYPE

KML - Low Profile Crescent CuberKM - Crescent CuberF - FlakerDCM - Dispenser Cubelet MakerDB - Dispenser BinB- BinDM - Countertop Dispenser

PRODUCTION

Approximate production/24 Hours@70°F Air/50°F Water

UNIT STYLEM- ModularS- StackableB - Self contained with bin

CONDENSER STYLE

A - Air cooledW - Water cooledR - Remote air cooled

GENERATION

Model designation(E = R-22 refrigerant unit / except F-250BAE

and KM-2400SRB3)

The model number, serial number, electricalspecifications and refrigerant data are found onthe unit name plate. (See name plate)

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NAMEPLATE

HOSHIZAKI ICE MAKERMODEL NUMBERSERIAL NUMBERAC SUPPLY VOLTAGE

COMPRESSOR

FAN

MAXIMUM FUSE SIZE

MAX. HACR BREAKER (USA ONLY)MAX. CIRC. BREAKER (CANADA ONLY)MINIMUM CIRCUIT AMPACITY

DESIGN PRESSUREREFRIGERANTMOTOR-COMPRESSOR THERMALLY PROTECTED

See the Nameplate for electrical and refrigeration specifi-cations. This Nameplate is located on the upper right handside of rear panel. Since this Nameplate is located on therear panel of the icemaker, it cannot be read when the backof the icemaker is against a wall or against another piece ofkitchen equipment. Therefore, the necessary electrical andrefrigeration information is also on the rating label, whichcan be easily seen by removing only the front panel of theicemaker. We reserve the right to make changes in speci-fications and design without prior notice.

LISTEDICE MAKERWITHOUTSTORAGE MEANS946Z

NSF®

COMPONENTv

C

HOSHIZAKI AMERICA, INC. Peachtree City, GA

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WARRANTY INFORMATION

REGISTRATION-

Two warranty registration cards are supplied with theequipment. They must be completed and sent in to initiatewarranty. The warranty begins on the date of installation ifregistration procedures are followed. If registration is notcompleted, the warranty date will be the date of sale ordate of shipment from the factory, respectively.

WARRANTY COVERAGE-

The warranty will cover defects in material or workman-ship under normal and proper use and maintenanceservice as specified by Hoshizaki. Coverage for parts andlabor is limited to the repair or replacement of parts orassemblies that in Hoshizaki's opinion are defective.

COVERAGE CHART-

ITEM PRODUCT PARTS LABOR

Total Unit KM Cuber 3 Years 3 YearsF/DCM 1 Year 1 Year

B/DB/DM 2 Years 2 YearsBev. Valves 1 Year 1 Year

Compressor & Air- KM Cuber 5 Years 3 YearsCooled Condenser F/DCM 5 Years 2 Years

Evaporator Plate KM Cuber 5 Years 5 Years

Evaporator, AugerGear 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, PuertoRico, and U. S. Virgin Islands.

Contact factory for warranty in other countries, territories,or possessions.

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KM INSTALLATION

GENERAL -

The ice machine is not intended for outdoor use.

OPERATING CONDITIONS - ALL MODELS

ITEM MODEL RANGEVoltage Range 115V units 104- 127V.

208-230 V units 187 - 264 V.

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 aircirculation and ease of maintenance or service. 20" topclearance for F/DCM.

PLUMBING REQUIREMENTS -

Water Supply:On KM units the water supply line size is critical due tothe water assisted harvest and the use of a ported inletwater valve solenoid. * Plumbing tubing size orequivilent.

MODEL Line Size Fitting SizeKM-250 - KM-800 3/8" * 1/2 FPT

KM-1200 - KM-2400 1/2" * 1/2 FPTAll F/DCM 3/8" * 1/2 FPT

*Water cooled condenser units require two separatesupplies sized as per list above.

Drain:MODEL Line Size Fitting SizeAll Bins 3/4" ID 3/4 FPTAll KM's 3/4" ID 3/4 FPTFlakers 3/4" ID 3/4 FPT*

DCM 3/4" ID 3/4 FPT**Some models have 2 drain outlets.

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Hoshizaki recommends that the ice machine drain andbin drain be piped separately to the drain connection pointallowing 1/4" per foot fall.

CONDENSATE DRAIN -

The condensate drain is generally connected to the icemachine drain for simplicity. It can be piped separately tothe drain exit if desired.

A 6" vent tee is recommended as per drawing:

FLOW RATES -

The minimum flow rate requirements for Hoshizaki icemaker units are as follows:

KM-250/280/AII Flakers 1.05 GPMKM-500 1.58 GPMKM-630/800/AII DCM's 2.11 GPMKM-1200/1600 3.96 GPMKM-2000/2400 4.23 GPM

Use this information when sizing a filter system for the icemachine application.

NOTE: A good rule of thumb is to utilize a 3 GPM flowrate filter for KM-250 through 800 and a 5 GPM flow ratefilter for KM-1200 or larger.

ReservoirDrain

CondensateDrain

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GND

GND

GND

Brown

White

Brown

Black

Red

Brown

White

208-230 VOLT/1PHASE208-230V/1 Phase units require a dedicated neutral dueto the use of 115V components.

GND

White

Brown

Black

ELECTRICAL CONNECTIONS -

115 VOLT/1 PHASE

115V.(2 wirew/gnd)

208-230 VOLT/3 PHASE

If high leg is present connect to black wire.A transformer can be used to provide 115v

control circuit. See next page for details.

The dedicatedneutralrequires aninsulatedconductorwhich runsdirectly to thepanel.

208-230V.(3 wirew/gnd)

208-230V.3 phase(3 wirew/gnd)

FanControlCircutFromUnit

115V.

115V.

115V.

REMOTE CONDENSER CONNECTIONS

115V.

Neutral

115V.

Neutral

115V.

Neutral

115V.

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Note:Electrical connections must be made in accordance withall national and local electrical codes.

Transformer ApplicationAll 3 phase models include a 115V transformer with a 208/230V selector switch. Be sure to select the position thatbest matches the in-coming voltage prior to supplying powerto unit. (Voltage from the center tap to case ground willread 67.5V due to transformer circuit.)

208-230V models include 115V controls. They require a115 / 208-230V circuit which has 4 wires including L1, L2,dedicated neutral, and gnd.

If a dedicated neutral is not available or the previous unitused a 3 wire circuit (L1,L2, & gnd.), a step-down trans-former can be used at the unit to provide power to the115V components. This will save on installation time andcost if a dedicated neutral is not present.

Transformer # 4A0817-01 or equivalent can be used forKM models. Transformer # 446240-01 or equivalent canbe used for F-1000 models. This transformer should bemounted inside the compressor compartment and wired

L1 N L2 BK W BN

✇✇✇✇

GND. L1 L2

230V 208V

UNIT

using the following generic diagram.

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REMOTE APPLICATIONS

CONDENSER CHART

CONDENSER MODEL MODEL NUMBERS

URC-6E KM-500/630MRE, F-1000MREURC-12E KM-800/1200MRE, KM-1200SREURC-20E KM-1600MRE, KM-1600/2000SRE,

F-2000MREURC-24C KM-2400SRB

When installing a remote application the unit/condensercombination must match with the above chart. A non-OEM multi-pass condenser can be used with prior writtenfactory approval.

REMOTE LINES-

Hoshizaki has 3 precharged line set lengths. 20 foot, 35foot, and 55 foot sets are available. The line sets areavailable in different line sizes for different models.

LINE SET IDENTIFICATION CODE

R22 - 35 6 10Refrigerant

Length In Feet

Liquid Line Size in 16th’s

Discharge Line Size in 16th’s

LINE SET APPLICATIONS

MODELS LINE SET LL (SIZE) DLKM-500/630, F-1000 R22-__46-2 1/4" OD 3/8" ODKM-800/1200 R22-__68-2 3/8" OD 1/2" ODKM-1600/2000/2400 R22-__610 3/8" OD 5/8" ODF-2000 R22-__610 3/8" OD 5/8" OD

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Remote Condenser Installation on Roof

Air Flow

DischargeLine

LiquidLine

LiquidLine

ICEMAKER

ICE STORAGE BIN

DischargeLine

2½” Dia. Hole inroof for tubing -Seal afterinstallation toprevent leaking

For best perfor-mance the RemoteCondenser shouldnot be more than33’ above theicemaker or morethen 10’ below it.These distancesare measured fromfitting to fitting.

For bestperformanceallow 24”clearance forair circulation

Electrical connectionsmust meet all localcodes

Remote CondenserFan MotorConnection

Secure Legsto Roof Curb

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LINE SET INSTALLATIONA universal line set adapter kit, part number OS-QUICK, isavailable if you need to field engineer your line set. Bothlines should be insulated separately the entire length ofrun.

The refrigerant charge for a new unit is distributed be-tween the unit head and the URC condenser. The line sethas a minimal holding charge of 15 to 30 psig refrigerantvapor.

If you need to field engineer your line set or shorten/lengthen a precharged line set you can do so by followingthese steps:

1. Using the OS-QUICK kit, braze the line set connec-tions. (If you shorten or lengthen a precharged lineset, recover the holding charge, cut or lengthen andbraze the connections.)

2. Pressurize the lines and leak check all braze joints.

3. Evacuate the lines through the service ports on theAeroquip quick connect fittings.

4. Charge both lines with 15 to 30 psig R-22 vapor.

To make Aeroquip connection to the unit head and con-denser:

1. Lubricate the threads and O-ring with cleanrefrigerant oil.

2. Tighten the female connector until it bottoms out.

Note: Be sure to use a back up wrench when tighteningthese fittings.

3. Then turn an additional 1/4 turn to assure a goodbrass to brass seal. Leak check the joints with soapbubbles or an electronic leak detector.

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FOR FACTORY SUPPORTCONTACT HOSHIZAKI TECHNICAL SUPPORT AT:

1 -800-233-1940E-Mail [email protected]

SYSTEM CHARGE - R-22The ice machine head and URC condenser are shippedwith enough refrigerant charge for up to 66 feet of line setlength. The maximum line set length is 100 equivalent feetfrom the head to the condenser.

For applications longer than 66 ft. up to the maximum 100ft. Iength, additional refrigerant must be added. For unitsutilizing 1/4" L.L. and 3/8" D.L., the line size should beincreased to 3/8"L.L. and 1/2"D.L. for the entire length ofthe run. Add 21 ounces plus 1/2 oz. per foot over 66 feet.For units utilizing 3/8"L.L., add 1/2 oz. per foot over 66feet.

NOTE:(1) Recommended line sizes are same as listed in

the line set application chart. (Page 7)(2) Older models utilize R-502 refrigerant or R-12

refrigerant. Always check the unit nameplate forthe correct refrigerant type.

(3) If refrigerant is added due to extended line setlength, mark the correct total charge on the unitnameplate for future reference.

(4) When routing and installing remote lines, alwaysuse standard refrigerant piping practices.

(5) Hoshizaki recommends eliminating any excessloops in a pre-charged line set application beforemaking the unit connections. This will eliminate oiltraps 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 AMOUNTThe total system charge is critical for proper operationaccording to Hoshizaki specification. Always weigh in theproper charge per the following charge chart. (Remoteunits show standard charge good for up to 66 feet.) Unitcharge information is also found on the unit Name Plate.

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HOSHIZAKI CUBERREFRIGERANT R-22 CHARGE CHART

MODEL TOTAL CHARGE REFRIGERANT

KM-250 BAE/BWE 12 Oz. R-22KM-250 MAE 12 Oz. “KM-250 MWE 11 Oz. “KM-280 MAE 11 Oz. “

MWE 11Oz. “KML-200 MAE 1Lb. “

MWE 11Oz. “KML-400MAE 1Lb. 5 Oz. “

MWE 15 Oz. “KM-500 MAE 1 Lb. 8 Oz. “

MWE 1 Lb. “MRE 4 Lbs. “

KM-630 MAE 50/60 1 Lb. 6 Oz. “MWE 50/60 1 Lb. 2 Oz. “MRE 4 Lbs. 2 Oz. “

KM-800 MAE 2 Lbs. 7 Oz. “MWE 1 Lb. 12 Oz. “MRE 11 Lbs. “

KM-1200MAE 3 Lbs. 10 Oz. “MWE 2 Lbs. “MRE 11 Lbs. “

KM-1600MRE 1/3 14 Lbs. 6 Oz. “KM-1200SAE 50/60 3 Lbs. 8 Oz. “

SWE 50/60 2 Lbs. “SRE 50/60 12 Lbs. 2 Oz. “

KM-1600SWE 1/3 2 Lbs. 14 Oz. “SRE1/3 14Lbs. 5 Oz. “

KM-2000 SRE3 16 Lbs. 9 Oz. “SWE3 3 Lbs. 7 Oz. “

KM-2400 SRB3 26 Lbs. 8 Oz. “

URC (Condenser charge is included in remote totalabove.)URC-6E 2 Lbs. 2 Oz. “URC-12E 4 Lbs. 7 Oz. “URC-20E 7 Lbs. 11 Oz “URC-24B 11 Lbs “

NOTE: To convert to grams multiply oz. X 28.35.

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HOSHIZAKI FLAKERS/DCM'SREFRIGERANT CHARGE CHART

MODEL TOTAL CHARGE REFRIGERANTF-250 BAE 8 Oz. *R-134AF-450 BAE 1 Lb. R-22F-650 MAE 1 Lb. 5 Oz. “

MWE 10 Oz. “F-1000 MAE 1 Lb. 8 Oz. “

MWE 14 Oz. “MRE 4 Lbs. 3 Oz. “

F-2000 MWE 1Lb. 14 Oz. “MRE 14 Lbs. 13 Oz. “

DCM-240 BAE 11.6 oz. “DCM-450 BAE 1 Lb. 1.4 Oz. “

BWE 11.6/13.4 Oz. (see nameplate)“DCM-700 BAE 1 Lb. 9 Oz. “

BWE 13.4 Oz. “

HEAT LOADThe heat of rejection information listed below by modelnumber should be used for sizing air conditioning equip-ment or for sizing a water cooled cooling tower applica-tion.

TOTAL HEAT REJECTIONAIR WATER COOLED

MODEL COOLED (CONDENSER ONLY)KM-250B/M 5450 BTU/h 5250 BTU/hKM-280M/KML-200M 5980 5650KLM-400M 7400 6100KM-500M 9400 8300KM-630M 8990 9060KM-630/50 7900 6060KM-800M 14300 12700KM-1200M 19500 17000KM-1200S 18330 15850KM-1200S/50 17020 14560KM-1600S --- 24400KM-2000S --- 23700F-250B 4350 ---F-450B 5000 2860F-650M 6830 5550F-1000M 8200 6800F-2000M --- 19000DCM-240B 4200 ---DCM-450B 9000 7750DCM-700B 10500 9680Figures shown are at 90° F air temp. 70° F water temp.Allow for a pressure diffenential of 7 psi across the watercooled condenser.

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COMPONENT TECHNICAL DATA -KM Control Board Factory SettingThere are 8 dip switches on the Alpine control board uti-lized in R-22 units. The dip switches are factory set foroptimum operation. The switches can be adjusted to pro-vide flexibility when the unit is operating in a bad waterlocation allowing more cleaning capability.

DIP SWITCH SETTING GUIDE

ADJUSTMENTS DIP

DEFROST 1 0 1 0 1

TIMER 2 0 0 1 1

seconds 60 90 120 180

PUMP OUT 3 0 1 0 1

4 0 0 1 1

seconds 10 10 10 20

MIN DEF 150 180 120 180

WTRVALVE OFF OFF ON OFF

PERIODIC 5 0 1 0 1

PUMP OUT

FREQUENCY 6 0 0 1 1

cycles 1/1 1/2 1/5 1/10

OPTIONAL 7

SWITCH

TEST 8

ALWAYS OFF

ALWAYS OFF

Switch Code 1=ON 0=OffINSTRUCTIONS:1. TO IMPROVE BUILT-IN CLEANING Adjust switches

per this guide. Switches 1& 2 provide for longer flushat the end of harvest. Switches 5 & 6 provide maxi

mum cleaning at every harvest cycle 1 / 1 setting. The 1 / 10 setting will pump-out less to conserve water (less cleaning).2. DO NOT ADJUST SWITCHES 3, 4, 7, & 8 FROM

THE FACTORY SETTINGS!3. DO NOT MAKE CONNECTION TO THE RED K-4

TERMINAL!.4. The replacement board should be adjusted to the

factory settings unless local condition requiresalternate settings.

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“E” Control Board Adjustment ChartThe new “E” control board is designed as aservice replacement for “C” and Alpine boards.Early “E” boards have 8 dip switches. The latest“E” boards have 10 dip switches.

NOTE:Switches 1 ~ 8 are same as Alpine control board.Switches 9 & 10 allow for adjustment of the maximumfreeze cycle timer. If unit originally has board with 10switches, adjust 9 & 10 to original setting. If original boardhas 8 switches adjust 9 & 10 to default setting OFF & OFF.

“E” BOARD DIP SWITCH SETTING GUIDE

ADJUSTMENTS DIP # Switch Code

1 0 1 0 1

2 0 0 1 1

seconds 60 90 120 180

PUMP OUT 3 0 1 0 1

TIME 4 0 0 1 1

seconds 10 10 10 20

seconds 150 180 120 180

status OFF OFF ON OFF

PERIODIC 5 0 1 0 1

PUMP OUT

FREQUENCY 6 0 0 1 1

cycles 1/1 1/2 1/5 1/10

OPTIONAL

SWITCH 7

TEST 8

MAX. FREEZE 9 1 1 0 0

TIME

10 1 0 1 0(Improved E

board only.) minutes 75/50hz 70 50 60

ALWAYS OFF

ALWAYS OFF

1=ON 0=OFF

Length of pumpout Min, DefrostTime Inlet WaterValve

Default

DEFROST

COMPLETION

TIMER

60/60hz

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SETTING CHART -FACTORY DIP SWITCH SETTING

MODEL : 1 2 3 4 5 6 7 8

KM-250BAE/BWE 1 0 1 0 0 0 0 0

KM-250A/KML-400A/W 0 0 0 0 1 1 0 0

KM-250MWE 1 0 0 0 1 1 0 0

KM-280A/KML-200W 0 1 0 1 1 1 0 0

KM-280W/KML-200A 0 0 0 1 1 1 0 0

KM-500M A/W/R E 0 0 0 0 1 1 0 0

KM-630M A/W/R E 0 0 0 0 1 1 0 0

KM-800M A/W/R E 0 0 1 0 1 1 0 0

KM-1200M A/W/R E 0 0 1 0 1 1 0 0

KM-1200S A/W/R E 0 0 1 1 1 1 0 0

KM-1600MRE 0 0 1 0 1 1 0 0

KM-1600S W/R E 0 0 1 1 1 1 0 0

KM-2000S W/R E 0 0 1 1 1 1 0 0

KM-2400SRB 0 0 1 0 0 0 0 0

In case of 10 dip switches, 9 & 10 should beadjusted OFF for all models listed above.

The original Alpine board, #2U0127-01 was installed on allKM models produced prior to Feb. 98. Models producedafter Feb 98 will have either #2U0127-01or the new “E”control board #2A0836-01. Universal Alpine board#2U0139-01 can replace a “C” or Alpine board. It has ablack jumper between relay X3 & X4. This jumper makesthis board a “C” board. Leave the jumper if there is a whitewire in the 10 pin connector. This jumper must be cut for anAlpine application (no white wire on 10 pin connector).

SWITCH CODE: 1 = ON 0 = OFF

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NOTE:Service replacement boards after Feb. 98 are #2A0836-02 or sub #2A1410-02. This “E” board is designed to re-place “C”, Alpine, or original (01) “E” boards. An applicationswitch is located between relay X3 & X4. Follow the in-structions on the board label to set this switch. If the 10 pinconnector has a white wire, switch to “C” position. If not,switch to “ALP”.

BE SURE TO FOLLOW THE INSTRUCTIONS SUPPLIED WITH THE BOARD.

The “E” service replacement board is smaller than the “C”or Alpine board. It will mount in the same location on 4 ofthe 6 mounting studs. You must cut the wire ties and stretchthe wiring to install the connectors. Each connection ismarked and connects the same as the original board.

If the black jumper is cut/not cut improperly”C” board) orthe application switch (“E” board) is in the wrong position,the inlet water valve will not energize correctly or the com-pressor will operate continually when the power switch isturned OFF.

“E” Control Board Functions -

An instruction label explaining the “E” board features isincluded somewhere on the unit (usually under the toppanel or on the control box cover). A stick-on label is alsoincluded with the service replacement. If you are replacingan “E” board, place the new label over the original label asit contains instructions for the application switch. This willadvise anyone performing future service that the originalboard has been replaced and explain the application switchas outlined below.

See the information on the label or the following for theboard features. The new diagnostic features are addedwhen this board replaces a “C” or Alpine board.

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“E” Control Board Functions continued:

The #2A1410-02 universal replacement board has an ap-plication switch between relays X3 & X4 that is not in-cluded on the original factory board supplied with the unit.This application switch allows this replacement board tobe used on older C and Alpine control board models. Theapplication switch has 2 positions (C & ALP). On R-404A models, this switch must be in the ALP position. If theswitch is left in the C position, the compressor contactorwill energize as soon as power is supplied to the unitwhether the power switch is ON or OFF.

There are 4 green LED’s which light in sequence through-out the unit operation. It is important to note that the greenLED’s are not numbered consecutively. LED1 is located atthe edge of the board beside the K-2 transformer connec-tion. The numbering sequence from the outside edge of theboard is 1, 4, 3, and 2.

The green LED’s are also used for a built-in output testwhich can be conducted to diagnose a bad board. Thelabel explains the output test procedure. The correct light-ing sequence for the output test is as follows. When thecontrol switch is switched ON with the output test switchS-3 ON, you will observe the following:the Red control power LED will light after 3 seconds. Thisindicates that the control transformer has correct outputvoltage. After a 5 second delay, LED2 lights. 5 secondslater LED2 goes out and LED3 lights. 5 seconds later LED3goes out and LED4 lights. 5 seconds later LED4 goes outand LED1 lights. 5 seconds later LED1 goes out and LED4lights to begin the normal sequence of operation. If theLED’s follow this sequence, the board is OK. If any otherlighting sequence occurs, the board is bad.

Once the correct sequence is determined, the output testswitch should be replaced in the OFF position.

A copy of the “E” board label is included on the next page.Review the board label thoroughly to understand the “E”board functions.

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ATTENTION !THIS UNIT HAS A CONTROL PRODUCTS IMPROVED “E” CONTROLBOARD 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 controlvoltage problem occurs. At startup a 5 second delay occurs while the boardconducts an internal timer check. A short beep occurs when the powerswitch is turned “ON” or “OFF”.

The green LED’s 1~4 represent the corresponding relays and energize andsequence 5 seconds from initial startup as follows:

Sequence Step LED’s on: Length:Min. Max. Avg. 1 Minute Fill Cycle LED 4 60 sec. Harvest Cycle LED 1, 4, & 2 2 min. 20 min. 3-5 min. Freeze Cycle LED 1 5 min. 60 min. 30-35 min. Reverse Pump Out LED 1, 3, & 2 10 sec. 20 sec. 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 enteringunit, 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 openthermistor, HGV not opening, TXV leaking by, low charge, orinefficient compressor.

3 beeps every 3 sec. = Freeze Back Up Timer. Freeze > Specified SettingYellow LED marked “F Timer” energizes. Check for F/S stuckclosed (up), WV leaking by, HGV leaking by, PM not pumping, TXVnot 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 thecontrol board and the bin control. Check connections and replacewire 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 powerOFF, 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.

24 11-01-02

Manual Reset SafetiesThe Alpine control board has one manual reset safety. It isthe 127°F high evaporator temperature safety. There is noindication that the Alpine board is off on this safety. Youwill only notice that the unit will restart in the 1 minute fillcycle when the power switch is shut OFF and Back ON.This is the only way to reset this safety. If this occurscheck for a hot gas circuit or valve problem, a headmasterstuck in bypass, hot water entering the unit, or a shortedthermistor. In case of a shorted thermistor, the unit will notrestart. You will hear a relay click after approximately 2seconds and the unit will remain off.

The “E” control board has 3 manual reset safeties. Theyare outlined in the control board function label. Thesesafeties shut the unit down and assist the service techni-cian 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 harvestcycles.3 Beeps & yellow LED = 2 consecutive maximum freezecycles. ( Factory setting for R-22 models is 60 minutes.)4 Beeps = Short circuit on mechanical bin control circuit.5 Beeps = Open circuit on mechanical bin control circuit.

Note: 4/5 beeps only function with dip 7 ON. To reseteither safety, press the white reset button on thecontrol board with the power ON. Next, proceed tocheck the items outlined on the function label.

The items listed on the function label represent the mostcommon reasons that the safety would function. Theremay be other remote possibilities however, the items listedshould be checked first.

VOLTAGE PROTECTIONBuilt-in voltage protection for the “E” board will automati-cally shut the unit down and beep if either a high or lowvoltage problem occurs as follows:6 Beeps = Low voltage condition.7 Beeps = High voltage condition.The unit will automatically restart when the voltage returnsto normal. If constant voltage fluctuation occurs, additionalexternal voltage protection will be required. The high andlow voltage protections are the only board alarms that willautomatically restart.

25 11-01-02

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26 11-01-02

HEAD PRESSURE CONTROLS

WATER COOLED

An adjustable (Pressure Modulated) water regulatingvalve is installed on the water cooled condenser outlet.Adjust the valve per this diagram to reflect the outlettemperature in the chart below.

ADJUSTMENT SCREW

TOP VIEW

Adjust:

CW - for higherpressure and outletwater temperature,lower water flow.

CCW - for lowerpressure and outletwater temperature,higher water flow.

Later models may have a # V46 Johnson Controls Pennvalve. This valve adjusts opposite from the one above.A label on the valve housing identifies the Penn valve.

CONDENSER OUTLET WATER TEMPERATURE RANGE

Model Range (F°)

KM-250 BWE 104 ~ 112

KM-250 MWE 108 ~ 114

KM-280MAE 99 ~ 105

KML-200MWE 99 ~ 105

KM-1200MWE 110 ~ 114 KM-1200 SWE 118 ~ 124

KM-1600 MWE 99 ~ 108 KM-1600 SWE 99 ~ 105

KM-2000 SWE 100 ~ 104 All Flaker/DCM 100 ~104

PENN VALVE

KML-400 MWE 99 ~ 105

KM-500 MWE 99 ~ 105

KM-630 MWE 102 ~ 108

KM-800 MWE 108 ~ 112

27 11-01-02

REMOTE HEAD PRESSURE CONTROLAll remote condenser units utilize a condensing pres-sure regulator (CPR/Headmaster) to maintain headpressure in low ambient conditions. The KM-2400SRB3 has a Sporland LAC-5 140psi valve mountedin the unit head.

The URC-20E has a 156 psi valve.

All other KM and Flaker remotes have a SporlandLAC-4190psi valve mounted in the condenser.REMOTE HEAD PRESSURE CONTROL CONNECTIONS

Troubleshooting a Head Master (CPR) valveThe symptoms of a bad headmaster are similar toan undercharged unit. To diagnose a bad headmas-ter, add additional refrigerant in 2 lb. increments andwatch the pressures. If the pressures begin to looknormal, the unit was undercharged. In this case,leak check the system to find the leak and use nor-mal refrigeration practices to recover, repair, evacu-ate and recharge the unit. If not, a bad headmasteris a possibility. Check to see if the valve is stuckopen by conducting temperature checks at the out-let of the headmaster. Replace the headmaster asnecessary. Use safe refrigeration practices whenremoving the valve and protect the valve from over-heating.

28 11-01-02

Liquid Line Valve -Hoshizaki KM remote cubers and some air and wa-ter cooled units include a liquid line solenoid downstream of the receiver and before to the expansionvalve. The purpose of this normally closed solenoidvalve is to isolate the high side refrigerant from theexpansion valve. The valve eliminates any liquid mi-gration through the expansion valve during the offcycle and will not allow refrigerant flow through theexpansion valve during an extended harvest.

It is important to remember that the 115volt solenoidshould be energized during the freeze cycle and de-energized during harvest.

Bypass Cooling -

R-22 refrigerant is very efficient in an ice machineapplication. The discharge temperature runs hotterand allows for a more efficient ice harvest as well asincreased refrigerant capacity. The one concernwith using R-22 in this application is compressoroperating temperatures. Hoshizaki uses bypasscooling to maintain cooler operating temperatures.KM units beginning with the KM-630 and larger in-clude some type of bypass cooling.

Bypass cooling is accomplished by using a bypasscapillary to feed liquid refrigerant from the liquid lineto the suction line. The liquid refrigerant flashes inthe suction line and provides addition cool gas tomaintain lower compressor operating temperatures.Bypass cooling can be continous or cycle depend-ing on the model. The capillary will sometimes beconnected to a bypass solenoid valve, which opensand closes as required to provide on-demand by-pass cooling. Bypass may be controlled through arelay and a bypass thermo-disc mounted on thecompressor dis-charge line. Review the unit wiringdiagram and refrigerant circuit diagram to determine

29 11-01-02

HIGH PRESSURE SAFETY SWITCH -An automatic reset high pressure safety switch isutilized on all Hoshizaki "E" series ice makers. Thepressure switch settings are as follows:MODELS PART NUMBER CUT OUT CUT IN

(psig) (psig)F-250 3U0069-03 228 ± 21.3 185 ± 21.3All KM Water Cooled / F-650/F-1000/ DCM-450

433441-01 355.6 ± 21.3 256 ± 21.3DCM-240 433441-03 377 ± 21.3 270 ± 21.3All KM Air Cooled/ Remote

433441-05 384 ± 21.3 284.5 ± 21.3F-450/F-2000/ DCM-700

433441-06 328± 21.3 228± 21.3

THERMO-DISC A Thermo-Disc is used on certain models as acontrol or discharge line high temperature safety.MODELS PART NUMBER CUT OUT CUT IN(Used as a control for bypass valve on these models)KM-1600 445595-01 221°F 200°FF-2000 MWE 449112-01 225°F 203°F (Used as safety on these models)KM-500 MWEKM-500 MREKM-2400 SRB3 440664-01 266°F 239°FF-2000 MWE / MRE 440664-03 257°F 230°F

BIN CONTROLAll KM - E and prior series units use a thermostaticbin control. The capillary bulb is mounted in the icedrop zone or on a drop down bracket which extendsinto the bin cavity. The drop down bracket should besecured to the unit base and plug connection mustbe made before the unit will operate.

how the bypass operates and trouble shooting pro-cedures.

You will also find that the KM-1200S/MAE modelopens the bypass valve during a long harvest to addmore refrigerant to the harvest loop. This improvesoperation during a long harvest.

30 11-01-02

If the bin control bulb is not contacting the ice pyramid, anextension bracket may be needed. A bin control extensionbracket is included with all “S” models. Be sure to installthe extension if it is supplied. When installing, make surethe bracket points downward so that the cubes will easilyfall away from the bin control bulbs.

The bin control bulb and ABS holder assembly must bemounted on the back side of the extension bracket. Thiswill eliminate premature shutoff due to ice hanging up onthe holder. In case of stacked “S” models, both ABS hold-ers will be attached together and mounted to the back ofthe extension bracket.

F/DCM Bin Control Flaker / DCM units use a mechanical bin control. A paddlepivots on a hinge pin to operate either a micro- switch ormagnetic proximity switch. For proper operation, make surethat the paddle swings freely. The F-450MAF-C cubeletunit uses an Infrared eye control as it is designed fordispenser applications.

CAPACITORSSee wiring diagram reference chart for capacitor ratings.Check capacitors with an ohm meter for a short or opencircuit. A capacitor checker can be used to check thecapacitance however, it is a good common practice tochange a run capacator any time a PSC motor is replaced.Always check the run capacitor if a PSC motor will notstart, is running slow, or overheating.

When replacing a thermostatic bin control, check the op-eration by holding ice against the thermostatic bulb with thecontrol switch in the wash position. The pump should stopwithin 6 to 10 seconds. Adjust the control “CCW” for afaster shut down.

___

31 11-01-02

HOSHIZAKI KM CUBERSEQUENCE 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 startup.

1. 1 Minute Fill Cycle

The unit always starts in the 1 minute fill cycle. Whenpower is applied to the unit the water valve isenergized and the fill period begins. After 1 minute theboard checks for a closed float switch. If the floatswitch is closed the harvest cycle begins. If not, theunit will not start without adequate water in the sump.This serves as a low water safety shut off. The watervalve will remain energized through additional1 minute cycles until water enters the sump and thefloat switch closes.

2. 1st Harvest Cycle

The compressor starts, hot gas valve opens, watervalve remains open and harvest begins. As theevaporator warms, the thermistor located on thesuction line checks for a 48° F. temperature. When48° F. is reached, the harvest is turned over to theadjustable control board defrost timer which isfactory set for normal conditions. This adjustment canvary the defrost timer from 1 to 3 minutes.

3. Freeze Cycle

After the timer terminates the harvest cycle, thehot gas and water valves close, and the iceproduction cycle starts. For the first 5 minutes thecontroller board will not accept a signal from the floatswitch. This 5 minute minimum freeze acts as ashort cycle protection. At the end of 5 minutesthe float switch assumes control. As ice builds on theevaporator the water level in the sump lowers. Thefreeze continues until the float switch opens andterminates ice production.

32 11-01-02

4. Harvest Pump Out

When the float switch opens and signals thecompletion of the freeze cycle, the harvest cyclebegins. The hot gas valve opens and the compressorcontinues to run. The drain timer starts counting the10/20 second pump out.

The water pump stops for 2 seconds and reverses,taking water from the bottom of the sump and forcingpressure against the check valve seat allowing waterto go through the check valve and down the drain. Atthe same time water flows through the small tube topower flush the float switch. When the draintimer stops counting, the pump out is complete.

Pump out always occurs on the 2nd harvest afterstartup. The Alpine control board allows foradjustment for pump out to occur every cycle, orevery 2nd, 5th or 10th cycle from this point.

5. Normal Harvest Cycle

The water valve opens to allow water to assist theharvest. As the evaporator warms, the thermistorreaches 48° F. The control board receives thethermistor signal and starts the defrost timer. Thewater valve is open during harvest (defrost) for amaximum of 6 minutes or the length of harvest,whichever is shorter. When the defrost timercompletes its count down, the defrost cycle iscomplete and the next freeze cycle starts.

The unit continues to cycle through 3, 4 and 5sequence until the bin control senses ice and shutsthe unit down.

33 11-01-02

34 11-01-02

KM CHECK OUT PROCEDURE

The following is a detailed explanation of the KM 10Minute Check Out procedure.

The 10 minute check out procedure is basically asequence check which can be used at unit startup or forsystem diagnosis. Using this check out procedure willallow you to diagnose electrical system and componentfailures in approximately 10 minutes under normaloperating conditions of 70°F or warmer air and 50°F orwarmer water temperatures. Before conducting a 10minute checkout, check for correct installation, propervoltage per unit nameplate and adequate water supply.As you go through the procedure, check to assure thecomponents energize and de-energize correctly. If not,those components and controls are suspect.

10 MINUTE CHECK OUT PROCEDURE1. 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” controlboard.

A) 1 Minute Fill Cycle begins – WV energized.After 1 minute, control board checks FS. If FS isclosed…unit cycles to Harvest. Continue to (B).If FS is open, unit repeats 1 minute fill cycle untilwater enters and FS closes (low water safetyprotection during initial start up and at the end ofeach harvest)

Diagnosis: If WV does not open, check for no supplyvoltage at WV terminals, bad coil, or plugged screenor external filter (no water flow). If unit fails to startharvest, check for open FS or bad 1 minute timer inboard.B) Initial Harvest Cycle – WV remains energized,

CC energizes to start C, HGV, & (FM on RSmodel) energize. Evaporator warms…thermistorsenses 48°F…turns operation of harvest tocontrol board defrost completion timer. Timercompletes counting (1 ~3 minutes)…Unit cyclesto freeze.

Diagnosis: Check if C is running, HGV is open, WVstill open. Avg. harvest cycle at factory setting is 2~ 3 minutes. How long does initial harvest last? 1.5minutes after initial harvest begins, touch Cdischarge line. Is it hot? If not check refrigerantpressures and C operation. If it is hot, touch inletline to the evaporator. Is it hot? If it is hot and unit isnot starting freeze cycle, check defrost

35 11-01-02

completion timer adjustment, thermistor for opencircuit, discharge line temperature, C efficiency,and if HGV is fully open.

C) Freeze cycle – C remains energized, PM, (LVon RS model), and FM energize…WV & HGVde-energize. Unit is held in freeze by 5 minuteshort cycle protection timer. After 5 minutesfreeze cycle operation to transferred to FS forfreeze termination. During first 5 minutes offreeze, confirm that evaporator temperaturedrops. After 7 minutes in freeze, remove blackFS lead from K5 connector…Unit shouldimmediately switch to pump out cycle.

Diagnosis: If evaporator is not cold, check for HGVstill open, TXV not opening properly, WVcontinuing to fill reservoir, improper unit pressures, and inoperative C. If unit remains in freezewith FS removed replace board. * Normal freezecycle will last 20 ~ 40 minutes depending onmodel and conditions. Cycle times andpressures should follow performance dataprovided in Tech –Specs.

D) Pump Out Cycle – (10/20 second pump out)C remains energized, HGV energizes, FM de-energizes, PM stops for 2 seconds and starts inreverse rotation for 10/20 seconds.( Thisremoves contaminants from the water reservoirthrough check valve and down the drain andallows for power flush of FS.) Check cleartubing at check valve housing or unit drain forwater flow.

Diagnosis: If PM does not reverse, check PM circuitand capacitor. If water does not pump out,remove housing and check/clean valveassembly.

E) Normal Harvest Cycle –same as Initial HarvestCycle – Return to B)…* Unit continues to cyclethrough B)…C)…& D) (Setting can be adjustedto skip D until every 2, 5, of 10 cycles)…until bincontrol is satisfied or power is switched OFF.• Unit always restarts at A).

Legend:C – Compressor CC – Contactor Coil FM – Condenser Fan MotorFS – Float Switch HGV – Hot Gas Valve LV – Line ValvePM – Pump Motor RS – Remote System WV – Inlet Water Valve

36 11-01-02

RESERVOIR FLUSH SYSTEMA displacement device ( cap or assembly ) is positionedover the top of the overflow stand pipe. This deviceallows sediment to be pulled from the bottom of thereservoir and flush down the drain when overflowoccurs. Water should always overflow the stand pipefor a short period towards the end of harvest to allow thisflushing action. To extend this flushing action adjust dipswitches 1 & 2 for longer harvest. If overflow does notoccur, you have restricted water flow into the unit.Check the inlet water valve screen, incoming water linesize, or the external filter system.

The displacement device must be in position for properoperation. If not, water goes down the drain during freezeand short cycling occurs.

PUMP-OUT CHECK VALVEA mechanical spring & seat check valve is located inthe pump-out housing. If this check valve sticks open,water flows down the drain during freeze and a 5 minutefreeze cycle occurs. In this case, check for a displacedseat, trash or a weak spring. Replace the spring if it isweak. When reinstalling the check valve, the seat alwaysfaces the pump supply.

KML PUMP OUTThe Standard KM series has a dual winding pump motorthat reverses direction during the pump-out cycle. Thereverse rotation pumps sediment down the drain. The KMLmodels have a single winding pump motor that does notreverse. Instead of a pump-out check valve and reversingpump, a drain solenoid and the pump motor are energizedby a relay so that sediment is pumped out.

KM CONTROL SWITCHThe standard KM models have a three position controlswitch. The switch positions are “ICE-OFF-WASH”. Also,a manual cleaning valve includes a micro-switch whichopens the control transformer circuit to the control boardduring the cleaning process. This cleaning valve must be inthe horizontal position to make ice.

The KML models have 2 switches. The control switch po-sitions are “ICE- OFF-SERVICE”. With the control switch inthe SERVICE position, the SERVICE switch is energized.

37 11-01-02

The service switch also has three positions, “DRAIN-CIRCULATE-WASH”. With the control switch in SERVICEand the service switch in DRAIN, the pump strarts anddrain valve solenoid opens to automatically drain thereservoir. In circulate, the pump motor circulates cleaner tothe outside of the evaporator. In WASH, the cleaningsolenoid energizes and the pump circulates cleaner to theinside and outside of the evaporator.

COMPONENT CHECKS:1. Float Switch: Check out the float switch with an ohmmeter. When the float is up, the switch is closed.

The symptoms of a sticking float are:Up/Closed: 60 minute freeze cycle, larger cubes,and pump cavities prior to harvest.Down/Open: Unit shuts down on low water

safety and water runs continuously.

Note: Units using “E” board will shut down on 3 beepsafety after 2 consecutive 60 minute freeze cycles.

2. Thermistor: Check out the thermistor mounting andcheck resistance versus temperature per this chart: THERMISTOR TEMPERATURE / RESISTANCE

SENSOR TEMP (F°) RESISTANCE (K OHMS)0 14.4

10 10.632 6.050 3.970 2.590 1.6

The symptoms of a bad thermistor are:Open: 20 minute harvest cycle

Note: Units using “E” board will shut down on 2 beepsafety after 2 consecutive 20 minute harvest cycles.

Shorted: Unit locks out on manual reset hightemperature safety.

Note: If evaporator reaches 127°F the thermistor signal(500 ohms) shuts down the unit on this manual reset. For“E” control boards, a 1 beep alarm will occur. To reset thisalarm, press the white reset button on the board with powerON. Then check the items listed on the control board labelfor a 1 beep alarm.

38 11-01-02

Note: The Thermistor must be mounted using a heatsink compound to assure good heat transfer and ac-curate sensing. Use Hoshizaki: Part Number 4AO683-01 or equivalent. (Radio Shack #276-1372 or GE Elec-tronics #10-8108, ect.)

3. The control board operates on 12VAC which is supplied by the control voltage transformer located in the control box. The secondary of this transformer is connected to the K2 connector on the control board. An interlock switch is in series with the secondary winding and is operated by the cleaning valve handle mounted on the side of the evaporator compartment. If this switch is not closed, no control voltage is supplied to K-2 and the control board will not operate. This switch eliminates the possibility of the compressor operating during the cleaning process.

4. The bin control used on all KM units is an adjust-able, thermostatic control. The thermostatic bulb is

mounted in the ice drop area. To adjust the bin con trol, hold ice against the bulb while the unit is oper ating. The unit should shut off within 6 to 10 sec onds. 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 djustment 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 bincontrol mounted in the ice drop zone. KM-1300M / Sand larger units have a drop down bracket thatmust be dropped down, secured, and plugged in atinstallation. The ice must contact the bulb tooperate the bin control. Some bin applicationsrequire an extension bracket or relocation of thebulb mounting to allow for proper shut down. Checkthis positioning if the control is adjusted properlyand ice continues to back up into the evaporatorsection. Assure that the extension bracket is in-stalled if included in the accessory bag. (See draw-ing for proper installation of extention bracker un-der BIN CONTROL section.)

39 11-01-02

The symptoms of a bad thermostatic control are:Stuck closed: The unit continues to operate when the binis full. This allows ice to back up in the evaporator com-partment and generally causes a freeze-up condition. Thiswill also occur if the bin control is adjusted too cold or fully“CW” which is the continious position. Check the adjust-ment and bulb location before you diagnose a stuck bincontrol.Stuck open : The unit will not start in the ice position. Aneasy method to check for an open bin control is to place thecontrol switch to WASH. If the pump starts, the bin controlis closed.

F/DCM bin controls may be a mechanical flapper with amagnetic proximity switch or a micro-switch assembly.Since these controls have moving parts, make sure that allparts move freely. Sticking can occur if scale builds up atthe pivot points. All flakers “E” and prior model flakers usethe mechanical proximity switch control. If the bin controlfails, the spout will fill with ice causing higher gear motorcurrent and the gear motor protect will trip or fuse willblow.5. To check the KM control board, check for 12VAC atconnector K-2. If control voltage is present, check for115VAC from pin 10 on the K-1 connector to a white neu-tral wire. Checking from pin to case can give a false read-ing in 3-phase models which have a transformer to provide115VAC for the 115V componants. If voltage is present,conduct the output test as outlined on the board functionlabel. The output test will show that the board issequenceing properly. If the output test results in an im-proper lighting sequence, replace the board. Conduct athorough 10 minute check out procedure to pinpoint theproblem area. See (10 MINUTE CHECK OUT).

Even though the output test result is correct, the outputvoltage could be bad. An additional check should be madeto check for proper output to each individual componant.Follow the wiring color code on the wiring diagram to checkthe output voltage at the K-1 connector to each componantas the unit cycles through the 10 minute check. If voltage isnot supplied to a componant when it should be or incorrectvoltage is present, the board relay contacts are likely badand the board should be replaced.

6. Check other components using a good quality multi-meterand normal electrical diagnostic procedures.

40 11-01-02

Diagnosing water problems.

Many common water related problems will causecubesto look unnatural. Looking at the ice in the bin will pointyou towards the problem area. Study these shapes andcauses to help you diagnose water related problems.

1.Normal cube No problem.Average cube size 1/2” thick x1 1/8” wide x 1 1/2” high.

2.Larger than normal cube with heavysaddled 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 icepossible bridging.

A FREEZE UP MAY OCCUR IF ICE STICKS DUE TOTHE LARGER EDGES.

41 11-01-02

3.Bridging or ice stripsa) Bridging that occurs on all ribs of all evaporator plates

is the result of excessive water in the reservoir. This iscaused by the inlet water valve leaking by. Check fora plugged bleed port in the water valve diaphragm or adefective 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 inspectionof the ice build up on the evaporator will show someribs 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.

42 11-01-02

4.

Melt away of back of cubea) 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. Checkfor a plugged inlet water valve screen, pluggedexternal filter, low water pressure, or a small waterline size.

EITHER OR BOTH OF THESE ITEMS CAN CAUSETHIS SYMPTOM.

5.

Small cube

a) Can be caused by a low volume of water at thebeginning of freeze. Check for adequate water flowduring harvest. See item 4 b)

b) If the pump out check valve is stuck open or has aweak spring, the water left in the reservoir will bepumped out during the first five minutes of freeze.This results in a short cycle and slivers of ice orsmall cubes.

c) Any loss of water, whether by leak, water trail, orloose stand pipe can cause this problem.

6. Freeze ups can be caused by 2, 3, or 4 above inany combination. The major cause however is adirty (scaled up ) water system or evaporator. Athorough cleaning will eliminate most freeze ups.The second most common reason for freeze up islow water flow. Always check the evaporator, andwater flow first, then go to other checks whendiagnosing freeze ups.

(Size will depend on how much water isin the reservoir.)

43 11-01-02

PLEASE COMPLETE WHEN DIAGNOSING A FREEZE-UP, 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 duringfreeze? [ ] [ ]

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-250~KM-800? [ ] [ ]

9. Only one water line per unit? If not ______ [ ] [ ]

10.Is water flow 5GPM for KM-1200 ~KM-2400? [ ] [ ]

11.Will bin control cycle OFF within 6-10seconds when in contact with ice? [ ] [ ]

12. Have you checked that the bin control capillary is not touching a heated source? [ ] [ ]

13.Are the evaporator separatorspositioned 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 __________psigDate filter last replaced _______________________

44 11-01-02

17. Date screen on water solenoid waslast cleaned ________Does water valve close completely whende-energized? [ ] [ ]

18. What is the water pressure? _________ psigTemperature? ________°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 NOoutlet of evaporator? (full freeze pattern) [ ] [ ]

21. Is ice still dropping when unit cycles intothe freeze mode? [ ] [ ]

22. After defrosting, was the unit leakchecked? [ ] [ ]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 watertemp._________°F

29. Is the hot gas valve opening? [ ] [ ]

30. List model and manufacturer of bin ________________________________________

31. If non-Hoshizaki bin, what modifications have beenmade to bin control mounting? [ ] [ ]

32. Has extension bracket been added to the bincontrol bracket? [ ] [ ]

33. Check ice drop weight. ________________________

45 11-01-02

CLEANING/SANITIZING PROCEDURE

A label which details the step by step cleaning/sanitizingprocedure is located on the inside front panel of the icemachine. These instructions are also provided in theInstruction Manual shipped with each unit. Follow theseinstructions to conduct a thorough cleaning andsanitizing of the water system.

Annual cleanings are recommended. More frequentcleanings may be required in bad water areas.

INLET WATER VALVE

The inlet water valve includes an 80 mesh screen toprotect the water system from debris. Always check andclear this screen during the cleaning procedure.

CLEANERS-

Hoshizaki recommends "Hoshizaki Scale Away' or"Lime-A-Way" (by Economics Laboratory, Inc.) howeverany FDA approved ice machine cleaner is acceptable. Ifyou carry a nickel safe cleaner, the acidic solution isweaker than normal cleaners to protect plated surfaces.You may need to use a heavier mixture of nickel safe tocut heavier scale deposits.

RECOMMENDED CLEANING SOLUTION MIXTURE

MODEL CLEANER WATER

KM-250 7 Fl. Oz. 1.3 Gal.KML-200/400 10.5 Fl. Oz. 2.0 Gal.KM-280/500/630/800 16 Fl. Oz. 3.0 Gal.KM-1200/1600 27 Fl. Oz. 5.0 Gal.KM-2000/2400 38 Fl. Oz. 7.0 Gal.All Flakers 9.6 Fl. Oz. 1.6 Gal.

The system should be sanitized using a solution of waterand 5.25% sodium hypochlorite. Any commercialsanitizer recommended for ice machine application isacceptable.

46 11-01-02

RECOMMENDED SANITIZING SOLUTION MIXTUREMODEL SANITIZER WATER

KM-250 .65 Fl. Oz. 1.3 Gal.KML-200/400 1 Fl. Oz. 2.0 Gal.KM-280/500/630/800 1.5 Fl. Oz. 3.0 Gal.KM-1200/1600 2.5 Fl. Oz. 5.0 Gal.KM-2000/2400 3.7 Fl. Oz. 7.0 Gal.All Flakers 2.5 Fl. Oz. 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 onefreeze cycle to the beginning of the next freezecycle.

2. Catch all of the ice from this freeze cycle andweigh the total batch.

3. Divide the total minutes in a 24 hour day (1440minutes) by the complete cycle time in minutes toobtain the number of cycles per day.

4. Multiply the number of cycles per day by the cyclebatch weight for the cuber production per 24hours.

(1440 • Total Cycle Time) x Ice Batch Weight=24 Hour Production

Once you calculate the production, check the incomingwater temperature, and ambient condensing temperatureat the cuber and cross reference to performance dataincluded in this manual to see if the calculation falls within10% of the specification.

For the most accurate production check, a normalfreeze cycle should be checked. If the evaporatorcompartment has been opened for service or if the unithas been cut off for a long period of time, the first freezecycle will be longer than normal. Timing this cycle canresult in an inaccurate production check. To avoid this,start the unit and allow it to operate for 10 minutes in thefreeze cycle, unplug the float switch lead and cause theunit to cycle into harvest mode. Replug the float switchand start timing as soon as the next freeze begins. Alsoremember that the evaporator compartment must beclosed during the production check. Removing the frontcover to check the ice buildup during a production checkwill allow heat into the evaporator and will affect the totalcycle time and actual production.

47 11-01-02

WATER AND REFRIGERATION CIRCUITDRAWING REFERENCE CHART

MODEL PAGE

KM-250B .................................................................... 48KM-250M .................................................................... 49KM-280M .................................................................... 50KML-200MAE, MWE ................................................... 51KML-400MAE, MWE ................................................... 51KM-500MAE, MWE ..................................................... 52KM-500MRE ............................................................... 53KM-630MAE, MWE ..................................................... 52KM-630MRE ............................................................... 53KM-800MAE, MWE ..................................................... 52KM-800MRE ............................................................... 53KM-1200MAE, MWE ................................................... 54KM-1200MRE ............................................................. 55KM-1600MRE ............................................................. 55KM-1200SAE, SWE ................................................... 56KM-1200SRE.............................................................. 57KM-1600SWE ............................................................. 56KM-1600SRE.............................................................. 57KM-2000SWE, SRE .................................................... 58KM-2400SRB ............................................................. 59

NOTE: Some drawings have been combined to repre-sent more than one model.

48 11-01-02

KM-250BAE, KM-250BWE

49 11-01-02

KM-250MAE, KM-250MWE

50 11-01-02

KM-280MAE, KM-280MWE

Note: KM-280MWE has heat exchanger

51 11-01-02

Note: KML-200 models have 1 evaporator plate.

KML-200MAE, KML-200MWE KML-400MAE, KML-400MWE

52 11-01-02

Note: The liquid bypass and external equalized TXV arefor KM-800 MAE/MWE only.

The KM-500 MAE and KM-630 MAE/MWE haveno suction heat exchanger.

KM-500MAE, KM-500MWEKM-630MAE, KM630MWEKM-800MAE, KM-800MWE

53 11-01-02

KM-630 MREKM-500 MREKM-800 MRE

Note: The KM-500MRE has no suction heatexchanger.

The external equalized TXV is for KM-800MRE only.

54 11-01-02

KM-1200 MAEKM-1200 MWE

55 11-01-02

KM-1200 MREKM-1600 MRE

56 11-01-02

KM-1200 SAEKM-1200 SWEKM-1600 SWE

X -

Thi

s liq

uid

bypa

ss is

not

incl

uded

on

the

KM

-16

00 S

WE

57 11-01-02

KM-1200 SREKM-1600 SRE

58 11-01-02

KM-2000 SWEKM-2000 SRE

59 11-01-02

KM-2400SRB3

60 11-01-02

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)

N

OT

E: T

otal

Cyc

le T

ime

= F

reez

e +

Har

vest

.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

MO

DE

L: K

ML

-200

M_E

Sup

ply

Vol

tage

: 115

/60/

1To

tal A

mpe

rage

(C

ompr

esso

r R

LA):

MA

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(9.

1A),

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WE

8.

3AIc

e P

rodu

ctio

n pe

r cy

cle:

3

.9 L

bs,

180

pcs.

Wat

er c

onsu

mpt

ion

for

MW

F c

onde

nser

: 9

0/70

40

6 G

al/2

4 hr

.

70/5

0 2

26 G

al/2

4 H

r.

PE

RF

OR

MA

NC

E D

ATA

50 70 90 50 70 90 50 70 90

50

70

90 50 70 90

Wat

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mp

(F°)

7080

9010

0

A

ir

W

ater

A

ir

Wat

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W

ater

A

ir

W

ater

250

238

241

232

230

223

218

215

240

220

226

208

214

199

203

190

220

190

210

184

199

175

187

167

2024

2122

2122

2423

2121

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24.5

2625

2824

3225

3226

4027

2.5

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2.9

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2.8

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260

223

266

224

268

224

286

227

268

224

278

225

286

226

288

228

276

230

284

233

293

233

300

240

2530

2631

2631

3135

2631

2833

3035

3337

3639

4243

42 4

453

52

61 11-01-02

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

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Am

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vest

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data

is r

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ded

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to th

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L: K

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pres

sor

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): B

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: 9A

, (8

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r cy

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220

pcs

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ater

con

sum

ptio

n fo

r B

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con

dens

er:

90/

70

274

Gal

/24

hr.

70

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116

Gal

/Hr.

PE

RF

OR

MA

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E D

ATA

50 70 90 50 70 90 50 70 90

50

70

90 50 70 90

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A

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230

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194

213

170

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140

209

194

198

185

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165

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135

175

183

179

152

176

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245

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236

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236

255

236

290

236

318

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343

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269

247

303

248

326

249

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249

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4840

50 4

050

4150

4050

4350

4351

44

5144

5344

53 4

454

49

62 11-01-02

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

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igh

Sid

e

Pre

ssur

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: 9A

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cle:

4

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bs,

240

pcs.

Wat

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onsu

mpt

ion

for

MW

E

Con

dens

er:

90

/ 70

31

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al/2

4 hr

:70

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50

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.

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le T

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= F

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to th

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50 70 90 50 70 90 50 70 90

50

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90 50 70 90

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A

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A

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242

224

208

213

178

204

147

196

222

210

191

202

184

193

140

188

200

198

182

187

170

180

132

175

2423

2823

3325

4125

26.5

2333

2433

2543

2629

26.5

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2946

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327

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423

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236

306

236

340

237

250

23

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3 3

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4 3

4324

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4040

4043

4146

4139

4340

43

4347

4647

3943

4043

4449

4650

63 11-01-02

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

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L: K

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uppl

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Tota

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pera

ge (

Com

pres

sor

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): M

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10.

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A

)

MW

E: 9

A,

(

A)

Ice

Pro

duct

ion

per

cycl

e:

5.7

Lbs

, 24

0 pc

s.W

ater

Con

sum

ptio

n fo

r M

WE

C

onde

nser

:

90

/

70

3339

Gal

/24

hr:

70

/ 50

138

Gal

/24

hr.

N

OT

E: T

otal

Cyc

le T

ime

= F

reez

e +

Har

vest

.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

PE

RF

OR

MA

NC

E D

ATA

50 70 90 50 70 90 50 70 90

50

70

90 50 70 90

Wat

erTe

mp

(F°)

7080

9010

0

A

ir

W

ater

A

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Wat

er

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W

ater

A

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W

ater

263

281

231

271

215

262

180

253

240

259

215

251

202

242

164

236

231

225

206

215

188

208

160

202

2729

3229

3430

4231

2830

3331

3532

4333

3031

3632

4133

4734

42

42

42

42

42

42

32

32

42

42

32

32

202

232

232

233

262

234

292

235

215

235

246

235

277

235

310

236

226

237

257

239

288

241

320

243

3338

3538

4839

5339

3342

3543

4846

5346

3347

3548

4949

5350

64 11-01-02

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)

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OT

E: T

otal

Cyc

le T

ime

= F

reez

e +

Har

vest

.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

MO

DE

L: K

ML

-400

M_E

Sup

ply

Vol

tage

: 115

/60/

1To

tal A

mpe

rage

(C

ompr

esso

r R

LA):

MA

E 1

3.25

A (

11.5

A),

M

WE

: 11.

5 A

Ice

Pro

duct

ion

per

cycl

e:

6.6

Lbs,

360

pcs

.W

ater

con

sum

ptio

n fo

r M

WF

con

dens

er:

90/

70

684

Gal

/24

hr.

70

/50

529

Gal

/24H

r.

PE

RF

OR

MA

NC

E D

ATA

50 70 90 50 70 90 50 70 90

5

0 7

090 50 70 90

Wat

erTe

mp

(F°)

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9010

0

A

ir

W

ater

A

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Wat

er

Air

W

ater

A

ir

W

ater

410

429

390

421

375

419

360

412

360

419

340

406

325

395

310

389

305

397

290

379

275

370

255

347

2220

2320

2421

2621

2421

2621

2822

2922

2922

3223

3424

3925

3.5

33

2.8

32.

73

2.8

32.

72

2.3

22

22

32.

63

2.4

22

22

200

233

218

233

223

234

225

236

223

234

254

234

280

235

285

236

247

238

273

241

301

241

320

247

3530

3830

39 3

040

3139

3045

3050

3051

30

4531

5032

5532

60 3

3

65 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DA

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OD

EL:

KM

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M_E

Sup

ply

Vol

tage

: 115

- 12

0/60

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tal A

mpe

rage

(Com

pres

sor R

LA):

MA

E 1

3A (1

1A)

MW

E: 1

2A (1

1A) M

RE

: 15A

(11A

)Ic

e P

rodu

ctio

n pe

r cy

cle:

10.4

Lbs

, 48

0 pc

s.W

ater

Con

sum

ptio

n fo

r M

WE

Con

dens

er:

90

/ 70

67

4 G

al/2

4 hr

:70

/

50

4

40

Gal

/24

hr.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

470

470

450

440

460

420

405

450

390

375

440

360

435

445

435

400

435

405

370

420

380

340

405

360

410

390

415

370

380

385

330

365

355

290

345

325

3029

3034

2934

3630

3638

3238

3231

3235

3135

3832

3842

3442

3335

3337

3737

4242

4248

4048

3.5

33.

52

32

23

22

32

22

22

22

22

22

22

22

22

22

22

22

22

216

232

199

239

232

218

264

232

235

292

232

256

219

232

199

249

233

222

270

235

238

302

235

262

220

238

203

253

238

223

284

239

245

320

239

270

4028

3441

2837

4328

4044

3443

4143

3743

4338

4443

4046

4643

4344

4346

4643

5047

4354

5044

NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

Pre

ssur

e da

ta is

rec

orde

d 5

min

utes

into

the

free

ze c

ycle

66 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

KM

-630

M_E

Sup

ply

Vol

tage

: 20

8-23

0/60

/1

(3-w

ire w

ith n

eutr

al)

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): M

AE

8A

(6A

) M

WE

: 6.5

A (

5A)

MR

E: 1

0A (

6A)

Ice

Pro

duct

ion

per

cycl

e:

14

.3Lb

s, 7

20 p

cs.

Wat

er C

onsu

mpt

ion

for

MW

E C

onde

nser

:

90

/

70

8

28 G

al/2

4 hr

:70

/

50

5

12 G

al/2

4 hr

.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

630

615

500

575

610

560

520

600

510

460

580

460

595

540

580

545

535

545

490

525

495

430

505

445

570

510

540

525

500

500

470

490

455

410

470

410

3233

3534

3336

3734

3743

3542

3336

3636

3638

4037

4145

3745

3539

3938

4140

4241

4348

4248

34

43

43.

52

43

24

22.

52.

52.

52

2.5

22

2.5

22

2.5

22

22

22

22

22

22

2

210

235

206

242

236

220

267

237

239

304

237

273

216

237

210

246

237

228

279

237

256

313

239

286

225

245

212

257

247

235

289

247

289

327

249

291

4041

4343

4344

4444

4547

4145

4445

4446

4547

4645

4848

4553

4851

4851

5350

5353

5154

5454

NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

Pre

ssur

e da

ta is

rec

orde

d 5

min

utes

into

the

free

ze c

ycle

67 11-01-02

50 70 90 50 70 90 50 70 90

50

70

90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RF

OR

MA

NC

E D

ATA

MO

DE

L: K

M-6

30M

AE

/50

Sup

ply

Vol

tage

: 220

-240

/50/

1To

tal A

mpe

rage

(C

ompr

esso

r R

LA):

MA

E 7

A (

6A)

M

WE

: 6.5

A (

6A)

Ice

Pro

duct

ion

per

cycl

e:

14

.3 L

bs, 7

20 p

cs.

A

ir

W

ater

A

ir

Wat

er

Air

W

ater

A

ir

W

ater

564

544

527

540

473

529

421

507

546

504

493

500

448

489

388

469

531

476

485

465

429

454

365

436

3534

3634

4135

4738

3638

3739

4440

5142

3741

4042

4643

5445

N

OT

E: T

otal

Cyc

le T

ime

= F

reez

e +

Har

vest

.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

Wat

er C

onsu

mpt

ion

for

MW

E C

onde

nser

: 90

/ 70

828

Gal

/24

hr.:

70 /

50

512

Gal

/24

hr.

34

34

24

23.

52

2.5

22.

52

2.5

22.

52

22

22

22

2

210

235

242

236

267

237

304

237

216

237

246

237

279

237

313

239

225

245

257

247

289

247

327

249

4041

4343

4444

4744

4445

4645

4645

4845

4851

5153

5353

5454

68 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

KM

-800

M_E

Sup

ply

Vol

tage

: 20

8-23

0/60

/1

(3-w

ire w

ith n

eutr

al)

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): M

AE

12A

(10

A)

MW

E: 1

1A (

10A

) M

RE

: 14A

(10

A)

Ice

Pro

duct

ion

per

cycl

e:

14

.3 L

bs,

720

pcs.

Wat

er C

onsu

mpt

ion

for

MW

E C

onde

nser

:

90

/ 7

0

711

Gal

/24

hr:

70

/ 50

508

Gal

/24

hr.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

826

861

860

776

833

842

769

822

807

721

820

723

818

833

838

767

802

820

760

780

790

694

767

705

798

813

811

750

787

794

736

767

765

650

745

683

2120

2022

.521

20.5

23.5

21.5

2226

2225

.522

.522

.522

24.5

23.5

22.5

24.5

2423

.528

24.5

2724

23.5

23.5

25.5

24.5

2426

2525

3026

284

44

44

43.

53.

53.

52.

53

33

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

22.

52

22

22

22

22

22

22

172

235

199

203

235

199

229

235

213

270

235

249

185

235

201

211

235

202

236

235

213

279

235

256

192

245

202

220

245

206

242

245

216

290

248

259

2424

2428

2424

3124

2634

2428

2824

2631

2426

3424

2638

2431

3134

2836

3431

3734

3144

3436

NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le

69 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

KM

-120

0M_E

Sup

ply

Vol

tage

: 20

8-23

0/60

/1

(3-w

ire w

ith n

eutr

al)

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): M

AE

15A

(11

.5A

) M

WE

: 12A

(10

.5A

) M

RE

: 14A

(11

A)

Ice

Pro

duct

ion

per

cycl

e:

28

.6 L

bs,

1440

pcs

.W

ater

Con

sum

ptio

n fo

r M

WE

Con

dens

er:

70

/ 50

678.

4 G

al/2

4 hr

:90

/

70

1

017

Gal

/24

hr.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

1200

1224

1193

1182

1188

1146

1127

1179

1129

1052

1168

1065

1190

1177

1191

1173

1142

1144

1080

1125

1125

1036

1120

1041

1152

1078

1116

1113

1065

1100

1052

1049

1045

937

1043

977

3031

.531

.533

3332

.535

3333

3834

36.5

3133

.532

3435

3436

.535

3439

.535

37.5

32.5

36.5

3636

3834

38.5

3837

4338

403.

53.

55

33.

55

33.

54.

52.

53.

54

2.5

2.5

32

2.5

32

2.5

32

2.5

2.5

22

2.5

22

2.5

22

2.5

22

2

228

256

228

249

256

228

277

263

242

320

263

270

235

256

228

263

263

235

299

270

249

327

270

277

242

263

228

270

263

235

299

270

258

341

270

284

4460

5360

6353

6563

5580

6463

4661

5461

6557

7365

6080

6764

5464

5765

6760

7367

6481

6768

NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le

70 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

KM

-120

0S_E

Sup

ply

Vol

tage

: 20

8-23

0/60

/1

(3-w

ire w

ith n

eutr

al)

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): S

AE

15A

(11

A)

SW

E: 1

2A (

10.5

A)

SR

E: 1

6A (

11A

)Ic

e P

rodu

ctio

n pe

r cy

cle:

30.9

Lbs

, 14

40 p

cs.

Wat

er C

onsu

mpt

ion

for

MW

E C

onde

nser

:

90

/ 7

0

1155

Gal

/24

hr:

70

/ 50

740

Gal

/24

hr.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

1245

1200

1240

1150

1150

1210

1100

1120

1190

1060

1110

1140

1210

1150

1210

1145

1120

1160

1090

1130

1130

1050

1080

1160

1190

1125

1100

1110

1110

1050

1040

1070

1010

990

950

950

3332

3237

3234

4032

3442

3436

3635

3339

3536

4135

3643

3539

3735

3640

3738

4337

3944

3841

4.5

4.5

4.5

44

43

44

2.5

33.

52.

53

2.5

2.5

32.

52.

52.

52

22.

52

22.

22.

52

22.

52

22

22

2

205

235

199

240

235

222

263

235

237

298

235

270

213

235

203

248

235

225

270

236

245

306

236

292

220

243

199

256

245

228

284

249

256

313

249

294

3653

5038

5350

3853

5041

5353

3653

5038

5350

4353

5043

5355

3757

5038

5751

4757

5447

5758

NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

P

ress

ure

data

is r

ecor

ded

5 m

inut

es in

to th

e fr

eeze

cyc

le

71 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Cyc

le T

ime

Free

ze

Cyc

le T

ime

Har

vest

Pre

ssur

eH

igh

Sid

e

Pre

ssur

eS

uctio

n

Am

bien

t Tem

p (F

°)70

8090

100

PE

RF

OR

MA

NC

E D

ATA

MO

DE

L: K

M 1

200S

_E50

Sup

ply

Vol

tage

: 220

- 2

40 /

50 /

1To

tal A

mpe

rage

(C

ompr

esso

r R

LA, s

ee u

nit n

ame

plat

e): S

AE

13A

, SW

E 1

2A, S

RE

13A

Ice

Pro

duct

ion

per

cycl

e:

3

0.9

Lbs,

144

0 pc

s.W

ater

Con

sum

ptio

n fo

r S

WE

50

C

onde

nser

:

90 /

70

1

144

Gal

/24

hr:

70

/ 50

6

97 G

al/2

4 hr

.

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

A

ir

W

ater

Rem

ote

1185

1150

1205

1060

1125

1140

990

1110

1100

955

1100

1050

1145

1110

1175

1060

1105

1090

980

1085

1030

940

1070

975

1125

1080

1070

1030

1070

985

935

1060

930

895

1050

875

NO

TES:

To

tal c

ycle

tim

e =

Free

ze +

Har

vest

Pres

sure

dat

a is

reco

rded

5 m

inut

es in

to fr

eeze

cyc

le

4353

4146

5341

4653

4150

5343

3853

4142

5343

4653

4346

5347

4054

4142

5443

4754

4647

5450

3337

.540

36.5

3842

4038

4242

4044

35.5

41.5

4038

.541

.543

.540

.541

.543

.542

.541

.546

3742

4441

.544

.546

4444

.548

45.4

45.5

504.

55.

54

4.5

54

35

3.5

2.5

43.

52.

53

32.

53

32.

52.

52.

52

2.5

2.5

22.

52.

52

22.

52

22

22

2

213

223

206

248

223

218

272

223

225

308

223

242

213

223

209

248

223

220

270

228

235

306

228

260

220

232

206

256

233

223

284

237

245

313

237

263

72 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Am

bien

t Tem

p (F

°)70

8090

100

Pre

ssur

eH

igh

Sid

e

1590

1540

1470

1380

1570

1515

1430

1350

1470

1405

1325

1220

Rem

ote

Rem

ote

Rem

ote

Rem

ote

Cyc

le T

ime

Fr

eeze

Cyc

le T

ime

Har

vest

Pre

ssur

eS

uctio

n NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

Pre

ssur

e da

ta is

reco

rded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

2324

2527

2526

2830

2730

3134

55

4.5

43

33

2.5

2.5

2.5

2.5

2

200

229

243

283

203

231

246

286

204

233

249

290

3637

3739

3637

3939

3739

3943

50 70 90

PE

RF

OR

MA

NC

E D

ATA

MO

DE

L: K

M-1

600M

RE

Sup

ply

Vol

tage

: 208

-230

/60

/ 1 (

3 w

ire w

ith n

eutr

al)

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): 2

0A (

17A

)Ic

e P

rodu

ctio

n pe

r cy

cle:

28.

6 Lb

s, 1

440

pcs.

73 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Am

bien

t Tem

p (F

°)70

8090

100

Pre

ssur

eH

igh

Sid

e

1560

1510

1440

1350

1540

1485

1400

1320

1440

1375

1295

1190

Rem

ote

Rem

ote

Rem

ote

Rem

ote

Cyc

le T

ime

Fr

eeze

Cyc

le T

ime

Har

vest

Pre

ssur

eS

uctio

n NO

TE

: Tot

al C

ycle

Tim

e =

Fre

eze

+ H

arve

st.

Pre

ssur

e da

ta is

reco

rded

5 m

inut

es in

to th

e fr

eeze

cyc

le.

2324

2527

2526

2830

2730

3134

55

4.5

43

33

2.5

2.5

2.5

2.5

2

200

229

243

283

203

231

246

286

204

233

249

290

3637

3739

3637

3939

3739

3943

50 70 90

PE

RF

OR

MA

NC

E D

ATA

MO

DE

L: K

M-1

600M

RE

3S

uppl

y V

olta

ge: 2

08-2

30/6

0/3

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): 1

3.5A

(10

A)

Ice

Pro

duct

ion

per

cycl

e: 2

8.6

Lbs,

144

0 pc

s.

74 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

KM

-160

0S_E

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sum

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r

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dens

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90

/ 70

1442

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hr:

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1520

1540

1510

1500

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1440

1480

1340

1465

1500

1455

1430

1445

1360

1425

1240

1295

1350

1285

1300

1275

1230

1255

1100

2323

2424

24.5

2625

2827

2627

.527

27.5

28.5

2832

3129

31.5

3031

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3236

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55

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33

33

33

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235

199

235

216

235

239

235

277

235

199

235

220

236

242

236

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250

225

252

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253

284

3633

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3736

3738

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Tim

e =

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le.

50 70 90

75 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

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mp

(F°)

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duct

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24 h

ours

Am

bien

t Tem

p (F

°)70

8090

100

PE

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AN

CE

DAT

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EL:

KM

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:

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89 G

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1540

1510

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50 70 90

76 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

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mp

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24 h

ours

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p (F

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:

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2026

1905

1990

1860

1970

1820

1940

1760

1970

1900

1960

1905

1952

1733

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1650

1810

1820

1780

1750

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50 70 90

77 11-01-02

50 70 90 50 70 90 50 70 90 50 70 90

Wat

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mp

(F°)

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ion

24 h

ours

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50 70 90

78 11-01-02

KM

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79 11-01-02

KM

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80 11-01-02

81 11-01-02

NOTE:A: Crankcase Heater, Remote Fan, and line valve for

KM-500 MRE onlyB: Fan and Thermostat on KM-500 MWE, MRE only.C: Condenser fan for MAE units replaces line valve / fan

on KI pin 3.

82 11-01-02

CKM-280 M_E

83 11-01-02

DKML-200 MAE, MWEKML-400 MAE, MWE

84 11-01-02

EKM-630 MAE, MWEKM-800 MAE, MWE

85 11-01-02

FKM-630 MAE 50, MWE 50

86 11-01-02

NOTE:Bypass valve for KM-1200 remotes only

G

87 11-01-02

NOTE:A: Fans, Relay and Bypass valve for air cooled onlyB: KM-1200 SAE has one fan only

H

88 11-01-02

I

KM-1200 SAE 50KM-1200 SWE 50

89 11-01-02

J

KM-1200 SRE 50

90 11-01-02

K

KM-1600 SWE

91 11-01-02

208-

230/

60/3

L

KM-1600 SWE3

3313

19-0

1A

WIR

E C

OLO

R C

OD

EB

R-B

RO

WN

W-W

HIT

EB

K-B

LAC

KR

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DO

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AN

GE

GY

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KD

Bu

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RLB

LUE

V-V

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TY

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W

92 11-01-02

M

93 11-01-02

N

94 11-01-02

O

95 11-01-02

P

96 11-01-02

FLAKER/DCM

INSTALLATION - GENERAL

Three things are critical for a proper F/DCM installation:

1. The water temperature should fall within the 45° Fto 90° F range.

Colder water can cause excess stress on theauger gear motor which may activate the gearmotor overload.

2. A filter system is very important in poor waterquality areas as high mineral content can causepremature bearing wear.

3. The unit should be level, front to back, side toside to assure proper evaporator water level andmaximum production.

CUBELET MODELS

The DCM product produces Cubelet ice. Certain flakermodels can also be converted to produce cubelet ice.This requires changing the extruding head and cutter atthe top of the evaporator assembly. The F-650M, F-1000M, and F-2000M models are produced as cubeletmodels and are designated by a - C at the end of themodel number.

Converting a flaker to a cubelet maker reduces theoverall production by around 8 %. The flaker gear motoris sized to handle the extra load of producing cubelet icewith only a slight increase in the running amperage. Theevaporator outlet temperature and operating pressureswill be similar to the standard flaker model. Use thetemperature and pressure information provided on thestandard flaker performance data provided as a benchmark when diagnosing a converted cubelet (- C) unit.

97 11-01-02

COMPONENT TECHNICAL DATA

GEAR MOTOR SAFETIES

The auger gear motor circuit includes two overloadsafeties. The primary safety is a manual reset, currenttype protector located in the control box. This is a timedelay protector which operates at .9 amp over thenormal gear motor amp draw. The secondary safety is athermal protector which is incorporated into the gearmotor windings.

AUGER BEARINGS -Bearing Type: Sleeve/AlignmentBearing Material: Poly/Carbon

The bearings are pressed into the top extruding headand lower brass housing. A repress program is availablethrough the local Hoshizaki Distributor.

BEARING INSPECTIONSAnnual bearing inspections are recommended. Morefrequent inspections may be necessary in poor waterquality areas.The steps for bearing inspections are as follows:(1 ) Gain access to the ice chute head by removing thetop panel and spout connectors as necessary.(2) Remove the thumbnuts which hold the ice chute headin place and lift it up and off of the evaporator (take careto place the O-ring in a safe location until you replace thehead.)(3) Remove the stainless steel bolt holding the cutter orbreaker in place and lift off to access the extruding headand auger shaft.(4) Replace the bolt into the auger shaft and use it topush the auger back and forth from left to right to checkfor 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 theauger shaft and bearing surface. Check severallocations around the auger shaft. If the gauge will go inbetween the shaft and bearing, it is time to install newbearings. Both top and bottom bearings should bereplaced if the top bearing is worn. If there is noexcessive movement in the auger shaft and the gaugedoes not fit, the bearings are okay. Replace the cutter, O-ring, ice chute head and connectors.

98 11-01-02

AUGER INSPECTION / BEARINGREPLACEMENT

A visual inspection of the auger bearing shaft surface isalso recommended annually in poor water areas. The stepsfor this inspection is as follows:

Note: Clean the evaporator prior to removing the auger.This will loosen scale around the extruding headand allow for easier removal.

(1) Follow steps 1 through 5 of the bearing inspectionprocedure above.

(2) Remove the (metric) Allen head cap screws that se-cure the extruding head in place.

(3) Thoroughly drain the water supply system.

4) Turn the cutter up-side down, replace the bolt and usethe cutter to lift the auger out of the evaporator. If heavyscale is present the auger may be difficult to remove. In thiscase, you will find it helpful to clean the evaporator systemfollowing the instructions located on the Inside front panel,before you attempt to remove the auger.

Older DCM units have a key welded on the inside of theevaporator cylinder. The auger has a key slot cut into thespiral flite. This keyway slot must align with the evaporatorkey before you can lift out the auger. Before attempting toremove the auger, remove the extruding head and lookinside the cylinder to align the slot and key while turning theauger.

(5) With the auger removed, remove the cutter and slidethe extruding head from the top of the auger. Visually in-spect the bearing surface at the top and bottom of theauger. Also inspect the auger flight and mechanical sealfor any damage. The extruding head contains the topbearing, the bottom bearing is pressed into the brass hous-ing at the bottom of the evaporator. To remove the housing:

(6) Remove the Allen screws that secure the evaporatorto the housing.

(7) Loosen the belly band screw and lift the evaporator up

99 11-01-02

and off of the housing. Holding the evaporator up, re-tightenthe belly band. This will hold the evaporator up so that youcan remove the housing.

(8) Remove the bolts that secure the housing to the gearmotor assembly and remove the brass housing. The me-chanical seal ceramic disk and boot are pressed into thetop of the housing. Remove these parts before you ex-change the bearings. The extruding head and brass hous-ing will be exchanged for a repressed set at your localdistributor. When you replace the new parts, reverse theorder above. Use a light coat of food grade lubricant aroundthe bottom of the evaporator and on the o-ring portion ofthe housing to the seal o-ring and help keep it in place asyou lower the evaporator. Inspect the mechanical seal thor-oughly and reuse it, if it is in good shape.

Flaker Safety’s Mechanical failures in an auger style ice machine can betime consuming and expensive repairs. Hoshizaki has in-corporated several safety’s in our Flaker and DCM unitswhich add protection against this type of failure.

The following safety’s are included in all Hoshizaki F andDCM units:1. Low water safety: Designed to protect against dryoperation or possible freeze up in the evaporator due tolow water flow. This safety utilizes the dual float switchand a 90 second timer to shut down the unit when waterflow is interrupted. The unit will automatically restart whenwater flow is resumed.

2. Protect relay safety: This safety incorporates a relay inthe gear motor circuit and will not allow the refrigerationsystem to operate unless the gear motor is running. If thegear motor fails during normal operation, the protect relayshuts down the compressor to protect against evaporatorfreeze-up.

3. Gear motor circuit safety’s: The gear motor has 2additional safety’s which will operate if the gear motor issubjected to excessive load or improper voltage. A cur-rent type manual reset safety or slow blow fuse is locatedin the control box and will trip when the gear motor amper-ageexceeds normal amp draw. This acts as a primary safetyfor the gear motor. A secondary internal thermal overload

100 11-01-02

is included in the motor windings. Both will work in con-junction with the protect relay to shut the unit down.

4. Voltage protect relay: This relay will shut the unit off incase of a voltage surge and automatically restart the unitwhen the voltage is correct.

5. High pressure switch: All Hoshizaki ice machines in-clude an automatic reset high pressure safety switch toshut down the unit in case of high head pressures.

6. Fuse protection: A lamp buss-type fuse is utilized in thecontrol circuit. Smaller units like the DCM-240 and F-300have a fuse in the incoming power circuit.

7. Short cycle protection timer: A 1 minute time delay isincluded in the start-up sequence to protect against shortcycling the gear motor or compressor.

8. Compressor protection is provided either internally or bymeans of an external motor circuit protector. This is anautomatic reset thermal type circuit breaker.

9. The F-2000 has a spout safety control to shut down theunit if the bin control fails for any reason. This is a manualreset safety and will notify the technician by means of aindicator light on the control box. To reset this safety, turnthe control switch OFF and back ON. This re-sets the hold-ing relay circuit and turns off the light.

The gear motor current protector serves as a back-up forthe bin control on other models. These safety’s protect theFlaker or DCM models from internal failures.

DUAL FLOAT SWITCH

Hoshizaki float switch, part number 435490-01 can be usedas a universal replacement on any Hoshizaki Flaker or DCMmodel in the field. It now subs for all previous float switchnumbers in our parts system.

Since the float switch is mounted into the water reservoir,it is susceptible to scale build-up. The amount of scalebuild-up will depend on the local water quality. Scale on the

101 11-01-02

switch shaft can cause the floats to stick. This will effectthe unit operation. In this case, the float switch should becleaned and checked.

The float switch is held in place on the top cover by a twistlock bracket. To remove it, twist the switch flange and lift.Soak the switch assembly in ice machine cleaner. While itis not necessary to do so, some technicians remove thefloats from the shaft during cleaning. If you remove them,note that the blue float is on top. Also it is important toclearly mark the top of the floats so that they can be re-placed correctly. (See drawing below). Installing the floatsupside down will effect the timing of the float switch op-eration. Once clean, rinse and wipe the cleaner off andcheck the switch with a good quality ohm meter.

This float switch has three wires (the black wire is com-mon) and two separate switches. Check the top switchby ohming out the black and red wires. When the float is upthe switch should be closed. Check the bottom switch byohming out the black and blue wires in the same manner. Ifeither switch fails, the assembly should be replaced.

(bottom) (top)

102 11-01-02

FLAKER WATER FILL SYSTEMThe reservoir in a Hoshizaki auger type ice maker feedswater by gravity flow to the evaporator cylinder. The levelof water in the reservoir is maintained by the operation ofthe dual float switch.

The dual float switch assembly is made up of two reedswitches inside of a sealed shaft. The reed switch con-tacts are operated by individual magnets attached inside ofthe 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 alatching circuit). Opening these contacts allows the bot-tom float switch control of the water control relay in thecontrol circuit. As the water level continues to drop, thebottom float contacts open to de-energize the water con-trol relay.De-energizing the water control relay closes a circuit tosupply 24 volts to the inlet water valve solenoid. This al-lows water to fill the reservoir. It also opens a circuit to thetimer board which starts a 90 second low water safetyshutdown timer.

When the water supply is available, the reservoir refills.As the reservoir level rises, these two switches swapjobs. The bottom float is now the latching circuit and thetop float re-energizes the water control relay. This willstop the safety timer and shut off the water flow.

If no water is available, i.e. the filter is stopped up or thewater supply is turned off, the unit cycles down and thewater valve remains energized. When the water supply isrestored, the reservoir fills and the top float switch re-energizes the water control relay to automatically restartthe unit. This system provides a consistent water level inthe reservoir and an automatic reset low water safetyprotection.

Since the float switch is mounted into the water reservoir,it is susceptible to scale build-up. The amount of scalebuild-up will depend on the local water quality. Scale onthe switch shaft can cause the floats to stick. This willeffect the unit operation. In this case, the float switchshould be cleaned and checked.

103 11-01-02

FLAKER TIMER BOARDThe solid state timer board used in Hoshizaki Flakers is asimple electronic sequence timer. In order for the board tosequence, certain circuits must be closed. In order to diag-nose a bad timer board, it is necessary to check thesecircuits to assure they are operating properly. If you aretrouble-shooting a timer, the first thing you should check isthe in coming control voltage. All Hoshizaki flakers have a24 volt control transformer. The output of this transformeris protected by a 1 amp buss type fuse. Control voltagecomes in the timer on pins 1 & 2. If you do not have 24 voltsat pins 1 & 2, check the transformer and fuse.

Now check for voltage across pins 7 & 8. This could beline voltage or control voltage, depending on the model.Review the unit wiring diagram prior to checking 7 & 8 todetermine the correct voltage. If voltage is present, thetimer board has cycled up which indicates there is not aproblem in the timer board. The problem is in the gear motorrelay circuit. remember that there is a time delay from thetime you turn the unit on to the time it cycles up completely.this time will be from 1 ~ 2.5 minutes, depending on themodel of flaker.

In order for the flaker to start up, the reservoir must be fulland both float switches must be closed. This closes thecontrol circuit to pins 3 & 4. Do not confuse these pins withthe line voltage terminals marked 3 & 4 on the compressorrelay located on the board. You can check this circuit witha volt meter across the pins or by placing a jumper acrossthem. If the unit cycles up with the jumper in place, theboard is good and your problem is in the water relay con-trol circuit.

Next, you should check the bin control circuit at pins 5 & 6.Check for a closed circuit with a volt meter or place ajumper across them. If the unit cycles up with the jumperin place, the board is good and the bin control circuit is theproblem.

The last circuit check is across pins 10 & 11. These pinsconnect to the gear motor protect relay and will shut downthe unit if the gear motor fails. Check for a closed circuitwith a volt meter or place a jumper across them. If the unitcycles up with the jumper in place, the board is good andthe gear motor protect circuit is suspect.

104 11-01-02

Flaker Sequence of Operation

The Hoshizaki Flaker utilizes a solid state sequence timerboard to switch the components on and off as needed.The sequence is as follows:

With proper voltage and water supplied to the Flaker andthe flush and ice switch is in the ice position, power issupplied to the inlet water valve. The unit will not startunless the reservoir is full and both floats on the dual floatswitch are closed (in the up position). The operation isthen turned over to the bin control. If the bin control isclosed and calling for ice, the gear motor and condenserfan motor are energized. One minute later, the compressorstarts. As the refrigeration systems cools the water in theevaporator, ice will start to form within 2 to 5 minutes. Thisdepends on the inlet water temperature and ambient condi-tions. Ice production will continue until the bin control issatisfied (opens). The shut down process is very simple.On the F-450, F-800, F-1000, and F-2000 units, the entireunit shuts down within 6 seconds after the bin controlswitch opens. On the F-300 and F-500, approximately 90seconds after the bin control switch opens, the compres-sor stops, on minute later the gear motor and condenserfan motor stop. This sequence of operation is accom-plished through a series of timers within the solid statetimer board.

105 11-01-02

106 11-01-02

DCM SEQUENCE OF OPERATION

DCM sequence for the ice making unit is similar to theF450, with a delay of the compressor at start up and adelay of the gear motor at shut down.

A periodic flush is not incorporated in the DCM units.DCM-450 and 700 models have periodic agitation in thebin to eliminate ice bridging. The solid state timer boardwill start the agitation motor for .6 seconds every 2 hours.It will also start the agitation motor for .6 seconds every10 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 tocatch the ice and a set of scales to weigh the ice. Afterthe unit has operated for 10 to 20 minutes, catch the iceproduction for 10 full minutes. Weigh the ice to establishthe batch weight. Multiply the batch weight by 144 for thetotal production in 24 hours. Some prefer to catch the icefor 20 minutes and multiply the weight by 72 for a morerealistic production check. It is true that a longer catch ismore accurate, however, it doubles your test time andmay only show a 1 to 2% difference in production.Performing a production check is an excellent way toprove proper F/DCM operation.

FLAKER PERIODIC FLUSH

Beginning with the F-650 and larger flakers, a periodicflush cycle is included. A 12 hour timer will cycle the unitdown and open the flush valve which allows the completewater system to drain. The unit will remain off for 15minutes which allows any ice remaining in the evaporatorto melt and flush the evaporator walls and mechanicalseal out. The inlet water valve is not energized during thisflush period. The unit will automatically restart after 15minutes on the flush timer.The F-450 will flush when the bin control is open.

107 11-01-02

108 11-01-02

WATER AND REFRIGERATION CIRCUITDRAWING REFERENCE CHART

MODEL DRAWING PAGE

F-250B ....................................... A .................... 104F-450B ....................................... A ................... 104F-650MAE, MWE ........................ B .................... 105F-1000MAE, MWE ...................... B .................... 105F-1000MRE ................................ C.................... 106F-2000MWE ............................... D.................... 107F-2000MRE3, MRE ..................... E .................... 108F-2000MLE ................................. F .................... 109DCM-240B .................................. G ................... 110DCM-450B .................................. H.................... 111DCM-700B .................................. H.................... 111

NOTE: Some drawings have been combined torepresent more than one model.

109 11-01-02

AF-250BAEF-450BAE

F-250 has a manual evaporator drain and no high sideaccess valve.

110 11-01-02

BF-650MAE, F-650MWE

F-1000MAE, F-1000MWE

111 11-01-02

CF-1000MRE

112 11-01-02

DF-2000MWE

113 11-01-02

E

F-2000MRE3F-2000MRE

114 11-01-02

FF-2000MLE

115 11-01-02

GDCM-240BAE

116 11-01-02

HDCM-450BAE, DCM-450BWEDCM-700BAE, DCM-700BWE

117 11-01-02

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ress

ure

PS

IG

183

213

214

213

245

215

276

215

183

213

214

213

245

213

276

215

183

216

214

216

245

216

276

216

24

2626

2627

2628

2724

2626

2628

2630

2724

2627

2628

2731

27

127 11-01-02

50 70 90 50 70 90 50 70 90

50

70

90

Wat

erTe

mp

(F°)

Pro

duct

ion

24 h

ours

Am

bien

t Tem

p (F

°)70

8090

100

PE

RFO

RM

AN

CE

DAT

AM

OD

EL:

DC

M-7

00 B

_ES

uppl

y V

olta

ge: 1

15-1

20 /

60

/ 1

Tota

l Am

pera

ge (

Com

pres

sor

RLA

): B

AE

14.

6A (

10A

)

BW

E: 1

4.1A

, (1

0A)

Wat

er C

onsu

mpt

ion:

(w

ater

coo

led

cond

.)

7

0 /

50

3

40

Gal

/24

hr,

90

/ 70

4

67

Gal

/24

hr.

A

ir

W

ater

A

ir

Wat

er

Air

W

ater

A

ir

W

ater

664

631

608

617

553

602

498

591

631

584

582

567

547

547

478

534

597

534

547

514

503

496

456

478

App

roxi

mat

e

Eva

pora

tor

Out

let

Tem

p (°

F)

Hea

dP

ress

ure

PS

IGS

uctio

nP

ress

ure

PS

IG

26

2627

2727

2730

3026

2627

2730

3031

3126

2627

2730

3034

33

149

212

171

213

199

213

232

213

152

213

176

213

201

215

233

215

155

215

182

215

208

215

235

216

14

15.8

1415

.815

.817

.617

.617

.614

15.8

1415

.815

.817

.617

.617

.615

.817

.615

.817

.617

.617

.619

.417

.6

128 11-01-02

FL

AK

ER

/ D

CM

Wir

ing

Dia

gra

m R

efer

ence

Ch

art

Sta

rtC

apac

itor

Run

Cap

acito

rFa

nC

apac

itor

Gea

rM

otor

Mod

el N

umbe

rP

age

Wiri

ng D

iagr

am

DC

M-2

40 B

AE

M12

910

0 M

FD

30 M

FD

- -

10 M

FD

DC

M-4

50 B

AE

, BW

EN

130

270

- 324

MF

D55

MF

D2.

5 M

FD

12 M

FD

DC

M-7

00 B

AE

, BW

EO

131

88 -

108

MF

D25

MF

D6

MF

D24

MF

D

F25

0 B

AE

P13

215

0 M

FD

20 M

FD

- -

10 M

FD

F-4

50 B

AE

Q13

327

0 - 3

24 M

FD

15 M

FD

2.5

MF

D10

MF

D

F-6

50 M

AE

, MW

ER

134

270

- 324

MF

D55

MF

D6

MF

D10

MF

D

F-1

000

MA

E, M

WE

, MR

ES

135

108

- 130

MF

D25

MF

D6

MF

D12

MF

D

F-1

000

MA

E 5

0, M

WE

50

T13

618

9 - 2

27 M

FD

25 M

FD

5 M

FD

12 M

FD

F-2

000

MW

E, M

RE

U13

713

5 - 1

62 M

FD

40 M

FD

10 M

FD

65 M

FD

F20

00 M

RE

3V

138

——

—65

MF

D

F-2

000

MLE

W13

9—

——

65 M

FD

129 11-01-02

130 11-01-02

131 11-01-02

132 11-01-02

133 11-01-02

134 11-01-02

135 11-01-02

136 11-01-02

TF-1000 MAE / 50F-1000 MWE / 50

137 11-01-02

U

F-2000MREF-2000MWE

138 11-01-02

F-2000MRE3V

139 11-01-02

F-2000MLE

W

140 11-01-02

NOTES

spec’s technician’s pocket guide - hoshizaki america, inc. · 5 11-01-02 hoshizaki model number...

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