Instruction/ maintenance manual of the product KM-201BAH Hoshizaki
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SER VICE MANUAL HOSHIZAKI SELF-CONTAINED CRESCENT CUBER MODEL KM-201BAH KM-260BAH KM-201BWH KM-260BWH NO. F015-774 ISSUED: MAR. 18, 2009 REVISED: JUN. 17, 201 1.
IMPORT ANT Only qualified service technicians should install, service or maintain the product. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the equipment in accordance with this manual may adversely affect safety , performance, and warranty coverage.
IMPORT ANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only quali fi ed service technicians should install, service, and maintain the icemaker . Read the warnings contained in this booklet carefully as they give important information regarding safety .
[a] KM-201BAH, KM-260BAH ----------------------------------------------------------------- 26 [b] KM-201BWH, KM-260BWH --------------------------------------------------------------- 27 2. WIRING DIAGRAM ------------------------------------------------------------------------------ 28 3.
[c] FUSE HOLDER ------------------------------------------------------------------------------- 66 [d] CONTROL BOARD -------------------------------------------------------------------------- 66 [e] P.
1 I. SPECIFICA TIONS 1. SPECIFICA TIONS [a] KM-201BAH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 6.1 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.
2 [b] KM-260BAH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.6 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.
3 [c] KM-201BWH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 5.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.
4 [d] KM-260BWH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.
5 II. GENERAL INFORMA TION 1. CONSTRUCTION [a] KM-201BAH, KM-260BAH T op Panel Side Panel (L) Front Cover Rear Panel Door Air Filter Louver Leg Side Panel (R) Power Supply Cord T op Cover Hot Gas V al.
6 [b] KM-201BWH T op Panel Side Panel (L) Front Cover Rear Panel Door Side Panel (R) Louver Power Supply Cord Leg T op Cover Drain V alve Hot Gas V alve Cleaning V alve Thermistor W ater Regulator Eva.
7 [c] KM-260BWH T op Panel Front Cover Side Panel (L) Rear Panel Door Side Panel (R) Louver Power Supply Cord L e g T op Cover Drain V alve Hot Gas V alve Thermistor Cleaning V alve W ater Regulator E.
8 [d] ICEMAKING COMP ARTMENT Spray Tube Evaporator W ater Supply Pipe Separator Cube Guide W ater T ank Over fl ow Pipe Drain V alve Cleaning V alve Separator W ater V alve Pump Motor Float Switch.
9 2. SEQUENCE OF OPERA TION The steps in the sequence are as outlined below . When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 9, 4, 7. [a] ONE MINUTE FILL CYCLE LED 8 is on.
10 the control board setting, pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle (S1 dip switch 5 & 6). [e] NORMAL HAR VEST CYCLE LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48°F (9°C).
11 Components Energized when the Control Switch is in the “SERVICE” Position When in the “SERVICE” position, the control switch supplies power to the service switch and the machine is in service mode. The service switch has three positions: “DRAIN”, “CIRCULA TE”, and “WASH”.
12 3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in crescent cubers. * All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully . 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge.
13 [a] CONTROL BOARD LA YOUT )$POUSPM#PBSE r 0651655&45#VUUPO VTFEUPUFTUSFMBZTPO DPOUSPMCPBSE r ,$POOFDUPS 0QFO r ,$POOFDUPS .
14 [b] FEA TURES a) Maximum W ater Supply Period - 6 minutes The inlet water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter .
15 seconds and the icemaker automatically stops. The control board will signal this problem using 7 beeps every 3 seconds. The icemaker also automatically stops in cases of insuf fi cient voltage (92V ac ± 5% or less). The control board will signal this problem using 6 beeps every 3 seconds.
16 6 Low V oltage (92V ac ± 5% or less) “ POWER OK” LED will turn off if voltage protection operates. The control voltage safeties automaticlly reset when voltage is corrected.
17 Fig. 1 Fig. 2 Freeze T imer (9 & 10) W ater Saver T imer (7 & 8) Pump-Out Frequency Control (5 & 6) Pump-Out T imer (3 & 4) Harvest T imer (1 & 2) S1 Dip Switch S2 Dip Switch An.
18 Pump-out cycle always occurs on the 2nd harvest after startup. Then, depending on the pump-out frequency control setting (S1 dip switch 5 & 6), pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle.
19 The freeze timer is factory adjusted, and no adjustment is required. Dip Switch Setting T ime (minutes) No. 9 No. 10 ON OFF 50 OFF OFF 60 OFF ON 70 ON ON 100 g) Pump-Out Pump Motor Delay (S2 dip sw.
20 S2 Dip Switch Setting Anti-Slush Control No. 5 No. 6 OFF OFF Activated (V er . 1.0) ON OFF Activated (V er . 2.0) OFF ON Deactivated ON ON Deactivated Control Board P01771-02 j) Harvest Promotion Control (S2 dip switch 2) [Program V er . 3.2] Do not adjust.
21 m) Overfreeze Detection Control (S2 dip switch 5) [Program V er . 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly .
22 1) Check the dip switch settings to assure that S1 dip switch 3, 4, 7, 8, 9 & 10 and S2 dip switch 1 through 6 are in the factory default position. S1 dip switch 1, 2, 5, & 6 are cleaning adjustments and the settings are fl exible. 2) Move the control switch to the “ICE” position and check for proper control voltage.
23 4) Check for resistance between the thermistor leads. Normal reading is within 4.7 to 6.2 k . Replace the thermistor if it exceeds the normal reading. 5. BIN CONTROL This machine uses a lever-actuated proximity switch (mechanical bin control) to control the ice level in the storage bin.
24 5) Disconnect the bin control at the 2-pin connector attached to the black wires coming from the K1 connector (pins 4 & 5) on the control board. 6) Check for continuity across the bin control leads. When calling for ice, the bin control proximity switch should be closed.
25 b) CIRCULA TE When the service switch is active and placed in the “CIRCULA TE” position, power is supplied to the pump only . This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator .
26 Evaporator Float Switch Cube Guide Drier Thermistor Suction Line Water Supply Water Valve Spray Tube Fan Condenser Expansion Valve Compressor A ccess Valve Strainer Hot Gas .
27 [b] KM-201BWH, KM-260BWH Evaporator Float Switch Drain Cube Guide Drier Cleaning V a lv e Thermistor Suction Line Water Supply Water Valve Spray Tube Water Condenser Expansion V.
28 2. WIRING DIAGRAM.
29 3. TIMING CHART [a] KM-201BAH 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec HARVEST CYCLE Thermistor senses 9°C after 6 min to 8 min 30 sec in harvest cycle (Ver 3.1 or later) 6min 60sec HARVEST CYCLE Thermistor senses 9°C after more than 8 min 30 sec in harvest cycle (Ver 3.
30 [b] KM-260BAH 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec HARVEST CYCLE Thermistor senses 9°C after 6 min to 8 min 50 sec in harvest cycle (Ver 3.1 or later) 6min 60sec HARVEST CYCLE Thermistor senses 9°C after more than 8 min 50 sec in harvest cycle (Ver 3.
31 [c] KM-201BWH 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec 30sec HARVEST CYCLE Thermistor senses 9°C after more than 8 min 30 sec in harvest cycle (Ver 3.1 or later) HARVEST CYCLE Thermistor senses 9°C after 6 min to 8 min 30 sec in harvest cycle (Ver 3.
32 [d] KM-260BWH 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec 10sec HARVEST CYCLE Thermistor senses 9°C after 6 min to 8 min 50 sec in harvest cycle (Ver 3.
33 4. PERFORMANCE DA T A [a] KM-201BAH 70/21 201 91 190 86 176 80 80/27 193 88 177 80 162 73 90/32 190 86 165 75 150 68 lbs./day kg./day 100/38 187 85 161 73 136 62 70/21 80/27 90/32 watts 100/38 70/21 72 0.27 61 0.23 54 0.20 80/27 64 0.24 48 0.18 44 0.
34 [b] KM-260BAH 70/21 263 119 245 111 227 103 80/27 249 113 220 100 207 94 90/32 245 111 200 91 185 84 lbs./day kg./day 100/38 244 111 196 89 171 78 70/21 80/27 90/32 watts 100/38 70/21 78 0.30 67 0.25 60 0.23 80/27 70 0.26 53 0.20 50 0.19 90/32 67 0.
35 [c] KM-201BWH 70/21 215 98 205 93 192 87 80/27 207 94 192 87 180 82 90/32 205 93 181 82 168 76 lbs./day kg./day 100/38 203 92 178 81 157 71 70/21 80/27 90/32 watts 100/38 70/21 55 0.21 52 0.20 47 0.18 80/27 52 0.20 47 0.18 42 0.16 90/32 52 0.20 43 0.
36 [d] KM-260BWH 70/21 268 122 259 117 242 110 80/27 261 118 247 112 228 103 90/32 259 117 237 108 218 99 lbs./day kg./day 100/38 254 115 233 106 201 91 70/21 80/27 90/32 watts 100/38 70/21 77 0.29 73 0.27 65 0.25 80/27 74 0.28 67 0.25 58 0.22 90/32 73 0.
37 IV . SERVICE DIAGNOSIS 1. DIAGNOSTIC PROCEDURE The diagnostic procedure is basically a sequence check which can be used at unit start- up or for system diagnosis.
38 starts after the thermistor temperature reaches 36°F (2°C). After this period, the freeze cycle operation is transferred to the fl oat switch for freeze termination. During the fi rst 5 minutes of freeze, con fi rm that the evaporator temperature drops.
39 2. NO ICE PRODUCTION PROBLEM P OSSIBLE CAUSE REME DY 1. OFF position. 1. Move to ON position. 2. Loose connections . 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace. 4. Voltage too hi gh. 4. Chec k and get recommended volt age. a) Power Supp ly 5.
40 PROBL EM POSSIBL E CAUSE REMEDY [1] (Continued) l) Control Board 1. De fective. 1. See “II. 3. [d] CONTROL BOARD CHECK PROCEDURE”. 1. Connector disconnected. 1. Reconnect. 2. Leads opened or defective switch. 2. Check and repl ace. a) Float Switch 3.
41 PROBL EM POSSIBL E CAUSE REMEDY a) Inlet Water Valve 1. Diaphragm does not close. 1. Check for water leaks with icemaker off. Replace if ne cessary. [4] Water continues to be supplied i n freeze cycle. b) Control Board 1. Defective. 1. See “II. 3.
42 3. EVAPORATOR IS FROZEN UP PROBL EM POSSIBL E CAUSE REMEDY 1. Leads shorted or defective switch. 1. Check and replac e. a) Float Switch 2. Float does not move freely. 2. Clean or replace. b) Inlet Water Valve 1. Diaphragm does not close. 1. Check for water leaks with icemaker off.
43 4. LOW ICE PRODUCTION PROBL EM POSSIBL E CAUSE REMEDY a) See chart 2 - [3] and ch eck dirty air filter or condens er, ambient or water temperature, water pre ssure, and refrigerant charge. [1] Freeze cyc le time is long. b) See chart 3 - [1] and check flo at switch, inlet wat er va lve, and control board.
44 6. OTHER PROBL EM POSSIBL E CAUSE REMEDY 1. Completely disconnecte d and dropped inside bin. 1. Place in position. 2. Detector broken. 2. Replace. 3. Detector out of position. 3. Plac e in position. 4. Defective reed switch. 4. Check for continuity and replace.
45 V . REMOV AL AND REPLACEMENT W ARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury , or fi re. 2. Move the control switch to the “OFF” position and turn of f the power supply before servicing.
46 3. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant fl ow . 4. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating.
47 8) If necessary , add any remaining charge to the system through the low-side. Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low-side access valve with the unit running. 9) Close the gauge manifold valves and disconnect the gauge manifold hoses.
48 3. COMPRESSOR W ARNING The compressor terminal cover must be refitted in its correct position. Otherwise, operation under high temperature and high humidity conditions may cause electric shock, fi re, or corrosion to shorten the service life. CAUTION 1.
49 13) Install the new drier (see “4. DRIER”). 14) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 15) Evacuate the system and charge it with refrigerant (see “1. [c] EV ACUA TION AND RECHARGE”). 16) Connect the solderless terminals and replace the terminal cover in its correct position.
50 7) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 8) Evacuate the system and charge it with refrigerant (see “1. [c] EV ACUA TION AND RECHARGE”). 9) Re fi t the panels in their correct positions. 10) Plug in the icemaker or connect the power source.
51 W ARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating. Do not braze with the valve body exceeding 275°F (135° C). 8) Install the new drier (see “4. DRIER”). 9) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
52 6. EXP ANSION V AL VE IMPORT ANT The water in the refrigeration circuit may exceed the capacity of the drier and freeze in the expansion valve. Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made.
53 Fig. 5 Remove Expansion V alve Cover fi rst Cut ties to make Bulb removable Bulb Insulation Hose Expansion V alve Bulb 7. AIR-COOLED CONDENSER CAUTION 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made.
54 7) Install the new condenser , then attach the fan motor bracket. 8) Remove the drier , then place the new drier in position. 9) Braze all fi ttings while purging with nitrogen gas fl owing at a pressure of 3 to 4 PSIG. 10) Use an electronic leak detector or soap bubbles to check for leaks.
55 6) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out. 7) Recover the refrigerant and store it in an approved container .
56 5) Install the new fan motor in the reverse order of the removal procedure. 6) Re fi t the panels in their correct positions. 7) Plug in the icemaker or connect the power source. Fig. 6 Fan Motor Bracket Screw Fan Motor 10. W A TER REGULA TING V AL VE (W A TER-COOLED MODEL) CAUTION 1.
57 4) Open the condenser water supply line drain valve. If connected to a closed loop water supply , also open the condenser return outlet drain valve. 5) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.
58 1 1. ADJUSTMENT OF W A TER REGULA TING V AL VE (W A TER-COOLED MODEL) The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use. Adjust the water regulator , if necessary , using the following procedures.
59 12. PUMP MOTOR 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel, rear panel and side panel (R). 3) Disconnect the connector of the pump motor lead. 4) Remove the water tank (see “19. W A TER T ANK”). 5) Remove the hose band connecting the pump motor discharge outlet and pull of f the rubber hose.
60 13. W A TER V AL VE 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the top panel, rear panel and side panel (R). 4) Disconnect the tab terminals. 5) Pinch and lower the hose clamp. 6) Disconnect the rubber hose from the water valve.
61 14. DRAIN V AL VE, CLEANING V AL VE 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the top panel, rear panel and side panel (R). 4) Disconnect the tab terminals. 5) Remove the hose clamps at the inlet and outlet sides.
62 15. FLOA T SWITCH 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel, rear panel and side panel (R). 3) Disconnect the connector of the fl oat switch lead. 4) Remove the two mounting screws. 5) Install the new fl oat switch in the reverse order of the removal procedure.
63 16. BIN CONTROL SWITCH 1) Remove the water tank (see “19. W A TER T ANK”). The bin control switch is located as shown below when viewed from the front.
64 17. THERMIST OR 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel and unscrew the rear panel. 3) Disconnect the connector of the thermistor lead (orange). 4) Remove the ties, insulation, thermistor holder , and thermistor in this order .
65 18. CONTROL BOX 1) Unplug the icemaker or disconnect the power source. 2) Remove the louver . 3) Remove the two mounting screws, and pull the control box toward you.
66 [a] POWER SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) T o prevent miswiring, check the terminal numbers and lead wire colors with the wiring label.
67 3) T o prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [f] CONTROL BOARD TRANSFORMER 1) Disconnect the connectors and closed end connectors connecting the control board. (The tie securing the harness may be removed.
68 20. CUBE GUIDE 1) Remove the water tank (see “19. WA TER T ANK”). 2) Lift off the cube guide out of the water tank. 3) T o re fi t the cube guide, fi t the notches on both sides to the stoppers in the water tank. 4) The unit is provided with three or four cube guides (quantity varies depending on model).
69 Fig. 19 Spray T ube Front Separator Pin 3) Remove the top cover and front cover . See Fig. 19. 4) Disconnect the silicone hose from the spray tube, and remove the spray tube from the evaporator bracket. 5 ) Remove the front separator by pushing the pins inserted into both sides of the evaporator bracket toward the center .
70 22. SPRA Y TUBE, W A TER SUPPL Y PIPE, SPRA Y GUIDE 1) Unplug the icemaker or disconnect the power source. 2) Remove the top panel. 3) Remove the top cover . 4) Remove the silicone hose and spray tube. See Fig. 20. 5) Remove the water spray pipe and spray guide from the evaporator plate.
71 23. DOOR 1) Open the door . 2) Unscrew and remove the hinges on both sides, and remove the door . 3) Re fi t the removed parts in the reverse order of the removal procedure.
72 VI. CLEANING AND MAINTENANCE INSTRUCTIONS IMPORT ANT Ensure all components, fasteners and screws are securely in place after any maintenance or cleaning is done to the equipment. 1. CLEANING W ARNING 1. Hoshizaki recommends cleaning this unit at least once a year .
73 6 ) Pour the cleaning solution into the water tank. Move the control switch to the “SERVICE” position and the service switch to the “W ASH” position. Close the door . 7) After 30 minutes, move the control switch to the “OFF” position. 8) Same as step 4.
74 they were removed. 5) Same as step 1. 6) Pour the sanitizing solution into the water tank, and allow the sanitizer to sit for 10 minutes. 7) Move the control switch to the “SER VICE” position and the service switch to the “W ASH” position. 8) After 15 minutes, move the control switch to the “OFF” position.
75 [c] AIR FIL TER (AIR-COOLED MODEL) The plastic mesh air fi lter removes dirt or dust from the air , and keeps the condenser from getting clogged. As the filter gets clogged, the icemaker ’s performance will be reduced. Check the fi lter at least twice a month.
76 “DRAIN” position. 2) After 2 minutes, move the control switch to the “OFF” position. 3) Open the door . Remove all ice from the storage bin and clean the storage bin. 4) Close the door . 5) Replace the louver in its correct position. 6) T urn off the power supply at the breaker box.
An important point after buying a device Hoshizaki KM-201BAH (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hoshizaki KM-201BAH yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hoshizaki KM-201BAH - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hoshizaki KM-201BAH you will learn all the available features of the product, as well as information on its operation. The information that you get Hoshizaki KM-201BAH will certainly help you make a decision on the purchase.
If you already are a holder of Hoshizaki KM-201BAH, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hoshizaki KM-201BAH.
However, one of the most important roles played by the user manual is to help in solving problems with Hoshizaki KM-201BAH. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hoshizaki KM-201BAH along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
