Service Manual. Modular Crescent Cuber Model KMS-1402MLJ. Including Condensing Unit Models SRK-15J/3. hoshizakiamerica.com

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1 Service Manual Modular Crescent Cuber Model KMS-1402MLJ Including Condensing Unit Models SRK-15J/3 hoshizakiamerica.com Number: Issued:

2 ARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit No installation or service should be undertaken until the technician has thoroughly read this Service Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation. Failure to install, operate, and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. Proper installation is the responsibility of the installer. Product failure or property damage due to improper installation is not covered under warranty. Hoshizaki provides this manual primarily to assist qualified service technicians in the installation, maintenance, and service of the appliance. Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an message, or write to the Hoshizaki Technical Support Department for assistance. Phone: ; (770) Fax: ; (770) Highway 74 South Peachtree City, GA Attn: Hoshizaki Technical Support Department NOTE: To expedite assistance, all correspondence/communication MUST include the following information: Model Number Serial Number Complete and detailed explanation of the problem. 2

3 IMPORTANT This manual should be read carefully before the icemaker is serviced. Read the warnings and guidelines contained in this booklet carefully as they provide essential information for the continued safe use, service, and maintenance of the icemaker. Retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information... 5 I. Construction and ater/refrigeration Circuit Diagrams... 7 A. Construction Icemaker Condensing Unit... 8 B. ater Circuit/Refrigeration Circuit Diagram... 9 II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart Operation Flow Chart Shutdown Flow Chart Freeze-Time Correction Chart B. Service Diagnosis C. Freeze-Time Correction Cycle (90 min.) D. Control Board Check E. Bin Control Check F. Float Switch Check and Cleaning G. Thermistor Check H. Switches Control Switch Service Switch I. Diagnostic Tables J. Freeze-Up Check List III. Settings and Adjustments A. Control Board Layout B. LED Lights and Audible Alarm Safeties C. Settings and Adjustments Default Dip Switch Settings Harvest Time (S4 dip switch 1 & 2) Pump-Out Time/Harvest Time During Pump-Out (S4 dip switch 3 & 4) Pump-Out Frequency Control (S4 dip switch 5) Harvest Pump Time (Harvest Assist Duration) (S4 dip switch 6) Harvest Pump Time (Harvest Assist)/Freeze-Time Correction (S4 dip switch 7) Factory Use (S4 dip switch 8) Freeze Timer (S4 dip switch 9 & 10) Float Switch Control Selector (S5 dip switch 1) Refill Counter (S5 dip switch 2 and 3) Minimum Harvest Time (S5 dip switch 4) Anti-Slush (S5 dip switch 5)

4 I. Refrigeration Circuit and Component Service Information A. Refrigeration Circuit Service Information B. Component Service Information Maintenance I. Preparing the Appliance for Periods of Non-Use II. Disposal III. Technical Information A. Specification and Performance Data Sheets KMS-1402MLJ with SRK-15J KMS-1402MLJ with SRK-15J SRK-15J SRK-15J B. iring Diagrams ire Harness Connections KMS-1402MLJ with SRK-15J KMS-1402MLJ with SRK-15J

5 Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. ARNING NOTICE IMPORTANT Indicates a hazardous situation which could result in death or serious injury. Indicates a situation which could result in damage to the appliance or property. Indicates important information about the use and care of the appliance. ARNING This appliance should be destined only to the use for which it has been expressly conceived. Any other use should be considered improper and therefore dangerous. The manufacturer cannot be held responsible for injury or damage resulting from improper, incorrect, and unreasonable use. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. To reduce the risk of death, electric shock, serious injury, or fire, follow basic precautions including the following: Only qualified service technicians should install and service this appliance. This appliance must be installed in accordance with applicable national, state, and local codes and regulations. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage to the appliance. To reduce the risk of electric shock, do not touch the control switch or service switch with damp hands. Before Servicing the KMS or SRK: To reduce the risk of electric shock, move the control switch to the "OFF" position and turn off the power supply to the SRK condensing unit. Place the KMS disconnect (if applicable) in the "OFF" position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently. Do not make any alterations to the appliance. Alterations could result in electric shock, injury, fire, or damage to the appliance. This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be properly supervised around this appliance. Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged. Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire. Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance. 5

6 For KMS ARNING, continued Risk of electric shock. Control switch in "OFF" position does not de-energize all loads. Power supply and ground connection are supplied from the SRK remote condensing unit via the wire harness provided. Do not connect the wire harness leads to an external power source. ire harness routing (conduit) and disconnect (if required) must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage to the appliance. THE APPLIANCE MUST BE GROUNDED. Failure to properly ground the appliance could result in death, serious injury, or damage to the appliance. For SRK Electrical connection must be hard-wired and must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage to the appliance. The remote condensing unit requires an independent power supply of proper capacity. See the nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuses, damage to existing wiring, or component failure. This could lead to heat generation or fire. THE REMOTE CONDENSING UNIT MUST BE GROUNDED. Failure to properly ground the remote condensing unit could result in death, serious injury, or damage to the appliance. NOTICE Follow the instructions in this manual carefully to reduce the risk of costly water damage. In areas where water damage is a concern, install in a contained area with a floor drain. Install the appliance in a location that stays above freezing. Normal operating ambient temperature must be within 45 F to 100 F (7 C to 38 C). Do not leave the appliance on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the appliance for these occasions, follow the instructions in "I. Preparing the Appliance for Periods of Non-Use." Do not place objects on top of the appliance. The dispenser unit/storage bin is for ice use only. Do not store anything else in the dispenser unit/storage bin. 6

7 I. Construction and ater/refrigeration Circuit Diagrams A. Construction 1. Icemaker Spray Tubes ash alve Hot Gas alve Harvest ater alve (2) Liquid Line alve Evaporator Liquid Line Shutoff alve Drier Suction Line Shutoff alve Thermistor Control Board Control Box Fill/Refill ater alve (1) Control Switch Service Switch Fuse Switch Box Drain ater alve Pump Motor Float Switch Bin Control Switch Cover Switch Bracket Switch Mount Extension Bracket Bin Control 7

8 2. Condensing Unit SRK-15J Control Box Fuse SRK-15J3 Control Box Fuse Condenser Headmaster (C.P.R.) Liquid Line alve Suction Line Shutoff alve Hot Gas alves Liquid Line Shutoff alve Check alve Fan Motors and Fan Blades Liquid Line Shutoff alve 2 Discharge Line Shutoff alve Thermostat (Discharge Pipe) Receiver Accumulator Crankcase Heater Compressor High Pressure Switch 8

9 B. ater Circuit/Refrigeration Circuit Diagram Spray Tube Evaporator Fill/Refill ater alve ( ( 1) ater Tank KMS-1402MLJ Harvest ater alve ( 2) Pump Motor ater Supply Drain ash alve Liquid Line alve Body SRK-15J/3 Drier Service alve Receiver Fan Liquid Line Shutoff alve Condenser Headmaster (C.P. R.) Check alve Access alve Discharge Line Shutoff alve Discharge Line Thermostat Strainers Liquid Line Shutoff alve Hot Gas alves Service alve Service alve Suction Line Liquid Line alve Thermistor Strainer Strainer Hot Gas alve Body Discharge Line High-Pressure Switch Accumulator Check alves Compressor Float Switch Drain alve Expansion alves 9

10 II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart 1. Operation Flow Chart Operation Flow Chart 4. Pump-Out Cycle Factory set for every 10th cycle (S4 dip switch 5) 3. Freeze Cycle Min. freeze time: 5 min. Max. freeze time: freeze timer setting (S4 dip switch 9 & 10). 2. Harvest Cycle time: 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), whichever is shorter. Max. harvest time: 20 min Minute Fill Cycle FS in control 5-min minimum freeze timer in control 1 to 3-min. harvest timer in control (S4 dip switch 1 & 2) Thermistor in control FS opens or freeze timer terminates Refill Harvest Pump Time 1 min. 50 sec. FS closed FS check PM energized 2 de-energized FS closed FS check Comp energized FMRs energized HGs energized D energized PM stops for 2 sec., then energized for 10/20 sec. LL de-energized Anti-Slush Thermistor temperature reaches 36 F (2.2 C) (5.8 kω). PM de-energized for 10 sec. Comp energized FMRs energized PM energized LLs energized 1 energized first 1 min. of freeze HGs de-energized Comp energized FMRs energized HGs energized 2 energized 1 de-energized 1 energized Thermistor temperature reaches 48 F (9 C) (3.9 kω or less). Harvest timer starts. FS open FS open If FS is open, Comp stops and cycle returns to 1-Min. fill. hen freeze time differential exceeded, freeze-time correction cycle starts. See "II.A.3. Freeze-Time Correction Chart." Components Energized when the Control Switch is in the "SERICE" Position hen in the "SERICE" position, the control switch supplies power to the service switch and the icemaker is in service mode. The service switch has three positions: "DRAIN," "CIRC." and "ASH." See the information below for details of each function. DRAIN Power is supplied to the pump and drain valve. This drains the water tank. CIRC. Power is supplied to the pump only. This operation can be used to circulate cleaner and sanitizer over the outside surface of the evaporator for extended periods of time. ASH Power is supplied to the pump and wash valve. This operation is used to circulate cleaner and sanitizer over both the inside and outside surfaces of the evaporator. Legend: Comp-compressor D-drain valve FMRs-fan motors-remote F/S-float switch HGs-hot gas valves (KMS and SRK) LLs-liquid line valves (KMS and SRK) PM-pump motor 1-fill/refill water valve 2-harvest water valve Cycle Steps Startup 10

11 2. Shutdown Flow Chart Shutdown and Restart BC Operation Shutdown Flow Chart 1. Bin Full Shutdown Delay: Fill Cycle 15 sec. after activation. Harvest Cycle At the end of the harvest cycle, or up to 15 sec. into the freeze cycle if activated at the end of the harvest cycle. Freeze Cycle 15 sec. after activation if activated at least 15 sec. before the 5-min. short cycle protection timer terminates. Otherwise, at the end of the next harvest cycle. 2. Icemaker Off All components de-energized. 3. Ice Level Lowered Icemaker starts at "1. 1-Minute Fill Cycle." To 1. 1-Minute Fill Cycle BC open (BC actuator paddle engaged) Green "BC CLOSED" LED off Yellow "BC OPEN" LED on Yellow "BC OPEN" LED continues. All components de energized. BC closed (BC actuator paddle disengaged) Green "BC CLOSED" LED on Yellow "BC OPEN" LED off Legend: BC bin control Note: Control board retains freeze-time correction count data between bin control restarts. 11

12 3. Freeze-Time Correction Chart Freeze Time Differential Exceeded. Minimum and Maximum Freeze times have exceeded differential parameters. Freeze-Time Correction function is enabled when S4 Dip Switch 7 is in the "ON" position. CB monitors freeze time. After 3 freeze cycles, CB compares the minimum and maximum differential of the 3 freeze cycle times. Every freeze cycle time after the third freeze cycle time is added to the minimum/ maximum calculation. Example: After 8 cycles, if the differential between the shortest cycle (minimum) and the longest cycle (maximum) is equal to or greater than 427 sec. a freeze-time correction cycle is initiated: Number of Freeze Cycles Differential alue in Sec Note: hen 1st freeze-time correction cycle is initiated, CB "POER OK" LED starts blinking. On 2nd freeze-time correction cycle, if CB "POER OK" LED has been reset, CB "POER OK" LED starts blinking. If CB "POER OK" had not been reset after 1st freeze-time correction cycle CB "POER OK" LED continues to blink. After 3rd freeze time correction cycle in 36 hours, CB yellow "EXT HAREST" LED starts blinking. Appliance continues to operate and LEDs continue to blink until ALARM RESET button is pressed with power on. Freeze-Time Correction Flow Chart Cycle Steps Steps 1 and 2 repeat 4 times (total 80 min.), then step 1 repeats for a 5th time to complete Freeze Time Correction Cycle Minute Harvest Cycle with Do not adjust S4 dip switch 7 out of the factory position. After step 2 completes 4th sequence (80 min. completed), repeat step 1 for 5th and final time Minute Fill/ Overflow Start Comp energized FMRs energized HGs energized PM energized energized energized Comp de-energized FMRs de-energized HGs de-energized PM de-energized Legend: Comp compressor FM fan motor FMRs fan motor-remote HGs hot gas valve PM pump motor inlet water valve After 5th 10-Minute Harvest Pump Cycle with Freeze-Time Correction Cycle Complete. Go to Step "3. Freeze Cycle" in Operation Flow Chart. Appliance Cycle Reset and Alarm Reset: Cycle Reset: Power Supply or Control Switch Turned Off and On again: Appliance turns off, then re-starts at 1.Fill Cycle. Alarm Reset: CB "ALARM RESET" pressed during or after a freeze-time correction cycle with power supply on: Appliance continues cycle with no interruption or reset. CB red "POER OK" LED blinking: CB red "POER OK" LED resets to solid. CB yellow "EXT HAREST" LED blinking: CB yellow "EXT HAREST: LED turns off. 12

13 B. Service Diagnosis ARNING This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. Risk of electric shock. Use extreme caution and exercise safe electrical practices. Risk of electric shock. Control switch (KMS) in "OFF" position does not de energize all loads. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the appliance is serviced. Make sure that none have fallen into the dispenser unit/storage bin. Make sure all food zones in the icemaker and dispenser unit/storage bin are clean after service. For cleaning procedures, see ". Maintenance." 1. Diagnostic Procedure The diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, proper voltage per nameplate, and adequate water supply. Note: hen checking high voltage (115AC), always choose a neutral () to establish a good neutral connection. On 3-phase models, the neutral () is provided through MT. To confirm a good neutral (), check for 60AC from neutral () to ground (GND). If 60AC is present, neutral () is good. If 60AC is not present, check AC main power supply to MT. If AC is present, check MT continuity. hen checking voltage from the CB K1 connector (10 pin connector), pull CB K1 connector out slightly to allow room for multimeter test leads contact. 1) Turn off the power supply, then access the control box. Clear any ice from BC. 2) Check that the 115AC 10A fuses in the KMS and SRK are good. Confirm that the location meets installation requirements: KMS-1402MLJ: The appliance is not intended for outdoor use. Normal operating ambient temperature should be within 45 F to 100 F (7 C to 38 C). No clearance is required for proper operation The appliance should not be located in a corrosive environment. SRK-15J/3: A dry and well ventilated area with 24" (61 cm) clearance in both front and rear for proper air circulation and ease of maintenance and/or service should they be required. 13

14 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5 sec. delay occurs. CB red "POER OK" LED and CB green "BC CLOSED" LED turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check BC. Move ice away from BC actuator paddle. If CB yellow "BC OPEN" LED stays on, see "II.E.1. Bin Control Check." Note: CB red "POER OK" LED remains on unless the 10.5AC power supply is interrupted (K2 connector). Check CB using the steps in "II.D. Control Board Check." Confirm CB green "BC CLOSED" LED is on. If CB yellow "BC OPEN" LED is on, remove ice from BC. If no ice is around BC and CB yellow "BC OPEN" LED is on, see "II.E.1. Bin Control Check." a) Power On Diagnosis: If CB red "POER OK" LED is off, confirm 10A fuse on both the KMS and the SRK are good. Confirm wire harness is connected and not damaged. Next, check SRK switches. Check for 115AC at both HPS wires () to neutral (). If 115AC is present on one and not the other, HPS is open. If HPS is open, see "b) HPS Diagnosis" below. If HPS is closed, check for 115AC at both DLT wires () to neutral (). If 115AC is present on one and not the other, DLT is open. If DLT is open, see "c) DLT Diagnosis" below. If DLT is closed, check for 115AC at control switch #2 () to neutral () then at control switch #3 () to neutral (). If 115AC is present on #2 () and not on #3 (), replace control switch. If 115AC is present on control switch #3 (), check for 10.5AC at CB K2 #1 red wire to CB K2 #2 red wire. If 10.5AC is not present, check CT wire connections and CT continuity. If open, replace CT. b) HPS Diagnosis: Check that all shutoff valves (4 total) are open and the condenser coil is not clogged or restricted. Let refrigeration circuit pressures equalize. If HPS does not reset and pressures are equalized, replace HPS. If pressures are not equalized, reclaim refrigerant and diagnose refrigeration circuit restriction. Check that there are no restrictions in the refrigeration circuit. Harvest Cycle: HGs, strainer, or check valve. Freeze Cycle: FMRs, TX, HM, LLs, strainer, check valve, drier, and damaged line set or fitting. c) DLT Diagnosis: Check that the condenser coil is not clogged or restricted. Let discharge line thermostat cool, if DLT does not close, replace DLT. Once closed, restart appliance, once Comp starts, check voltage and amp draw. See "5a),a) Comp Diagnosis" below. 14

15 4) 1-Min. Fill Cycle LED 4 is on. 1 energizes. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGs, and FMRs energized), continue to step 5a. If FS is open, 1 remains energized until FS closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: Check that water enters the water tank. If not, check that the water supply line shut-off valve is open and screens or external filters are clear. Check for 115AC at CB K1 #6 (O) to neutral (). If 115AC is not present, replace CB. If 115AC is present, and 1 does not energize, check for 115AC at X10 relay terminal #6 (O) to neutral () and X10 relay terminal #2 (/O) to neutral (). If 115AC is present on relay terminal #6 (O) and not on relay terminal #2 (/O), check for 115AC on X10 relay terminal #8 (P) to neutral (), if 115AC is present replace CB. If 115AC is not present replace X10 relay. If 115AC is present, and 1 does not energize, check for 115AC at 1. If 115AC is present, check 1 coil continuity. If open, replace 1. If the water tank fills, but the appliance fails to start harvest (Comp energized), check for open FS. See "II.F. Float Switch Check and Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace CB. 5a) Initial Harvest Cycle LEDs 1, 4, and 2 are on. 1 continues. Comp, FMRs, HGs, 2, X10 relay, X12 relay, and X13 relay energize. 1 de-energizes. CB monitors the warming of the evaporator via the thermistor located on the suction line. hen the thermistor reaches 48 F (9 C), CB reads 3.9 kω from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). 2 and X12 relay are energized during harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), whichever is shorter. See step 5b below. X13 remains energized throughout harvest cycle to prevent D from energizing. a) Comp Diagnosis: Check that evaporator is warming. If not, confirm that Comp energizes. If not, check for 115AC at CB K1 #1 () to neutral (). If 115AC is not present, check for 115AC at CB K1 #10 () to neutral (). If 115AC is present at #10 () and not at #1 (), replace CB. If 115AC is present, check for 115AC at MC solenoid (SRK). If 115AC not present, check wire harness connections. If 115AC is present, confirm contacts are closed. If not, replace MC. If MC contacts are closed, check Comp start and run capacitors, start relay (single phase), and Comp motor winding. b) HGs Diagnosis: If Comp is energized and evaporator is not warming, check that HGs energize and open. Check for 115AC at CB K1 #2 (P) to neutral (). If 115AC is not present, replace CB. If 115AC is present, check for 115AC at HGs coil (KMS and SRK) and check HGs coils continuity. Replace as needed. c) LLs Diagnosis: Confirm that both LLs are de-energized (KMS and SRK) and closed (not bypassing). If energized, replace CB. If de-energized and bypassing, replace LLs (KMS and SRK). 15

16 d) Relays: 1. X10 (1 and 2): If 1 continues and 2 does not energize, check for 115AC between X10 relay terminal #4 (GY) to neutral () and X10 relay terminal #2 (/O) to neutral (). If 115AC is present at relay terminal #2 (/O) and not at relay terminal #4 (GY), check for 115AC at relay terminal #8 (P). If 115 AC is present at relay terminal #8 (P) and not at relay terminal #4 (GY), replace relay. If 115AC is present at relay terminal #4 (GY) and not at relay terminal #2 (/O) and 1 contines, clean or replace X12 Relay (D Lockout relay 1) and X13 Relay (D Lockout relay 2): If D energizes (water flowing down the drain) check for 115AC at X12 relay terminal #8 (GY) to neutral (). If 115AC is not present see "d)1. X10 (1 and 2)" above. If 115AC is present, check X12 relay terminal #6 (Y) to neutral () and #4 (P) to neutral (). If 115AC is not present from X12 relay terminal #6 (Y) to neutral (), check for 115AC on X10 relay terminal #5 () and relay terminal #3 (Y) to neutral (). If 115AC is present on X10 relay terminal #5 () and not on relay terminal #3 (Y) replace X10 relay. If 115AC is present on relay terminal #6 (Y) and not on X12 relay terminal #4 (P) replace X12 relay. If 115AC is present on X12 relay terminal #4 (P), check for 115 AC at X13 relay terminal #8 (P) to neutral (). If 115AC is present, check for 115AC at X13 relay terminal #2 (/) to neutral (). If 115AC is present at X13 relay terminal #2 (/), replace X13 relay. If 115AC is not present on X13 relay terminal #2 (/) and water is going down the drain, clean or replace D. 3. X11 (D/HPT relay): If PM energizes during initial harvest, check X11 relay terminal #8 (DBU) to neutral (). If 115AC is present, and CB LED 3 is off, replace CB. If 115AC is not present, check for 115AC at X11 terminal #6 (R) to neutral (). If 115AC is present and CB LED 3 is off, replace X11 relay. Check X11 relay terminal #5 (/BU) to neutral (). If 115AC is present, check X11 relay terminal #8 (DBU) to neutral (). If 115AC is present on X11 relay terminal #8 (DBU) and CB LED 3 is off, replace CB. 16

17 5b) Harvest Pump Timer LEDs 1, 3, and 2 are on. hen the thermistor reaches 48 F (9 C), CB reads 3.9 kω from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). hen 2 de-energizes, LED 4 turns off, X12 relay de-energizes. LED 3 turns on and X11 relay energizes, allowing PM to energize. Comp, FMRs, HGs, X10, and X13 relays continue. Diagnosis: Place a thermometer on the suction line next to the thermistor. Has it warmed to 48 F (9 C) or warmer? Confirm thermistor status. See "II.G. Thermistor Check." If the thermistor reading is in proper range, dip switch 7 is on, and PM does not energize before harvest terminates, replace CB. If 2 continues, check for 115AC at CB K1 #6 (O) to neutral (). If 115AC is present, and LED 4 is off, replace CB. If 115AC is not present, and 2 continues, check 2 diaphragm for leaking by. Clean or replace. If LED 3 is on and PM is not energized, check for 115AC at X11 relay terminal #8 (DBU) to neutral (). If 115AC is not present at X11 terminal relay #8 (DBU), replace CB. If 115AC is present, check for 115AC at X11 relay terminal #4 (P) to neutral () and X11 relay terminal #6 (R). If 115AC is present at X11 relay terminal #4 (P) and not at X11 relay terminal #6 (R), replace X11 relay. If 115AC is present at X11 relay terminal #6 (R), check control switch contact continuity between terminals #6 (R) and #5 (/R). If contacts are open, replace control switch. If contacts are closed and 115AC is present between control switch terminal #5 (/R) and neutral (), check PM capacitor and motor winding continuity. 5c) Initial Harvest Cycle Termination Diagnosis: hen the thermistor reaches 48 F (9 C), CB reads 3.9 kω from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.G. Thermistor Check." Once harvest timer terminates, LED 3 & 2 turn off and freeze cycle starts. If 1-min. fill cycle starts after harvest timer terminates, check that FS is clean and operating properly, see "II.F. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle. If not, replace CB. Note: The minimum total time allowed by CB for a complete harvest cycle is based on S5 dip switch 4. Maximum harvest time allowed is 20 min. NOTICE! S4 dip switch 7 must remain on. Otherwise, PM will not energize during the last seconds of harvest. 17

18 6) Freeze Cycle LED 1 is on. Comp, FMRs, and PM continue. LLs energize. HGs, X10, X11, and X13 relays de energize. Appliance is held in freeze by a 5-min. short cycle protection timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle terminates. Note: PM power supply switches from CB K1 #5 (DBU) in HPT to K1 #4 (R) in freeze. Refill LEDs 1 and 4 are on. The KMS 1402MLJ uses a single F/S with a double F/S, UF/S refill initiation float switch setting (S5 dip switch 1) and is set for 1 refill (S5 dip switch 2 through 3). hen the freeze cycle starts, CB monitors UF/S. No UF/S exists on the KMS-1402MLJ, therefore CB reads an open UF/S signal when the freeze cycle starts and immediately initiates a refill (CB energizes 1 through X10 relay). Since there is no UF/S to close and terminate the refill, the refill lasts for the maximum time of 1-minute. During the 1-minute refill, LED 4 is on. Comp, FMRs, LLs, and PM continue. Anti-Slush: hen anti-slush is enabled (S5 dip switch 5 "ON"), PM de-energizes when thermistor reaches 36 F (2.2 C) (5.8kΩ) for 10 sec. then, energizes for the remainder of the freeze cycle. a) Freeze Cycle Diagnosis: Confirm Comp, FMRs, and PM continue. Confirm that LLs energize. Next, confirm HGs, X10, X11, and X13 relays de-energize. During the first 5 min. of freeze, confirm evaporator is cooling. If not, confirm that 1 and 2 are de-energized (not leaking by), HGs de-energized (not bypassing), LLs energize, TX and HM operate correctly, Comp is efficient, and refrigerant charge is correct. See "III.A. Specification and Performance Data Sheets." b) Comp and FMRs Diagnosis: If Comp and FMRs de-energize once freeze begins, check that appliance has not shut off on HPS or DLT ("POER OK" LED off). If so, check "3)b) HPS Diagnosis" or "3)c) DLT Diagnosis" above. If CB "POER OK" LED is on (KMS), check for 115AC at CB K1 #9 () to neutral (). If 115AC is not present and LED 1 is on, replace CB. If 115AC is present, check for 115AC at MC coil (SRK). If 115AC is not present, check wire harness connections. Next, check for 115AC at MC coil. If 115AC is present, check MC coil and contacts continuity. Replace as needed. Next, check Comp start relay, start and run capacitors (single phase), and Comp motor winding continuity. If Comp is energized but evaporator is not cooling, check for an inefficient Comp. See "III.A. Specification and Performance Data Sheets." FMRs Diagnosis: If Comp is energized but FMRs are not, check for 115AC at MC terminal "NO" black () wire to neutral (). If 115AC is not present, and MC is energized replace MC. If 115AC is present, check FMRs capacitors, motor windings, and fan blades for binding. c) 1, 2, and HGs Diagnosis: 1/2: If 1or 2 energized or bypassing, check for 115AC at CB K1 #6 (O) to neutral (). If 115AC is present after PM energizes and LEDs 2 and 4 are off, replace CB. If 115AC is not present, clean or replace 1 or 2 (bypassing). HGs: If HGs did not de energize at the end of harvest and LED 2 is off, check for 115AC at CB K1 #2 (P) to neutral (). If 115AC is present and LEDs 2 and 3 are off, replace CB. If 115AC is not present, replace (defective) HGs. 18

19 d) PM Diagnosis: Confirm water is flowing over evaporator from PM and not 1 or 2. If PM de-energizes once freeze begins (except for anti-slush), check for 115AC at CB K1 #4 (R) to neutral (). If 115AC is not present, replace CB. If 115AC is present and PM is de-energized, check for 115AC at control switch #5 (/R) to neutral (). If 115AC is present at CB K1 #4 (R) and not at control switch #5 (/R), check control switch continuity between #5 (/R) and #6 (R). Replace as needed. If 115AC is present at control switch #5 (/R) to neutral (), check PM capacitor and motor winding continuity. e) LLs Diagnosis: If LLs do not energize, check for 115AC at CB K1 #3 () to neutral (). If 115AC is not present, replace CB. If 115AC is present, check wire harness, wiring connections, coil voltage and continuity. Replace as needed. f) Refrigerant Pressures, HM, and TX Diagnosis: If evaporator is still not cooling, check refrigerant pressures. See "III.A. Specification and Performance Data Sheets." Next, check HM operation. If refrigeration pressures are above HM setpoint and HM is bypassing, replace HM. Check TX for proper operation. Remove TX bulb and hold it in your hand, refrigerant low-side pressure should rise, place TX bulb in ice water, refrigerant low-side pressure should drop. A 10 to 15 pound pressure swing between warm and cold conditions indicate a good TX. If a 10 to 15 pound swing is not present, replace TX. g) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with FS removed but would previously not switch out of freeze with FS connected (long freeze - 3 beep alarm), see "II.F. Float Switch Check and Cleaning." Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions. Cycle times and pressures should follow performance data provided in this manual. See "III.A. Specification and Performance Data Sheets." h) Short Freeze Cycle Diagnosis: Confirm water tank fills and overflows during 1 min. fill and harvest cycles. If not, check water supply filters, shut-off valve, 1 and 2 screens. If water tank empties before 5 min. timer terminates and freeze cycle is short, check that D is not bypassing or energized (water flowing through D). If D is bypassing, remove and clean D, replace as needed. If water tank is full, see "II.F. Float Switch Check and Cleaning." for erratic operating FS. 19

20 7) Pump-Out Cycle LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the first pump-out is determined by S4 dip switch 5. See the table below. S4 Dip Switch Setting No. 5 Control Board Settings Pump-Out Frequency Control Board OFF Every 10 cycles After 11th freeze cycle ON Every cycle After 2nd freeze cycle Comp and FMRs continue, HGs energize. Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and 2 and X12 relay energize, energizing X13 relay. NOTICE! S4 dip switch 3 & 4 must not be set to 3 off and 4 on. Otherwise, LED 4 turns on energizing 2, X12, and X13 relays. Once X13 relay energizes, D cannot energize. LLs de energize. PM stops for 2 sec., then restarts for 10/20 sec. depending on pump out timer (S4 dip switch 3 & 4) setting. hen the pump out timer terminates, pump out is complete. The pump-out frequency control (S4 dip switch 5) is factory set, and generally no adjustment is required. However, the pump out frequency control can be set to have a pump-out occur every cycle. For details, see "III.C.4. Pump Out Frequency Control (S4 dip switch 5)." a) Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect CB black K5 connector (FS connector). Check that CB LEDs 1, 3, and 2 are on, PM stops, then restarts, D energizes, and water is flowing down the drain through D. b) CB Diagnosis: PM: If PM does not stop and restart, check that CB LEDs 1, 3, and 2 are on. If not and pump-out is called for, replace CB. If LEDs 1, 3, and 2 are on, X11 relay energizes. If not, check for 115AC at CB K1 #5 (DBU) to neutral (). If 115AC is not present, replace CB. If 115AC is present at CB K1 #5 (DBU) and X11 relay is not energized, continue to "c) PM Diagnosis:" below. D: If D is not energized, check for 115AC at CB K1 #1 () to neutral (). If LED 2 is on and 115AC is not present at CB K1 #1 (), replace CB. If 115AC is present at CB K1 #1 () to neutral (), continue to "d) D Diagnosis" below. c) PM Diagnosis: If 115AC is present at CB K1 #5 (DBU), X11 relay energizes. Check for 115AC at X11 relay #8 (DBU) to neutral (). If 115AC is not present, check wiring connections from CB K1 #5 (DBU) to X11 relay #8 (DBU). If 115AC is present at X11 relay #8 (DBU) and PM does not restart, check for 115AC at X11 relay terminal #4 (P) and terminal #(6) to neutral (). If 115AC is present on #4 (P) and not on #6 (R), replace X11 relay (sticking contacts). If 115AC is present at X11 relay #6 (R) and PM is de-energized, check for 115AC at control switch #6 (R) and #5 (/R) to neutral (). If 115AC is present at #6 (R) and not at #5 (/R), replace control switch. If 115AC is present at control #5 (/R), check PM capacitor, motor winding, wiring connections, and impeller for binding. 20

21 d) D Diagnosis: X10 Relay: If 115AC is present at CB K1 #1 () to neutral () and D is de energized, check for 115AC at X10 relay #5 () and #3 (Y) to neutral (). If 115AC is present at #5 () and not at #3 (Y), confirm X10 relay is de-energized. If de-energized, replace X10 relay (sticking contacts). If energized, confirm LEDs 1, 2, and 3 are on. If LED 1, 3, and 2 are on and X10 relay is energized, replace CB. X13 Relay: Next, If 115AC is present at X10 #3 (Y) to neutral (), check for 115AC at X13 #6 (Y) and #2 (/) to neutral (). If 115AC is not present on #6 (Y), check wiring from X10 relay #3 (Y). If 115AC is present at X6 (Y) and not at #2 (/), confirm X13 is de-energized. If energized, confirm CB LEDs 1, 2, and 3 are on. If LEDs 1, 2, and 3 are on and X13 relay is energized, X12 relay must be energized also. Replace CB. If 115AC is present at X13 #2 (/), check for 115AC at X11 relay #3 (/). X11 Relay: Check for 115AC at X11 relay #3 (/). If 115AC is not present check wiring connections from X13 relay #2 (/). If 115AC is present at X11 #3 (/ ), check for 115AC at X11 #5 (/BU) to neutral (). If 115AC is present at X11 #3 (/) and not at #5 (/BU), confirm 115AC from X11 relay #8 (DBU) to #7 (). If 115AC is present, replace X11 relay (sticking contacts). If 115AC is present at X11 relay #5 (/BU) and D is de energized, check wiring to D from X11 relay #5 (/BU), D coil continuity, make sure the drain line is not clogged and that D is clean and operating properly. 8)Normal Harvest Cycle Same as the initial harvest cycle. Return to step 5a) above. Note: Appliance continues to cycle until BC is satisfied or power is switched off. The appliance always restarts at the 1-min. fill cycle. 2. Shutdown Diagnosis hen the appliance is running, hold ice in contact with the thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. BC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations. Diagnosis: See "II.E. Bin Control Check." CB red K4 connector must have the jumper in place. hen the jumper is in place, the green "BC CLOSED" LED remains on. If the jumper is not in place, yellow "BC OPEN" LED turns on and the icemaker turns off and remains off until the jumper is replaced in its original position. 3. Freeze-Time Correction Cycle Diagnosis 1) See "II.C. Freeze-Time Correction Cycle (90 min.)."" Legend: BC bin control; CB control board; Comp compressor; CT control transformer; C cleaning valve; D drain valve; FMRs fan motor remote; FS float switch; HGs hot gas valve; HM headmaster (C.P.R.); HPS high-pressure switch; LLs liquid line valve; MC magnetic contactor: MT main transformer; PM pump motor; TX thermostatic expansion valve; 1 fill/re-fill water valve; 2 harvest water valve 21

22 C. Freeze-Time Correction Cycle (90 min.) Freeze-Time Correction function is enabled when S4 Dip Switch 7 is in the "ON" position and initiates when the minimum and maximum freeze times have exceeded differential parameters. Freeze-time correction timer and count starts at the beginning of the 2nd freeze cycle after startup from power off condition. Freeze-time correction timer and count continues and retains its freeze-time correction timer and count during a BC off cycle and resumes its freeze time correction timer and count on the 2nd freeze cycle after BC restart. If freeze time differential is exceeded (see table below), freeze time correction cycle starts and CB red "POER OK" LED blinks. hen freeze time correction cycle occurs 3 or more times within a 36 hour period, CB yellow "EXT HAREST" LED blinks with CB red "POER OK" LED. Appliance starts in freeze cycle after a freeze time correction cycle. To reset CB LEDs, press ALARM RESET button on CB with power on. CB resets LEDs and appliance continues cycle without interruption. 1) Freeze Time Differential Initiation: CB starts monitoring freeze times on the second freeze time. After 3 freeze cycles (4th total), CB begins to compare minimum and maximum freeze time cycles. Every freeze cycle time after the first freeze cycle time is added to the freeze time list. Minimum and maximum freeze time differential comparisons begin on the third cycle and are monitored up to 10 cycles. On the 11th cycle the first freeze cycle time is dropped to maintain the 10 maximum number of cycles. Example: After 8 cycles (excluding first cycle), if the differential between the shortest cycle (minimum) and the longest cycle (maximum) is equal to or greater than 427 sec. a freeze-time correction cycle is initiated: Number of Differential Freeze Cycles alue in Sec

23 2) Freeze-Time Correction Sequence: First occurrence within 36 hr., minimum and maximum freeze times have exceeded differential parameters. CB "POER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Second occurrence within 36 hr., minimum and maximum freeze times have exceeded differential parameters. If not reset, CB "POER OK" LED continues blinking. If reset from first occurrence, CB "POER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Third occurrence within 36 hr. minimum and maximum freeze times have exceeded differential parameters. CB yellow "EXT HAREST" LED starts blinking. Also, If not reset, CB "POER OK" LED continues blinking. If reset, CB "POER OK" LED starts blinking. Freeze-Time Correction Cycle starts. Total freeze-time correction cycle last for 90 min. At the end of 80 min., the final step initiates and final Harvest Pump Time (Harvest Assist) with 2 (10 min.) starts. Once the final Harvest Pump Time (Harvest Assist) with 2 (10-min.) terminates (90 min. complete), normal freeze cycle begins. 2a) 10-Min. Harvest Pump Time (Harvest Assist) with 2: CB "POER OK" LED blinking. CB LEDs 1, 4, 3, and 2 are on and Comp, FMRs, HGs, PM, and 2 energize. 10-min. timer starts. Once 10 min. timer terminates, CB LEDs 1, 3, and 2 turn off and Comp, FMRs, HGs, 2 and PM de-energize. 1 energizes. 2b) 10-Min. Fill: CB LED 4 on and 1 energized. 10-min. timer starts. 2c) Final 10-Min. Harvest Pump Time (Harvest Assist) with 2: CB "POER OK" LED blinking. Once 10 min. timer terminates, CB LEDs 1, 4, 3, and 2 are on and Comp, FMRs, HGs, PM and 2 energize. 10-min. timer starts. Once 10-min. timer terminates, normal freeze cycle begins. CB LED 1 on and Comp, FMRs, and PM continue. HGs and 2 de-energize. Note: After 3rd Freeze-Time Correction Cycle in 36 hours, CB signals with blinking CB yellow "EXT HAREST" LED. Appliance continues normal operation. CB "POER OK" LED and CB yellow "EXT HAREST" LED continue blinking in normal operation sequence. 3) Appliance Cycle Reset and CB Alarm Reset: Cycle Reset: Power supply or control switch turned off and on again: Appliance turns off, then re-starts at 1.Fill Cycle. Alarm Reset: CB "ALARM RESET" pressed during or after a freeze-time correction cycle with power supply on: Appliance continues cycle with no interruption or reset. CB red "POER OK" LED blinking: CB red "POER OK" LED resets to solid. CB yellow "EXT HAREST" LED blinking: CB yellow "EXT HAREST: LED turns off. Legend: BC bin control; CB control board; Comp compressor; CT control transformer; C check valve; FMRs fan motors remote; FS float switch; HGs hot gas valves; HM headmaster (C.P.R.); HPS high-pressure switch; LLs liquid line valves; MC magnetic contactor; PM pump motor; TX thermostatic expansion valve; 1 fill/re-fill water valve; 2 harvest water valve 23

24 D. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB while CB is beeping. ARNING! Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the icemaker starts at the 1-minute fill cycle. For audible alarm information, see "III.B. LED Lights and Audible Alarm Safeties." 1) Check the dip switch settings to assure that S4 dip switch 3, 4, 6, 7, 8, 9, 10 and S5 dip switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, and 5 are cleaning adjustments and the settings are flexible. For factory default settings, see "III.C.1. Default Dip Switch Settings." 2) Move the control switch to the "ICE" position. If the red "POER OK" LED is on, control voltage is good, continue to step 3. If the "POER OK" LED is off, check CT secondary circuit. CT output is 10.5AC at 115AC primary input. If the secondary circuit has proper voltage and the red LED is off, replace CB. If the secondary circuit does not have proper voltage, check CT primary circuit. Check for 115AC at CB K1 connector pin #10 () to neutral () for 115AC. Always choose a white () neutral wire to establish a good neutral connection when checking voltages. For additional checks, see "II.I.1. No Ice Production." 3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control switch is in the "ICE" position, then press the "OUTPUT TEST" button. For the correct lighting sequence, see the table below. Note that the order of the LEDs from the outer edge of the control board is 1, 4, 3, 2. Components (e.g., compressor) cycle during the test. Control Board Correct LED Lighting Sequence 1, 4, 3, 2 Following the test, the icemaker begins operation at the 1-minute fill cycle for both. If the LEDs do not light as described above, replace CB. 24

25 4) To verify voltage output from CB to the components, slide the CB K1 connector out far enough to allow multimeter lead contact. ith the icemaker in the cycle to be tested, check output voltage from the corresponding pin on CB K1 connector to a neutral () wire. If output voltage is not found and the appropriate LED is on, replace CB. 5) Check CB control connectors K3, K4, and K5 for correct DC per table below. Note: Pin #1 is DC ground (GND) on each connector. K3 Thermistor Pin # DC #1 to #2 5DC #1 to #3 5DC #2 to #3 0DC K4 Bin Control Pin # DC #1 to #2 5DC #1 to #3 5DC #2 to #3 0DC K5 Float Switch Pin # DC #1 to #2 1.2DC #1 to #3 2DC #2 to #3 1.2DC Legend: CB control board; CT control transformer CB Thermistor Bin Control Float Switch K4 K3 BLACK RED HITE K5 25

26 E. Bin Control Check 1. Bin Control Check This appliance uses a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required. To check BC, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the base cover and clear any ice away from BC. BC Connector 5) Disconnect BC connector from CB K4 connector. 6) Check for continuity across the wires of BC connector. hen the actuator paddle is not engaged, BC switch is closed. If open, check that the actuator paddle is not sticking. Clean if necessary. See "II.E.2. Bin Control Cleaning." If BC switch still reads open, replace BC. 7) Press and hold the actuator paddle; check for continuity across the wires of BC connector. hen the actuator paddle is engaged, BC switch is open. If closed, check that the actuator paddle is not restricted. Clean if necessary. See "II.E.2. Bin Control Cleaning." If BC switch still reads closed, replace BC. Bin Control Bracket BC Actuator Paddle Fig. 1 8) Reconnect BC connector to CB K4 connector, then move the control switch to the "ICE" position. Turn on the power supply. 9) Check that CB green "BC CLOSED" LED is on. 10) Allow the icemaker to cycle on. Press and hold the actuator paddle. CB yellow "BC OPEN" LED should turn on and the icemaker should shut down according to the chart below. If it does not, replace CB. Cycle at Bin Control Activation Fill Cycle Harvest Cycle Freeze Cycle Shutdown 15 sec. after activation. At the end of the harvest cycle, or up to 15 sec. into the freeze cycle if activated at the end of the harvest cycle. 15 sec. after activation if activated at least 15 sec. before the 5-min. short cycle protection timer terminates. Otherwise, at the end of the next harvest cycle. Legend: BC bin control; CB control board 26

27 2. Bin Control Cleaning Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick. In this case, BC should be cleaned. ARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the dispenser unit/storage bin. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the top and right side panels. Remove the control box cover, then clear any ice away from BC. 4) Disconnect BC connector from CB K4 (red) connector, then remove BC from the icemaker. 5) Remove the actuator paddle from the switch mount. See Fig. 2. 6) ipe down BC with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water. 7) Reassemble BC and replace it in its correct position. Note: If the magnet was removed for cleaning, be sure to replace it in its correct position. 8) Reconnect BC connector to CB K4 (red) connector. 9) Move the control switch to the "ICE" position. 10) Replace the control box cover, right side, top, and front panels in their correct positions. 11) Turn on the power supply to start the automatic icemaking process. Bin Control Proximity Switch Closed (calling for ice) Actuator Paddle To Control Board K4 (red) Connector Bin Control Proximity Switch Actuator Paddle Bin Control Proximity Switch Open (bin full, icemaker off or shutting down) Switch Mount Magnet 27 Fig. 2

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