Hoshizaki America, Inc. Stackable Crescent Cuber Models KM-1800SAH/3 KM-1800SWH/3 KM-1800SRH/3 A Superior Degree of Reliability SERVICE MANUAL www.hoshizaki.com Number: 73131 Issued: 11-11-2005 Revised: 5-24-2007
IMPORTANT Only qualified service technicians should attempt to service or maintain this unit. No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the unit. Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, write or send an e-mail message to the HOSHIZAKI Technical Support Department for assistance. HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City, GA 30269 Attn: HOSHIZAKI Technical Support Department Phone: 1-800-233-1940 Technical Service (770) 487-2331 Fax: 1-800-843-1056 (770) 487-3360 E-mail: techsupport@hoshizaki.com Web Site: www.hoshizaki.com NOTE: To expedite assistance, all correspondence/communication MUST include the following information: Model Number Serial Number Complete and detailed explanation of the problem
Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should service and maintain the icemaker. This manual should be made available to the technician prior to service or maintenance. CONTENTS I. Specifications... 5 A. Icemaker... 5 1. KM-1800SAH (air-cooled)... 5 2. KM-1800SAH3 (air-cooled, 3 phase)... 6 3. KM-1800SWH (water-cooled)... 7 4. KM-1800SWH3 (water-cooled, 3 phase)... 8 5. KM-1800SRH (remote air-cooled)... 9 6. KM-1800SRH3 (remote air-cooled, 3 phase)... 10 B. Condensing Unit... 11 1. URC-20F... 11 II. General Information... 13 A. Construction... 13 1. KM-1800SAH/3... 13 2. KM-1800SWH/3... 14 3. KM-1800SRH/3... 15 B. Sequence of Operation... 16 1. One Minute Fill Cycle... 16 2. Initial Harvest Cycle... 16 3. Freeze Cycle... 16 4. Pump-Out Cycle... 16 5. Normal Harvest Cycle... 16 C. Control Board... 18 1. Control Board Layout... 19 2. Features... 20 a) Maximum Water Supply Period 6 minutes... 20 b) Harvest Backup Timer and Freeze Timer... 20 c) High Temperature Safety... 20 d) Low Water Safety... 20 e) High Voltage and Low Voltage Cut-outs... 20 f) LED Lights and Audible Alarm Safeties... 21 3. Controls and Adjustments... 22 a) Default Dip Switch Settings... 22 b) Harvest Control Thermistor... 22 c) Harvest Timer (dip switch 1 & 2)... 23 d) Pump-Out Timer (dip switch 3 & 4)... 23 e) Pump-Out Frequency Control (dip switch 5 & 6)... 24 f) Freeze Timer (dip switch 9 & 10)... 24 g) Bin Control... 24 4. Control Board Check Procedure... 25 5. Control Board Replacement... 25 III. Technical Information... 26 A. Water Circuit and Refrigerant Circuit... 26 3
1. KM-1800SAH/3... 26 2. KM-1800SWH/3... 27 3. KM-1800SRH/3... 28 B. Wiring Diagrams... 29 1. KM-1800SAH... 29 2. KM-1800SAH3... 30 3. KM-1800SWH, KM-1800SRH... 31 4. KM-1800SWH3, KM-1800SRH3... 32 C. Performance Data... 33 1. KM-1800SAH (air-cooled)... 33 2. KM-1800SAH3 (air-cooled, 3 phase)... 34 3. KM-1800SWH (water-cooled)... 35 4. KM-1800SWH3 (water-cooled, 3 phase)... 36 5. KM-1800SRH (remote air-cooled)... 37 6. KM-1800SRH3 (remote air-cooled, 3 phase)... 38 IV. Service Diagnosis... 39 A. 10-Minute KM Diagnostic Procedure... 39 B. Diagnostic Charts... 40 1. No Ice Production... 40 2. Evaporator is Frozen Up... 44 3. Low Ice Production... 45 4. Abnormal Ice... 45 5. Other... 45 V. Removal and Replacement of Components... 47 A. Service for Refrigerant Lines... 47 1. Refrigerant Recovery... 47 2. Evacuation and Recharge (R-404A)... 47 B. Brazing... 48 C. Removal and Replacement of Compressor... 48 D. Removal and Replacement of Drier... 49 E. Removal and Replacement of Expansion Valve... 50 F. Removal and Replacement of Hot Gas Valve and Line Valve... 51 G. Removal and Replacement of Evaporator... 52 H. Removal and Replacement of Thermistor... 52 I. Removal and Replacement of Fan Motor... 53 J. Removal and Replacement of Water Valve... 53 K. Removal and Replacement of Pump Motor... 54 L. Removal and Replacement of Spray Tubes... 54 M. Removal and Replacement of Water Regulating Valve Water Cooled Model Only.. 55 N. Adjustment Of Water Regulating Valve Water-Cooled Model Only... 56 O. Removal and Replacement of Headmaster (Condenser Pressure Regulator - C.P.R.) Remote Air-Cooled Model Only... 57 VI. Cleaning and Maintenance Instructions... 58 A. Cleaning and Sanitizing Procedures... 58 1. Cleaning Procedure... 59 2. Sanitizing Procedure - Following Cleaning Procedure... 60 B. Maintenance... 61 C. Preparing the Icemaker for Long Storage... 61 4
I. Specifications A. Icemaker 1. KM-1800SAH (air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 18 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1756 (797) 1685 (764) 1589 (721) Reference without *marks 80 1702 (772) 1592 (722) 1496 (679) 90 1685 (764) *1514 (687) 1416 (642) 100 1579 (716) 1491 (676) 1326 (601) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 42.9lbs. (19.4 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2979 (4.9) 2780 (3.8) WATER gal./24hr (gal./100 lbs.) 348 (23.0) 680 (38.7) EXTERIOR DIMENSIONS (WxDxH) 48" x 27 3/8" x 36 7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 344 lbs. ( 156 kg ), Shipping 440 lbs. ( 200 kg ) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT - CONDENSATE DRAIN 3/8" OD Pipe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18K6E-PFV-237 CONDENSER Air-cooled, Fin and Tube Type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 4 lb. 7 oz. ( 2000 g ) DESIGN PRESSURE High 467 PSIG, Low 230 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 5
2. KM-1800SAH3 (air-cooled, 3 phase) AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 11 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1757 (797) 1683 (764) 1597 (724) Reference without *marks 80 1701 (772) 1587 (720) 1507 (684) 90 1683 (764) *1506 (683) 1422 (645) 100 1579 (716) 1486 (674) 1344 (610) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 42.9 lbs. (19.4 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2949 (4.7) 2562 (3.5) WATER gal./24hr (gal./100 lbs.) 328 (21.8) 694 (39.5) EXTERIOR DIMENSIONS (WxDxH) 48" x 27 3/8" x 36 7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 344 lbs. ( 156 kg ), Shipping 440 lbs. ( 200 kg ) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT - CONDENSATE DRAIN 3/8" OD Pipe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18K6E-PFV-237 CONDENSER Air-cooled, Fin and Tube Type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 4 lb. 7 oz. ( 2000 g ) DESIGN PRESSURE High 467 PSIG, Low 230 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 6
3. KM-1800SWH (water-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 12.4 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1816 (824) 1810 (821) 1789 (811) Reference without *marks 80 1812 (822) 1803 (818) 1774 (805) 90 1810 (821) *1797 (815) 1770 (803) 100 1801 (817) 1791 (812) 1746 (792) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 44.2 lbs. (20 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2550(3.4) 2500(3.3) WATER gal./24hr (gal./100 lbs.) 347(19.3) 668(36.8) WATER COOLED CONDENSER 1651(92) 972(54) gal./24hr (gal./100 lbs.) EXTERIOR DIMENSIONS (WxDxH) 48" x 27-3/8" x 36-7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 368 lbs. (167 kg), Shipping 440 lbs. (200 kg) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT Condenser Outlet 1/2" FPT - CONDENSATE DRAIN 3/8" OD Tube CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL Water Regulator BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18-K6E-PFV CONDENSER Water-cooled, Tube in tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 3 lb. 2 oz. (1400g) DESIGN PRESSURE High 427PSIG, Low 230PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 7
4. KM-1800SWH3 (water-cooled, 3 phase) AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 9.7 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1761 (799) 1766 (801) 1726 (783) Reference without *marks 80 1765 (801) 1773 (804) 1707 (774) 90 1766 (801) *1778 (806) 1722 (781) 100 1742 (790) 1765 (801) 1671 (758) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 43.7 lbs. (20 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2590(3.5) 2420(3.3) WATER gal./24hr (gal./100 lbs.) 327(18.4) 674(38.3) WATER COOLED CONDENSER 1282(72) 870(49) gal./24hr (gal./100 lbs.) EXTERIOR DIMENSIONS (WxDxH) 48" x 27-3/8" x 36-7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 368 lbs. (167 kg), Shipping 440 lbs. (200 kg) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT Condenser Outlet 1/2" FPT - CONDENSATE DRAIN 3/8" OD Tube CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL Water Regulator BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18-K6E-TF5 CONDENSER Water-cooled, Tube in tube type EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 3 lb. 2 oz. (1400g) DESIGN PRESSURE High 427PSIG, Low 230PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 8
5. KM-1800SRH (remote air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 16.5 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1817 (824) 1768 (802) 1643 (745) Reference without *marks 80 1780 (807) 1704 (773) 1546 (701) 90 1768 (802) *1651 (749) 1504 (682) 100 1723 (782) 1617 (733) 1369 (621) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 47.8 lbs. (21.7 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2890(4.2) 2730(3.6) WATER gal./24hr (gal./100 lbs.) 439(26.6) 721(39.7) EXTERIOR DIMENSIONS (WxDxH) 48" x 27 3/8" x 36 7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 344 lbs. (156 kg), Shipping 440 lbs. (200 kg) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT - CONDENSATE DRAIN 3/8" OD Pipe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18K6E-PFV CONDENSER Air-Cooled Remote, Condenser Unit URC-20F EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve Condensing Pressure Regulator on URC-20F (210 PSI Set) REFRIGERANT CHARGE R-404A, 15 lb. 7.0 oz. (7,000g) (Icemaker 7 lbs. 12.0 oz. Cond. Unit 7 lb. 11.0 oz.) DESIGN PRESSURE High 467PSIG, Low 230PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin, Remote Condenser Unit OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 9
6. KM-1800SRH3 (remote air-cooled, 3 phase) MODEL: KM-1800SRH3 AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 10.9 A ( 5 Min. Freeze AT 104 F / WT 80 F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. ( F) PER 24 HR. Temp.( F) 50 70 90 lbs./day ( kg/day ) 70 *1775 (805) 1722 (781) 1618 (734) Reference without *marks 80 1735 (787) 1653 (750) 1531 (695) 90 1722 (781) *1595 (723) 1479 (671) 100 1691 (767) 1568 (711) 1372 (622) SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 47.7 lbs. (21.7 kg) 2160 pcs. APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70 F 70/50 F ELECTRIC W (kwh/100 lbs.) 2860(4.3) 2660(3.6) WATER gal./24hr (gal./100 lbs.) 456(28.6) 774(43.6) EXTERIOR DIMENSIONS (WxDxH) 48" x 27 3/8" x 36 7/16" (1219 x 695 x 925 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 344 lbs. (156 kg), Shipping 440 lbs. (200 kg) CONNECTIONS - ELECTRIC Permanent - Connection - WATER SUPPLY Inlet 1/2" FPT - DRAIN Outlet 3/4" FPT - CONDENSATE DRAIN 3/8" OD Pipe CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe COOLING WATER CONTROL N/A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic, Model CS18K6E-TF5 CONDENSER Air-Cooled Remote, Condenser Unit URC-20F EVAPORATOR Vertical type, Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve Condensing Pressure Regulator on URC-20F (210 PSI Set) REFRIGERANT CHARGE R-404A, 15 lb. 7.0 oz. (7,000g) (Icemaker 7 lbs. 12.0 oz. Cond. Unit 7 lb. 11.0 oz.) DESIGN PRESSURE High 467 PSIG, Low 230 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal ) COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal ) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES -SUPPLIED N/A -REQUIRED Ice Storage Bin, Remote Condenser Unit OPERATING CONDITIONS VOLTAGE RANGE 187-253 V AMBIENT TEMP. 45-100 F WATER SUPPLY TEMP. 45-90 F WATER SUPPLY PRESSURE 10-113 PSIG Note: We reserve the right to make changes in specifications and design without prior notice. 10
B. Condensing Unit 1. URC-20F Unit: mm (inches) 11
Specifications Model: URC-20F AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR ( QTY. 2 ) 115 V Total 2.6FLA 130 W EXTERIOR DIMENSIONS (WxDxH) 46-3/8" x 15-11/16" x 25-15/16" ( 1178 x 398 x 659 mm ) (DIMENSIONS INCLUDING LEGS (WxDxH) 48-7/16" x 18-1/8" x 40-7/8" ( 1230 x 460 x 1039 mm ) EXTERIOR FINISH Galvanized Steel WEIGHT Net 134 lbs. (61 kg ) Shipping 145 lbs. ( 66 kg ) CONNECTIONS - ELECTRIC Permanent - Connection - REFRIGERATION Discharge Line 1-1/16-12 UNF Fitting (#10 AEROQUIP) Liquid Line 5/8-18 UNF Fitting ( #6 AEROQUIP ) CONDENSER Air-cooled, Fin and tube type FAN MOTOR PROTECTION Thermal Protection REFRIGERANT CONTROL Condensing Pressure Regulator REFRIGERANT CHARGE R-404A, 7 lbs. 11 oz. ( 3500 g ) DESIGN PRESSURE High 467 PSIG OPERATING CONDITIONS VOLTAGE RANGE 104 ~ 127 V AMBIENT TEMP. -20 ~ 122 F ACCESSORIES -SUPPLIED Leg 2 pcs Hex. Head Bolt w/washer 8 x 16 8 pcs Hex. Nut 8 8 pcs Note: We reserve the right to make changes in specifications and design without prior notice. 12
II. General Information A. Construction 1. KM-1800SAH/3 Evaporator Spray Tubes Water Supply Inlet Water Valve Hot Gas Valve Junction Box Check Valves (3) Condenser Condenser Fan Motors (2) Water Pump Float Switch Cleaning Valve Expansion Valves (3) Compressor Bin Control Thermostat Control Switch Control Box Line Valve Capacitor Box (KM-1800SAH) Drier Transformer Box (KM-1800SAH3) 13
2. KM-1800SWH/3 Evaporator Spray Tubes Water Valve Expansion Valves (3) Water Supply Inlet Check Valves (3) Hot Gas Valve Junction Box Control Box Water-cooled Condenser Line Valve Water Pump Float Switch Cleaning Valve Compressor Water Regulator Capacitor Box (KM-1800SWH) Transformer Box (KM-1800SWH3) Drier Control Switch Bin Control Thermostat 14
3. KM-1800SRH/3 Evaporator Spray Tubes Water Valve Expansion Valves (3) Water Supply Inlet Check Valves (3) Hot Gas Valve Junction Box Control Box Receiver Tank Water Pump Float Switch Cleaning Valve Compressor Control Switch Bin Control Thermostat Line Valve Drier Capacitor Box (KM-1800SRH) Transformer Box (KM-1800SRH3) 15
B. Sequence of Operation 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 1, 4, 3, 2. 1. One Minute Fill Cycle LED 4 is on. WV opens and the fill period begins. After 1 minute, the board checks for a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV will remain energized through additional 1 minute cycles until water enters the sump and F/S closes. This serves as a low water safety to protect the water pump. 2. Initial Harvest Cycle LEDs 1, 4, and 2 are on. WV remains open, Comp and FMR energize, HGV opens, and harvest begins. As the evaporator warms, the thermistor located on the suction line checks for a 48 F (9 C) temperature. When 48 F (9 C) is reached, a 3.9 kω signal turns the harvest over to the adjustable harvest timer which is factory set for normal conditions. The timer has settings of 60, 90, 120, and 180 seconds (dip switch 1 & 2). The water valve is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is shorter. When the harvest timer completes its count down, the harvest cycle is complete and the freeze cycle starts. The minimum total time allowed by the board for a complete harvest cycle is 2 minutes. 3. Freeze Cycle LED 1 is on. Comp and FMR continue to run, PM and FMS energize, LLV opens, HGV and WV close and the freeze cycle starts. For the first 5 minutes the control board will not accept a signal from F/S. This 5 minute minimum freeze acts as a short cycle protection. At the end of 5 minutes, F/S assumes control. As ice builds on the evaporator the water level in the sump lowers. The freeze continues until F/S opens and terminates ice production. 4. Pump-Out Cycle LEDs 1, 3, and 2 are on. Comp and FMR continue to run, HGV opens, LLV closes, and FMS deenergizes. PM stops for 2 seconds and reverses, taking water from the bottom of the sump and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain. At the same time water flows through the small tube to power flush the F/S. When the pump-out timer stops counting, the pump out is complete. Pump out always occurs on the 2nd harvest after startup. Then, depending on the control board setting, pump out occurs every cycle, or every 2nd, 5th or 10th cycle (dip switch 5 & 6). 5. Normal Harvest Cycle LEDs 1, 4, and 2 are on. Comp and FMR continue to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48 F (9 C). The control board then receives the thermistor's 3.9 kω signal and starts the harvest timer. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is shorter. When the harvest timer completes its count down, the harvest cycle is complete and the next freeze cycle starts. The unit continues to cycle through 3, 4 and 5 sequence until the bin control senses ice and shuts the unit down. Legend: Comp compressor; FMR remote fan motor; FMS self-contained fan motor; F/S float switch; HGV hot gas valve; LLV Liquid Line Valve; PM pump motor; WV inlet water valve 16
KM-1800SAH/3, KM-1800SWH/3, KM-1800SRH/3 Sequence Flow Chart and Component Operation Cycle Steps Initial startup always begins here "E" board will have 5 second delay 1. One Minute Fill Cycle F/S Check WV Energized F/S open 2. Harvest Cycle 3. Freeze Cycle Maximum inlet water valve time: 6 minutes Maximum harvest time: 20 minutes Thermistor in control F/S closed Comp energized HGV energized FMR energized WV continues 1 to 3 minute timer in control F/S Check Thermistor temp reaches 48 F (9 C) (3.9 kω or less) Harvest timer starts F/S open Minimum freeze time: 5 minutes Maximum freeze time: freeze timer setting 5 minute timer in control F/S closed Comp continues FMR continues HGV de-energized WV de-energized PM energized FMS energized If F/S is open, compressor stops and cycle returns to 1 minute fill F/S in control Freeze cycle operation turned over to F/S 4. Pump-Out Cycle Pump motor stops for 2 sec. and then reverses for 10/20 sec. each 1, 2, 5, or 10 cycles. Comp continues FMR continues HGV energized FMS de-energized Legend: Comp - compressor FMR - remote fan motor FMS - self-contained fan motor F/S - float switch HGV - hot gas valve PM - pump motor WV - inlet water valve Components Energized when the Control Switch is in the "WASH" Position The "WASH" position on the control switch is used when cleaning and sanitizing the unit. When in the "WASH" position, power is supplied to the pump motor. With the cleaning valve closed, the cleaner and sanitizer flow over the outside of the evaporator plate assembly. With the cleaning valve open, the cleaner and sanitizer flow over both the outside and the inside of the evaporator plate assembly. Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not re-start when the control switch is placed in the "ICE" position. 17
C. Control Board A HOSHIZAKI exclusive solid-state control is employed in KM-1800SAH/3, KM 1800SWH/3 and KM-1800SRH/3 Stackable 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. It is especially important to touch the metal part of the unit when handling or replacing the board. 3. Do not touch the electronic devices on the board or the back of the board to prevent damage to the board. 4. Do not change wiring and connections. Do not misconnect K3, K4 and K5, because the same connector is used for the thermistor and float switch. K4 is not connected. 5. Always replace the whole board assembly if it goes bad. 6. Do not short out power supply to test for voltage. 18
1. Control Board Layout Control Products "E" Control Board Alarm Reset Switch Dip Switch Output Test Switch (used to test relays on board) Backup Freeze Timer LED Connector K3 Harvest Control (thermistor) Backup Harvest Timer LED Alarm Buzzer Power LED (lights when power is supplied to the board) Relay LEDs (4) (indicate which relays are energized as listed below) LED 2 Hot Gas Valve (HGV) Self-Contained Fan Motor (FMS) (FMS off when LED on) LED 3 Pump Motor (PM) (on at pump out only) LED 4 Water Valve (WV) LED 1 Compressor (Comp) Remote Fan Motor (FMR) Transformer Connector Connector K4 Open (not connected) Microprocessor (board revision level indicated by last 2 digits on label) Connector K5 Float Switch Part Number Connector K1 Pins #1 through #10 #1, 9 Magnetic Contactor #2 Hot Gas Valve #3 Line Valve Self-Contained Fan Motor (FMS) #4 Pump Motor (icemaking) #5 Pump Motor (drain) #6 Water Valve #7, 10 Power (line, bin control) #8 Open Switch for "C" board and "ALPINE" board (service boards only) Part Number Type Control Board 2A1410-01 (factory); 2A1410-02 (service) HOS-001A (Control Products - 10 Pin) 19
2. Features a) Maximum Water Supply Period 6 minutes Inlet water valve opening, in the harvest cycle, is limited by the harvest timer. The water valve cannot remain open longer than the maximum period. The water valve can close in less than six minutes if the harvest cycle is completed. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete. The control board will signal this problem using 2 beeps every 3 seconds. The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle takes longer than the time specified to complete. The control board will signal this problem using 3 beeps every 3 seconds. The time is factory set using dip switches 9 & 10. The reset button on the control board must be pressed with power on to reset either of these safeties. c) High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety. This protects the unit from excessively high temperatures. If the evaporator temperature rises above 127 ± 7 F (53 ± 4 C), the thermistor operates the safety. This shuts down the circuit and the icemaker automatically stops. The control board will signal this problem using 1 beep every 3 seconds. The reset button on the control board must be pressed with power on to reset the safety. d) Low Water Safety If the pump motor is operated without water, the mechanical seal can fail. To prevent this type of failure, the control board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle. If the float switch is in the up position (electrical circuit closed), the control board changes to the ice making cycle. If the float switch is in the down position (electrical circuit open), the control board changes to additional one minute water fill cycles until water enters the sump and the float switch closes. When the float switch closes, the control board changes to the ice making cycle. The unit will not start without adequate water in the sump. This serves as a low water safety to protect the pump motor from mechanical seal failure. For water-cooled model, if the water is shut off, the unit is protected by the high pressure switch. e) High Voltage and Low Voltage Cut-outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut-outs. If miswiring (especially on single phase 3 wire models) causes excessive voltage (147Vac ±5% or more) on the control board, the high voltage cut-out shuts down the circuit in 3 seconds and the icemaker automatically stops. The control board will signal this problem using 7 beeps every 3 seconds. The icemaker also automatically stops in cases of insufficient voltage (92Vac ±5% or less). The control board will signal this problem using 6 beeps every 3 seconds. When the proper supply voltage is resumed, the icemaker automatically starts running again. 20
f) LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned OFF. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. For more information, see "II.B. Sequence of Operation." Sequence Step LED Energized Time LEDs are On Components Min. Max. Avg. 1 Minute Fill Cycle 4 WV 60 seconds Harvest Cycle 1, 4, and 2 WV, HGV, Comp, FMR 2 minutes 20 minutes 3 to 5 minutes Freeze Cycle 1 Comp, PM, FMR/FMS, LLV 5 minutes freeze timer 30 to 35 minutes setting Reverse Pump Out 1, 3, and 2 Comp, HGV, 10 seconds 20 seconds factory setting PM, FMR The built in safeties shut down the unit and have alarms as follows: No. of Beeps Type of Alarm Notes (every 3 sec.) 1 High Evaporator Temp. (temperature > 127 F) (53 C) 2 Harvest Backup Timer (harvest > 20 min. for two cycles in a row) 3 Freeze Timer (freeze > specified setting for two cycles in a row) Timer is factory set using dip switches 9 & 10 21 Check for harvest problem (stuck HGV or relay), hot water entering unit, stuck HM, or shorted thermistor. Orange LED marked H TIMER lights up. Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient compressor. Yellow LED marked F TIMER lights up. Check for F/S stuck closed (up), WV leaking by, HGV leaking by, TXV not feeding properly, low charge, HM not bypassing, or inefficient compressor. To manually reset the above safeties, press the alarm reset button with the power supply on. 6 Low Voltage (92Vac ±5% or less) 7 High Voltage (147Vac ±5% or more) Red LED will turn off if voltage protection operates. The control voltage safeties automatically reset when voltage is corrected. Legend: Comp compressor; FMR remote fan motor; FMS self-contained fan motor; F/S float switch; HGV hot gas valve; HM headmaster (C.P.R.); LLV Liquid Line Valve; PM pump motor; TXV thermostatic expansion valve; WV inlet water valve
3. Controls and Adjustments a) Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: Dip Switch No. 1 2 3 4 5 6 7 8 9 10 KM-1800SAH/3 OFF OFF ON ON ON ON OFF OFF ON OFF KM-1800SWH/3 OFF OFF ON ON ON ON OFF OFF OFF OFF KM-1800SRH/3 OFF ON ON ON ON ON OFF OFF ON OFF Freeze Timer (9 & 10) Normally in the OFF position. Pump-Out Frequency Control (5 & 6) Pump-Out Timer (3 & 4) Harvest Timer (1 & 2) b) Harvest Control Thermistor A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer. No adjustment is required. If necessary, check for resistance between thermistor leads, and visually check the thermistor mounting, located on the suction line next to the evaporator outlet. Temperature ( F) Temperature ( C) Resistance (kω) 0-18 14.401 10-12 10.613 32 0 6.000 50 10 3.871 70 21 2.474 90 32 1.633 Check a thermistor for resistance by using the following procedure: 1) Disconnect the connector K3 on the board. 2) Remove the thermistor. See "V. H. Removal and Replacement of Thermistor." 3) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes. 4) Check for a resistance between thermistor leads. Normal reading is within 3.5 to 7 kω. Replace the thermistor if it exceeds the normal reading. 22
c) Harvest Timer (dip switch 1 & 2) The harvest timer starts counting when the thermistor reads 48 F (9 C) at the evaporator outlet. No adjustment is required under normal use, as the harvest timer is adjusted to the suitable position. However, a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning. Before changing this setting, call the HOSHIZAKI Technical Support Department at 1 800 233 1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production. Dip Switch Setting Time No. 1 No. 2 (seconds) OFF OFF 60 ON OFF 90 OFF ON 120 ON ON 180 d) Pump-Out Timer (dip switch 3 & 4) When a freeze cycle is completed, the pump motor stops, and the icemaker resumes operation in 2 seconds. Then, during cycles when a pump out is called for, the pump motor drains the water tank for the time determined by the pump-out timer. The pumpout timer also acts in place of the harvest timer during cycles with a pump out. The pump-out timer is factory-adjusted, and no adjustment is required. Dip Switch Setting Time (seconds) No. 3 No. 4 T1 T2 OFF OFF 10 150 ON OFF 10 180 OFF ON 10 120 ON ON 20 180 T1: Time to drain the water tank T2: Harvest timer at pump out Pump out always occurs on the 2nd harvest after startup. Then, depending on the pumpout frequency control setting (dip switch 5 & 6), pump out occurs every cycle, or every 2nd, 5th or 10th cycle. 23
e) Pump-Out Frequency Control (dip switch 5 & 6) The pump motor drains the water tank at the frequency set by the pump-out frequency control. The pump-out frequency control is factory-adjusted to drain the water tank every 10 cycles, and no adjustment is required. However, where water quality is bad and the icemaker needs a pump drain more often, the pump-out frequency can be adjusted as shown in the table below: Dip Switch Setting No. 5 No. 6 Frequency OFF OFF every cycle ON OFF every 2 cycles OFF ON every 5 cycles ON ON every 10 cycles f) Freeze Timer (dip switch 9 & 10) CAUTION Adjust to proper specification, or the unit may not operate correctly. The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. The freeze timer is factory adjusted and no adjustment is required. g) Bin Control Dip Switch Setting Time No. 9 No. 10 (minutes) OFF OFF 60 OFF ON 50 ON OFF 70 ON ON 60 CAUTION When the ambient temperature is below 45 F (7 C), the bin control thermostat operates to stop the icemaker even if the ice storage bin is empty. When the thermostat is set in the prohibited range, the icemaker operates continuously even if the ice storage bin is filled with ice. Setting in the prohibited range might cause severe damage to the icemaker resulting in failure. No adjustment is required under normal use, as the bin control is factory-adjusted. Adjust it, if necessary, so that the icemaker stops automatically within 10 seconds after ice contacts the bin control thermostat bulb. 24
4. Control Board Check Procedure Before replacing a control board 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. 1) Check the dip switch settings to assure that #3, 4, 7, 8, 9, & 10 are in the factory default position. On units with a slide-type output test switch, the output test switch (S3) should be "OFF." Switches 1, 2, 5, & 6 are cleaning adjustments and the settings are flexible. 2) Turn the control switch to "ICE" and check for proper control voltage. If the red LED is on, the control voltage is good. If the red LED is off, check the control transformer circuit. 3) Check the 115 volt input at the 10-pin connector. Check the brown wire at pin #10 to a white neutral wire for 115 volts. (Always choose a white neutral wire to establish a good neutral connection when checking voltages.) A jumper also feeds 115 volts into pin #7. If no voltage is present, check the 115 volt supply circuit. 4) The output test switch provides a relay sequence test. On units with a slide-type output test switch, move the control switch to the "OFF" position, move the output test switch to the "ON" position, then move the control switch to the "ICE" position. On units with a push-type output test switch, make sure the control switch is in the "ICE" position, then press the output test switch. The correct lighting sequence should be none, 2, 3, 4, 1, and 4, normal sequence every 5 seconds. Components (e.g., the compressor) will cycle during the test. Note that the order of the relays from the outer edge of the board is 1, 4, 3, 2. Note: If the LEDs light in a different sequence or the 5 second interval does not occur, the control board is bad and should be replaced. 5) After checking the sequence, place the output test switch back in the "OFF" position on units with a slide-type switch. The output test switch must remain in the "OFF" position during normal operation. On units with a push-type output test switch, the unit automatically resumes normal operation after the test. The unit begins normal operation with the 1 minute fill cycle. 5. Control Board Replacement The application switch located between relay X3 & X4 must be set to match the original board application. Place this switch in the "ALP" position if there is no white wire supplied to the K1 connector. If there is a white wire, place the switch in the "C" position. If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch "OFF" or the unit will not start. The dip switches should be adjusted to the factory default settings as outlined in this manual. Dip switch #8 must remain in the "OFF" position. 25
III. Technical Information A. Water Circuit and Refrigerant Circuit 1. KM-1800SAH/3 26
2. KM-1800SWH/3 27
3. KM-1800SRH/3 28
B. Wiring Diagrams 1. KM-1800SAH * Transformer Output 10.5V at 115V * Pressure Switch Cut-out 412±21.3 PSIG Cut-in 327±21.3 PSIG 29
2. KM-1800SAH3 * Transformer Output 10.5V at 115V * Pressure Switch Cut-out 412±21.3 PSIG Cut-in 327±21.3 PSIG 30
3. KM-1800SWH, KM-1800SRH * Transformer Output 10.5V at 115V * Pressure Switch Water-Cooled Model Remote Model Cut-out 384± 21 PSIG 412± 21 0 0 PSIG Cut-in 284±21 PSIG 327±21 PSIG 31
4. KM-1800SWH3, KM-1800SRH3 * Transformer Output 10.5V at 115V * Pressure Switch Water-Cooled Model Remote Model Cut-out 384± 21 PSIG 412± 21 0 0 PSIG Cut-in 284±21 PSIG 327±21 PSIG 32
C. Performance Data 1. KM-1800SAH (air-cooled) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1756 797 1685 764 1589 721 80/27 1702 772 1592 722 1496 679 90/32 1685 764 1514 687 1416 642 lbs./day kg./day 100/38 1579 716 1491 676 1326 601 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 90/32 watts 100/38 2910 2986 3039 APPROXIMATE WATER 70/21 680 2.57 583 2.21 496 1.88 CONSUMPTION PER 24 HR. 80/27 606 2.29 455 1.72 394 1.49 90/32 583 2.21 348 1.32 275 1.04 gal./day m 3 /day 100/38 456 1.73 331 1.25 207 0.78 FREEZING CYCLE TIME 70/21 80/27 31 33 33 36 36 39 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 80/27 90/32 min. 100/38 4.2 3.4 2.5 HEAD PRESSURE 70/21 230 16.2 251 17.6 277 19.4 80/27 246 17.3 278 19.5 303 21.3 90/32 251 17.6 300 21.1 326 22.9 PSIG kg/cm 2 G 100/38 255 17.9 306 21.5 350 24.6 SUCTION PRESSURE 70/21 50 3.5 51 3.6 54 3.8 80/27 51 3.6 53 3.8 56 3.9 90/32 51 3.6 55 3.9 58 4.1 PSIG kg/cm 2 G 100/38 52 3.7 56 3.9 60 4.2 2780 2825 2838 33 37 6.0 2838 2915 2979 39 40 5.3 2881 2937 3010 42 45 4.6 5.4 4.3 3.9 5.3 3.5 3.0 TOTAL HEAT OF REJECTION FROM CONDENSER 24720 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 33
2. KM-1800SAH3 (air-cooled, 3 phase) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1757 797 1683 764 1597 724 80/27 1701 772 1587 720 1507 684 90/32 1683 764 1506 683 1422 645 lbs./day kg./day 100/38 1579 716 1486 674 1344 610 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 90/32 watts 100/38 2818 2965 3080 APPROXIMATE WATER 70/21 694 2.63 587 2.22 508 1.92 CONSUMPTION PER 24 HR. 80/27 612 2.32 446 1.69 405 1.53 90/32 587 2.22 328 1.24 269 1.02 gal./day m 3 /day 100/38 454 1.72 314 1.19 215 0.81 FREEZING CYCLE TIME 70/21 80/27 32 34 34 37 37 40 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 80/27 90/32 min. 100/38 4.1 2.9 2.5 HEAD PRESSURE 70/21 240 16.9 262 18.4 283 19.9 80/27 257 18.1 291 20.5 306 21.5 90/32 262 18.4 315 22.1 333 23.4 PSIG kg/cm 2 G 100/38 291 20.5 319 22.4 350 24.6 SUCTION PRESSURE AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 70/21 52 3.7 53 3.7 55 3.9 80/27 53 3.7 54 3.8 57 4.0 90/32 53 3.7 55 3.9 58 4.1 PSIG kg/cm 2 G 100/38 54 3.8 56 3.9 60 4.2 2562 2649 2676 34 38 6.0 2676 2825 2949 40 41 5.1 2763 2875 3017 43 45 4.6 5.3 4.0 3.9 5.1 3.0 2.7 TOTAL HEAT OF REJECTION FROM CONDENSER 24150 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 34
3. KM-1800SWH (water-cooled) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1816 824 1810 821 1789 811 80/27 1812 822 1803 818 1774 805 90/32 1810 821 1797 815 1770 803 lbs./day kg./day 100/38 1801 817 1791 812 1746 792 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 2500 2511 2515 2534 2519 2530 90/32 watts 100/38 2510 2550 2550 APPROXIMATE WATER 70/21 1640 6.21 1745 6.60 2284 8.65 CONSUMPTION PER 24 HR. 80/27 1720 6.51 1883 7.13 2642 10.00 90/32 1745 6.60 1998 7.56 2676 10.13 gal./day m 3 /day 100/38 2071 7.84 2157 8.17 3298 12.49 FREEZING CYCLE TIME 70/21 80/27 31 31 31 32 32 32 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 80/27 90/32 min. 100/38 4.0 2.9 2.4 HEAD PRESSURE 70/21 256 18.0 255 17.9 255 17.9 80/27 255 17.9 253 17.8 255 17.9 90/32 255 17.9 252 17.7 253 17.8 PSIG kg/cm 2 G 100/38 256 18.0 252 17.7 254 17.9 SUCTION PRESSURE 70/21 50 3.5 50 3.5 50 3.5 80/27 50 3.5 50 3.5 50 3.5 90/32 50 3.5 50 3.5 50 3.5 PSIG kg/cm 2 G 100/38 50 3.5 50 3.5 50 3.5 2515 31 31 5.7 2550 32 32 4.9 2550 33 33 4.4 5.1 3.9 3.7 4.9 3.0 2.7 TOTAL HEAT OF REJECTION FROM CONDENSER TOTAL HEAT OF REJECTION FROM COMPRESSOR WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE 26,200 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 3,500 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 125 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)] less than 10 PSIG Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 35
4. KM-1800SWH3 (water-cooled, 3 phase) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1761 799 1766 801 1726 783 80/27 1765 801 1773 804 1707 774 90/32 1766 801 1778 806 1722 781 lbs./day kg./day 100/38 1742 790 1765 801 1671 758 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 2420 2458 2470 2535 2455 2474 90/32 watts 100/38 2439 2580 2510 APPROXIMATE WATER 70/21 1544 5.85 1563 5.92 1952 7.39 CONSUMPTION PER 24 HR. 80/27 1559 5.90 1588 6.01 2178 8.25 90/32 1563 5.92 1609 6.09 2122 8.03 gal./day m 3 /day 100/38 1746 6.61 1729 6.55 2593 9.82 FREEZING CYCLE TIME 70/21 80/27 31 31 31 32 32 32 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 80/27 90/32 min. 100/38 4.0 2.9 2.4 HEAD PRESSURE 70/21 253 17.8 252 17.7 253 17.8 80/27 252 17.7 250 17.6 253 17.8 90/32 252 17.7 249 17.5 251 17.7 PSIG kg/cm 2 G 100/38 253 17.8 249 17.5 253 17.8 SUCTION PRESSURE 70/21 50 3.5 50 3.5 51 3.6 80/27 50 3.5 50 3.5 51 3.6 90/32 50 3.5 50 3.5 51 3.6 PSIG kg/cm 2 G 100/38 50 3.5 50 3.5 52 3.7 2470 31 31 5.7 2590 33 33 4.9 2548 33 33 4.4 5.1 3.9 3.7 4.9 3.0 2.7 TOTAL HEAT OF REJECTION FROM CONDENSER TOTAL HEAT OF REJECTION FROM COMPRESSOR WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE 25,900 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 3,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 97 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)] less than 10 PSIG Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 36
5. KM-1800SRH (remote air-cooled) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1817 824 1768 802 1643 745 80/27 1780 807 1704 773 1546 701 90/32 1768 802 1651 749 1504 682 lbs./day kg./day 100/38 1723 782 1617 733 1369 621 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 90/32 watts 100/38 2780 2900 2970 APPROXIMATE WATER 70/21 721 2.73 639 2.42 557 2.11 CONSUMPTION PER 24 HR. 80/27 658 2.49 530 2.01 466 1.76 90/32 639 2.42 439 1.66 366 1.38 gal./day m 3 /day 100/38 528 2.00 422 1.60 298 1.13 FREEZING CYCLE TIME 70/21 80/27 32 33 34 36 37 39 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 80/27 90/32 min. 100/38 4.2 3.6 2.8 HEAD PRESSURE 70/21 220 15.5 227 16.0 247 17.4 80/27 226 15.9 237 16.7 262 18.4 90/32 227 16.0 245 17.2 268 18.9 PSIG kg/cm 2 G 100/38 235 16.5 250 17.6 290 20.4 SUCTION PRESSURE AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 70/21 40 2.8 41 2.9 44 3.1 80/27 41 2.9 43 3.1 46 3.2 90/32 41 2.9 45 3.2 48 3.3 PSIG kg/cm 2 G 100/38 42 3.0 46 3.2 50 3.5 2730 2766 2777 34 35 5.4 2777 2839 2890 38 39 4.9 2823 2875 2932 41 44 4.4 5.0 4.2 3.8 4.9 3.7 3.2 TOTAL HEAT OF REJECTION FROM CONDENSER TOTAL HEAT OF REJECTION FROM COMPRESSOR CONDENSER VOLUME 24,600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 3,300 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 214 CU. IN (URC-20F) Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 37
6. KM-1800SRH3 (remote air-cooled, 3 phase) APPROXIMATE ICE PRODUCTION PER 24 HR. 70/21 1775 805 1722 781 1618 734 80/27 1735 787 1653 750 1531 695 90/32 1722 781 1595 723 1479 671 lbs./day kg./day 100/38 1691 767 1568 711 1372 622 APPROXIMATE ELECTRIC CONSUMPTION 70/21 80/27 90/32 watts 100/38 2725 2873 2970 APPROXIMATE WATER 70/21 774 2.93 681 2.58 591 2.24 CONSUMPTION PER 24 HR. 80/27 703 2.66 558 2.11 489 1.85 90/32 681 2.58 456 1.73 376 1.42 gal./day m 3 /day 100/38 556 2.11 437 1.66 302 1.14 FREEZING CYCLE TIME 70/21 80/27 32 33 34 37 37 40 90/32 min. 100/38 HARVEST CYCLE TIME 70/21 80/27 90/32 min. 100/38 4.3 3.5 2.8 HEAD PRESSURE 70/21 225 15.8 232 16.3 242 17.0 80/27 231 16.2 242 17.0 252 17.7 90/32 232 16.3 250 17.6 260 18.3 PSIG kg/cm 2 G 100/38 234 16.5 252 17.7 270 19.0 SUCTION PRESSURE AMBIENT TEMP. WATER TEMP. (ºF/ºC) (ºF/ºC) 50/10 70/21 90/32 70/21 43 3.0 44 3.1 46 3.3 80/27 44 3.1 46 3.3 48 3.4 90/32 44 3.1 48 3.4 50 3.5 PSIG kg/cm 2 G 100/38 45 3.2 48 3.4 52 3.7 2660 2705 2719 34 35 5.8 2719 2796 2860 39 39 5.1 2780 2847 2917 42 45 4.6 5.3 4.3 4.0 5.1 3.6 3.2 TOTAL HEAT OF REJECTION FROM CONDENSER TOTAL HEAT OF REJECTION FROM COMPRESSOR CONDENSER VOLUME 25,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 3,300 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 214 CU. IN (URC-20F) Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice. 38
IV. Service Diagnosis A. 10-Minute KM Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70 F or warmer air and 50 F or warmer water temperatures. Before conducting a 10 minute checkout, check for correct installation, proper voltage per unit nameplate and adequate water supply. As you go through the procedure, check to assure the components energize and de-energize correctly. If not, those components and controls are suspect. Check for voltage at the 10-pin connector. 1) Turn power off and access the control box. 2) Turn power on and place the control switch in "ICE" position. A 5 second delay occurs. 3) One Minute Fill Cycle The inlet water valve is energized. After 1 minute, the control board checks the float switch. If the float switch is closed, the unit cycles to harvest. If closed, continue to step 4. If the float switch is open, the unit repeats the 1 minute fill cycle until water enters and the float switch closes (low water safety protection during initial start up and at the end of each harvest). Diagnosis: If the water valve does not open, check for no supply voltage at water valve terminals, bad coil, or plugged screen or external filter (no water flow). If unit fails to start harvest, check for open float switch or bad 1 minute timer in board. 4) Initial Harvest Cycle Inlet water valve remains energized, contactor coil energizes to start the compressor (and fan motor on a remote condenser unit), and the hot gas valve energizes. The evaporator warms and the thermistor senses 48 F (9 C). The control board then receives the thermistor's 3.9 kω signal and turns operation of harvest over to the harvest timer. The timer completes counting (1 to 3 minutes). The unit then cycles to freeze. Diagnosis: Check if compressor is running, hot gas valve is open, water valve still open. Average harvest cycle at factory setting is 2 to 3 minutes. How long does initial harvest last? 1.5 minutes after initial harvest begins, touch the compressor discharge line. Is it hot? If not check refrigerant pressures and compressor operation. If it is hot, touch the inlet line to the evaporator. Is it hot? If it is hot and the freeze cycle is not starting, check the harvest timer adjustment, the thermistor for open circuit, the discharge line temperature, compressor efficiency, and if the hot gas valve is fully open. 5) Freeze Cycle Compressor remains energized, pump motor, (line valve on remote condenser unit), and fan motor energize. The inlet water valve and hot gas valve deenergize. The unit is held in freeze by a 5 minute short cycle protection timer. After the 5 minute short cycle protection timer terminates, the freeze cycle operation is transferred to the float switch for freeze termination. During the first 5 minutes of freeze, confirm that the evaporator temperature drops. After 7 minutes in freeze, remove the black float switch lead from the K5 connector. The unit should immediately switch to the pump-out cycle. Diagnosis: If the evaporator is not cold, check to see if the hot gas valve is still open or if the expansion valve is not opening properly, if the water valve is continuing to fill the reservoir, if there are improper unit pressures, an inoperative compressor, or an inoperative headmaster (C.P.R.) (remote condenser unit only). If the unit remains in freeze with the float switch removed, replace the board. 39