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Manual Hoshizaki KM-2400SRF3

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  • Hoshizaki KM-2400SRF3 - page 1

    ™ SER VICE MANUAL NUMBER: 73090 KM-2400SRF3 KM-2400SRH3 ST ACKABLE CRESCENT CUBER R eliability is a beautiful thing TM REVISED: DEC, 14, 2003 ISSUED: DEC. 23, 1999 ...

  • Hoshizaki KM-2400SRF3 - page 2

    2 HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City , GA 30269 Attn: HOSHIZAKI T echnical Support Department Phone: 1-800-233-1940 T echnical Service (770) 487-2331 Fax: (770) 487-3360 NOTE: T o expedite assistance, all correspondence/communication MUST include the following information: • Model Number • Serial Number • Complete and ...

  • Hoshizaki KM-2400SRF3 - page 3

    3 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 PAGE I. SPECIFICATIONS ....................... ...

  • Hoshizaki KM-2400SRF3 - page 4

    4 7. REMOVAL AND REPLACEMENT OF EVAPORATOR ....................................... 38 8. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE ...................... REGULATOR (C.P.R.) ......................................................................................... 3 9 9. REMOVAL AND REPLACEMENT OF THERMISTOR ..................................... ...

  • Hoshizaki KM-2400SRF3 - page 5

    5 I. SPECIFICATIONS KM-2400SRF3, KM-2400SRH3 (Remote air-cooled, 3 phase) We reserve the right to make changes in specifications and design without prior notice. ...

  • Hoshizaki KM-2400SRF3 - page 6

    6 2. CONDENSING UNIT, URC-24F ...

  • Hoshizaki KM-2400SRF3 - page 7

    7 SPECIFICATIONS MODEL: URC-24F EXTERIOR DIMENSIONS (W x D x H) REFRIGERANT CHARGE URC-24F WEIGHT CONNECTIONS REFRIGERANT ELECTRICAL CONDENSER AC SUPPLY VOLTAGE AMBIENT CONDITION Galvanized Steel 36” x 19-3/4” x 43-3/4” (915 x 501 x 1111 mmmm) R404A 11 lbs. (5000 g) Net 168 lbs. (76 kg) Shipping 179 lbs. (81 kg) One Shot Couplings (Aeroquip) ...

  • Hoshizaki KM-2400SRF3 - page 8

    8 Evaporator Spray Tube Water Valve Water Supply Inlet Transformer Box Header Junction Box CPR Valve Receiver Tank Drier Line Valve Water Pump Float Switch Pressure Switch Cleaning Valve Control Box Expansion Valve Hot Gas Valve Compressor II. GENERAL INFORMA TION 1. CONSTRUCTION ...

  • Hoshizaki KM-2400SRF3 - page 9

    9 2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-2400SRF3 and KM-2400SRH3 Stackable Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system. 3) All models are pretested and factory-adjusted. [b] CONTROLLER BOAR ...

  • Hoshizaki KM-2400SRF3 - page 10

    10 2) Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle. But the Defrost Timer does not start counting until the Thermistor senses 48°F at the Evaporator outlet. The period from the end of the freeze cycle up to the point of the Thermistor's sensing varies depending on the ambient and water temp ...

  • Hoshizaki KM-2400SRF3 - page 11

    11 The green LED’s 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows: Sequence Step LED’s on Length: Min. Max. Avg. 1 Minute Fill Cycle LED4 60 sec. Harvest Cycle LED1, 4, & 2 2 min. 20 min. 3-5 min. Freeze Cycle LED1 5 min. 60 min. 30-35 min. Reverse Pump Out LED1, 3, & 2 10 sec. ...

  • Hoshizaki KM-2400SRF3 - page 12

    12 (Control Products HOSHIZAKI001 Board) 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 ener- gized with the control switch OFF or the unit will not start. The dip switches should be adjusted per the adjustment chart publis ...

  • Hoshizaki KM-2400SRF3 - page 13

    13 (Control Products HOS-001A Board) ...

  • Hoshizaki KM-2400SRF3 - page 14

    14 4. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts. [c] SEQUENCE 1st Cycle 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 2. After 1 minute. Defrost cycle starts. IMPORTANT Water Valve opening is limited to 6 minutes. 5. After the first 5 minutes in freeze cycle. Ready to c ...

  • Hoshizaki KM-2400SRF3 - page 15

    15 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited to 50 minutes even if Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. Drain timer starts counting. 2. Drain timer stops counting. Pump drain is completed 3. Thermistor reads 48° F. Defrost Timer starts counting. IMPORTANT Water Val ...

  • Hoshizaki KM-2400SRF3 - page 16

    16 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited to 50 minutes even if Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. 2. Thermistor reads 48° F. Defrost Timer starts counting. IMPORTANT Water Valve opening is limited to 6 minutes. 4. After the first 5 minutes in freeze cycle. ...

  • Hoshizaki KM-2400SRF3 - page 17

    17 DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10 OFF OFF ON OFF OFF OFF OFF OFF OFF ON [d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: Switch Nos. 1 and 2: Used for adjustment of the Defrost Timer. The Defrost Timer starts counting when the Thermistor reads a certain temperature at the Evaporator outlet. Switch Nos ...

  • Hoshizaki KM-2400SRF3 - page 18

    18 1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor. The resistance varies depending on the Suction Line temperatures. The Thermistor detects the temperature of the Evaporator outlet to start the Defrost Timer. No adjustment is required. If necessary, check for resistance between Thermistor leads, and visually ch ...

  • Hoshizaki KM-2400SRF3 - page 19

    19 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 T 1 T 2 OFF OFF 10 seconds 150 seconds ON OFF 10 seconds 180 seconds OFF ON 10 seconds 120 seconds ON ON 20 seconds 180 seconds T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Drain Counter ...

  • Hoshizaki KM-2400SRF3 - page 20

    20 6) Bin Control CAUTION When the ambient temperature is below 45°F, 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 con- tinuously even if the Ice Storage Bin is filled with ice. Setting in the prohib- ited range might cause s ...

  • Hoshizaki KM-2400SRF3 - page 21

    21 (iv) After Step (iii), de-energize the unit and confirm that the Defrost Timer is in the minimum position. Disconnect the resistor from the Controller Board, and energize the unit. After the 1 minute water supply cycle, the defrost cycle starts. Reconnect a 1.5 k Ω - 3.5 k Ω resistor to the Connector K3 (pins #1 and #2) after the first 2 min ...

  • Hoshizaki KM-2400SRF3 - page 22

    22 III. TECHNICAL INFORMA TION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT ...

  • Hoshizaki KM-2400SRF3 - page 23

    23 2. WIRING DIAGRAM High Pressure Switch ACB-2UB09 Cut-out 41 2 PSIG Cut-in 327 ± 21 PS IG +21 0 ...

  • Hoshizaki KM-2400SRF3 - page 24

    24 3. TIMING CHART *1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” ...

  • Hoshizaki KM-2400SRF3 - page 25

    25 *1 The Pump Motor waits for 2 seconds before starting a drain cycle. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” *2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” ...

  • Hoshizaki KM-2400SRF3 - page 26

    26 4. PERFORMANCE DA T A KM-2400SRF3, KM-2400SRH3 (Remote air-cooled, 3 phase) We reserve the right to make changes in specifications and design without prior notice. Note: Pressure data is recorded at 5 minutes into freezing cycle. The data NOT in BOLD should be used for reference only. ...

  • Hoshizaki KM-2400SRF3 - page 27

    27 PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker a) Power Supply 1. “OFF” position. 1. Move to “ON” position. will not start 2. Loose connections. 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace. 4. Voltage too high. 4. Check and get recommended voltage. b) Fuse (Inside Fused 1. Blown out. 1. Check for short circuit Discon ...

  • Hoshizaki KM-2400SRF3 - page 28

    28 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective. 1. See “II.2[e] CHECKING CONTROLLER BOARD.” m) Interlock Switch 1. “OFF” position. 1. Move to “ON” position. (Cleaning Valve) 2. Bad contacts. 2. Check for continuity and replace. [2] Water a) Float switch 1. Connector disconnected. 1. Place in position. continues to 2. ...

  • Hoshizaki KM-2400SRF3 - page 29

    29 PROBLEM POSSIBLE CAUSE REMEDY [5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get comes from water level in Water Tank recommended pressure. Spray Tubes. too low. Water Pump b) Water Solenoid 1. Dirty mesh filter or orifice 1. Clean. will not start, or Valve and water level in Water freeze cycle Tank too low. time is ...

  • Hoshizaki KM-2400SRF3 - page 30

    30 2. EV APORA TOR IS FROZEN UP PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) Float Switch 1. Leads short-circuit or 1. Check and replace. time is too defective switch. long. 2. Float does not move freely. 2. Clean or replace. b) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks Valve with icemaker off. c) Controller Board 1. ...

  • Hoshizaki KM-2400SRF3 - page 31

    31 PROBLEM POSSIBLE CAUSE REMEDY [1] Icemaker will a) Bin Control 1. Set too cold. 1. Adjust warmer. not stop when Thermostat 2. Defective. 2. Replace. bin is filled with ice. [2] Abnormal a) Pump Motor 1. Bearings worn out. 1. Replace. noise b) Fan Motor 1. Bearings worn out. 1. Replace. 2. Fan blade deformed. 2. Replace fan blade. 3. Fan blade do ...

  • Hoshizaki KM-2400SRF3 - page 32

    32 V. REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture quickly. Therefore it is important to prevent moisture from entering the system when replacing or servicing pa ...

  • Hoshizaki KM-2400SRF3 - page 33

    33 5) Disconnect the Vacuum Pump, and attach a Refrigerant Service Cylinder to the High- side line. Remember to loosen the connection, and purge the air from the Hose. See the Charge Label in the machine compartment. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used. 6) A liquid charge ...

  • Hoshizaki KM-2400SRF3 - page 34

    34 3. REMOV AL AND REPLACEMENT OF COMPRESSOR IMPORT ANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. Note: Due to the ability of the POE oil in the compressor to absorb moisture quickly, the Compressor must not be opened more than ...

  • Hoshizaki KM-2400SRF3 - page 35

    35 15) Evacuate the system, and charge it with refrigerant. See the Charge Label in the machine compartment for the required refrigerant charge. 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Replace the panels in their correct positions. 18) Turn on the power supply. 4. REMOV AL AND REPLACEMENT OF DRIER IMPO ...

  • Hoshizaki KM-2400SRF3 - page 36

    36 5. REMOV AL AND REPLACEMENT OF EXP ANSION V AL VE IMPORT ANT Sometimes moisture in the refrigerant circuit exceeds the Drier capacity and freezes up at the Expansion Valve. Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. 1) Turn o ...

  • Hoshizaki KM-2400SRF3 - page 37

    37 6. REMOV AL AND REPLACEMENT OF HOT GAS V AL VE AND LINE V AL VE CAUTION Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. IMPORT ANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other rep ...

  • Hoshizaki KM-2400SRF3 - page 38

    38 11) Connect the new Solenoid leads. 12) Attach the Solenoid to the valve body, and secure it with a screw. 13) Replace the panels in their correct positions. 14) Turn on the power supply. 7. REMOV AL AND REPLACEMENT OF EV APORA T OR IMPORT ANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Dri ...

  • Hoshizaki KM-2400SRF3 - page 39

    39 8. REMOV AL AND REPLACEMENT OF CONDENSING PRESSURE REGULA TOR (C.P .R.) IMPORT ANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repair or replacement has been made. 1) Turn off the power supply. 2) Remove the panels from the remote condenser unit. 3) Recover the r ...

  • Hoshizaki KM-2400SRF3 - page 40

    40 9. REMOV AL AND REPLACEMENT OF THERMIST OR CAUTION 1. Fragile, handle very carefully. 2. Always use a recommended sealant (High Thermal Conductive Type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent. 4. Do ...

  • Hoshizaki KM-2400SRF3 - page 41

    41 10. REMOV AL AND REPLACEMENT OF F AN MOT OR Note: When replacing a Fan Motor with defective winding, it is recommended that a new capacitor be installed. 1) Turn off the power supply. 2) Remove the panels. 3) Remove the Junction Box Cover from the remote condenser unit. 4) Remove the closed end connectors from the Fan Motor leads. 5) Remove the ...

  • Hoshizaki KM-2400SRF3 - page 42

    42 1 1. REMOV AL AND REPLACEMENT OF W A TER V AL VE 1) Turn off the power supply. 2) Close the Water Supply Line Shut-off Valve. 3) Remove the Front Panel. 4) Remove the Valve Outlet Tubing by releasing the Clamp. 5) Remove the Bracket from the unit. 6) Remove the Fitting Nut and Water Valve. 7) Disconnect the Terminals from the Water Valve. 8) Ins ...

  • Hoshizaki KM-2400SRF3 - page 43

    43 7) Remove the closed end connectors from the Pump Motor leads. 8) Remove the two screws and the Pump Motor Bracket. 9) Remove the Pump Housing, and check the Impeller. 10) If the Impeller is defective, install a new Impeller. 11) Install the new motor or new parts, and replace the removed parts in the reverse order of which they were removed. 12 ...

  • Hoshizaki KM-2400SRF3 - page 44

    44 VI. CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. 1. PREPARING THE ICEMAKER FOR LONG STORAGE WARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice f ...

  • Hoshizaki KM-2400SRF3 - page 45

    45 [2] Drain the Potable Water Tank: 1) Turn off the power supply. 2) Move the Control Switch to the “OFF” position. 3) Drain the Water Tank by removing the Insulation Panel and the Cap located on the front bottom part of the Ice Dropping Hole. See Fig. 3. 4) Replace the removed parts in their correct positions. 5) Remove all ice from the Stora ...

  • Hoshizaki KM-2400SRF3 - page 46

    46 2. CLEANING PROCEDURE IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. WARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to ind ...

  • Hoshizaki KM-2400SRF3 - page 47

    47 [a] CLEANING PROCEDURE 1) Dilute 38 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 7 gal. of water. 2) Remove all ice from the Evaporator and the Storage Bin. Note: To remove cubes on the Evaporator, turn off the power supply and turn it on after 3 minutes. The defrost cycle st ...

  • Hoshizaki KM-2400SRF3 - page 48

    48 19) Turn on the power supply to fill the Water Tank with water. 20) Turn off the power supply after 3 to 5 minutes. 21) Remove the Front Panel, and fully open the Cleaning Valve. 22) Move the Control Switch to the “Wash” position. 23) Replace the Front Panel in its correct position. 24) Turn on the power supply to rinse off the cleaning solu ...

  • Hoshizaki KM-2400SRF3 - page 49

    49 [b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute a 5.25% Sodium Hypochlorite solution (chlorine bleach) with water (Add 3.5 fl. oz. of sanitizer to 7 gal. of water). 2) Remove the Insulation Panel, if it is in its normal position. 3) Pour the sanitizing solution into the Water Tank. 4) Replace the Insulation Panel and the Front ...

  • Hoshizaki KM-2400SRF3 - page 50

    50 3. MAINTENANCE IMPORT ANT This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. 1) Stainless Steel Exterior To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2) Storag ...

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