Hoshizaki KM-100A User manual

SERVICE MANUAL
HOSHIZAKI
SELF-CONTAINED
CRESCENT CUBER
MODEL KM-100A
KM-125A
NO. F003-756
ISSUED: JUN.18,2008
REVISED: JUN.17,2011

IMPORTANT
This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualied service technicians
should install, service, and maintain the icemaker. Read the warnings
contained in this booklet carefully as they give important information
regarding safety. Please retain this booklet for any further reference that may
be necessary.
 CONTENTS PAGE
I. SPECIFICATIONS -------------------------------------------------------------------------------------1
1. SPECIFICATIONS ----------------------------------------------------------------------------------1
[a] KM-100A ------------------------------------------------------------------------------------------1
[b] KM-125A ------------------------------------------------------------------------------------------2
II. GENERAL INFORMATION -------------------------------------------------------------------------3
1. CONSTRUCTION ----------------------------------------------------------------------------------3
[a] KM-100A, KM-125A ---------------------------------------------------------------------------3
[b] ICEMAKING COMPARTMENT -------------------------------------------------------------4
2. SEQUENCE OF OPERATION ------------------------------------------------------------------5
[a] ONE MINUTE FILL CYCLE ------------------------------------------------------------------5
[b] INITIAL HARVEST CYCLE ------------------------------------------------------------------5
[c] FREEZE CYCLE -------------------------------------------------------------------------------5
[d] DRAIN CYCLE ----------------------------------------------------------------------------------6
[e] NORMAL HARVEST CYCLE ---------------------------------------------------------------6
3. CONTROL BOARD --------------------------------------------------------------------------------8
[a] CONTROL BOARD LAYOUT ---------------------------------------------------------------9
[b] FEATURES ------------------------------------------------------------------------------------ 10
[c] CONTROLS AND ADJUSTMENTS ------------------------------------------------------ 12
[d] CONTROL BOARD CHECK PROCEDURE------------------------------------------- 17
[e] CONTROL BOARD REPLACEMENT --------------------------------------------------- 18
4. HARVEST CONTROL - THERMISTOR ---------------------------------------------------- 18
5. BIN CONTROL ------------------------------------------------------------------------------------ 19
[a] EXPLANATION OF OPERATION -------------------------------------------------------- 19
[b] BIN CONTROL CHECK PROCEDURE ------------------------------------------------ 19
6. SWITCHES ---------------------------------------------------------------------------------------- 20
[a] CONTROL SWITCH ------------------------------------------------------------------------- 20
[b] SERVICE SWITCH -------------------------------------------------------------------------- 20
III. TECHNICAL INFORMATION -------------------------------------------------------------------- 21
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT --------------------------------------- 21
2. WIRING DIAGRAM ------------------------------------------------------------------------------ 22
[a] PRODUCTION 2008 (Auxiliary Code: T-1, U-1) -------------------------------------- 22
[b] PRODUCTION 2009 (Auxiliary Code: U-1) OR LATER ---------------------------- 23
3. TIMING CHART ----------------------------------------------------------------------------------- 24
[a] KM-100A ---------------------------------------------------------------------------------------- 24
[b] KM-125A ---------------------------------------------------------------------------------------- 25
i

IV. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 26
1. 10-MINUTE DIAGNOSTIC PROCEDURE ------------------------------------------------- 26
2. NO ICE PRODUCTION ------------------------------------------------------------------------- 28
3. EVAPORATOR IS FROZEN UP -------------------------------------------------------------- 31
4. LOW ICE PRODUCTION ----------------------------------------------------------------------- 32
5. ABNORMAL ICE ---------------------------------------------------------------------------------- 32
6. OTHER ---------------------------------------------------------------------------------------------- 33
V. REMOVAL AND REPLACEMENT -------------------------------------------------------------- 34
1. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 34
[a] SERVICE INFORMATION ----------------------------------------------------------------- 34
[b] REFRIGERANT RECOVERY ------------------------------------------------------------- 35
[c] EVACUATION AND RECHARGE -------------------------------------------------------- 35
2. BRAZING ------------------------------------------------------------------------------------------- 36
3. COMPRESSOR ----------------------------------------------------------------------------------- 37
4. DRIER ----------------------------------------------------------------------------------------------- 38
5. HOT GAS VALVE --------------------------------------------------------------------------------- 39
6. EXPANSION VALVE ----------------------------------------------------------------------------- 40
7. FAN MOTOR --------------------------------------------------------------------------------------- 42
8. PUMP MOTOR ------------------------------------------------------------------------------------ 43
9. WATER VALVE ------------------------------------------------------------------------------------ 44
10. DRAIN VALVE ------------------------------------------------------------------------------------- 45
11. FLOAT SWITCH ---------------------------------------------------------------------------------- 46
12. BIN CONTROL SWITCH ----------------------------------------------------------------------- 47
13. THERMISTOR ------------------------------------------------------------------------------------ 48
14. CONTROL BOX ---------------------------------------------------------------------------------- 49
[a] POWER SWITCH ---------------------------------------------------------------------------- 50
[b] FUSE -------------------------------------------------------------------------------------------- 50
[c] FUSE HOLDER ------------------------------------------------------------------------------- 50
[d] CONTROL BOARD -------------------------------------------------------------------------- 50
[e] POWER RELAY ------------------------------------------------------------------------------ 50
[f] CONTROL BOARD TRANSFORMER -------------------------------------------------- 51
15. WATER TANK ------------------------------------------------------------------------------------- 51
16. CUBE GUIDE ------------------------------------------------------------------------------------- 52
17. SEPARATOR -------------------------------------------------------------------------------------- 52
18. SPRAY TUBE, WATER SUPPLY PIPE, SPRAY GUIDE ------------------------------- 54
19. DOOR ----------------------------------------------------------------------------------------------- 55
VI. CLEANING AND MAINTENANCE INSTRUCTIONS -------------------------------------- 56
1. CLEANING ----------------------------------------------------------------------------------------- 56
[a] CLEANING PROCEDURE ----------------------------------------------------------------- 56
[b] SANITIZING PROCEDURE --------------------------------------------------------------- 57
2. MAINTENANCE ---------------------------------------------------------------------------------- 58
[a] EXTERIOR PANELS ------------------------------------------------------------------------ 58
[b] STORAGE BIN AND SCOOP ------------------------------------------------------------- 58
[c] AIR FILTER ------------------------------------------------------------------------------------ 59
[d] CONDENSER --------------------------------------------------------------------------------- 59
3. PREPARING THE ICEMAKER FOR LONG STORAGE -------------------------------- 59
ii

1
I. SPECIFICATIONS
1. SPECIFICATIONS
[a] KM-100A
POWERFACTOR
5-35°C
0.7-8bar(0.07-0.8Mpa)
ACSUPPLYVOLTAGE
AMPERAGE
STARTINGAMPERAGE
ELECTRICALCONSUMPTION
POWERSUPPLYCAPACITY
ICEPRODUCTIONPER24h
WATERCONSUMPTIONPER24h
SHAPEOFICE
FREEZECYCLETIME
ICEPRODUCTIONPERCYCLE
DIMENSIONS
EXTERIOR
MAXSTORAGECAPACITY
INSULATION
CONNECTIONS-ELECTRIC
-WATERSUPPLY
-DRAIN
ICEMAKINGSYSTEM
HARVESTINGSYSTEM
COMPRESSOR
CONDENSER
HEATREJECTION
EVAPORATOR
REFRIGERANTCONTROL
REFRIGERANTCHARGE
ICEMAKINGCONTROLSYSTEM
HARVESTINGCONTROLSYSTEM
BINCONTROLSYSTEM
ICEMAKINGWATERCONTROLSYSTEM
PACKAGE
ACCESSORIES
ICEMAKERPROTECTION
ELECTRICALPROTECTION
CONT.BOARDCIRCUITPROTECTION
COMPRESSORPROTECTION
REFRIGERANTCIRCUITPROTECTION
Approx.64kg(AT.32°C,WT.21°C)
VOLTAGERANGE
AMBIENTTEMP.
WATERSUPPLYTEMP.
OPERATIONCONDITIONS
LOWWATERPROTECTION
WEIGHT
67%
0.96kVA(4.2A)
Approx.101kg(AT.10°C,WT.10°C)
Approx.88kg(AT.21°C,WT.15°C)
1Phase220-24050Hz
3.40(AT.32°C,WT.21°C)
15A
584W(AT.32°C,WT.21°C)
Approx.0.54m3(AT.10°C,WT.10°C)
Approx.0.22m3(AT.21°C,WT.15°C)
Approx.0.11m3(AT.32°C,WT.21°C)
CrescentCube
Approx.26min(AT.21°C,WT.15°C)
Approx.1.7kg/182pcs(AT.21°C,WT.15°C)
610mm(W)X712mm(D)X840mm(H)(+152mmLeg）
StainlessSteel,PlasticDoor,GalvanizedSteel(Rear)
Approx.45kg(BinContSettingApprox.35kg)
PolyurethaneFoam
X-typeConnection(WithPlug)
InletG1/2"(connectedatrearside)
OutletG3/4"(connectedatrearside)
VerticalEvaporatorwithwaterflowonbothsides
WaterSupplyHarvestCycleandHotGasDefrost
HermeticModelSC10DL(Danfoss)
Air-cooled,FinandTubetype
1250W(1075kcal/h)(AT.32°C,WT.21°C)
Verticaltype,StainlessSteelandCopper
ThermostaticExpansionValve
R404A/340g
FloatSwitch
HotGasandWater,ThermistorandTimer
MechanicalBinSwitch
TimerControlled,OverflowPipe
ClassIAppliance,5AFuse
HighVoltageCut–out
Auto–resetOverloadProtector(Internal)
Auto–resetHighPressureControlSwitch
FloatSwitch
Netweight62kg/Grossweight75kg
Carton695mm(W)X800mm(D)X955mm(H)
InstructionManual
InterlockbyControlBoard
Scoop,Leg(4pcs)
DrainAdapter,OutletHose
Duct,Screw(3pcs)
Wereservetherighttomakechangesinspecificationsanddesignwithoutpriortonotice.
WATERSUPPLYPRESS.
198-254V
1-40°C

2
[b] KM-125A
0.7-8bar(0.07-0.8Mpa)
198-254V
1-40°C
5-35°C
ACSUPPLYVOLTAGE
AMPERAGE
STARTINGAMPERAGE
ELECTRICALCONSUMPTION
POWERFACTOR
POWERSUPPLYCAPACITY
ICEPRODUCTIONPER24h
WATERCONSUMPTIONPER24h
SHAPEOFICE
FREEZECYCLETIME
MAXSTORAGECAPACITY
DIMENSIONS
EXTERIOR
ICEPRODUCTIONPERCYCLE
INSULATION
CONNECTIONS-ELECTRIC
-WATERSUPPLY
-DRAIN
ICEMAKINGSYSTEM
HARVESTINGSYSTEM
COMPRESSOR
CONDENSER
HEATREJECTION
EVAPORATOR
REFRIGERANTCONTROL
REFRIGERANTCHARGE
ICEMAKINGCONTROLSYSTEM
HARVESTINGCONTROLSYSTEM
BINCONTROLSYSTEM
ICEMAKINGWATERCONTROLSYSTEM
ELECTRICALPROTECTION
CONT.BOARDCIRCUITPROTECTION
COMPRESSORPROTECTION
REFRIGERANTCIRCUITPROTECTION
WEIGHT
PACKAGE
LOWWATERPROTECTION
ICEMAKERPROTECTION
ACCESSORIES
OPERATIONCONDITIONS
VOLTAGERANGE
AMBIENTTEMP.
WATERSUPPLYTEMP.
WATERSUPPLYPRESS.
Wereservetherighttomakechangesinspecificationsanddesignwithoutpriortonotice.
1Phase220-24050Hz
4.50A(AT.32°C,WT.21°C)
19A
774W(AT.32°C,WT.21°C)
67%
1.43KVA(5.9A)
Approx.128kg(AT.10°C,WT.10°C)
Approx.115kg(AT.21°C,WT.15°C)
Approx.102kg(AT.32°C,WT.21°C)
Approx.0.73m3(AT.10°C,WT.10°C)
Approx.0.40m3(AT.21°C,WT.15°C)
Approx.0.18m3(AT.32°C,WT.21°C)
CrescentCube
Approx.24Min(AT.21°C,WT.15°C)
Approx.55kg(BinContSettingApprox.45kg)
762mm(W)X712mm(D)X840mm(H)(+152mmLeg）
StainlessSteel,PlasticDoor,GalvanizedSteel(Rear)
Approx.2.1kg/238pcs(AT.21°C,WT.15°C)
PolyurethaneFoam
X-typeConnection(WithPlug)
InletG1/2"(connectedatrearside)
OutletG3/4"(connectedatrearside)
VerticalEvaporatorwithwaterflowonbothsides
WaterSupplyHarvestCycleandHotGasDefrost
HermeticModelSC12DL(Danfoss)
Air-cooled,FinandTubetype
1650W(1420kcal/h)(AT.32°C,WT.21°C)
Verticaltype,StainlessSteelandCopper
ThermostaticExpansionValve
R404A/360g
FloatSwitch
HotGasandWater,ThermistorandTimer
MechanicalBinSwitch
TimerControlled,OverflowPipe
ClassIAppliance,5AFuse
HighVoltageCut-out
Auto–resetOverloadProtector(Internal)
Auto–resetHighPressureControlSwitch
Scoop,Leg(4pcs)
DrainAdapter,OutletHose
FloatSwitch
InterlockbyControlBoard
Duct,Screw(3pcs)
Netweight70kg/Grossweight85kg
Carton845mm(W)X800mm(D)X955mm(H)
InstructionManual

3
II. GENERAL INFORMATION
1. CONSTRUCTION
[a] KM-100A, KM-125A
     TopPanel
SidePanel(L)
      FrontCover
RearPanel
      Door
      AirFilter      Duct
      Louver
      Leg
      SidePanel(R)    PowerSupplyCord
      TopCover  HotGasValve   Thermistor
      Evaporator DrainValve    Condenser
FanMotor
      Separator      Compressor
      WaterTank      WaterValve
      Expansion      FloatSwitch
      Valve
OverowPipe            Drier
      PumpMotor
      ControlSwitch
      ServiceSwitch
      ControlBox
Front View Rear View
          BinControlSwitch
With Tank Removed

4
[b] ICEMAKING COMPARTMENT
       SprayTube
Evaporator
          WaterSupplyPipe
Separator
  CubeGuide
    WaterTank
          OverowPipe
DrainValve
Separator
WaterValve
PumpMotor
FloatSwitch

5
2. 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5,6,8,4,7.
[a] ONE MINUTE FILL CYCLE
LED8ison.WVopensandthell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.
[b] INITIAL HARVEST CYCLE
LEDs5,6,and8areon.WVremainsopen,Compenergizes,HGVopens,andharvest
begins.As the evaporator warms, the thermistor located on the suction line checks
fora9°Ctemperature.When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(S1dipswitch1&2).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.WV
isopenduringharvestforamaximumof6minutesorthelengthofharvestminus0,10,
30,or50seconds(adjustablebyS1dipswitch7&8),whicheverisshorter.LED8goes
off when WV closes. PM energizes and runs for the last 0, 10, 30, or 50 seconds of
harvestdependingonS1dipswitch7&8setting.LED7comesonwhenPMenergizes.
Attheendofharvest,thecontrolboardchecksthepositionofF/Sandproceedstothe
freezecycleifitisclosedorcallsfora1-minutellifitisopen.
[c] FREEZE CYCLE
LEDs5&7areon.Compcontinuestorun,PMandFMSenergize,HGVclosesandthe
freezecyclestarts.Fortherst5minutesafterthethermistortemperaturereaches2°C,
thecontrolboardwillnotacceptasignalfromF/S.Thisminimumfreezeperiodactsasa
shortcycleprotection.Attheendofthisperiod,F/Sassumescontrol.Astheevaporator
cools,thethermistorlocatedonthesuctionlinechecksthetemperatureandPMstops
(see“III.3.TIMINGCHART”fordetails).Thisistopreventslushing.Asicebuildsonthe
evaporatorthewaterlevelinthesumplowers.ThefreezecontinuesuntilF/Sopensand
terminatesiceproduction.

6
[d] DRAIN CYCLE
LEDs4,5,6,and7areon.Compcontinuestorun,HGVopens,andFMSde-energizes.
PMstopsfor2seconds,DVenergizes,thenrestartstotakewaterfromthesumpand
forceitthroughDVanddownthedrain.Whenthedraintimerstopscounting,thedrain
iscomplete.Thedraintimerhassettingsof10and20seconds(S1dipswitch3&4).
Drain cycle always occurs on the 2nd harvest after startup. Then, depending on the
controlboardsetting,draincycleoccurseverycycle,orevery2nd,5th,or10thcycle(S1
dipswitch5&6).
[e] NORMAL HARVEST CYCLE
LEDs5,6,and8areon.Compcontinuestorun,HGVremainsopenandWVopens.As
theevaporatorwarms,thethermistorreaches9°C.Thecontrolboardthenreceivesthe
thermistor's3.9kΩsignalandstartstheharvesttimer.WVisopenduringharvestfora
maximumof6minutesorthelengthofharvestminus0,10,30,or50seconds(adjustable
by S1 dip switch 7 & 8), whichever is shorter. LED 8 goes off when WV closes. PM
energizesandrunsforthelast0,10,30,or50secondsofharvestdependingonS1dip
switch7&8setting.LED7comesonwhenPMenergizes.Attheendofharvest, the
controlboardchecksthepositionofF/Sandproceedstothefreezecycleifitisclosed
orcallsfora1-minutellifitisopen.
The unit continues to cycle through [c], [d], and [e] sequence until the bin control is
activatedandshutstheunitdown.Whenthebincontrolisactivated,the"POWEROK"
LEDashes.
Legend:Comp–compressor;DV–drain valve;FMS–self-containedfan motor;F/S–oat
switch;HGV–hotgasvalve;PM–pumpmotor;WV–inletwatervalve

7

8
3. CONTROL BOARD
* A HOSHIZAKI exclusive solid-state control is employed in KM-100A and KM-125A
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before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.
5.Alwaysreplacethewholeboardassemblywhenitgoesbad.
6.Donotshortoutthepowersupplytotestforvoltage.

9
[a] CONTROL BOARD LAYOUT
"H" Control Board
 ConnectorK7
 Transformer
ConnectorK3
MagneticContactor
ConnectorK4
Open
POWEROKLED
(Lightswhenpoweris
suppliedtotheboard.
Flasheswhenbincontrol
isactivated.)
ConnectorK5
Pins
#1FanMotor
#2HotGasValve
#3PumpMotor
#4WaterValve
#5Open
#6DrainValve
ConnectorK6
Open
ConnectorK1
Pins
#1,3FloatSwitch
#2Open
#4,5BinControl
#6,7Thermistor
#8,9Open
ConnectorK2
Open AlarmBuzzerS1DipSwitchS2DipSwitch AlarmResetButton
RelayLEDs(6)
(indicatewhichrelays
areenergizedas
listedbelow)
LED5(X1Relay)
Compressor(Comp)
RemoteFanMotor
(FMR)
LED6(X2Relay)
HotGasValve(HGV)
Self-ContainedFan
Motor(FMS)(FMSoff
whenLEDon)
LED8(X4Relay)
InletWaterValve(WV)
(HarvestWaterValve
(HWV)onunitswith
twoinletwatervalves)
LED9(X5Relay)
FreezeWaterValve
(FWV)onunitswith
twoinletwatervalves
(serviceboardonly)
LED4(X6Relay)
DrainValve(DV)
LED7(X3Relay)
PumpMotor(PM)
ConnectorK8
Open
OutputTestButton
(usedtotestrelayson
board)
ControlBoard
AuxiliaryCode V0orEarlier V1orLater
PartNumber P00013-02 P01771-02
Type HKM2006V003

10
[b] FEATURES
a) Maximum Water Supply Period - 6 minutes
Theinletwatervalvewillbeopenduringharvestfor6minutesorthelengthofharvest
minus0,10,30,or50seconds(adjustablebyS1dipswitch7&8),whicheverisshorter.
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S1dipswitch9&
10.
The alarm 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53°C±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 alarm
resetbuttononthecontrolboardmustbepressedwithpowerontoresetthesafety.
d) Low Water Safety
The control board checks the position of the oat switch at the end of the initial one
minutewaterll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 next cycle. If the oat switch is in the down position (electrical circuit
open), the control board changes to additional one minute water ll cycles until water
entersthe sump andtheoatswitch closes. Whentheoatswitch closes, thecontrol
board changes to the next cycle. The unit will not start without adequate water in the
sump.Thisservesasalowwatersafetytoprotectthewaterpump.
Forwater-cooledmodel,ifthecondenserwatersupply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(294Vac
±5%ormore)onthecontrolboard,thehighvoltagecut-outshutsdownthecircuitin3

11
secondsandtheicemakerautomaticallystops.Thecontrolboardwillsignalthisproblem
using7beepsevery3seconds.
Theicemakeralsoautomaticallystopsincasesofinsufcientvoltage(184Vac±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.
f) LED Lights and Audible Alarm Safeties
Thecontrolboard includes LED indicator lights, audiblealarmsafeties, and an output
testfeature.The"POWEROK"LEDindicatescontrolvoltageandwillremainonunless
acontrolvoltageproblemoccurs.The“POWEROK”LEDashescontinuouslywhenthe
binisfullandDVenergizesforamaximumof5minutestodrainthewatertank.
Atstartup,a5seconddelayoccurstostabilizethecircuit.LEDs4through8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 5, 6, 8, 4, 7. For more information, see "2.
SEQUENCEOFOPERATION".
SequenceStep LED Energized
Components
TimeLEDsareOn
Min. Max. Avg.
1MinuteFillCycle 8 WV 60seconds
HarvestCycle 5,6,8 WV,HGV,
Comp 2minutes 20minutes 3to5minutes
Last0,10,30,or50seconds(adjustablebydipswitch)ofharvest,WVde-energizes
andPMenergizes(LEDs5,6,and7areon)
FreezeCycle 5,7 Comp,PM,
FMS 5minutes freezetimer setting 25to30minutes
Drain 5,6,4,7 Comp,HGV,
DV,PM 10seconds 20seconds factorydefault setting
Thebuiltinsafetiesshutdowntheunitandhavealarmsaslistedbelow.
No.ofBeeps
(every3sec.) TypeofAlarm Notes
1
HighEvaporatorTemp.
(temperature>53°C)
Checkforharvestproblem(stuckHGVor
relay),hotwaterenteringunit,stuckHM,or
shortedthermistor.
2
HarvestBackupTimer
(harvest>20min.fortwo
cyclesinarow)
Checkforopenthermistor,HGVnot
opening, TXV leaking by, low charge,
inefcientComp,orWRVleakingby.
3
FreezeTimer
(freeze>specifiedsetting
fortwocyclesinarow)
Timerisfactorysetusing
S1dipswitch9&10
Check forafloat switchstuckclosed(up),
WVleakingby,HGVleakingby,PMnot
pumping,TXVnotfeedingproperly,low
charge,orinefcientComp.
Toresettheabovesafeties,pressthe"ALARMRESET"buttonwiththepowersupply
on.

12
6LowVoltage
(184Vac±5%orless)
"POWEROK"LEDwillturnoffifvoltage
protectionoperates.
Thecontrolvoltagesafetiesautomaticlly
resetwhenvoltageiscorrected.
7HighVoltage
(294Vac±5%ormore)
Legend:Comp–compressor;DV–drainvalve;FMS–self-containedfanmotor;HGV–hot
gas valve; PM–pump motor; TXV–thermostatic expansion valve; WRV–water
regulatingvalve;WV–inletwatervalve
[c] CONTROLS AND ADJUSTMENTS
a) Default Dip Switch Settings
Thedipswitchisfactory-adjustedtothefollowingpositions:
S1DipSwitchNo. 1 2 3 4 5 6 7 8 9 10
KM-100A OFF OFF OFF OFF ON ON OFF ON ON OFF
KM-125A OFF OFF OFF OFF ON ON ON OFF ON OFF
ControlBoard ProgramVer.
(AuxiliaryCode) S2DipSwitchNo. 1 2 3 4 5 6
P00013-02 2.5orearlier
(V-0orearlier)
KM-100A ON OFF OFF OFF OFF ON
KM-125A ON OFF OFF OFF OFF ON
P01771-02 3.1(V-1,V-2)
3.2(V-3orlater)
KM-100A ON OFF OFF OFF OFF OFF
KM-125A ON OFF OFF OFF OFF OFF
DonotadjusttheS2dipswitch.Thesemustbeleftinthefactorydefaultposition,orthe
unitwillnotoperateproperly.
Fig. 1
FreezeTimer(9&10)
WaterSaverTimer(7&8)
DrainFrequencyControl(5&6)
DrainTimer(3&4)
HarvestTimer(1&2)
S1DipSwitch
b) Harvest Timer (S1 dip switch 1 & 2)
Used for adjustment of the harvest timer. The harvest timer starts counting when the
S2DipSwitch
*FunctionsofS2dipswitchnos.2
through6dependonprogramversion.

13
thermistorreadsacertaintemperatureattheevaporatoroutlet.
DipSwitchSetting Time
(seconds)
No.1 No.2
OFF OFF 60
ON OFF 90
OFF ON 120
ON ON 180
c) Drain Timer (S1 dip switch 3 & 4)
Once every ten freeze cycles, the drain valve opens to drain the water tank for the
time determined by the drain timer. These switches also determine the time to delay
completionofadefrostcycle,i.e.theminimumdefrosttime.
Donotchangethissetting,ortheunitwillnotoperateproperlyorproducehighquality
ice.
DipSwitchSetting Time(seconds)
No.3 No.4 T1 T2
OFF OFF 10 120
ON OFF 10 180
OFF ON 20 120
ON ON 20 180
T1:Timetodrainthewatertank
T2:Harvesttimeratdrain
Drain cycle always occurs on the 2nd harvest after startup. Then, depending on the
drain frequency control setting (dip switch 5 & 6), drain cycle occurs every cycle, or
every2nd,5th,or10thcycle.
d) Drain Frequency Control (S1 dip switch 5 & 6)
Thewatertankdrainsatthefrequencysetbythedrainfrequencycontrol.
Thedrain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 drain more often, the drain frequencycan be adjusted as shown in thetable
below.
DipSwitchSetting Frequency
No.5 No.6
OFF OFF everycycle
ON OFF every2cycles
OFF ON every5cycles
ON ON every10cycles

14
e) Water Saver Timer (S1 dip switch 7 & 8)
Thewatersavertimerallowsthewatervalvetocloseandthepumpmotortocirculate
waterinthetankduringthenalpartofharvest.Thewatervalveisopenduringharvest
for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds
(determined by the water saver timer setting), whichever is shorter. When the water
valvecloses,thepumpmotorenergizesandrunsforthetimedeterminedbythewater
savertimersetting.
Thewatersavertimerisfactory-adjusted,andnoadjustmentisrequired.
DipSwitchSetting Time
(seconds)
No.7 No.8
OFF OFF 0
ON OFF 10
OFF ON 30
ON ON 50
f) Freeze Timer (S1 dip switch 9 & 10)
CAUTION
Adjusttoproperspecication,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.
DipSwitchSetting Time
(minutes)
No.9 No.10
OFF OFF 60
ON OFF 80
OFF ON 100
ON ON 120
g) Pump-Out Pump Motor Delay (S2 dip switch 1)
Thepump-outpumpmotordelay determineswhetherornotthe pumpmotorde-
energizesfor2secondsbeforerestartingatthebeginningofadraincycle.
Thepump-outpumpmotordelayisfactoryadjusted,andnoadjustmentisrequired.
S2DipSwitchSetting Delay
(seconds)
No.1
OFF 0
ON 2

15
Control Board P00013-02
h) Rell Counter (S2 dip switch 2, 3, & 4) [Program Ver. 2.5 or earlier]
Do not adjust. These must be left in the factory default position or the unit will not
operateproperly.TheKM-100AandKM-125Adonotrell.
i) Anti-Slush Control (S2 dip switch 5 & 6) [Program Ver. 2.5 or earlier]
Do not adjust. These must be left in the factory default position or the unit will not
operateproperly.
Theanti-slushcontrol(Ver.1.0,Ver.2.0)helpspreventslushingduringthefreezecycle
onsmallicemakers.
ItisdeactivatedontheKM-100AandKM-125A.
Whenactivated(Ver.1.0),thethermistorlocatedonthesuctionlinechecksfora34°F
(1°C)temperatureastheevaporatorcools.When34°F(1°C)isreached,a5.9kΩsignal
causesthecontrolboardtode-energizethepumpmotorfor10seconds.
Whenactivated(Ver.2.0),thethermistorlocatedonthesuctionlinechecksfora50°F
(10°C) temperature as the evaporator cools. When 50°F (10°C) is reached, a 3.9 kΩ
signal causes the control board to de-energize the pump motor for 10 seconds and
energize it for 50 seconds repeatedly. When 34°F (1°C) is reached, a 5.9 kΩ signal
causesthecontrolboardtode-energizethepumpmotorfor10seconds,energizeitfor
50seconds,de-energizeitagainfor10seconds,thenenergizeitcontinuously.
S2DipSwitchSetting Anti-SlushControl
No.5 No.6
OFF OFF Activated(Ver.1.0)
ON OFF Activated(Ver.2.0)
OFF ON Deactivated
ON ON Deactivated
Control Board P01771-02
j) Harvest Promotion Control (S2 dip switch 2) [Program Ver. 3.1, Ver. 3.2]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.
Whenactivated,this control promotes harvest of ice ontheevaporator that is hard to
remove.Iftheharvestcycleexceeds6minutes,thepumpmotorstartstooperatefora
maximumof3minutes.
S2DipSwitchSetting HarvestPromotion
Control
No.2
OFF Activated
ON Deactivated

16
k) Rell Counter (S2 dip switch 3) [Program Ver. 3.1, Ver. 3.2]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.TheKM-100AandKM-125Adonotrell.
l) Harvest Completion Detection Control (S2 dip switch 4) [Program Ver. 3.1, Ver.
3.2]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.
ItisdeactivatedontheKM-100AandKM-125A.
Whenactivated,this control determines whether iceremainson the evaporator at the
endofaharvestcycleandatthebeginningofafreezecycle.Ificedropsandactivates
thebincontrolswitchinthelast10secondsofaharvestcycle,thecontroldetermines
thatice still remainsontheevaporator and extendstheharvestcycle for 30seconds.
If thebincontrolswitch isactivatedatthe beginningofafreeze cycle,thecontrol
determinesthaticestillremainsontheevaporatorandstartsaharvestcycleafterthe
minimumfreezecycletimehaspassed.
S2DipSwitchSetting HarvestCompletion
DetectionControl
No.4
OFF Deactivated
ON Activated
m) Overfreeze Detection Control (S2 dip switch 5) [Program Ver. 3.1, Ver. 3.2]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.
ItisdeactivatedontheKM-100AandKM-125A.
Whenactivated,thethermistordetectsthetemperatureoftheevaporatoroutlettond
overfreeze in a harvest cycle and at the beginning of a freeze cycle. If the difference
betweenthemaximumtemperatureafterthewatersavertimerstartscountingandthe
temperatureattheendofaharvestcycleis4Kormoreandifthetemperatureattheend
ofaharvestcycleis48°F(9°C)orless,theharvestcycleisextendedfor30seconds.
If the difference between the temperature at the beginning of a freeze cycle and the
minimumtemperatureafter30secondsinthefreezecycleis2.5Kormoreandlessthan
3.5K,thenextharvestcycleisextendedfor30seconds.Iftheaboveconditionsoccur
insuccession,thenumberofoccurrencetimes30secondswillbeaddedtotheharvest
cycletime.Iftheabovetemperaturedifferenceis3.5Kormore,thefreeze cycleends
aftertheminimumfreezecycletimeandaharvestcyclestarts.
S2DipSwitchSetting OverfreezeDetection
Control
No.5
OFF Deactivated
ON Activated

17
n) Anti-Slush Control (S2 dip switch 6) [Program Ver. 3.1]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.
Whenactivated(Ver.2.0),thethermistorlocatedonthesuctionlinechecksfora50°F
(10°C) temperature as the evaporator cools. When 50°F (10°C) is reached, a 3.9 kΩ
signal causes the control board to de-energize the pump motor for 10 seconds and
energize it for 50 seconds repeatedly. When 34°F (1°C) is reached, a 5.9 kΩ signal
causesthecontrolboardtode-energizethepumpmotorfor10seconds,energizeitfor
50seconds,de-energizeitagainfor10seconds,thenenergizeitcontinuously.
S2DipSwitchSetting Anti-SlushControl
No.6
OFF Activated(Ver.2.0)
ON Deactivated
o) Anti-Slush Control (S2 dip switch 6) [Program Ver. 3.2]
Donotadjust.Thismustbeleftinthefactorydefaultpositionortheunitwillnotoperate
properly.
Whenactivated(Ver.1.1),thethermistorlocatedonthesuctionlinechecksfora41°F
(5°C)temperatureastheevaporatorcools.When41°F(5°C)isreached,a4.8kΩsignal
causesthecontrolboardtode-energizethepumpmotorfor10seconds.
Whenactivated(Ver.2.0),thethermistorlocatedonthesuctionlinechecksfora50°F
(10°C) temperature as the evaporator cools. When 50°F (10°C) is reached, a 3.9 kΩ
signal causes the control board to de-energize the pump motor for 10 seconds and
energize it for 50 seconds repeatedly. When 34°F (1°C) is reached, a 5.9 kΩ signal
causesthecontrolboardtode-energizethepumpmotorfor10seconds,energizeitfor
50seconds,de-energizeitagainfor10seconds,thenenergizeitcontinuously.
S2DipSwitchSetting Anti-SlushControl
No.6
OFF Activated(Ver.1.1)
ON Activated(Ver.2.0)
[d] 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S1dipswitch3,4,7,8,9,&10andS2
dipswitch1through6areinthefactorydefaultposition.S1dipswitch1,2,5,&6are
cleaningadjustmentsandthesettingsareexible.