Hoshizaki KMD-450MAH User manual

Hoshizaki
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models
KMD-450MAH
KMD-450MWH
Modular Crescent Cuber
Hoshizaki America, Inc.
SERVICE MANUAL
™
Number: 73161
Issued: 9-3-2009

2
IMPORTANT
Only qualied service technicians should install, service, and maintain the
icemaker. No service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual. Failure to service and maintain
the equipment in accordance with this manual may adversely affect safety,
performance, component life, and warranty coverage.
Hoshizaki provides this manual primarily to assist qualied service technicians in the
service and maintenance of the icemaker.
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: [phone] Technical Support
[phone]
Fax: [phone]
[phone]
E-mail: [email protected]
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. 

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CONTENTS
Important Safety Information ................................................................................................. 6
I. Specications...................................................................................................................... 7
A. Icemaker ....................................................................................................................... 7
1. KMD-450MAH (air-cooled) ....................................................................................... 7
2. KMD-450MWH (water-cooled)................................................................................. 8
II. General Information ........................................................................................................... 9
A. Construction.................................................................................................................. 9
1. KMD-450MAH (air-cooled) ....................................................................................... 9
2. KMD-450MWH (water-cooled)............................................................................... 10
B. Sequence of Operation ................................................................................................11
1. Sequence Cycles and Shutdown ............................................................................11
a) 1-Minute Fill Cycle .............................................................................................11
b) Initial Harvest Cycle .........................................................................................11
c) Freeze Cycle ....................................................................................................11
d) Pump-Out Cycle .............................................................................................. 12
e) Normal Harvest Cycle...................................................................................... 12
f) Shutdown.......................................................................................................... 12
2. Sequence Flow Chart............................................................................................ 14
C. Control Board .............................................................................................................. 15
1. Control Board Layout ............................................................................................. 16
2. Features................................................................................................................. 17
a) Maximum Water Supply Period - 6 minutes ..................................................... 17
b) Harvest Backup Timer and Freeze Timer......................................................... 17
c) High Temperature Safety.................................................................................. 17
d) Low Water Safety............................................................................................. 17
e) High Voltage and Low Voltage Cut-outs........................................................... 17
f) LED Lights and Audible Alarm Safeties ............................................................ 18
3. Controls and Adjustments...................................................................................... 19
a) Default Dip Switch Settings.............................................................................. 19
b) Harvest Timer (S1 dip switch 1 & 2)................................................................. 20
c) Pump-Out Timer (S1 dip switch 3 & 4)............................................................. 20
d) Pump-Out Frequency Control (S1 dip switch 5 & 6) ........................................ 21
e) Harvest Pump Timer (S1 dip switch 7 & 8) ...................................................... 21
f) Freeze Timer (S1 dip switch 9 & 10) ................................................................. 22
g) Pump-Out/Drain Selector (S2 dip switch 1) ..................................................... 22
h) Float Switch Selector (S2 dip switch 2)............................................................ 23
i) Rell Counter (S2 dip switch 3 & 4)................................................................... 23
j) Factory Use (S2 dip switch 5) ........................................................................... 23
k) Anti-Slush Control (S2 dip switch 6)................................................................. 23
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.

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D. Bin Control .................................................................................................................. 24
E. Float Switch................................................................................................................. 24
F. Thermistor.................................................................................................................... 24
G. Switches ..................................................................................................................... 25
1. Control Switch ........................................................................................................ 25
2. Service Switch....................................................................................................... 25
a) DRAIN.............................................................................................................. 25
b) CIRCULATE..................................................................................................... 25
c) WASH............................................................................................................... 25
III. Technical Information ...................................................................................................... 26
A. Water Circuit and Refrigeration Circuit ........................................................................ 26
1. KMD-450MAH (air-cooled) ..................................................................................... 26
2. KMD-450MWH (water-cooled)............................................................................... 27
B.
Wiring Diagram and Multimeter Access Points ................................................................28
1. Wiring Diagram....................................................................................................... 28
2. Multimeter Access Points....................................................................................... 29
a) Diagnostic Connector....................................................................................... 29
b) Compressor Terminal Block ............................................................................. 29
C. Performance Data ....................................................................................................... 30
1. KMD-450MAH (air-cooled) ..................................................................................... 30
2. KMD-450MWH (water-cooled)............................................................................... 31
IV. Service Diagnosis ........................................................................................................... 32
A. Diagnostic Procedure ................................................................................................. 32
B. Control Board Check ................................................................................................... 36
C. Bin Control Check and Cleaning ................................................................................. 37
1. Bin Control Check .................................................................................................. 37
2. Bin Control Cleaning.............................................................................................. 37
D. Float Switch Check and Cleaning ............................................................................... 38
1. Float Switch Check ................................................................................................ 38
2. Float Switch Cleaning............................................................................................ 39
E. Thermistor Check........................................................................................................ 41
F. Diagnostic Charts ........................................................................................................ 42
1. No Ice Production................................................................................................... 42
2. Evaporator is Frozen Up ........................................................................................ 45
3. Low Ice Production ................................................................................................ 47
4. Abnormal Ice ......................................................................................................... 48
5. Other...................................................................................................................... 49
V. Removal and Replacement of Components .................................................................... 50
A. Service for Refrigerant Lines....................................................................................... 50
1. Refrigerant Recovery ............................................................................................. 50
2. Brazing .................................................................................................................. 51
3. Evacuation and Recharge (R-404A)...................................................................... 51
B. Removal and Replacement of Compressor................................................................. 52
C. Removal and Replacement of Expansion Valve.......................................................... 53
D. Removal and Replacement of Hot Gas Valve or Liquid Line Valve ............................ 54
E. Removal and Replacement of Evaporator................................................................... 55
F. Removal and Replacement of Air-Cooled Condenser.................................................. 56
G. Removal and Replacement of Water-Cooled Condenser............................................ 56

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H. Removal and Replacement of Water Regulating Valve (water-cooled model)............. 58
I. Adjustment of Water Regulating Valve (water-cooled model)........................................ 59
J. Removal and Replacement of Thermistor.................................................................... 60
K. Removal and Replacement of Fan Motor (air-cooled and remote air-cooled models). 61
L. Removal and Replacement of Water Valves ................................................................ 61
M. Removal and Replacement of Pump Motor ................................................................ 62
N. Removal and Replacement of Control Board.............................................................. 62
VI. Cleaning and Maintenance............................................................................................. 63
A. Cleaning and Sanitizing Instructions ........................................................................... 63
1. Cleaning Procedure................................................................................................ 63
2. Sanitizing Procedure - Following Cleaning Procedure ........................................... 65
B. Maintenance................................................................................................................ 66
C. Preparing the Icemaker for Long Storage ................................................................... 67

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Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, or damage to the unit.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
CAUTION Indicates a situation which could result in damage to the unit.
IMPORTANT Indicates important information about the use and care of the
unit.
WARNING
This icemaker should be destined only to the use for which it has been
expressly conceived. Any other use should be considered improper and
therefore dangerous. The manufacturer cannot be held responsible for
eventual damage caused by improper, incorrect, and unreasonable use.
To reduce the risk of death, electric shock, serious injury, or re, follow
basic precautions including the following:
•Electricalconnectionmustbehard-wiredandmustmeetnational,state,and
local electrical code requirements. Failure to meet these code requirements
could result in death, electric shock, serious injury, re, or severe damage to
equipment.
•Thisunitrequiresanindependentpowersupply.Seethenameplatefor
proper voltage and breaker/fuse size. Failure to use a proper breaker or fuse
can result in a tripped breaker, blown fuse, or damage to existing wiring. This
could lead to heat generation or re.
•THIS UNIT MUST BE GROUNDED. Failure to properly ground this unit could
result in death or serious injury.
•Thisunitshouldbedisassembledorrepairedonlybyqualiedservice
personnel to reduce the risk of electric shock, injury, or re.
•Donotmakeanyalterationstotheunit.Alterationscouldresultinelectric
shock, injury, re, or damage to the unit.

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I. Specications
A. Icemaker
1. KMD-450MAH (air-cooled)
Note: We reserve the right to make changes in specications and design without prior
notice.
AC SUPPLY VOLTAGE 115-120/60/1 (3 wire with netrual for 115V)
AMPERAGE 10.0 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 15 A
MAXIMUM FUSE SIZE 15 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *457 (207) 436 (198) 398 (180)
Reference without *marks 80 441 (200) 409 (186) 365 (165)
90 436 (198) *387 (176) 344 (156)
100 425 (193) 377 (171) 304 (138)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 9.6 lbs. (4.3 kg) 432pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 880(5.48) 810(4.28)
WATER gal./24HR (gal./100 lbs.) 73(18.9) 192(42.1)
CEC/CEE TIER LEVEL 3
ENERGY STAR YES
EXTERIOR DIMENSIONS (WxDxH) 30" x 24-1/4" x 22-1/8" (762 x 617 x 562 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 130 lbs. (59 kg), Shipping 170 lbs. (77 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
5/8" 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 N/A
BIN CONTROL SYSTEM Mechanical Lever Switch and Timer
COMPRESSOR Hermetic, Model RST45C1E-CAA-202
CONDENSER Air-Cooled , Fin and tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 1 lb. 5.2 oz. (600g)
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 Dispenser or Ice Storage Bin
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

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2. KMD-450MWH (water-cooled)
Note: We reserve the right to make changes in specications and design without prior
notice.
AC SUPPLY VOLTAGE 115-120/60/1 (3 wire with netrual for 115V)
AMPERAGE 8.5A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 15 A
MAXIMUM FUSE SIZE 15 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *460 (209) 447 (203) 415 (188)
Reference without *marks 80 450 (204) 429 (195) 389 (177)
90 447 (203) *415 (188) 377 (171)
100 436 (198) 406 (184) 343 (156)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 9.3 lbs. (4.2 kg) 432pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 790(4.55) 790(4.14)
WATER gal./24HR (gal./100 lbs.) 74(17.8) 145(31.6)
WATER COOLED CONDENSER 523(126) 315(68)
gal./24HR (gal./100 lbs.)
CEC/CEE TIER LEVEL 3
ENERGY STAR N/A
EXTERIOR DIMENSIONS (WxDxH) 30" x 24-1/4" x 22-1/8" (762 x 617 x 562 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 130 lbs. (59 kg), Shipping 170 lbs. (77 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Cond. Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT Cond. Outlet 3/8" FPT
5/8" 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 Pressure Regulator
BIN CONTROL SYSTEM Mechanical Lever Switch and Timer
COMPRESSOR Hermetic, Model RST45C1E-CAA-202
CONDENSER Water-cooled, Tube in tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 1 lb. 0.9 oz. (480g)
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 Dispenser or Ice Storage Bin
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

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II. General Information
A. Construction
1. KMD-450MAH (air-cooled)
Spray Tube
Water Supply Inlet
Junction Box
Condenser
Control Box
Drier
Hot Gas Valve
Compressor
Float Switch
Pump Motor
Bin Control
Control Switch
Expansion Valve
Inlet Water
Valve
Wash Valve
Condenser Fan
Motor
Drain Valve
Water Tank
Spray Guide
Service Switch
Water Guide

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2. KMD-450MWH (water-cooled)
Water Supply Inlet
Junction Box
Condenser
Control Box
Drier
Hot Gas Valve
Compressor
Float Switch
Pump Motor
Bin Control
Control Switch
Expansion Valve
Inlet Water
Valve
Wash Valve
Water Regulator
Drain Valve
Water Tank
Service Switch
Spray Tube
Spray Guide
Water Guide