Hoshizaki KML-631MAH User manual

Hoshizaki
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models
KML-631MAH
KML-631MWH
KML-631MRH
Low-Profile Modular Crescent Cuber
Hoshizaki America, Inc.
SERVICE MANUAL
™
Number: 73150
Issued: 5-9-2007
Revised: 2-18-2008

2
IMPORTANT
Only qualified service technicians should attempt to install, service, or maintain
this 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, and warranty coverage.
HOSHIZAKI provides this manual primarily to assist qualified 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 Service
[phone]
Fax: [phone]
[phone]
E-mail: techsuppor[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. 

3
CONTENTS
I. Specifications...................................................................................................................... 6
A. Icemaker ....................................................................................................................... 6
1. KML-631MAH (air-cooled)....................................................................................... 6
2. KML-631MWH (water-cooled) ................................................................................. 7
3. KML-631MRH (remote air-cooled) .......................................................................... 8
B. Condenser Unit ............................................................................................................. 9
1. URC-9F ................................................................................................................... 9
II. General Information ......................................................................................................... 11
A. Construction................................................................................................................ 11
1. KML-631MAH (air-cooled)..................................................................................... 11
2. KML-631MWH (water-cooled) ............................................................................... 12
3. KML-631MRH (remote air-cooled) ........................................................................ 13
B. Sequence of Operation ............................................................................................... 14
1. One Minute Fill Cycle ............................................................................................ 14
2. Initial Harvest Cycle .............................................................................................. 14
3. Freeze Cycle ......................................................................................................... 14
4. Pump-Out Cycle ................................................................................................... 14
5. Normal Harvest Cycle .......................................................................................... 14
C. Control Board.............................................................................................................. 16
1. Control Board Layout............................................................................................. 17
2. Features ................................................................................................................ 18
a) Maximum Water Supply Period – 6 minutes....................................................... 18
b) Harvest Backup Timer and Freeze Timer ........................................................... 18
c) High Temperature Safety .................................................................................... 18
d) Low Water Safety ............................................................................................... 18
e) High Voltage and Low Voltage Cut-outs ............................................................. 18
f) LED Lights and Audible Alarm Safeties............................................................... 19
3. Controls and Adjustments ..................................................................................... 20
a) Default Dip Switch Settings ................................................................................ 20
b) Harvest Timer (dip switch 1 & 2) ........................................................................ 20
c) Pump-Out Timer (dip switch 3 & 4)..................................................................... 21
d) Pump-Out Frequency Control (dip switch 5 & 6) ................................................ 21
e) Freeze Timer (dip switch 9 & 10)........................................................................ 22
4. Control Board Check Procedure............................................................................ 22
5. Control Board Replacement .................................................................................. 22
D. Harvest Control – Thermistor ...................................................................................... 23
E. Bin Control .................................................................................................................. 23
IMPORTANT
This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualified 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.

4
F. Switches ...................................................................................................................... 23
1. Control Switch ....................................................................................................... 23
2. Service Switch....................................................................................................... 24
a) DRAIN ................................................................................................................ 24
b) CIRCULATE ....................................................................................................... 24
c) WASH ................................................................................................................. 24
III. Technical Information ...................................................................................................... 25
A. Water Circuit and Refrigeration Circuit........................................................................ 25
1. KML-631MAH (air-cooled)..................................................................................... 25
2. KML-631MWH (water-cooled) ............................................................................... 26
3. KML-631MRH (remote air-cooled) ........................................................................ 27
B. Wiring Diagrams.......................................................................................................... 28
1. KML-631MAH, KML-631MWH and KML-631MRH (auxiliary codes: S-0 and S-2) 28
2. KML-631MAH and KML-631MWH (auxiliary codes: T-0 and later)........................ 29
3. KML-631MRH (auxiliary codes: T-0 and later) ....................................................... 30
C. Performance Data ....................................................................................................... 31
1. KML-631MAH (air-cooled)..................................................................................... 31
2. KML-631MWH (water-cooled) ............................................................................... 32
3. KML-631MRH (remote air-cooled) ........................................................................ 33
IV. Service Diagnosis ........................................................................................................... 34
A. 10-Minute Diagnostic Procedure ................................................................................ 34
B. Diagnostic Charts........................................................................................................ 35
1. No Ice Production .................................................................................................. 35
2. Evaporator is Frozen Up........................................................................................ 39
3. Low Ice Production ................................................................................................ 40
4. Abnormal Ice ......................................................................................................... 40
5. Other...................................................................................................................... 40
V. Removal and Replacement of Components .................................................................... 42
A. Service for Refrigerant Lines ...................................................................................... 42
1. Refrigerant Recovery............................................................................................. 42
2. Brazing .................................................................................................................. 42
3. Evacuation and Recharge (R-404A)...................................................................... 43
B. Removal and Replacement of Compressor ................................................................ 44
C. Removal and Replacement of Expansion Valve ......................................................... 45
D. Removal and Replacement of Hot Gas Valve or Line Valve ....................................... 45
E. Removal and Replacement of Evaporator .................................................................. 46
F. Removal and Replacement of Water Regulating Valve - Water Cooled Model Only.... 47
G. Adjustment of Water Regulating Valve - Water-Cooled Model Only ........................... 48
H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)
- Remote Air-Cooled Model Only.............................................................................. 48
I. Removal and Replacement of Thermistor .................................................................... 49
J. Removal and Replacement of Fan Motor .................................................................... 50
K. Removal and Replacement of Water Valves ............................................................... 50
L. Removal and Replacement of Pump Motor................................................................. 51

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VI. Cleaning and Maintenance Instructions ......................................................................... 52
A. Cleaning and Sanitizing Procedures ........................................................................... 52
1. Cleaning Procedure............................................................................................... 52
2. Sanitizing Procedure – Following Cleaning Procedure.......................................... 53
B. Maintenance................................................................................................................ 54
C. Preparing the Icemaker for Long Storage ................................................................... 54

6
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V)
AMPERAGE 7.6 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 *575 (261) 553 (251) 515 (234)
Reference without *marks 80 558 (253) 525 (238) 481 (218)
90 553 (251) *501 (227) 459 (208)
100 543 (246) 491 (223) 420 (191)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 9.0 lbs. (4.1 kg) 480 pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1290(6.2) 1250(5.2)
WATER gal./24HR (gal./100 lbs.) 130(26.0) 275(47.8)
EXTERIOR DIMENSIONS (WxDxH) 30" x 27 3/8" x 26" (762 x 695 x 660 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 199 lbs. (90 kg), Shipping 220 lbs. (100 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
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 CS08KQE-PFV-255
CONDENSER Air-Cooled, Fin and tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 2 lb. 10.3 oz. (1200g)
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 or Ice Dispenser
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
I. Specifications
A. Icemaker
1. KML-631MAH (air-cooled)
Note: We reserve the right to make changes in specifications and design without prior
notice.

7
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V)
AMPERAGE 6.8 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 *632 (287) 631 (286) 593 (269)
Reference without *marks 80 632 (286) 631 (286) 572 (259)
90 631 (286) *630 (286) 579 (263)
100 611 (277) 618 (280) 532 (241)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 9.7 lbs. (4.4 kg) 480 pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1160(4.4) 1140(4.3)
WATER gal./24HR (gal./100 lbs.) 156(24.8) 275(43.5)
WATER COOLED CONDENSER 750(119) 448(71)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 30" x 27 3/8" x 26" (762 x 695 x 660 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 186 lbs. (84 kg), Shipping 217 lbs. (98 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT Condenser Outlet 3/8" FPT
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 CS08KQE-PFV-255
CONDENSER Water-cooled, Tube in tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 1 lb. 9.6 oz. (725g)
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 or Ice Dispenser
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
2. KML-631MWH (water-cooled)
Note: We reserve the right to make changes in specifications and design without prior
notice.

8
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V)
AMPERAGE 7.8 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 *636 (288) 622 (282) 578 (262)
Reference without *marks 80 626 (284) 604 (274) 545 (247)
90 622 (282) *589 (267) 535 (243)
100 605 (274) 576 (261) 486 (220)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 9.4 lbs. (4.2 kg) 480 pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1300(5.3) 1250(4.7)
WATER gal./24HR (gal./100 lbs.) 141(24.0) 277(43.5)
EXTERIOR DIMENSIONS (WxDxH) 30" x 27-3/8" x 26" (762 x 695 x 660 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 199 lbs. (90 kg), Shipping 220 lbs. (100 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
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 CS08KQE-PFV-255
CONDENSER Air-Cooled Remote, Condenser Unit URC-9F
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
Condensing Pressure Regulator on URC-9F
REFRIGERANT CHARGE R404A, 9 lb. 8.4 oz. (4320g)
(Icemaker 5 lb. 9.6 oz. Cond. Unit 3 lb. 14.8 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 or Ice Dispenser
Remote Condenser Unit (URC-9F)
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
3. KML-631MRH (remote air-cooled)
Note: We reserve the right to make changes in specifications and design without prior
notice.

9
B. Condenser Unit
1. URC-9F
Unit: mm [inches]

10
AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker)
FAN MOTOR 115 V Total 1.3FLA 65W
EXTERIOR DIMENSIONS (WxDxH) 32-3/16" x 15-11/16" x 21-15/16" (817 x 398 x 558 mm)
DIMENSIONS INCLUDING LEGS (WxDxH) 34-5/16" x 18-1/8" x 36-15/16" (871 x 460 x 938 mm)
EXTERIOR FINISH Galvanized Steel
WEIGHT Net 81 lbs. ( 37 kg ) Shipping 92 lbs. ( 42 kg )
CONNECTIONS - ELECTRIC Permanent - Connection
- REFRIGERANT 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 3 lbs. 14.8 oz. (1780g)
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.