Hoshizaki Modular Crescent Cuber Instruction Manual

Important Safety Information

⚠️ WARNING

Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No installation or service should be undertaken until the technician has thoroughly read this Instruction Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation. Failure to install, operate, and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. Proper installation is the responsibility of the installer. Product failure or property damage due to improper installation is not covered under warranty.

Hoshizaki provides this manual primarily to assist qualified service technicians in the installation, maintenance, and service of the appliance.

Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance.

Phone: 1-800-233-1940; (770) 487-2331

Fax: 1-800-843-1056; (770) 487-3360

E-mail: techsupport@hoshizaki.com

HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department

ℹ️ NOTICE: To expedite assistance, all correspondence/communication MUST include the following information:

• Model Number: _________________________
• Serial Number: _________________________
• Complete and detailed explanation of the problem.

IMPORTANT

This manual should be read carefully before the appliance is installed and operated. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use and maintenance of the appliance. Retain this manual for any further reference that may be necessary.

CONTENTS

• Important Safety Information ................................................................................................. 4
• I. Specifications...................................................................................................................... 6
• A. Electrical and Refrigerant Data ..................................................................................... 6
• 1. KM-350M_J.............................................................................................................. 6
• 2. KM-520M_J ............................................................................................................. 6
• 3. KM-660M_J ............................................................................................................. 7
• B. Dimensions/Connections .............................................................................................. 8
• 1. Air-Cooled Models (MAJ) ......................................................................................... 8
• 2. Water-Cooled Models (MWJ)................................................................................... 9
• 3. Remote Models (MRJ)........................................................................................... 10
• 4. Remote Condenser Unit URC-5F (use with KM-520MRJ or KM-660MRJ) ............11
• II. Installation and Operating Instructions ............................................................................ 12
• A. Location ...................................................................................................................... 12
• B. Checks Before Installation........................................................................................... 13
• C. How to Remove Panels ............................................................................................... 13
• D. Setup........................................................................................................................... 14
• E. Electrical Connection .................................................................................................. 15
• F. Water Supply and Drain Connections .......................................................................... 16
• G. Remote Condenser Unit Installation ........................................................................... 20
• 1. Location ................................................................................................................. 20
• 2. Checks Before Installation ..................................................................................... 21
• 3. Setup ..................................................................................................................... 21
• 4. Line Set Size and Refrigerant Charge ................................................................... 21
• 5. Line Set Installation ............................................................................................... 22
• 6. Electrical Connection............................................................................................. 26
• 7. Stacking Remote Condenser Unit .......................................................................... 27
• H. Final Checklist............................................................................................................. 28
• 1. Pre-Startup............................................................................................................. 28
• 2. Post-Startup........................................................................................................... 29
• I. Startup.......................................................................................................................... 30
• 1. Bin Control Setting ................................................................................................. 30
• 2. Appliance Startup and Bin Control Check ............................................................. 33
• III. Maintenance ................................................................................................................... 35
• A. Maintenance Schedule................................................................................................ 35
• B. Cleaning and Sanitizing Instructions ........................................................................... 36
• IV. Preparing the Appliance for Periods of Non-Use ............................................................ 38
• V. Disposal ........................................................................................................................... 40

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property.

⚠️ WARNING

Indicates a hazardous situation which could result in death or serious injury.

ℹ️ NOTICE

Indicates a situation which could result in damage to the appliance or property.

❗ IMPORTANT

Indicates important information about the installation, use, and care of the appliance.

⚠️ WARNING

The appliance 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 injury or damage resulting from improper, incorrect, and unreasonable use. Failure to install, operate, and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.

To reduce the risk of death, electric shock, serious injury, or fire, follow basic precautions including the following:

• Only qualified service technicians should install and service the appliance.
• The appliance must be installed in accordance with applicable national, state, and local codes and regulations.
• 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, fire, or damage.
• The appliance requires an independent power supply of proper capacity. See the nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuse, damage to existing wiring, or component failure. This could lead to heat generation or fire.
• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker could result in death or serious injury.
• Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
• To reduce the risk of electric shock, do not touch the control switch or mode switch with damp hands.
• Do not make any alterations to the appliance. Alterations could result in electric shock, serious injury, fire, or damage.
• The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

⚠️ WARNING, continued

• Children should be properly supervised around the appliance.
• Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged.
• Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire.
• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance.

Additional Warning for Remote Models

• THE REMOTE CONDENSER UNIT MUST BE GROUNDED. The power supply and ground connection to the remote condenser unit are supplied from the icemaker. Failure to properly ground the remote condenser unit could result in death or serious injury.
• Wire routing (conduit) and disconnect (if required) must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage.

ℹ️ NOTICE

• Follow the water supply, drain connection, and maintenance instructions carefully to reduce the risk of costly water damage.
• In areas where water damage is a concern, install in a contained area with a floor drain.
• Install the appliance in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C).
• Do not leave the appliance on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the appliance for these occasions, follow the instructions in "IV. Preparing the Appliance for Periods of Non-Use."
• Do not place objects on top of the appliance.
• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in the dispenser unit/ice storage bin.

I. Specifications

A. Electrical and Refrigerant Data

The rating label and nameplate provide electrical and refrigerant data. The rating label can be seen by removing the front panel. The nameplate is located on the rear panel. For certification marks, see the nameplate.

We reserve the right to make changes in specifications and design without prior notice.

1. KM-350M_J

2. KM-520M_J

3. KM-660M_J

B. Dimensions/Connections

1. Air-Cooled Models (MAJ)

Diagram Description: Side, Rear, and Bottom views of the Air-Cooled Icemaker (MAJ) model, showing dimensions in millimeters and inches. Key connection points include: ICEMAKER WATER INLET (1/2" FPT), CONDENSATION DRAIN OUTLET (3/8" OD HARD TUBE), MOUNTING HOLES, ELECTRICAL SUPPLY (7/8" DIA OPENING), and ICE DROP ZONE AND DRIP OPENING.

ℹ️ NOTICE:

• Allow 6" (15 cm) clearance at rear, sides, and top for proper air circulation and ease of maintenance and/or service should they be required.
• The storage bin opening must match the bottom opening as in the illustration.

2. Water-Cooled Models (MWJ)

Diagram Description: Side, Rear, and Bottom views of the Water-Cooled Icemaker (MWJ) model, showing dimensions in millimeters and inches. Key connection points include: ICEMAKER WATER INLET (1/2" FPT), CONDENSATION DRAIN OUTLET (3/8" OD HARD TUBE), CONDENSER WATER OUTLET (3/8" FPT), MOUNTING HOLES, ELECTRICAL SUPPLY (7/8" DIA OPENING), CONDENSER WATER INLET (1/2" FPT), and ICE DROP ZONE AND DRIP OPENING.

ℹ️ NOTICE:

• Allow 6" (15 cm) clearance at rear, sides, and top for proper air circulation and ease of maintenance and/or service should they be required.
• The storage bin opening must match the bottom opening as in the illustration.

3. Remote Models (MRJ)

Diagram Description: Side, Rear, and Bottom views of the Remote Icemaker (MRJ) model, showing dimensions in millimeters and inches. Key connection points include: CONDENSATION DRAIN OUTLET (3/8" OD HARD TUBE), DISCHARGE LINE FIELD CONNECTION, LIQUID LINE FIELD CONNECTION, MOUNTING HOLES, ICEMAKER WATER INLET (1/2" FPT), and ELECTRICAL SUPPLY (7/8" DIA OPENING), ICE DROP ZONE AND DRIP OPENING.

ℹ️ NOTICE:

• Allow 6" (15 cm) clearance at rear, sides, and top for proper air circulation and ease of maintenance and/or service should they be required.
• The storage bin opening must match the bottom opening as in the illustration.

4. Remote Condenser Unit URC-5F (use with KM-520MRJ or KM-660MRJ)

Diagram Description: Top and Rear views of the Remote Condenser Unit URC-5F, showing dimensions in millimeters and inches. Key features include: ELECTRICAL SUPPLY OPENING (22 [7/8] DIA), and connection ports for refrigerant lines.

ℹ️ NOTICE:

• Allow 24" (61 cm) clearance at front and rear for proper air circulation and ease of maintenance and/or service should they be required.

Icemaker Model | URC-5F Heat of Rejection AT 90°F (32°C)

II. Installation and Operating Instructions

⚠️ WARNING

• The icemaker must be installed in accordance with applicable national, state, and local codes and regulations.
• Failure to install, operate, and maintain the icemaker in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after installation. Make sure that none have fallen into the dispenser unit/ice storage bin.

A. Location

ℹ️ NOTICE:

• The icemaker is not intended for outdoor use. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C); Normal operating water temperature must be within 45°F to 90°F (7°C to 32°C). Operation of the icemaker, for extended periods, outside of these normal temperature ranges may affect icemaker performance.
• The icemaker will not work at sub-freezing temperatures. To prevent damage to the water supply line, drain the icemaker if the air temperature is going to go below 32°F (0°C). See "IV. Preparing the Appliance for Periods of Non-Use."
• The icemaker should not be located next to ovens, grills, or other high heat producing equipment.
• Allow 6" (15 cm) clearance at rear, sides, and top for proper air circulation and ease of maintenance and/or service should they be required.
• The location should provide a firm and level foundation for the equipment.

B. Checks Before Installation

• Visually inspect the exterior of the shipping container and immediately report any damage to the carrier. Upon opening the container, any concealed damage should also be immediately reported to the carrier.
• Remove the shipping carton, tape, and packing material. If any are left in the icemaker, it will not work properly.
• See the nameplate on the rear panel, and check that your voltage supplied corresponds with the voltage specified on the nameplate.
• Remove the panels to prevent damage when installing the icemaker. See "II.C. How to Remove Panels."
• Remove the package containing the accessories.
• Remove the protective plastic film from the panels. If the icemaker is exposed to the sun or to heat, remove the film after the icemaker cools.
• Check that the refrigerant lines do not rub or touch lines or other surfaces, and that the fan blade (if applicable) turns freely.
• Check that the compressor is snug on all mounting pads.
• The icemaker can be installed on a dispenser unit or ice storage bin. The ice storage bins listed below are recommended.

For further options, contact your local Hoshizaki distributor.

❗ NOTICE! Remote models must be connected to an appropriate remote condenser unit. The remote condenser units listed below are recommended. Connection to a different remote condenser unit will void the warranty unless Hoshizaki approves a different remote condenser unit for your specific application. For further details, contact your local Hoshizaki distributor.

C. How to Remove Panels

Diagram Description: Figure 1 illustrates the panels of the icemaker and how to remove them. It shows the Front Insulation Panel, Top Panel, Front Panel, Base Cover, Right Side Panel, and a Screw used for removal. The process involves removing screws and lifting/sliding panels.

• Front Panel: Remove the screw. Lift up and towards you.
• Top Panel: Lift up at front slightly, push rearward and lift off.
• Right Side Panel: Remove the screw. Slide the right front corner to the right slightly, then push rearward and lift off.
• Front Insulation Panel: Lift up slightly and pull towards you.
• Base Cover: Lift up slightly and pull towards you.

D. Setup

1. Dispenser Unit/Ice Storage Bin and Icemaker Setup

⚠️ WARNING

• The installer must ensure the dispenser unit/ice storage bin is compatible with the icemaker, and the dispenser unit/ice storage bin and icemaker are properly attached and secured.
• Do not allow top kits to interfere with the bin control lens sensing area or the icemaker will not operate properly.

1. If mounting the icemaker on top of a dispenser unit, follow the dispenser unit's setup procedure. If mounting the icemaker on top of an ice storage bin, unpack the ice storage bin and attach the 4 adjustable legs provided (bin accessory) to the bottom of the ice storage bin.
2. Position the dispenser unit/ice storage bin in its permanent location.
3. If required, install an adapter kit or top kit. Contact your local Hoshizaki distributor for recommendations.
4. Level the dispenser unit/ice storage bin in both the left-to-right and front-to-rear directions. If using an ice storage bin, adjust the ice storage bin legs to level.
5. Place the icemaker on top of the dispenser unit/ice storage bin.
6. 6a) Dispenser Unit: Follow the dispenser unit, adapter kit, or top kit instructions for securing the icemaker. If no instructions are available, secure the icemaker using the mounting brackets provided. Rotate the mounting brackets so that they fit flush to the dispenser unit. See Fig. 2a. Secure the mounting brackets to the icemaker with the bolts provided. Secure the mounting brackets to the dispenser unit with self-tapping screws (not provided). ℹ️ NOTICE! Use care to avoid damage to dispenser unit components when attaching the mounting brackets. For dispenser unit bin control setting see "II.J. Bin Control Check and Setting."
7. 6b) Ice Storage Bin: Follow the ice storage bin, adapter kit, or top kit instructions for securing the icemaker. If no instructions are available, secure the icemaker using the 2 mounting brackets and the bolts provided. See Fig. 2b.

Diagram Description: Figure 2a shows the mounting of an icemaker onto a dispenser unit using mounting brackets and self-tapping screws. Figure 2b shows the mounting of an icemaker onto an ice storage bin using mounting brackets and bolts.

E. Electrical Connection

⚠️ WARNING

For All Models

• 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, fire, or damage.
• The icemaker requires an independent power supply of proper capacity. See the nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuse, damage to existing wiring, or component failure. This could lead to heat generation or fire.
• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker could result in death or serious injury.
• Electrical connection must be made in accordance with the instructions on the "WARNING" tag, provided with the pig tail leads. See Fig. 3.

Additional Warnings for Remote Models

• THE REMOTE CONDENSER UNIT MUST BE GROUNDED. Power supply and ground connection to the remote condenser unit are supplied from the icemaker. See "II.G.6. Electrical Connection." Failure to properly ground the remote condenser unit could result in death or serious injury.
• To reduce the risk of electric shock, make all remote condenser unit connections before connecting the icemaker power supply.

ℹ️ NOTICE

On remote models, the appliance must have power for a minimum of 4 hours prior to startup to prevent compressor damage.

• Usually an electrical permit and services of a licensed electrician are required.
• The maximum allowable voltage variation is ±10 percent of the nameplate rating.
• On 115/60/1 models, the white lead must be connected to the neutral conductor of the power source. ℹ️ NOTICE! Miswiring may result in severe damage to the icemaker.
• The opening for the power supply connection is 7/8" DIA to fit a 1/2" trade size conduit.

Diagram Description: Figure 3 shows a wiring diagram for the electrical connection of the icemaker. It indicates the need for grounding, the connection of the white lead to the neutral conductor, and the use of a junction box. It includes a warning label stating "THIS UNIT MUST BE GROUNDED".

F. Water Supply and Drain Connections

See Figs. 4 through 6

⚠️ WARNING

Water supply and drain connections must be installed in accordance with applicable national, state, and local regulations.

ℹ️ NOTICE

• Normal operating water temperature should be within 45°F to 90°F (7°C to 32°C). Operation of the appliance, for extended periods, outside of this normal temperature range may affect appliance performance.
• Water supply pressure must be a minimum of 10 PSIG and a maximum of 113 PSIG. If the pressure exceeds 113 PSIG, the use of a pressure reducing valve is required.
• To prevent damage to the appliance, do not operate the appliance when the water supply is off, or if the pressure is below 10 PSIG. Do not run the appliance until the proper water pressure is reached.
• External filters, strainers, or softeners may be required depending on water quality. Contact your local Hoshizaki Certified Service Representative or local Hoshizaki distributor for recommendations.
• A plumbing permit and services of a licensed plumber may be required in some areas.
• The icemaker drain line, dispenser unit/ice storage bin drain line, and water-cooled condenser drain line (if applicable) must be run separately. The condensation drain line can be connected to the icemaker drain line or can be run separately.
• Drain lines must have 1/4" fall per foot (2 cm per 1 m) on horizontal runs to get a good flow. A vented tee connection is also required for proper flow.
• Drain lines should not be piped directly to the sewer system. An air gap of a minimum of 2 vertical inches (5 cm) should be between the end of the drain pipes from the icemaker and condensation drain, dispenser unit/ice storage bin, and water-cooled condenser (if applicable) and the floor drain.

1. Icemaker

Diagram Description: Figure 4 illustrates the water supply and drain connections for Air-Cooled and Remote Models. It shows the Icemaker Water Supply Inlet (1/2" FPT), Icemaker Drain Outlet (3/4" FPT), Bin Drain Outlet (3/4" FPT), Icemaker Condensation Drain Outlet (3/8" OD Hard Tube), Shut-Off Valve, Drain Valve, Vent Tube, and a detail showing a 2" (5 cm) air gap to the Floor Drain.

• An icemaker water supply line shut-off valve and drain valve must be installed.
• Be sure there is sufficient extra water supply line and drain line for the appliance to be pulled out for service.

2. Water-Cooled Condenser

a) Connection to an Open Drain System

Diagram Description: Figure 5 illustrates the water supply and drain connections for Water-Cooled Models to an Open Drain System. It shows the Icemaker Water Supply Inlet, Condenser Water Supply Inlet (1/2" FPT), Condenser Drain Outlet (3/8" FPT), Icemaker Drain Outlet (3/4" FPT), Bin Drain Outlet (3/4" FPT), Icemaker Condensation Drain Outlet (3/8" OD Hard Tube), Vent Tube, Shut-Off Valve, Drain Valve, and a detail showing a 2" (5 cm) air gap to the Floor Drain.

• A condenser water supply line shut-off valve and drain valve must be installed.
• In some areas, a back flow preventer may be required in the cooling water circuit.
• In order to maintain the proper high side pressure, the condenser water supply inlet temperature should not drop below 45°F (7°C) and the condenser drain outlet temperature must be in the 104°F to 115°F (40°C to 46°C) range. Once the icemaker installation is complete, confirm the condenser drain outlet temperature 5 minutes after a freeze cycle starts. If the condenser drain outlet temperature is not in the proper range, use a flat blade screwdriver to rotate the adjustment screw on the water-regulating valve until the temperature is in the proper range (rotate counterclockwise to raise temperature or clockwise to lower temperature).

b) Connection to a Closed Loop System

Diagram Description: Figure 6 illustrates the water supply and drain connections for Water-Cooled Models to a Closed Loop System. It shows the Icemaker Water Supply Inlet, Condenser Water Supply Inlet (1/2" FPT), Condenser Return Outlet (3/8" FPT), Icemaker Drain Outlet (3/4" FPT), Bin Drain Outlet (3/4" FPT), Icemaker Condensation Drain Outlet (3/8" OD Hard Tube), Vent Tube, Shut-Off Valve, Drain Valve, and a detail showing a 2" (5 cm) air gap to the Floor Drain.

• Shut-off valves and drain valves must be installed at both the condenser water supply inlet and condenser return outlet.
• Minimum water flow to the condenser is 4 GPM.
• The pressure differential between the condenser water supply inlet and condenser return outlet must be no less than 10 PSIG.
• When using a glycol blend, the solution mixture should be less than 30% glycol.
• In order to maintain the proper high side pressure, the condenser water supply inlet temperature should not drop below 45°F (7°C) and the condenser return outlet temperature must be in the 104°F to 115°F (40°C to 46°C) range. Once the icemaker installation is complete, confirm the condenser return outlet temperature 5 minutes after a freeze cycle starts. If the condenser return outlet temperature is not in the proper range, use a flat blade screwdriver to rotate the adjustment screw on the water-regulating valve until the temperature is in the proper range (rotate counterclockwise to raise temperature or clockwise to lower temperature).

G. Remote Condenser Unit Installation

⚠️ WARNING

• Installation of remote condenser unit must be performed by properly trained and EPA-certified service personnel.
• The remote condenser unit must be installed in accordance with applicable national, state, and local codes and regulations.
• Failure to install the remote condenser unit within these guidelines may adversely affect safety, performance, component life, and warranty coverage.
• Power supply and ground wire to the remote condenser unit are supplied from the icemaker. For details, see section "II.G.6. Electrical Connection."

1. Location

ℹ️ NOTICE

• The remote condenser unit is intended for outdoor use. Normal operating ambient temperature must be within -20°F to +122°F (-29°C to +50°C). Operation of the remote condenser unit, for extended periods, outside of this normal temperature range may affect appliance performance.
• The maximum line length for the standard line sizes and refrigerant charge is 66' (20 m). With larger line sizes and/or additional refrigerant, the maximum line length is 100' (30.5 m). For details, see "II.G.4 Line Set Size and Refrigerant Charge."
• The maximum vertical distance between the remote condenser unit and the icemaker is 33' (10 m) above or 10' (3 m) below the icemaker. These distances are measured fitting to fitting. See Fig. 7.

The remote condenser unit must be positioned in a permanent site under the following guidelines:

• A firm and flat site.
• A dry and well ventilated area with 24" (61 cm) clearance at front and rear for proper air circulation and ease of maintenance and/or service should they be required. See Fig. 8.

Diagram Description: Figure 7 shows the maximum vertical distances allowed between the icemaker and the remote condenser unit (33' above, 10' below). Figure 8 illustrates the required minimum clearance of 24" (61 cm) at the front and rear of the remote condenser unit for air circulation.

2. Checks Before Installation

• 1) Remove the shipping carton, tape, and packing material.
• 2) Check that the refrigerant lines do not rub or touch lines or other surfaces, and that the fan blades move freely.

3. Setup

Diagram Description: Figure 9 shows the assembly of legs, bolts, and nuts for setting up the remote condenser unit. It depicts a leg, plate, nut, and a bolt with split lock washer and flat washer.

1. Assemble 2 sets of legs using the legs, bolts, and nuts provided. See Fig. 9.
2. Position 1 of the plates provided between a set of legs and the remote condenser unit, then secure the legs to the remote condenser unit with the bolts and nuts provided. Repeat on the other side with the remaining set of legs.
3. The bottom of each leg has a mounting hole. Secure the legs to the permanent site with 4 bolts (not included).

4. Line Set Size and Refrigerant Charge

ℹ️ NOTICE

The icemaker, line set, and remote condenser unit must contain the same type of refrigerant. Mixing of refrigerants will result in improper operation and possible damage to the refrigeration system.

5. Line Set Installation

Precharged factory line sets, available as optional equipment from Hoshizaki America, are recommended. For details, see "II.G.5.a) Factory Line Set Installation." Field fabricated line sets are allowed. For details, see "II.G.5.b) Field Fabricated Line Set Installation."

a) Factory Line Set Installation

1. Route the factory line set (see "II.G.4 Line Set Size and Refrigerant Charge" for details) from the remote condenser unit to the icemaker. Leave a service loop behind the icemaker to allow the icemaker to be pulled out for service. See Fig. 10. Factory fabricated line sets are precharged and do not need to be evacuated. If the line set is too long or too short, see "II.G.5.a)(1) Factory Line Set Modification."

ℹ️ NOTICE

• Ensure that there are no traps and no kinks in the line set. The service loop is not considered an oil trap.
• Do not coil extra line set.
• 2) Connect the refrigerant lines to the appropriate male fittings on the remote condenser unit first and then at the icemaker. Make a proper connection as follows:
  1. Remove the protective covers from the male fitting and female coupling.
  2. Apply Polyol Ester (POE) refrigerant oil or Parker Super O Lube to the entire male fitting, including O-ring, diaphragm, and threads before making the connection. See Fig. 11. ℹ️ NOTICE! Do not use thread sealant on the fittings. Use POE refrigerant oil or Parker Super O Lube only. Couplings are one-time use only.
  3. Make sure the male fitting and female coupling are properly aligned, then start the connection by hand to ensure that it is not cross threaded.
  4. Place a backup wrench on the back of the female coupling, then tighten the connection with a wrench until it is tight. At this point, the nut has covered most of the threads on the male fitting. ℹ️ NOTICE! Failure to use a backup wrench may result in damage to the line set and possible refrigerant leaks.
  5. Mark a reference line on the female coupling and the remote condenser unit or icemaker panel. Using a backup wrench on the back of the female coupling, tighten the six-sided nut of the female coupling an additional 1/6 turn. See Fig. 12. ℹ️ NOTICE! Confirm connection is free of leaks.
• 3) If you lengthened the line set as outlined in "II.G.5.a)(1) Factory Line Set Modification" and it exceeds 66' (20 m), see "II.G.4. Line Set Size and Refrigerant Charge" for proper charging of the appliance.

Diagram Description: Figure 10 shows the connection of refrigerant lines between the Remote Condenser Unit and the Icemaker, including a service loop. Figure 11 illustrates applying POE oil or Parker Super O Lube to the male fitting. It also shows a "DO NOT USE THREAD SEALANT" warning. Figure 12 demonstrates the tightening procedure for the coupling, indicating the use of a backup wrench and an additional 1/6 turn after initial tightening.

(1) Factory Line Set Modification

1. Recover the line set charge through the Schrader access ports on the Parker quick connect couplings and store it in an approved container. Do not discharge the refrigerant into the atmosphere. Remove the extra line set length or add extra tubing. When adding extra tubing, insulate the additional copper tubes separately.
2. Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the lines through the Schrader access ports on the Parker quick connect couplings (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). ⚠️ WARNING! Do not use R-404A as a mixture with pressurized air for leak testing.
3. Evacuate through the Schrader access ports on the Parker quick connect couplings and charge with R-404A refrigerant vapor to a pressure of 15 to 30 PSIG. Go to step 2 in "II.G.5.a) Factory Line Set Installation."

b) Field Fabricated Line Set Installation

⚠️ WARNING

• R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C).
• R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous.
• Do not use silver alloy or copper alloy containing arsenic.
• Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the line set tubing through the service valve access ports (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). Do not use R-404A as a mixture with pressurized air for leak testing.

1. Route the copper tube liquid line and copper tube discharge line (see "II.G.4 Line Set Size and Refrigerant Charge" for details) from the remote condenser unit to the icemaker. Leave a service loop behind the icemaker to allow the icemaker to be pulled out for service. See Fig. 10. Note: The service loop is not considered an oil trap. The maximum line length for the standard line sizes and refrigerant charge is 66' (20 m). With larger line sizes and/or additional refrigerant, the maximum line length is 100' (30.5 m). For details, see "II.G.4 Line Set Size and Refrigerant Charge.

ℹ️ NOTICE

• Ensure that there are no traps and no kinks in the line set. The service loop is not considered an oil trap.
• Do not coil extra line set.
• 2) Remove any extra line set length, then insulate the two copper tubes separately.
• 3) Install (braze) Parker quick connect couplings on each end. OS-QUICK, a universal quick connect coupling kit available as optional equipment from Hoshizaki America, is recommended.

ℹ️ NOTICE

• Before brazing, remove the Schrader valve core from the access port.
• When brazing, protect the coupling by using a wet cloth to prevent the coupling from overheating.
• Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
• 4) Allow the coupling to cool, then replace the Schrader valve core. Attach the gauge manifold hoses.
• 5) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the lines through the Schrader access ports on the Parker quick connect couplings (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). ⚠️ WARNING! Do not use R-404A as a mixture with pressurized air for leak testing.
• 6) After checking the line set for leaks, vent the nitrogen charge from the line set.
• 7) Evacuate the line set. Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends on pump capacity.
• 8a) Line Set up to 66' (20 m): After evacuation, charge each line set tube with R-404A vapor to a pressure of 15 to 30 PSIG.
• 8b) Line Set Over 66' (20 m): After evacuation, add the appropriate amount of additional R-404A. See "II.G.4 Line Set Size and Refrigerant Charge" for details.
• Hoshizaki Technical Support is available at 1-800-233-1940 for recommendations.
• 9) Close both gauge manifold valves, remove the gauge manifold hoses, then replace and tighten the access port cap.

10) Connect the refrigerant lines to the appropriate male fittings on the remote condenser unit first and then at the icemaker. Make a proper connection as follows:

1. Remove the protective covers from the male fitting and female coupling.
2. Apply Polyol Ester (POE) refrigerant oil or Parker Super O Lube to the entire male fitting, including O-ring, diaphragm, and threads, before making the connection. See Fig. 11. ℹ️ NOTICE! Do not use thread sealant on the fittings. Use POE refrigerant oil or Parker Super O Lube only. Couplings are one-time use only.
3. Make sure the male fitting and female coupling are properly aligned, then start the connection by hand to ensure that it is not cross threaded.
4. Place a backup wrench on the back of the female coupling, then tighten the connection with a wrench until it is tight. At this point, the nut has covered most of the threads on the male fitting. ℹ️ NOTICE! Failure to use a backup wrench may result in damage to the line set and possible refrigerant leaks.
5. Mark a reference line on the female coupling and the remote condenser unit or icemaker panel. Using a backup wrench on the back of the female coupling, tighten the six-sided nut of the female coupling an additional 1/6 turn. See Fig. 12. ℹ️ NOTICE! Confirm connection is free of leaks.

6. Electrical Connection

⚠️ WARNING

• Electrical connection must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage.
• To reduce the risk of electric shock, make all remote condenser unit connections before connecting the icemaker power supply.
• THE REMOTE CONDENSER UNIT MUST BE GROUNDED. Install a ground wire from the icemaker fan motor junction box to the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating. Failure to properly ground the remote condenser unit could result in death or serious injury.
• Install line and neutral wires from the fan motor leads in the icemaker fan motor junction box to the leads in the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating.
• Do not connect the fan motor leads in the icemaker to incoming power source. Do not connect the fan motor leads in the icemaker together. Do not allow the leads to contact the junction box walls.
• Do not connect the remote condenser unit to an external power source.

ℹ️ NOTICE

On remote models, the appliance must have power for a minimum of 4 hours prior to startup to prevent compressor damage.

• Usually an electrical permit and services of a licensed electrician are required.
• The opening for the power supply connection is 7/8" DIA to fit a 1/2" trade size conduit.

1. Remove the remote condenser unit louver panel. See Fig. 13.
2. Remove the icemaker fan motor junction box cover. Remove the remote condenser unit junction box cover.

Diagram Description: Figure 13 shows the removal of panels for electrical connection on the Remote Condenser Unit and Icemaker. It indicates screws for the Louver Panel and Junction Box Cover on the Remote Condenser Unit, and a screw for the Fan Motor Junction Box Cover on the Icemaker.

• 3) Install a ground wire from the icemaker fan motor junction box to the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating.
• 4) Install line and neutral wires from the fan motor leads in the icemaker fan motor junction box to the leads in the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating.
• 5) Replace the junction box covers and the louver panel in their correct positions.

7. Stacking Remote Condenser Unit

Diagram Description: Figure 14 shows how to stack remote condenser units. It depicts an Upper Remote Condenser Unit being placed on top of a Lower Remote Condenser Unit and secured with screws.

1. Install the lower remote condenser unit as described earlier in this section.
2. Place the upper remote condenser unit on top of the lower remote condenser unit. See Fig. 14.
3. Secure the upper remote condenser unit to the lower remote condenser unit with the 4 screws provided.
4. Install refrigerant lines and make electrical connection as described earlier in this section.

H. Final Checklist

1. Pre-Startup

• 1) Is the icemaker level?
• 2) Is the icemaker in a site where the ambient temperature is within 45°F to 100°F (7°C to 38°C) and the water temperature within 45°F to 90°F (7°C to 32°C) all year around?
• 3) Is there at least 6" (15 cm) clearance at rear, sides, and top of the icemaker?
• 4) Have the shipping carton, tape, and packing material been removed from the icemaker? Is the cube guide in the correct position?
• 5) Have all electrical and water connections been made? Do electrical and water connections meet applicable national, state, and local code and regulation requirements?
• 6) Has the power supply voltage been checked or tested against the nameplate rating? Has a proper ground been installed to the icemaker? On remote models, has a proper ground also been installed to the remote condenser unit?
• 7) Are the water supply and drain lines sized as specified? Are the water supply line shut-off valve(s) and drain valve(s) installed? Has the water supply pressure been checked to ensure a minimum of 10 PSIG and a maximum of 113 PSIG?
• 8) Is the compressor snug on all mounting pads? Have the refrigerant lines been checked to make sure they do not rub or touch other lines or surfaces? Has the fan blade (if applicable) been checked to make sure it turns freely?
• 9) On remote models:
  • Is the line set sized as specified, insulated, tightened, and free of leaks and kinks?
  • If the line set exceeds 66' (20 m), has the line set size (if applicable) and charge been adjusted as specified?
  • Has the appliance power supply been on for a minimum of 4 hours?
  • Is the remote condenser unit in a site where the ambient temperature is within -20°F to +122°F (-29°C to +50°C) all year around?
  • Is there at least 24" (61 cm) clearance around the remote condenser unit?

2. Post-Startup

⚠️ WARNING

• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after installation. Make sure that none have fallen into the dispenser unit/ice storage bin.
• Confirm that all internal and external connections are free of leaks.

• 1) Has the bin control been set to the proper setting for the application?
• 2) Has the bin control operation been confirmed?
• 3) Are all components, fasteners, and thumbscrews securely in place?
• 4) Has the end user been given the instruction manual, and instructed on how to operate the appliance and the importance of the recommended periodic maintenance?
• 5) Has the end user been given the contact information of an authorized service agent?
• 6) Has the warranty registration been completed and submitted to the factory?

I. Startup

1. Bin Control Setting

An ultrasonic sensor is used as the bin control to control the level of ice in the dispenser unit/ice storage bin. The bin control setting must be set to match the application to avoid possible icemaker movement, water leakage, or ice overflow.

⚠️ WARNING

• Improper adjustment may adversely affect safety, performance, component life, and warranty coverage.
• On dispenser unit applications, do not increase ice level above the recommended setting listed below. Higher ice levels could result in icemaker movement, water leakage, or ice overflow.

ℹ️ NOTICE

Do not allow top kits or top kit risers (if applicable) to interfere with the bin control lens sensing area or the icemaker will not operate properly.

1. Make sure that the power supply is off. Remove the front, top, and right side panels to allow access to the control board. Also remove the base cover. See Fig. 15. Note: If front access to the control box is required, remove the control box mounting screws, then slide the control box forward and rotate the control box for access. See Fig. 16.

Diagram Description: Figure 15 shows the Icemaker with the Base Cover removed, revealing the Control Box. Figure 16 illustrates how to access the Control Box by removing mounting screws and sliding/rotating it.

For Standard Ice Storage Bins, Hoshizaki DB and DM Dispenser Units, and Coca-Cola Freestyle® Dispenser Units

⚠️ WARNING

Confirm that the final ice level location does not allow for icemaker movement, water leakage, or ice overflow.

Diagram Description: Figure 17 shows diagrams of the Icemaker with Standard Ice Storage Bin and with a Hoshizaki DB-200H Dispenser Unit. It illustrates the Bin Control Lens and different Setting levels (#1 to #5). It also shows a Control Board with the Bin Control Setting dial and recommended settings for different applications. A warning states "Do not use this setting with dispensers."

For Non-Hoshizaki Dispenser Units

⚠️ WARNING

Confirm that the final ice level location does not allow for icemaker movement, water leakage, or ice overflow.

ℹ️ NOTICE

The ice level must be lower than the top of the dispenser unit. Also, be sure the top kit or top kit riser (if applicable) are clear from the bin control lens sensing area.

Diagram Description: Figure 18 shows a diagram of the Icemaker connected to a Non-Hoshizaki Dispenser Unit. It illustrates the Bin Control Lens, Top Kit, Icemaker Restart Level, and Maximum Full Bin Level of Ice. It also shows a Control Board with the Bin Control Setting dial and indicates the "Factory Default for Standard Ice Storage Bins" warning: "Do not use this setting with dispensers."

2. Appliance Startup and Bin Control Check

⚠️ WARNING

• All parts are factory-adjusted. Improper adjustments may adversely affect safety, performance, component life, and warranty coverage.
• Make sure the icemaker has been installed as outlined in this manual and that the water supply is on.
• Improper adjustment may adversely affect safety, performance, component life, and warranty coverage.

ℹ️ NOTICE

• If the icemaker is turned off, wait for at least 3 minutes before restarting the icemaker to prevent damage to the compressor.
• To prevent damage to the water pump seal, do not leave the control switch in the "PUMP" position for extended periods when the water tank is empty.
• At startup, confirm that all internal and external connections are free of leaks.
• Do not allow top kits or top kit risers (if applicable) to interfere with the bin control lens sensing area or the icemaker will not operate properly.

Additional Notice for Remote Models

• The icemaker must have power for a minimum of 4 hours prior to startup to prevent compressor damage.

1. If not already removed, remove the front, top, and right side panels and base cover. Make sure the bin control setting has been adjusted as outlined in "II.I.1. Bin Control Setting."
2. Open the water supply line shut-off valve(s).
3. Move the mode switch on the control box to the "ICE" position, then move the control switch to the "ON" position. Turn on the power supply, and allow the icemaker to operate.
4. Confirm the control board "BIN CLS" LED is off (bin empty). See Fig. 19.

Diagram Description: Figure 19 shows a Control Board with the "BIN CLS LED" highlighted. It also shows a table indicating the status of the "BIN CLS" LED based on the ice level in the bin (OFF for Empty, ON for Full).

• 5) If the control board "BIN CLS" is on (indicating a full bin), correct any interference from the top kit or top kit riser (if applicable).
• 6) 1 min. fill cycle begins. Place an object 5" to 7" (127 to 178 mm) away from the bin control lens. See Fig. 20. 15 sec. later, the icemaker shuts down. Remove the object from the bin control lens. 30 sec. later, the icemaker restarts. For bin control shutdown times per cycle, see the table below.

Diagram Description: Figure 20 shows the Icemaker with the Bin Control Lens and an object placed near it to simulate ice level. It also shows the Control Switch, Mode Switch, and Compressor Base.

Diagram Description: Figure 21 shows the Icemaker with the Base Cover removed, illustrating the disconnection of the pump tubing to drain the water tank. It also shows the Control Switch, Mode Switch, and Water Tank.

III. Maintenance

The appliance must be maintained in accordance with the instruction manual and labels provided. Consult with your local Hoshizaki Certified Service Representative about maintenance service.

⚠️ WARNING

• Only qualified service technicians should service the appliance.
• To reduce the risk of electric shock, do not touch the control switch or mode switch with damp hands.
• Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after any maintenance is done to the appliance. Make sure that none have fallen into the dispenser unit/ice storage bin.

A. Maintenance Schedule

The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations.

B. Cleaning and Sanitizing Instructions

The icemaker must be cleaned and sanitized at least once a year. More frequent cleaning and sanitizing may be required in some water conditions.

⚠️ WARNING

• To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.
• Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution.
• Always wear liquid-proof gloves and goggles to prevent the cleaning and sanitizing solutions from coming into contact with skin or eyes.
• Do not leave the icemaker unattended when panels are off.

ℹ️ NOTICE

To prevent damage to the water pump seal, do not leave the control switch in the "PUMP" position for extended periods when the water tank is empty.

Preparation

1. Remove the front panel, then move the control switch to the "OFF" position. Make sure the mode switch is in the "ICE" position. After 3 minutes, move the control switch to the "ON" position and replace the front panel.
2. Allow the appliance to run until the compressor energizes. Once the compressor energizes, allow the appliance to run for an additional 3 minutes, then remove the front panel. Move the control switch to the "OFF" position.
3. Remove all ice from the dispenser unit/ice storage bin. ⚠️ WARNING! If on a dispenser unit, turn off the dispenser unit power supply after dispensing the ice.

Cleaning

1. Move the mode switch to the "CLEAN" position, then move the control switch to the "ON" position (1 short beep occurs, then 3 seconds later 1 long beep occurs). Replace the front panel. The water tank drains and then fills.
2. When the control board starts beeping (2 beep sequence), remove the front panel. Move the control switch to the "OFF" position.
3. Remove the front insulation panel, then pour 10.4 fl. oz. (308 ml) of Hoshizaki "Scale Away" into the water tank. Replace the front insulation panel.
4. Move the control switch to the "ON" position (1 short beep occurs, then 3 seconds later 1 long beep occurs). Replace the front panel. To avoid excessive foaming in the water tank, there is a 1 minute delay before circulation begins. After approximately 30 minutes of circulation, the icemaker performs 3 rinse cycles.
5. When the control board starts beeping (5 beep sequence), remove the front panel. Move the control switch to the "OFF" position.
6. In bad or severe water conditions, turn off the power supply, then remove, clean (cleaning solution = 5 oz. Hoshizaki "Scale Away" per gallon of warm water), rinse, and replace the cube guide, float switch, water supply tubes, spray tubes, and spray guides; turn on the power supply when complete. Otherwise, continue to step 10.

Sanitizing

1. 10) Confirm the mode switch is in the "CLEAN" position, then move the control switch to the "ON" position (1 short beep occurs, then 3 seconds later 1 long beep occurs). Replace the front panel. The water tank drains and then fills.
2. 11) When the control board starts beeping (2 beep sequence), remove the front panel. Move the control switch to the "OFF" position.
3. 12) Remove the front insulation panel, then pour 0.6 fl. oz. (18 ml) of an 8.25% sodium hypochlorite solution (chlorine bleach) into the water tank. Replace the front insulation panel. ❗ IMPORTANT! Use regular bleach with no additives. Using a bleach with additives causes excessive foaming during sanitizing, reducing the effectiveness of sanitizing.
4. 13) Move the control switch to the "ON" position (1 short beep occurs, then 3 seconds later 1 long beep occurs). Replace the front panel. To avoid excessive foaming in the water tank, there is a 1 minute delay before circulation begins. After approximately 30 minutes of circulation, the icemaker performs 3 rinse cycles.
5. 14) When the control board starts beeping (5 beep sequence), remove the front panel. Move the control switch to the "OFF" position.
6. 15) Clean the dispenser unit/ice storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.
7. 16) Move the mode switch to the "ICE" position, then move the control switch to the "ON" position. Note: If on a dispenser unit, turn on the dispenser unit power supply.
8. 17) Replace all panels in their correct positions.

IV. Preparing the Appliance for Periods of Non-Use

ℹ️ NOTICE

• When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage.
• To prevent damage to the water pump seal, do not leave the control switch in the "PUMP" position for extended periods when the water tank is empty.

When the icemaker is not used for two or three days under normal conditions, it is sufficient to move the control switch to the "OFF" position. When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below.

1. Remove the water from the icemaker water supply line:

1. Turn off the power supply, then remove the front panel.
2. Move the control switch to the "OFF" position.
3. Close the icemaker water supply line shut-off valve, then open the icemaker water supply line drain valve.
4. Allow the line to drain by gravity.
5. Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve.
6. Move the mode switch to the "ICE" position, then move the control switch to the "ON" position.
7. Replace the front panel in its correct position, then turn on the power supply.
8. Blow the icemaker water supply line out using the compressed air or carbon dioxide supply.
9. Close the icemaker water supply line drain valve.

2. Drain the water tank:

1. Turn off the power supply, then remove the front panel.
2. Move the control switch to the "OFF" position.
3. Remove the base cover, then disconnect one end of the pump tubing to drain the water tank. See Fig. 22. After the water tank has drained, reconnect the pump tubing.
4. Remove all ice from the dispenser unit/ice storage bin. Clean the dispenser unit/ice storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.
5. Replace the base cover and the front panel in their correct positions.

Diagram Description: Figure 22 shows the Icemaker with the Base Cover removed, illustrating the disconnection of the pump tubing to drain the water tank. It also shows the Control Switch, Mode Switch, and Water Tank.

3. On water-cooled models, remove the water from the water-cooled condenser:

1. Make sure the power supply is off, then remove the front, top, and right side panels.
2. Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve.
3. Open the condenser water supply line drain valve. If connected to a closed loop system, also open the condenser return line drain valve.
4. Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.
5. Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out.
6. Close the drain valve(s).
7. Replace the panels in their correct positions.

V. Disposal

The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.

HOSHIZAKI AMERICA, INC.

618 Hwy. 74 South, Peachtree City, GA 30269 USA (P) 770.487.2331 (F) 770.487.3360 hoshizakiamerica.com 1A6547-010