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P34F Service Manual

1. SOLENOID PROBE DEUS CONTROL qos 230V WIRIN E EVEL LINE RELAY LEVEL RELAY LI Z U E P 5 LI L t Ip ib 14 12 ll IO 9 8 7 6 5 4 3 2 DUO 0 o 2 eleje JE CABLE TO PROBE FIGURE 6 4 Level Column Wiring for P34F all Voltages 50 60 Hz 2 16 12 6 6 P34F Service Manual ELECTRICAL CONTROLS INCOMING POWER 4 n 0001000 000 v gi E FB loo lbo n Leo m 9 i ve loo fo i 1M10L 1M20L FIGURE 6 5 Part Wind Start Compressor Motor Starter Motor Starter
2. MOL FIGURE 6 6 Across the Line Compressor Motor Starter control panel Supplies power to lowside unit not shown TABLE 6 4 Description of Control Panel Parts 2 16 12 6 8 P34F Service Manual ELECTRICAL CONTROLS This page is blank 11 19 12 P34F Service Manual 7 1 2 9 2012 MAINTENANCE 7 Maintenance Preventative Maintenance A careful inspection of the Tube Ice machine for leaks and correct operational functions at the time of installation and start up will begin its long satisfactory life of service In order to insure this degree of dependability a systematic maintenance program is necessary Therefore the following schedule is suggested as a minimum A Daily 1 2 3 4 5 6 7 Check operating pressures suction discharge oil Check ice quality Check out time maintain 30 seconds of continued harvest after last ice is out Check compressor oil level Check refrigerant operation level Check frost pattern on freezer shell and suction line Check make up water float valve adjustment B Weekly in addition to daily checks 1 2 Check all belts for proper tension Do not use belt dressings Check for leaks after 400 hours or four weeks of operation C Monthly in addition to weekly checks 1 2 3 4 5 6 7 Check calibration and operat
3. 2 3 Ice Making Section Cleaning Procedure 7 3 Ice Quality 8 7 Important Safety 1 2 Inspection First Arrival 2 1 Installation 3 1 Installation Review A Checklist 3 14 L Length 10 1 Lifting 3 1 Lifting diagram for P34F 3 5 Liquid Feed Solenoid Valve 20 9 23 Liquid Outlet Stop Valve 58 1 7 Low Discharge Pressure 8 9 Low Ice Capacity 8 6 8 7 Low Pressure Gage Stop Valve 69 1 6 Low Pressure Switch 9 6 M Machine Room 3 1 Machine Short Cycles 8 11 Machine Stopped 8 2 8 3 Maintenance Checklist 7 1 Maintenance
4. VALVE s A RH ELI 1 a B i i ilL 4 j 4 b v E d 5 d 3 fr Y lt LH PAA EQUALIZER LINE STOP VALVE k FIGURE 1 4 P34F Left Side 1 7 INTRODUCTION VALVE ACCESS OIL DRAIN VALVE DISCHARGE STOP CHECK VALVE VALVE RECEIVER SAFETY THREE WA VALVE CHARGING VALVE 1 8 P34F Service Manual INTRODUCTION This page is blank 11 19 12 P34F Service Manual 2 1 RECEIPT OF YOUR TUBE ICE MACHINE 2 Receipt Of Your Tube Ice Machine Only service personnel experienced in refrigeration systems and qualified to work on high amperage electrical equipment should be allowed to install or service this Tube Ice machine Eye protection should be worn by all personnel working on or around the Tube Ice machine It is very important that you are familiar with and adhere to all local state and federal etc ordinances and laws regarding the handling storing and use of R 22 R404a refrigerant An approved refrigerant mask should be readily available for use in an emergency and all personnel
5. 9 24 See FIGURES 1 1 through 1 4 for location Space Requirements 3 1 Space Diagram 3 2 3 3 Spare Parts List 11 8 Specifications for P24F 2 3 11 2 Start Push Button 2PB 5 5 6 3 5 3 Start Up amp Operation 5 1 Start Up Checklist 5 2 Storage prior to installation and start up 2 3 Stop Push Button 1PB 5 5 6 3 Suction Line Frosting to Compressor 8 12 T Temperature Pressure Chart 11 7 Thaw Gas Check Valve 101 1 7 Thaw Gas Solenoid Valve 18 1 5 1 9 9 22 Thaw Gas Stop Valve 90 1 5 1 9 9 22 Thawing Timer 2 9 8 Three Way Valve 52 1 7 Troubleshooting 8 1 U V Valves 9 24 Valves location see FIGURES 1 1 through 1 4
6. EN 48 COMPRESSOR COOLING STOP VALVE N 58 LIQUID OUTLET KING VALVE 44 RECEIVER DRAIN VALVE FIGURE 1 1 P34F Front Side Control Panel 2 9 12 P34F Service Manual 1 5 INTRODUCTION dcm A 55 DISCHARGE LINE STOP VALVE LIQUID FEED SOLENOID ET A VALVES TS 4 2 CAPACITIVE LEVEL PROBE Tw Xt 2 FREEZER n 4 S ES NE p ES Dog WI nd PN TN py P i d 5 Em Ti 4 E M 4 67 LEVEL COLUMN SIGHTGLASS 24 CONDENSER WATER OUT 4 67 LEVEL COLUMN SIGHTGLASS 7 d Y d DENSER WATER IN 4 2 Aor p T d CONSTANT FEED SOLENOID e By ANT FEED SOLENOID m N le 17 EXPANSION V m 5 ES E 29 LIQUID LINE STOP VALVE bj SERE 7 CA d SN N 1 T H L pu A L Jm
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8. AINA EN Ist S NIA OO CO LO E SE SE LO lt eo 65 tO sh 10 P CO CO 74 2 F R 12 R 22 R 502 R 134a R 404A R 717 50 46 7 97 4 52 488 101 0 54 510 908 1048 9 1 8 7 8 3 TON OLN lt uuo qm esee oem oo Jos 5 22 5 2 o r o 60 162 10 i O2 60 00 a cc o 2 10 r xr r 00 xt O lm 2 10
9. 2 1 Description 2 1 Safety tags and labels 2 2 Receiver R22 Recovery Valve 44 1 11 Receiver Access Valve 59 1 10 P24A amp P34AService Manual Recommended Spare parts list 11 6 Refrigerant Adding 5 3 Refrigerant Leaks 9 21 Refrigerant Charge 5 2 Refrigerant MSDS Appendix Refrigerant Removal 9 20 Refrigeration System Review 5 1 Rotation 3 13 S Safety Notice 1 2 Safety Switches Safety Symbols and What They Mean 1 2 Safety Tags and Labels 2 1 Safety Valves 3 8 See FIGURES 1 3 Servicing Operations 9 1 Shipping weight 2 3 Shut Down by Oil Pressure Switch 8 11 Solenoid Valves
10. 7 3 Cleaning Ice Making Section COMpreSsSor 7 6 Compressor Crankcase 9 6 Compressor Discharge Valve 35 Compressor Inspection 9 24 Compressor Maintenance 7 6 Compressor Loosing Oil Excessively Compressor Oil Changing 9 24 Compressor Oil Pressure Low 8 10 Compressor Running Unloaded During Freeze Compressor Servicing 9 26 Compressor Suction Valve 34 1 4 Compressor Suction Access Valve 77 Condenser R22 Recovery Valve 44 1 6 Condenser R22 Charging Valve 44 1 6 Condenser Cleaning Condenser Access Valve 59 1 7 Condenser Safety Valves 50 1 7 Condenser Water In And Out Condenser Water Requirements 3 8 Condenser Water Usage 11 4 Constants Control Circuit Protection 9 8 Control Panel 5 5 6 2 6 3 Control Panel Parts 6 2 6 3 Conversion Fa
11. INE LOAD Fuses 9 S FUSES O OAD D 4 2 INE LOAD 5 HD INE 18 288 5 LOAD 6 Sie si fn 8 7 8 9 10 FIGURE 10 1 Phase Protector wiring schematic Step 1 Connect Power Monitor wires 1 2 3 to Compressor Motor Starter 1M terminals L1 L2 L3 Step 2 Connect Power Monitor wires 4 5 6 to Compressor Motor Starter 1M terminalsT1 T2 T3 Step 3 Connect Power Monitor wire 7 to Terminal Block TB terminal 12 Step 4 Connect Power Monitor wire 8 to Terminal Block TB terminal 22 Step 5 Remove Jumper 15 from Pump Motor Starter 2M overload to Cutter Motor Starter 3M overload Step 6 Connect Power Monitor wire 9 To Pump Motor Starter 2M overload Step 7 Connect Power Monitor wire 10 To Cutter Motor Starter 3M overload 2 9 12 10 6 2 9 12 OPTIONS AND ACCESSORIES Troubleshooting for Power Monitor SYMPTOM DISPLAY SOLUTION Load will not energize Parameters will not change when arrows pressed LEDS blink periodically but unit never comes up Control LED does not go out when control is off System trips out on low or high line voltage Output relay never turns on Unit makes sizzling sound whistling or LOAD LED Blinking System on line Indicates parameters when SETUP is pressed Occasional Flash CONTROL LED always on FAULT LED flashes due to f
12. m12 NOTE E FREEZER Ai 36 NOTE D 16 1 1 4 amp 1 1 2 TUBES 14 6 1 TUBES SEE NOTE F E IL P n LE 5 ICE DISCHARGE f h 8 1 2 4 Il ouo 9 AS REQ D 4 bz NOTE 4 NOTE A OTES A REQUIRED TO SERVICE CUTTER ASSEMBLY B REQUIRED TO REMOVE COMPRESSOR CRANKSHAFT C REQUIRED MINIMUM FOR SERVICING D REQUIRED TO CLEAN OR REPLACE CONDENSER TUBES EITHER END 36 SQUARE OPENING NOT REQUIRED IF THERE 15 AT LEAST 8 0 CLEARANCE BETWEEN END OF CONDENSER AND WALL EITHER END E REQUIRED ABOVE FREEZER TO SERVICE FREEZER TUBES F MACHINE SHOWN WITH STANDARD SUPPORTS INCREASE AS REQUIRED TO ACCOMODATE EXTENDED BASE IF USED G REQUIRED FOR ICE HANDLING EQUIPMENT CUSTOMER NOTES THIS DRAWING IS INTENDED TO BE USED AS A GUIDE ONLY FOR MINIMUM SPACE REQUIREMENT SERVICING AND OPERATING A P34F VOGT TUBE ICE MACHINE SPACE REQUIREMENTS FOR OTHER EQUIPMENT SUCH AS CONVEYERS AUGERS BAGGERS ETC MUST BE CONSIDERED FI
13. 10 3 Fault 10 4 Locking out setup 10 4 Nominal voltage 10 2 Parameters 10 2 Phase unbalance 10 3 Read mode 10 5 Reset 10 3 Troubleshooting 10 6 Voltage range 10 2 Wiring 10 5 Pressure Temperature Chart 11 7 Preventive Maintenance 7 1 Preventive Maintenance Form 7 2 1 1 Principle of Operation 4 1 Production Check 7 2 Pumpdown 9 20 Q R R22 amount required 5 2 Rated Capacity 2 3 Receipt of Machine 2 1 Inspection
14. TL N i N 8 fe i Y A LL NV CHAMBER N FIGURE 1 2 P34F Right Side 2 9 12 1 6 P34F Service Manual INTRODUCTION HM Pe P 88 T ACCUMULATOR lt lt As vl 5 CONDENSER gt INS LL 13 HEAT EXCHANGER 15 co _ COMPRESSOR DRIVE MOTOR 90 THAWING GAS STOP VALVE 90 THAWING GAS STOP VALVE A y Jee eos 18 THAWING GAS SOLENOID i VALVE we STRAINER 4 hed ER GEAR REDUCER A 50 CUTTER MOTOR 7 12 MAKE UP WATER FLOAT VALV 3 63 LUSH WATER INLET VALVE N 62 MAKE UP WATER INLET VALVE NA 3 TANK DRAIN VALVE FIGURE 1 3 P34F Back Side 2 9 12 2 9 12 P34F Service Manual 91 LIQUID RETURN STOP V
15. R SAFETY CONTROLS TN 378 ub CRANKCASE HEATER a COMP MOTOR STARTER PART WIN 1 X 27 EN 2541 IM10L IM20L 298 SAFETY HHH TIMER DT 60 SEC Z9AB M OL X D 298 1 Sc RY LL 2 EOMP MOTOR STARTER m c ACROSS LINE START 4 9 8 START 2 vA OIL PRESSURE H OPS R ELAPSED TIME INDICATOR 27 P SOLENOID VALVE 1 LIQUID FEED SOLENOID VALV NOTE NOT USED OMP LOAD ALL COMPRESSORS PILOT LIGHT WHITE R22 FEED SOLENOID VALVE A2 LIQUID FEED T LIGHT BLUE FREEZING 1CR STARTER COIL FREEZER WATER PUMP RELAY HARVEST CYCLE LATCHING RELAY MPLETION OF CYCLE WHEN FREEZER PRESS ANUAL HARVEST OLENIOD VALVE SOLENIOD VALVE SOLENOID VALVE H WATER FLUSH SOLENOID VALVE OMP UNLOAL R im STARTER COIL CUTTER MOTOR TIME DELAYE PILOT LIGHT RED THAWING STARTER COIL CONVEYOR MOTOR STARTER COIL TOWER FAN 7M STARTER COIL CONDENSER PUMP 43 RELAY FREEZE CYCLE LATCHING RELAY ALLOWS COMPLETION 17 A BIN STAT 54 PROB 9 CONTROL 4 CENEL PROBE FIGURE 6 3 Electrical Schematic for P34F all Voltages 50 60 Hz 2 16 12 P34F Service Manual 6 5 ELECTRICAL CONTROLS
16. and push the Manual Harvest button Check voltage and amps against motor rating If tripping repeats but ice is not jammed check the gear reducer for resistance cutter bearings for wear drive gear and ring gear for proper engagement and reducer motor for defect or single phasing Bin level control optional open Adjust or replace control as required If bin level control is not used make sure jumper wire 8 and 9 is installed at of the terminal block 2 9 12 2 9 12 P34F Service Manual Symptom Machine Stopped con t Possible Cause Possible Remedy High Low pressure safety switch 1PS tripped Low oil pressure tripped OPS Defective control panel component such as 1PB 1SS 1M contact 2CR contact Circuit breaker CB2 or CB3 for pump or cutter motor tripped High refrigerant level in evaporator due to liquid feed valve 1 leaking through High refrigerant level in evaporator due to Check liquid level control for proper operation level controller failure and set point Replace defective part 8 3 TROUBLESHOOTING If the machine stops by low pressure cutout the switch will reset automatically when the pressure rises to the cut in setting Check thaw gas valve 18 to make sure it opens during harvest time If the machine stops by high pressure cutout the switch will have to be manually reset after the pressure drops below the cut in setting Check the head pressure during the
17. however there are certain changes to be made in order to convert to crushed ice production The following modifications are required Remove the existing cutter adapter plate and install new adapter plates for crushed ice Remove the existing tines disc assembly and install new crushed ice disc assembly Remove the existing ice shield and scraper and install new shield and scraper Readjust the freezer pressure switch to produce ice 3 16 1 4 thick for crushed ice mop To remove and install cutter parts it is necessary to remove the water tank assembly for unrestricted access The result is ice that is approximately 1 2 long and frozen only 3 16 1 4 thick A modification of this type is not one you would want to make every time a temporary change to crushed ice is wanted Contact your distributor for more information and complete details Length of Ice Ice length can be adjusted by increasing or decreasing the length of the spacer under the adapter plates The water tank assembly must be removed for this modification When installing the adapter plates make sure the horizontal dimension from the cutter blade edge to the edge of the adapter plate is as follows 7 8 space for 1 tubes 1 1 8 space for 1 1 4 tubes 3 8 space for 1 1 2 tubes See Figure 9 8 for illustration of this critical adjustment CAUTION Always witness several ice making cycles after making conversions or modifications to make sure all ice is clear
18. 1055 991 875 946 851 69 977 1050 986 872 942 849 977 105 0 98 6 872 942 849 71 969 1040 977 864 935 842 969 104 0 977 86 4 935 842 73 960 103 1 968 858 927 836 96 0 103 1 96 8 858 927 836 78 940 1007 946 841 90 9 821 940 100 7 946 841 909 821 79 936 1003 941 837 90 6 818 936 1003 941 837 906 818 80 932 998 93 7 834 90 3 815 932 998 937 834 903 815 86 908 972 912 815 882 798 908 972 91 2 815 882 798 89 897 959 90 0 806 873 79 0 897 959 90 0 80 6 873 79 0 90 893 955 896 803 869 787 893 955 89 6 803 869 787 Capacity rating based on 70 F ambient conditions 100 F SDT temperature Capacity rating is average for the model Individual machines may vary up to 5 above or below Capacity rating is for clear ice production with makeup water containing no more than 200ppm total dissolved solids Table 11 2 2 9 12 11 4 P34F Service Manual TABLES amp CHARTS Condensing Entering Leaving Water Flow Pressur Average Total Heat Water Water of Rejection 2 033 590 2 033 590 2 033 590 2 033 590 _ 10 830 95 4 20359 2 033 590 2 033 590 2 033 590 Table 11 3 P34F Condenser Water Usage Cylinder Ice Crushed Ice Make Up Water Tube Size Temp F L
19. 4 19 kJ kg C 0 24 BTU Ibm F 32 35 Ibs ft 144 BTU hr 1 BTU Ib F 12 000 BTU hr 14 7 psia 62 4 8 33 lbs gal 12013 Ib day 0 0749 Ibs ft 0 0100 Ibs gal 2545 6 BTU hr 1 34 horsepower 9 81 m sec TABLE 11 8 Tc 5 9 Ty 9 5 Tc 32 1 34 32 2 8317e 2 3 7854e 3 7 48 1 11 06 P24F Service Manual 12 Index A A Brief History Of Henry Vogt Machine Co 1 1 Across the Line Start Compressor starter Adding Refrigerant 5 3 Assembly Drawing 1 4 1 5 1 6 1 7 Automatic blowdown Harvest Cycle Auxiliary Controls or Equipment 3 13 B Basic Product Warranty inside back cover Bearing Bracket and Cutter Disc Removal 9 15 Belt Tension Belt Replacement 9 Bin Level Control 6 1 Blowdown 9 1 C Capacity Ratings P24F Capacitive Level Control 6 5 9 1 Charging Refrigeration System Precautions 1 3 5 2 Charging Valve Freezer 28 Circulating Water Pump Motor 9 10 9 11 Cleaning Procedure Ice Making Section
20. The compressor oil should be changed at close intervals during initial break in operation and up to the first 1000 hours see Table 7 4 Your machine was test operated at the factory and compressor oil was drained crankcase cleaned suction strainer sock cleaned new oil filter installed if applicable and clean oil added prior to shipping Note It is the owner s responsibility to make sure normal maintenance is initiated to insure that the compressor is not subjected to premature wear or failure due to neglect or lack of sufficient maintenance and care Frequency 3rd Thereafter 1500 Change oil and Filter 500 hr 1500 hr 4000 hr every 4000 hrs Clean suction strainer cloth 200 hr 500hr Remove if clogging is minimal See Mycom manual for operation of Cuno oil filter system recommend daily turning of handle TABLE 7 4 Compressor Maintenance The above maintenance is only a guide The compressor should be inspected anytime there is unusual noise damage is suspected or the oil becomes discolored The oil should be changed any time the compressor is opened For specific recommendations and instructions refer to the particular compressor manufacturer s manual See Compressor Oil Changing and Inspection P34F Service Manual 7 7 2 9 2012 MAINTENANCE Cutter Gear Reducer The oil level of the gear reducer should be checked monthly or when there is any evidence of leakage The correct oil l
21. When ordering a seal specify pump size type serial number and manufacturer s name as indicated on the nameplate P34F Service Manual 9 23 SERVICING OPERATIONS Solenoid Valves The P34F is equipped with several solenoid valves that perform various functions during the ice producing process The Thaw Gas Solenoid Valve This valve opens during the thaw cycle to allow warm gas to pass from the receiver to the freezer Repair or replace as follows 1 With the receiver pressure higher than the freezer pressure manually open the valve by turning the manual stem in until you hear gas passing through the valve 2 Close the two hand stop valves 90 tight on either side of solenoid valve when there is vapor only in that part of the line 3 Loosen the 1 4 tubing compression nut at the strainer slightly to reclaim that section of the thaw gas line and continue to reclaim until all pressure is relieved 4 Repair or replace the valve as needed making sure all connections are tight 5 With the valve manually opened stem in open slightly only one stop valve 90 and purge air from the line through the 1 4 tubing compression nut at the strainer Then close that valve 90 and open the other 90 valve to purge air from that section of the line 6 When reclaiming is complete tighten the compression nut and manually close the solenoid valve 7 Reopen stop valves 90 and check for leaks 8 Assure that the pressure is 65 70 psig R
22. through the condenser tubes A reservoir of liquid refrigerant is accumulated in the receiver and is required for thawing purposes Liquid from the receiver flows through the filter drier 46 and the heat exchanger 13 to the liquid feed solenoid valve 20A which opens and closes by action of the capacitive level probe 65 The liquid is then expanded through the hand expansion valve 17 and into the evaporator 2 freezer The liquid is also fed through a bypass line and the constant feed solenoid valve 20B which is open throughout the freeze cycle The cold wet refrigerant that is fed though these valves floods the evaporator and is in contact with the outside of the ice making tubes which water is being circulated through The heat contained in the water passes through the wall of the tubes lowering the temperature of the water and causing it to freeze and form a long tube of ice that adheres to the inside of the freezer tubes Since the purest water freezes first the circulating water continues to wash the dissolved solids down into the sump area of the water tank 7 The flushing valve 63 helps to rid the water tank of increased dissolved solids by flushing them out the overflow during the harvest thawing period The wet suction gas leaves the freezer 2 and passes through the suction accumulator 88 and heat exchanger 13 where liquid droplets are removed allowing the super heated dry gas to enter the suction side of the compr
23. 360 7 156 198 0 11 ee 105 5 90 18 140 130 136 154 154 90 1308 133 123 129 145 145 Includes 25 blowdown per cycle Table 11 4 P34F Make Up Water Usage gpm 2 9 12 11 5 TABLES amp CHARTS P34FService Manual Freeze Time minutes Water Temperature deg F 90 70 N 2 9 53 S x Suction Pressure Discharge Pressure psig R22 psig R22 Table 11 5A P34F Normal Operating Vitals for R 22 Data extracted from Vogt Ratings Program Freeze Time minutes 80 Water Temperature deg F 90 70 N 2 S x Suction Pressure Discharge Pressure psig R404a psig R404a Table 11 5B P34F Normal Operating Vitals for R 404a Data extracted from Vogt Ratings Program 2 9 12 P34F Service Manual 11 6 TABLES amp CHARTS TEMPERATURE PRESSURE CHART FOR COMMON REFRIGERANTS F psig gt ac i EP cO F 02 65 23 9 O O O ANINA c t0 T T QI cO CO CO P OO pr
24. All Voltages 50 60 Hz 6 4 Electrical Controls 6 1 F Fan Control cooling tower 9 7 Fan Control Switch Float Valve Make Up Water 9 1 Flushing Water In 3 6 Foundation 3 1 3 4 Freeze Period 41 Freeze Protection Diagram 3 10 3 11 Freeze Up Due To Extended Freeze Period Freeze Up Due To Ice Failing To Discharge 8 5 Freezer Recovery Valve 61 1 4 Freezer Pressure Switch 2 9 Freezer Access Valve 76 1 7 Freezer Safety Valves 51 1 7 G Gage Glass Stop Valve 31 1 4 Gear Reducer Replacement H Hand Expansion Valve 17 Harvest Period 4 2 12 2 INDEX High Compressor Discharge Temperature 8 11 High Discharge Pressure 8 8 High Low Pressure Switch 1PS 9 6 High Suction Pressure 8 9 How Your Tube Ice Machine Works 4 1 Ice Lb Kg Harvest
25. Hower Pump Pf sonnets outed __ __ 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F ambient and 25 blowdown 2 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower 3 Makeup water is maximum value and includes 25 blowdown each cycle 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 5 Tower sized for 75 F wet bulb temperature Vogt reserves the right to change designs and specifications without notice Table 11 1 2 9 12 P34FService Manual 11 3 TABLES amp CHARTS P34F Capacity Ratings Makeup Rated Capacity 1000 Ibs day Water POH OZ e i1 112 1 114 112 1 114 112 1 11 11 2 45 1095 1184 115 966 1041 950 1095 1184 115 96 6 1041 93 0 49 106 8 116 0 109 1 94 9 1023 91 5 106 8 116 0 109 1 94 9 1023 91 5 57 102 8 111 3 104 7 91 6 98 9 88 7 102 8 111 3 104 7 91 6 98 9 88 7 60 1014 109 7 103 1 905 977 877 101 4 109 7 1031 90 5 977 877 62 100 9 108 6 102 1 89 7 96 9 870 100 9 108 6 102 1 89 7 96 9 87 0 65 995 1070 100 6 886 957 99 5 107 0 100 6 88 6 95 7 86 0 67 986 1060 99 6 879 949 854 986 106 0 99 6 879 949 854 68 982 1055 991 875 946 85 1 982
26. R 22 R404a in Appendix A For further information concerning refrigerants and handling practices see internet web site www dupont com suva If a refrigeration system is being charged from refrigerant cylinders disconnect each cylinder when empty or when the system is fully charged A gage should be installed in the charging line to indicate refrigerant cylinder pressure The cylinder may be considered empty of liquid refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary excessive or illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant brought on by an increase in temperature CAUTION Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 120 F R 22 R404A and should be stored in a manner t
27. V Belt Maintenance 7 7 Voltage Unbalance 3 12 Warranty Basic Product inside back cover Water Cooled Condenser Cleaning 7 4 Water Distributors Chart 7 3 Cleaning procedure 7 4 Water Flush Solenoid Valve 63 Water contamination of R22 R404A 9 21 Water Tank 7 4 9 17 1 11 06 12 3 INDEX Water Tank Drain Valve 39 1 4 Water Tank and Cutter Parts Weights 9 14 Water Tank 9 10 Parts list 9 11 Water Tank Drain 3 6 Water Tank Installation 9 17 Water Tank Overflow 3 6 Water Tank 9 14 Wiring and Electrical Connections 3 11 Wiring Schematic All Voltages 50 60 Hz 6 4 X Y Z 12 4 P24F Service Manual INDEX 1 11 06
28. and the relays themselves Because the signal from the probe is unique it requires the control unit to interpret and convert it to an understandable signal and display The control unit which has a watertight enclosure is mounted in an accessible area away from the movement of material and equipment CAUTION Do not install conduit connections into top of control unit water can condense in conduit and drip down on control unit electronics causing failure 9 2 P34F Service Manual SERVICING OPERATIONS CONTROL UNIT LB3 SIMULATION MODE INDICATOR LIGHT AMBER DIGITAL READOUT OPERATION MODE INDICATOR LIGHT GREEN Vari Level LEVEL SIMULATION HANSEN TECHNOLOGIES CORPORATION ADJUSTMENT SCREW HIGH LEVEL CALIBRATION SCREW ec PRECALIBRATED CALIBRATION SIMULATION SIMULATION BUTTON PUSH HOLD FOR SIMULATION LIQUID LEVEL PERCENT ABOVE PROBE BOTTOM LOW LEVEL CALIBRATION LOW LEVEL CALIBRATION SCREW PRECALIBRATED SET POINT ADJUSTMENTS INDICATOR LIGHT TYPICAL LEVEL SETTING LB1 SLIDE KNOBS LEVEL DIFFERENTIAL KNOBS LB2 HIGH LEVEL LOW CONTROL LEVEL REPLACEABLE 3 AMP FUSES PART NO 77 0206 QUICK DISCONNECT PLUGS LBS ELECTRICAL TAPE OR SHRINK TUBING SHIELD AND GROUNDING WIRE TO PROBE ENCLOSED UNDERNEATH TYPICAL CONTROL UNIT SETTINGS Set Point Adjustments Differential Set Point
29. centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 The capacitive level probe 65 opens and closes the liquid feed A solenoid valve 20A and maintains the desired refrigerant level in the freezer 2 evaporator The constant feed solenoid valve 20B remains open during this period Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 heat exchanger 13 and to the compressor 3 Here the cool gas is compressed to a high temperature high pressure gas which discharges through the oil separator 14 then through the heat coil of the condenser and then into the P34F condenser receiver 15 In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid goes out the liquid line through a strainer 43 liquid solenoid valves 20A amp 20B check valve 101 and hand expansion valve 17 At the hand expansion valve 17 the refrigerant expands from a saturated high pressure liquid state to a low pressure low temperature liquid This cold liquid enters the freezer 2 where it absorbs heat from the circulating water in the freezer tubes Cool gas is again pulled out of the freezer through the suction outlet thereby completing the cycle The freezing period is completed by action of the freezer pressure switch 2PS in the control panel The water pump 6 stops and the solenoid
30. contactor 1 Used to start compressor motor Energizes first Overload Relay 1 Provide over current protection for one half of motor 1M2 Motor Starter contactor 1 Used to start compressor motor Is energized approximately 1 second after is energized Overload Relay 1 Provides over current protection for one half of motor Circuit Breaker 3 pole Provides short circuit protection and a disconnecting means to lowside control panel Supplies power to lowside unit Fuse Block 1 Provides short circuit protection for one half of motor 3 fuses Fuse Block 2 Provides short circuit protection for one half of motor 3 fuses Power Monitor Fuses Provides short circuit protection for the power monitor 3 fuses PM Power Monitor Provides protection for machine against abnormal power conditions optional Relay Relay used to energize 1M2 contactor Note R1 is a control relay used on machines where contactor 1M2 is too large for TR to energize Terminal Block 1 Main Power connection Terminal Block 2 Secondary terminal block Connections to Lowside panel TR Delay Timer Used to delay second motor starter M2 Timer either connected to or 1M2 coil connection 51 panel Highside Disconnect Used to disconnect power from panel when panel door opened not shown TABLE 6 3 Description of Control Panel Parts 2 16 12 P34F Service Manual 6 7 ELECTRICAL CONTROLS INCOMING POWER y p H
31. for condenser at 80 ft total discharge head for a typical installation However due to cooling tower location and pressure drop through water lines the water pump should be sized for each installation The ice machine is supplied with a fan control switch for cycling the cooling tower fan on and off thereby maintaining the proper operating head pressure If the condenser inlet water temperature is expected to be below 75 F 24 C a water regulating valve should be installed in the condenser water inlet line and adjusted to maintain a head pressure of not less than 190 psig See FIGURES 3 5 through 3 7 for possible cold climate installations with indoor sump Safety Valves Six safety pressure relief valves are an integral part of the packaged 1 machine Two are located in low side of the system on the freezer and two are in high side of the system on the receiver Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes 2 9 12 3 9 INSTALLING YOUR TUBE ICE MACHINE P34F Service Manual s JN IV TIVE Jf dNNS 9NIIOOO H3JIVM d dNNS 4 7930 08 NO YOLOW S319AO LVLSOWYSHL SJ3MOL NOLON SNIN3dO 1 YSMOL 9 FIGURE 3 4 Cooling Tower Piping Diagram 2 9 12 3 10 INSTALLING YOUR T
32. for record keeping Date Model Serial The following service performed and checked Hour meter reading Ambient temperature inside F Make Up water float valve adjusted properly Water distributors clean and in place All drains freely draining Cleaned and flushed water tank Compressor oil changed Cleaned and inspected inside compressor crankcase Changed compressor oil filter Checked adjusted compressor belt tension Lubricate compressor motor bearings Check change cutter gear reducer oil Check adjust cutter drive gear meshing Leak check entire system Check liquid refrigerant level in receiver Compressor crankcase heater working Compressor net oil pressure gage reading less suction L JEJE JEJE E EE TE TEE EE JE JEJE Motor amps Compressor Cutter Pump ___ Suction psig end of freeze Discharge psig end of freeze Suction psig end of thaw Discharge psig end of thaw Compressor water Tower fan cycles Off Production Check Ice Ib Per Harvest Name 2 9 2012 P34F Service Manual 7 3 2 9 2012 MAINTENANCE Ice Making Section The ice making section of the Tube Ice machine should be cleaned at least twice a year more often if water conditions cause mineral build up Use an approved food grade ice machine cleaner The water pump is used to circulate the cleaner through the system For complete instructions follow the Cleaning Procedur
33. in a hazardous area or sprayed with water The machine should be installed in an area where water will not stand but will readily drain away from the machine Space Requirements Refer to the space diagrams Figures 3 1A and 3 1B for recommended minimum clearance around the machine for ease of servicing and observation Pay particular attention to the additional space required If it ever becomes necessary to mechanically clean the condenser tubes extra space will be required on one end preferably on the opposite end from the water inlet and outlet for the cleaning tools Foundation Refer to the foundation drawings Figure 3 2 for recommended minimum foundation requirements The figures show anchor bolt details and machine anchor hole details Contact your local distributor for seismic anchoring requirements in your area WARNING Lifting or moving heavy equipment should only be attempted by competent rigging and hoisting contractors Never allow personnel near or under heavy equipment when it is being moved or lifted Failure to comply could result in personal injury or loss of life WARNING Lifting Procedures Your Tube Ice machine is provided with lifting lugs for the purpose of unloading and moving the machine to its operation location Refer to the enclosed drawings for instructions and illustrations of their use P34F Figure 3 3 Machine weight 25 000 Ibs See TABLE 2 1 This figure is intended as a guide to unl
34. machine and remove the water tank assembly so the cutter is accessible see water tank removal 2 Locate the new adapter plate holding the correct dimension A from the edge of the plate to the edge of the blade See Figure 9 8 3 Using two C clamps to hold the adapter plate securely in place drill four 7 16 diameter holes through the adapter plate and through the cutter plate at the same time so they will adjoined properly 4 Countersink the holes in the adapter plate to make the bolt heads flush with the plate 5 Install bolts and spacers as illustrated and tighten securely Note the length of ice is determined by the spacer length Refer to Ice Length for details 6 Install the water tank assembly to the machine Note Length of cylinder ice can be changed See Section 10 11 19 12 P34F Service Manual 9 21 11 19 12 SERVICING OPERATIONS Pumpdown The function of the pump down is to transfer the liquid refrigerant from the freezer evaporator into the receiver Pump down should only be performed when the freezer is clear of ice Its main purposes are 1 To check the total refrigerant charge To perform service or repair work on the machine To winterize the machine To remove excess water from the refrigerant A N To prepare the machine for disconnection or moving To perform a pump down follow this procedure 1 With the machine running close the liquid feed stop valve 58
35. minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain is closed Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Check refrigerant level mark on the receiver and on the painted portion of the gage glass guard Be sure to keep the gage glass cocks closed when finished checking the level Check for closed valve defective solenoid valve 20 level controller defective or filter drier restricted The liquid line will normally have frost on the down stream side of a restriction especially as the suction pressure decreases Check level controller set point 8 8 P34F Service Manual TROUBLESHOOTING Symptom High discharge pressure check gage accuracy Possible Cause Possible Remedy Insufficient water flow through the cooling Check the condenser water pump to make sure tower or condenser it is pumping enough water as specified in TABLE 3 2 Check sump strainer screen and clean Check condenser pump direction of rotation Fan control out of adjustment Check adjustment Refer to FIGURE 9 4 Fan Control Replace if defective Non condensable in system If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant will be cooler although the pressure will be high Cooling tower or evap condenser i
36. motor starter 1M Terminals L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of the compressor cutter motor and water pump is required see rotation check Also if one leg of the 3 phase power is higher or lower wild then it should be connected to terminal L2 Connect the ground wire to the ground terminal provided Make sure wires 22 and 27 are connected to the elapse time ET indicator in the control panel 2 9 12 3 12 INSTALLING YOUR TUBE ICE MACHINE NOTE CONFIGURATION SHOWN FOR ACROSS LINE CONFIGURATION INCOMING POWER IS CONNECTED TO COMPRESSOR CONTACTOR 1M IN COMPRESSOR MOTOR STARTER CONTROL PANEL LOWSIDE CONTROL PANEL LOWSIDE CONTROL PANEL POWERED FROM L1 L2 AND L3 OF COMPRESSOR MOTOR STARTER CONTROL PANEL FIGURE 3 8 P34F Service Manual COMPRESSOR MOTOR STARTER CONTROL PANEL INCOMING POWER of 55 Power Supply Connections Part Wind Start Voltage Unbalance Voltage unbalance can cause motors to overheat and fail Voltage imbalance between any two legs should be no greater than 2 Example Supply voltage 230 3 60 Voltage Readings 220 Volts BC 225 Volts Average 220 225 227 3 224 Volts AC 227 Volts AB 224 220 4 Volts Highest Deviation BC 225 224 1 Volts AC 227 224 3 Volts Voltage Unbalance 100 x 4 224 1 78 Acce
37. nearest the receiver 2 Open the water tank drain valve partially to allow a continuous flow of warm make up water into the water tank and still maintain a good level in the tank An auxiliary supply of warm water not to exceed 100 F may be used if available Warmer water affords a more complete pump down 3 Allow the machine to operate and complete two freeze and harvest cycles 4 After the second harvest cycle unplug the harvest timer 5 Let machine run until machine shuts off on the compressor low pressure switch at approximately 15 psig Lower pressure can be obtained by lowering the setpoint on the switch see Figure 9 3 Do not operate the machine below 2 psig This could cause non condensables to be drawn into the machine if a vacuum is achieved 6 When the desirable pump down is obtained close the thawing gas stop valve 90 and the discharge line stop valve 55 Other valves may also be closed to isolate a particular area which may require attention 7 To perform a total pump down it may be necessary to apply heat directly to the bottom of the freezer in order to boil off the liquid refrigerant and oil mixture Removal of Refrigerant from the Machine Liquid refrigerant can be removed from the machine through the receiver drain valve 44 Refer to Sections 1 2 and Appendix A for special warnings and instructions regarding the handling of refrigerant Make sure you are familiar with and technically qualified to
38. next freeze cycle See FIGURE 9 3 Section 9 High Low Pressure Switch Manually reset the switch after the switch heater cools Check the crankcase oil level 1 4 3 4 full Add oil if below 1 4 glass before attempting to restart the machine Restart the machine and check net oil pressure net oil pressure oil pump line pressure minus crankcase suction pressure See FIGURE 9 5 Section 9 Oil Pressure Switch See Low Compressor Oil Pressure Net oil pressure range 45 55 psig See FIGURE 6 3 Wiring Schematic and check for open circuit Refer to FIGURES 6 1 and 6 2 Control Panel to identify parts Check for loose wires Replace defective part restart machine check power supply and current draw Check for loose connection on all terminals reset breaker and check amp draw against breaker rating Check voltage and current unbalance Section 3 Replace breaker if defective Check the manual opening stem to make sure it is in the automatic position stem screwed out Check for leakage by sound temperature difference and frost during the freeze cycle Leakage should stop by closing the hand stop valve downstream of thaw gas valve Isolate and repair or replace the valve as needed 8 4 P34F Service Manual TROUBLESHOOTING Symptom Freeze up due to extended freeze period Possible Cause Possible Remedy Freezer pressure switch 2PS set too low or Adjust switch or replace if defective See defective FIGURE
39. not further cleaning is feasible 7 Clean the inside of each tube as well as possible being careful not to damage the tube Follow the instructions for the particular tool being used 8 Flush each tube with water to remove all loose material and prevent contamination of the cooling tower and sump 9 Clean the ends of the tube sheets so the new gasket will seal properly 10 Insert the stud bolts to the proper depth and install the replacement gasket Make sure the gasket does not cover the extended tube ends 11 Install the end covers heads and fasten securely in place with the hex nuts 12 Reconnect the water piping and turn on the power Check for leaks by turning the Hand Auto switch to Hand allowing the condenser pump to run 13 Turn the switch back to Auto and wait for the crankcase heater to warm up compressor before starting the machine 11 19 12 P34F Service Manual 11 19 12 9 11 SERVICING OPERATIONS 45446 49164 43346149 32 67 53166 40448 45 50456 68169170 4755165 6 51 SECTIONAL DETAIL BEARING BRACKET ITEM 34 SHOWN ROTATED FOR CLARITY Figure 9 7A P34F Cutter Assembly Figure 9 7B P34F Water Tank Assembly 9 12 P34F Service Manual SERVICING OPERATIONS P34F Part Number Water Tank Assembly 19T450083400 Water Box Cover Not Shown 19T2150C0200 See Pump Model 12
40. of Loctite RC 609 retainer or a suitable substitute to the inner surface and bearing shoulder of the top of the bearing bracket 3 Insert a bearing in the top housing and set it in place 10 11 12 13 14 15 16 17 18 19 20 21 22 Clean the cutter shaft and press the top bearing onto the shaft Slide the upper bearing spacer on the shaft and begin driving the shaft down through the middle bearing of the housing Do not start the top shaft bearing in the housing Partially fill the housing with grease MPG 2 or a USDA approved grease Use enough to fill the area between the two upper bearings forcing some out the pipe plug hole when the shaft and top bearing are seated Finish driving the shaft and bearing into the housing until it is firmly seated Turn the bracket and shaft upside down and fill the housing around the shaft with MPG 2 or suitable substitute grease Slide the lower bearing spacer over the shaft and into the housing With the top end of the shaft supported install the lower bearing on the shaft driving it down into the housing firmly against the housing shoulder Slide the seal spacer ridged end in flat end out and seal open face out onto the shaft together Uniformly tap the seal into the housing against its shoulder NOTE The purpose of the seals and excluders are to prevent moisture from entering the housing area not to hold the grease in Wipe off excess grease and in
41. should be aware of its location and proper use CAUTION Inspection As soon as you receive your machine inspect it for any damage If damage is suspected note it on the shipper s papers i e the trucker s Bill of Lading Immediately make a separate written request for inspection by the freight line s agent Any repair work or alteration to the machine without the permission of Tube Ice LLC can void the machine s warranty You should also notify your Vogt distributor or the factory Description Of Machine A Vogt package Tube Ice machine is a complete ice producing plant requiring only make up water supply condenser water supply electrical connection and the proper refrigerant charge The machine has been fully factory tested prior to shipment and should require minimum adjustment The compressor oil is drained and the compressor suction strainer is cleaned and the cloth filter is removed The crankcase is inspected and cleaned by removing the side hand hole cover swabbing out the remaining oil and wiping the interior sides and bottom with a clean dry cloth New oil is added and the compressor is evacuated then pressurized to 20 25 psig with refrigerant Refer to your compressor manual for additional operation service maintenance instructions and information Safety Tags and Labels Be sure to read and adhere to all special tags and labels attached to valves or applied to various areas of the machine They provide impo
42. switch or thaw timer out of Check hole size in Tube Ice See TABLE 7 2 adjustment Crushed ice should be 3 16 1 4 thick Check and adjust thawing time Thawing should be 30 seconds longer than it takes for all the ice to clear the freezer Excessive ice chips in the water tank causing Check incoming water temperature 45 F short cycling minimum Check flushing valve to make sure ice chips are being melted and flowing out the tank overflow during the harvest cycle Compressor running unloaded or not pumping Check compressor motor amp draw Check for full volume belt slippage and tighten as needed Check for leaking compressor suction or discharge valves Refer to your compressor manual See other related symptoms Restriction in the refrigerant liquid line or level Check for a partially closed valve or an controller not operating properly obstruction at the filter drier solenoid valve or hand expansion valve The liquid line will normally have frost on the downstream side of a restriction especially as the suction pressure decreases Check level controller set point Low refrigerant charge causing re freeze Check the receiver gage glass mark for the proper level Check for and repair leaks Add refrigerant Warm make up water for ice making Capacity of the machine is proportional to ice making water temperature Warmer water will reduce the ice making capacity Refer to Section 11 Capacity Table Check float adjustment and
43. switch so the unit will power up a few seconds after power is applied Nominal Voltage Set this value at the Incoming Line Voltage Use the arrow keys to change voltage 190 610 Voltage Adjustment Default voltage is 208 Voltage Range Use the arrow keys to set the under over percentage 2 to 2596 of incoming voltage This will turn off equipment for a specified time 1f incoming voltage exceeds set percentage The recommended voltage range is 10 Default is 10 Delay On Break Ranges from Off to 10 minutes in 1 minute increments Use the arrow keys for adjustment Delay On Break is energized when the Load Relay is deactivated and the load will remain off until the specified time has elapsed Default is 5 minute Delay On Make Ranges from Off to 10 minutes in 1 minute increments Use the arrow keys for adjustment Delay On Make is energized when the control voltage is reactivated and the load will remain off until the specified time has elapsed Default is 1 minute Operation continued 2 9 12 2 9 12 P34F Service Manual 10 3 OPTIONS AND ACCESSORIES Phase Unbalance Use the arrow keys to set the Phase Unbalance percentage 2 to 2096 of incoming 3 Phases This will turn off equipment for a specified time if incoming Phase Unbalance exceeds set percentage The recommended setting is 5 Default is 5 Delay On Fault Ranges from Off to 15 seconds in 1 second increments Use the arrow keys for ad
44. t 10 c 69 oo 3 90 60 00 E NE 2 4 o 10 0 1 2195 QN MT T 6 5 Deg F 12 R 22 R 502 R 134a R 404A R 717 39 Deg 38 49 13 50 67 65 36 66 36 44 22 60 63 75 44 63 23 80 25 54 79 34 38 30 70 46 68 17 15 83 16 60 42 58 02 32 76 34 49 74 Q 1 N e z eo i 48 72 24 07 87 08 11 6 pressures are in Ibs in gage psig 2 9 12 P34FService Manual REFERENCE INFORMATION CONVERSION FACTORS English to Metric dete _ Multiply by 11 7 TABLES amp CHARTS pec Joule J Du 9 2903e 2 6 416 e 4 1054 48 2546 2 Een Pressure Ibf fc Paschals Ibf in psi Paschals in Hg psi in H O psi iE NI gaU S m it gal U S TABLE 11 7 CONSTANTS Specific heat of Water Specific heat of Air 1 Ton Refrigeration Weight of Water Weight of air 1 Kilowatt Gravitational accel 1 BTU Ibm F
45. to signal that the liquid level is becoming too high The high level set point is the highest level that the liquid should ever reach before a compressor cutout occurs The level in P34F should be 70 The differential adjustment control should be set at 2 The high level indicator light red will be on when the relay is de energized 9 4 P34F Service Manual SERVICING OPERATIONS SIMULATION The purpose of the built in level simulator is to enable the level set points and differentials to be very accurately set and to be checked for proper system operation Before entering the simulation mode be aware of the following IMPORTANT Control devices solenoid valves contactors etc can operate while in the simulation mode For calibration and electrical checkout disconnect the main circuits of the compressor motor pump motor etc where necessary to prevent damage or remove the relay quick disconnect plug in control unit To enter simulation mode depress and hold the simulation button the amber simulation mode light will be on When in simulation mode the digital readout displays the simulated pretend liquid level While continuing to depress the simulation button use a small screwdriver in the other hand to rotate the level simulation adjustment screw to change the simulated liquid level and display Observe the operation of the indicator lights If necessary make adjustments to level set point and differential knobs When the
46. valve 20A and constant feed solenoid valve 20 closes After a delay of 20 30 seconds the cutter motor starts the thaw gas D solenoid valve 18 opens and the harvest thaw timer 2TR is activated Warm gas from the receiver is discharged through the thaw chamber 16 check valve 101 and into the freezer There it warms the refrigerant and the outer surface of the freezer tubes allowing the ice to release on the inside of the tubes and drop down onto the rotating cutter for sizing After sizing the ice drops on the tines cutter disc and discharged through the ice discharge opening See Freeze Period and Harvest Period for more detailed description of machine Freeze Period The Tube Ice is frozen inside the stainless steel tubes of the freezer 2 by the direct application of refrigerant to the outside shell side of the tubes Ice is produced from constantly recirculating water down each tube As the ice thickness increases the freezer pressure decreases At a set pressure the freezer pressure switch 2PS energizes the relay which stops the water pump closes the A liquid feed solenoid valves 20A amp 20B turns out the two pilot lights refrigerant feed and freezing 4 2 P34F Service Manual 2 9 12 HOW YOUR TUBE ICE MACHINE WORKS Harvest Period About 20 30 seconds after the 1CR relay is energized the thaw gas valve 18 opens the H water flush solenoid valve 63 opens the compresso
47. washer 5 8 12A 2250B11300000 1 4 S S Sq Head Pipe Plug 2 12A 2475T00010000 Gasket 3 4 OD x 7 16 12A 2600R02000000 Key 3 8 x 5 167 3 4 S S 12A 2785501000000 12A 2900M07020000 Cotter Pin 3 16 x 1 1 2 S S 12A 2900M08010000 utter Support Washer 19T4001S0224 as S Lock washer 3 8 S S 12A 2250B10900000 as S S Nini Jojo C 19T4065R0100 12A 4080502000000 191409050300 19T4130C0100 19T4130C0200 19 4130 0300 19 41030 04 197413070400 12A 4138501000000 12B 2060801000000 12C 2615005000000 191400150163 191400150411 Splash Curtain 12A 4078C02000000 Din DID AD WIN 191450500 1972150 0200 See Pump Model 12A2222L11190000 12A222L1115000 12A 260080900000 12A 253250606000 12A 24505070000 12A 305050401000 12A 2785804000000 12A2210E01000000 12422156111000 124221511000 12A2215H6110000 12 221514113000 1242218 1112000 124 222681115000 12 224041309000 12A 2240812160000 1974130C0200 11 19 12 P34F Service Manual 9 13 11 19 12 SERVICING OPERATIONS Cutter Gear Reducer The cutter motor and gear reducer 54 Figure 9 74 drive the ring gear of the cutter assembly It is important that the teeth of the drive gear and the ring gear mesh properly both vertically and horizontally The drive gear and hub can be raised or lowered on the gear reducer shaft to obtain
48. water inlet connections are attached properly The water inlet shutoff valve 62 for the water tank should be open The water level in the water tank should be at a height where the make up float valve will be closed when the machine is idle and water is not running out of the overflow 9 2 See that the condenser cooling water is connected properly and the valves are opened for circulation 3 Hill the cooling tower sump and check the tower manufacturer s installation and operation instructions to make sure it is ready to run 4 Check condenser cooling water pump rotation 5 Check rotation of augers or ice handling equipment to make sure they are rotating in the proper direction 6 Check all tagged valves and make sure they are in their correct operational position opened closed or automatic 7 Seethat the electrical disconnect is closed and the proper power is supplied to the machine 8 See that the compressor oil temperature is 100 110 F and there is no liquid refrigerant in the crankcase The oil level should be 1 2 3 4 of the sight glass 9 Check the elapsed time indicator ET and make sure wire 22 and 27 are attached 10 Reconfirm Rotation Check for compressor cutter and water pump See Section 3 Refrigerant Charge Prior to shipping the machine is charged with the required amount of refrigerant and pumped down to the condenser receiver All valves tagged prior to shipping must be opened prior to starting the mach
49. 22 or 80 85 psig R404a in the freezer during harvest m 12 4200 1404 2 SOLENOID VALVE 12A4140S18 STRAINER LUI q FIGURE 9 9 Thaw Gas Solenoid Valve 11 19 12 9 24 P34F Service Manual SERVICING OPERATIONS 11 19 12 The Liquid Feed A1 and A2 Solenoid Valves 20A and 20B 20A solenoid is opened and closed during the freeze cycle by the float switch 10 in order to maintain the proper freezer refrigerant level The smaller A2 20B solenoid valve is a by pass valve that is opened continuously during the freeze cycle to assist the A1 solenoid during pulldown Both valves are closed when the machine is off and in harvest to prevent liquid flow from the receiver to the freezer Repair or replace as follows l With the receiver pressure higher than the freezer pressure close the hand stop valve 58 upstream in the liquid line between the receiver and liquid feed solenoid valve Manually open screw stem in and allow the liquid to flow to the freezer and clear this part of the line of liquid leaving only vapor Close the other hand stop valve 29 downstream This will isolate the solenoid val
50. 3 60 25 200 3 50 45 400 3 50 Tube Size In 4 s of an inch _ 1 S 11 6 1 T 1 agn 2 Model Designation for P Series Ice Machines 2 9 12 P34F Service Manual 2 3 RECEIPT OF YOUR TUBE ICE MACHINE Rated Capacity The Tube Ice machine is rated to produce a given amount of ice when operating under the proper conditions as specified in this manual You should be prepared to handle the ice produced as it is discharged from the machine and move it to your storage or bagging area promptly The following specifications are given to help you do just that Model P34F 1 5 Model P34F 1 25 Model P34F 1 Makeup Water Capacity Tons day Capacity Tons day Capacity Tons day Temp 2000 Ibs 24 hours 2000 Ibs 24 hrs 2000 Ibs 24 hours 55 F 13 C Ice lb harvest 17281bs 785 Kg 1414165 642 Kg 998165 453 Kg Shipping weight 25 250 Ibs 11 453 Kg 25 250 Ibs 11 453 Kg 25 250 Ibs 11 453 Kg Operating weight 27 000 Ibs 12 250 Kg 27 000 Ibs 12 250 Kg 27 000 Ibs 12 250 Kg Notes 1 Makeup water is average flow and includes 25 blowdown Peak flow rate is 15 GPM at 40 PSI minimum When water quality is good machine can be operated with 5 to 10 blowdown 2 Ratings are at 90 F ambient for ice machine 3 Capacity ratings are based on 85 F water entering condenser For entering water temperatures above 85 F deduct 4 in capacity for each 5 F 4 C
51. 6 3 3 14 P34F Service Manual INSTALLING YOUR TUBE ICE MACHINE IMPORTANT Be sure to follow the wiring schematic when incorporating overloads of conveyor fan or pump motor starters i e 5 MOL 6 MOL 7 MOL Also remove jumpers as instructed This is necessary to provide proper protection for the Tube Ice machine and its component parts IMPORTANT Installation Review A Checklist Make a visual check to be sure these steps have been taken BEFORE continuing CHECK PRIOR TO OPENING VALVES check all joints for leaks that may have developed during shipment NOTE the machine was shipped with a positive pressure of 20 25 PSIG which should be indicated on the suction and discharge gages CHECK All water supply and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK All field installed equipment augers conveyors cooling towers bin level controls etc for proper installation CHECK The applicable portion of the warranty registration start up report for proper completion CHECK Cutter gear reducer oil level oil should run out of side pipe plug when removed CHECK The water distributors at top of freezer to make sure they are all in position one seated
52. 9 2 Water tank drain valve make up water float Close repair or replace valve as needed The valve or flushing valve stuck or opened float valve should be adjusted low enough that water should not run out the tank overflow during the freeze cycle Thaw gas solenoid valve 18 leaking through Check the manual opening stem to make sure it during freeze is in the automatic position stem screwed in Check for leakage by sound temperature difference and frost during the freeze cycle Leakage should stop by closing the hand stop valve downstream of thaw gas valve Isolate and repair or replace the valve as needed Level control set to high Check liquid level control for proper operation and set point Replace defective part Compressor running unloaded If the compressor is running unloaded the motor amp draw will only be 6096 7096 of the normal amp draw of a loaded compressor Check the delay timer DT electrical circuit to make sure the UR SOL coil is not energized Refer to the compressor manual for normal oil pressure needed to load the compressor cylinders and any further procedures to check the mechanical function of the unloader mechanism 2 9 12 2 9 12 P34F Service Manual 8 5 TROUBLESHOOTING Symptom Freeze up due to ice failing to discharge Possible Cause Possible Remedy Extended freeze period Thaw time too short Insufficient heat for thawing due to low condensing pressure Insufficient
53. A 2222111190000 12A 2222111150000 12A 2600R08000000 12A 2600R09000000 12A 2240A11300000 12A 2250B11300000 2 PVC Ell 2 MPT x Insert 12A 2450E16000000 2 PVC Round Flange 12A 2532F06060000 2 FPT Valve 12A 4200G14010000 1 _ 12A 4108040009000 12A 2450807000000 12A 3050804010000 12A 4200406020000 12A 4170101000000 12A 2422W0010000 WC 90 Ell 7 8 ODC 12A 2417W0005000 3 4 Brass Service Valve 1 for P34A 12A 4205G0602000 3 4 MPT x 1 2 PVC Bushing 12A 2450B04000000 1 2 MPT x 1 4 PVC Bushing 12A 2450B05000000 3 4 MPT x 7 8 ODC Adapter 12A 2400W0023000 12A 4200H06010000 12A 4200 0100000 12A 4200HP0200000 Key 1 4 x 1 4 x 3 3 16 S S 12A 2785504000000 19T2010A05 12A 2020M02000000 19 2025 0106 191203580200 19T2160C0501 19T2163D0403 T B Ba WW bo Go Go Go 9 2 B C B 5 12A 2210801000000 12 2210 04000000 12A 2215G1110000 C C C C N ap Screw 5 8 11 x 1 1 2 S S 4 12A 2215L11130000 arriage Bolt 3 8 16x1 1 4 4 12A 2218H11120000 Mach Screw 3 8 16 x 2 Flat 8 12A 2226H11150000 Hex Nut 3 8 16 S S 12 12A 2240A13090000 ap Screw 3 8 16 x 1 S S 8 12A 2215H1110000 Slotted Nut 1 14 NF S S 12A 2240E12160000 ap Screw 3 8 16 x 1 12A 2215H6110000 vo Lock washer 5 16 S S 12A 2250B10800000 Lock
54. C70 cd t P 34F TUBE ICE MACHINE Service Manual 50 P34F Service Manual 1 1 INTRODUCTION 1 Introduction Tube Ice LLC A Brief History Of Our Company In 1938 Vogt built the first Tube Ice machine and revolutionized the ice making industry Our first sized ice machine quickly replaced the old can ice plants which required hard labor and large amounts of floor space for freezing cutting and crushing ice by hand Vogt Energy Saving Tube Ice Machines Are Cost Effective Today Vogt Tube Ice machines enjoy a well earned reputation as the most energy efficient dependable ice making equipment in the world Using as little as one half to one third the energy required by competitors ice makers Tube Ice machines produce the same amount of ice in restaurants sports arenas packing plants and wholesale operations around the globe at great savings In addition Tube Ice machines are renowned for their long life giving many customers more than 35 years of dependable service Ask someone who owns one Preview the skill in engineering and fabrication that we ve learned in over a century of experience is reflected in every Tube Ice machine Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s economic and reliable operation has been proven over and over again in a network of varied types of i
55. CT FROM CRANE TO MACHINE AS ILLUSTRATED POSITION B RAISE MACHINE SLOWLY UNTIL BACK EDGE OF MACHINE CLEARS GROUND iut LIFTING MACHINE UPRIGHT POSITION C USING FOUR 4 POINT HOOKUP CONNECT USING TWO 2 POINT HOOKUP CONNECT FROM CRANE TO MACHINE AS ILLUSTRATED FROM CRANE 2 TO MACHINE AS ILLUSTRATED POSITION D RAISE MACHINE AND MOVE IT TO OPERATING SITE RAISE MACHINE TO LEVEL UPRIGHT POSITION THEN LOWER MACHINE TO GROUND LOWER MACHINE TO FINAL POSITION FIGURE 3 3 Lifting Procedure for P34F 3 6 P34F Service Manual INSTALLING YOUR TUBE ICE MACHINE Piping and Drain Connections See Figure 1 1 to 1 4 for connection locations CAUTION Exterior shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 40 psig The maximum allowable pressure is 100 psig CAUTION Compressor Compressor Condenser Water Water Make up Flushing Cooling Cooling Water Tank Tank Model Water In Water In In water Out In and Out Drain Overflow 3 4 FPT TABLE 3 1 Water Supply and Drain Connections Make Up Water In The water required for ice making must be potable water safe for human consumption and should be of the highest quality available The best way to determine water quality is to have a complete water quality analysis by a qualified laboratory It is advisable to install a particle filter in the mak
56. Feed Solenoid Valve Filter Drier Access Valve Condenser Water Inlet W C Machines Freezer Access Valve 2 Condenser Water Outlet W C Machines Compressor Suction Access Valve Refrigerant Charging Valve 78 Compressor Discharge Access Valve Liquid Line Stop Valve Discharge Pressure Gage Stop Valve Gage Glass Stop Valve 90 Thawing Gas Stop Valve 3 Compressor Suction Service Valve Receiver Liquid Return Stop Valve Compressor Discharge Service Valve Equalizer Line Stop Valve Oil Charging Drain Valve Compressor Oil Pressure Safety Control OPS Water Tank Drain Valve 2 FPT Check Valve Piping Nomenclature 9 a EUR EA EC ET 4 3 P34F Service Manual HOW YOUR TUBE ICE MACHINE WORKS i 471 HSPTH a LYINI d 3XVW 1310 FATWA 53 134 1 e3WNOISn2 AG SVD 9NMVHI 2 06 LFUNO 3ATVA AIJA 29 e GINOIT Z 3 be 6 6 zi NIVMO M31 VM Z 9 H YILYM PE 29 26 H og 5 2 GATA o ya x sv FIDA I9 1 CHINE CSW p T a ze 04 Lig 101 1 06 Om 25 sev im Je f 7 e PUR
57. GURE 3 1B P34F Space Diagram RearView 2 9 12 P34F Service Manual 3 4 INSTALLING YOUR TUBE ICE MACHINE XINOLSNI M3ddOH Y e T Le Y 6 I AS REQ D n Sv 117139 1708 HOHONV 2 0 5 3 3315 4 3dld 2 1 Z 1108 MOHONV 8 G sNOLVv10938 ONIGTING VHSO 1v343Q034 ONY W901 11 NI NOLLVONNOS SHL 0108 OL 1 3HL 40 ALNNIGISNOdS3SY SHL SI LI SO33N 114 1538 01 YSWOLSNOD JHL Q3NIAS3130 38 AINOHS ONIOIAYSS 3043 11 QNNOYV 9 3HL 40 3ZIS WNLOV jHL 391 3901 8 431539905 345 GsIYINOAY WNNWININ JHL SI SIHL NO NMOHS NOILVONNOS JHL 40 325 SHL TALON YSAWOLSNSD S9YVHOSIO 321 9 6 6 40 FIGURE 3 2 P34F Foundation Layout 2 9 12 2 9 12 P34F Service Manual 3 5 INSTALLING YOUR TUBE ICE MACHINE POSITION A LIFTING MACHINE FROM TRUCK USING THREE 3 POINT HOOKUP CONNECT POSITION A LIFTING MACHINE UPRIGHT CRANE TO MACHINE AS ILLUSTRATED USING TWO 2 POINT HOOKUP CONNE
58. High Level 2 70 Control Level 2 20 40 Low Level Not Used Not Used FIGURE 9 1 Capacitive Level Control 11 19 12 P34F Service Manual 11 19 12 9 3 SERVICING OPERATIONS See Section 6 of this manual for control unit electrical wiring diagram Before connecting electrical power check the voltage on the control unit nameplate and the power supply at the wire leads to be sure that they are the same Supply voltage must be within 10 or 15 of listed voltage Connect power supply leads to the quick disconnect plug Terminals 1 amp 2 and secure into the appropriate marked socket The probe is the device that actually measures the liquid level It accomplishes this by sending a small specialized signal out into the refrigerant liquid and vapor This signal returns via the level column back to electronics inside probe housing The strength of the returning signal is measured to determine level This information is continuously sent to the control unit through the control cable When installing the probe match its serial number with the control unit Remove the probe from the packing crate being careful not to bend or whip the probe Use nonelectrically isolating pipe thread sealant do not use Teflon tape on the 34 MPT fitting on the probe and insert in top of the level column Tighten probe on hex do not grip probe housing flats or electrical box Pressure test for leaks Probes are supplied from the factory wi
59. PROBE The following procedure is only required if probe integrity is questioned With the probe wire removed from its socket check the insulating resistance of the Teflon enclosed probe rod using a 500V Megger Connect the positive side to the probe wire the negative side to the probe housing The result should be over 1000 Mega Ohms halocarbon probes should be over 50 Mega Ohms If not contact the factory TABLE 9 1 Trouble shooting Guide for level controller 9 6 P34F Service Manual SERVICING OPERATIONS 11 19 12 Hand Expansion Valve The hand expansion valve is located directly after the 20A solenoid valve This valve should be set at a point where the float switch is open for a length of time approximately equal to the time it is closed Freezer Pressure Switch The freezing time period for producing ice of a desired thickness is controlled by the freezer pressure switch 2PS Figure 9 2 located inside the control panel The original switch was set at the factory to produce ice of recommended thickness Look at the Certificate of Test which was provided with the machine for a sample set of pressure readings with corresponding time periods and water temperatures Also see TABLE 11 5A Operating Vitals for typical settings When making adjustments allow two ice discharging cycles between adjustments Switch adjustment is as follows See Figure 9 2 Turn the low signal adjustment nut CCW until low sign
60. Program form 7 2 Make Up Water Float Valve 12 1 6 Make Up Water Flow Rate 2 3 Make Up Water In 3 6 Make Up Water Temperature 2 3 Make Up Water Usage 11 4 Manual Harvest Push Button 6 3 Cooling Tower Recommendations 3 8 Metric Conversion 11 8 Model Designation Chart 2 2 Model P34F Drawings front side view 1 4 right side view 1 5 back side view 1 6 left side view 1 7 N Non Condensable Gases 9 21 Normal Operating Vitals 11 5 Oil Pressure Switch 9 7 Oil Return Line Stop Valve 70 1 6 1 11 06 P24F Service Manual Operating Features 4 1 Operating TipS 5 4 Operating Vi
61. SE ja 431002 10 5 T3NVd 9 79 1171 n u rA 5 viz 92 a SY e lt bs MEE uz S4 le z 5 BE 8 3 lt gt x 797 anon zl ES 5188 Z E lt ls 1 9 S 802 1 1 7 lez ia S 5 x 5 8 z 79 Ec E m m 5 5 voz E e Kt mee 52 X m z 1vo34 al E ese YLVI pa 4 E S 59 4 TIO e o o 69 SS 439NVH2X3 LV3H E 16 19 efe TNI l M3SN30NOO G1 ZG ug 1 697 zg LIINI 431 YISNIANOD 137100 FIGURE 4 1 for P34F Schemat iping P 2 9 12 P34F Service Manual 5 1 START UP amp OPERATION 5 Start Up amp Operation Refrigeration System Review The refrigeration system uses R 22 or R 404a refrigerant Following the piping schematic Figure 4 1 you will see that during the machine s freeze cycle the compressor discharge gas goes through the oil separator 14 to remove any oil present in the discharge gas and return the oil to the suction accumulator 88 From the oil separator the discharge gas continues through a heat coil in the lower part of the condenser receiver 15 It is then discharged into the condenser and condensed into a liquid by the removal of heat by water passing
62. UBE ICE MACHINE c5 zZz ZS ZS COOLING TOWER A WATER gt gt COOLED CONDENSER CHECK VALVE T INDOOR SUMP FIGURE 3 5 1 PUMP 2 WAY VALVE Poor Freeze Protection Because low flow rate high freeze chance WWW MD cum aA COOLING TOWER AAAA c WATER gt m gt COOLED F4 CONDENSER Same flow rate to cooling tower Only enough water to maintain head a CHECK VALVE INDOOR SUMP 1 PUMP 3 WAY VALVE Better Freeze Protection 2 9 12 P34F Service Manual P34F Service Manual 3 11 INSTALLING YOUR TUBE ICE MACHINE ee ann COOLING TOWER WATER COOLED CONDENSER CHECK VALVE INDOOR SUM TuS Outdoor pump is off until P d indoor sump needs cooling FIGURE 3 7 2 PUMP 2 WAY VALVE Best Freeze Protection Wiring and Electrical Connections WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work with the Tube Ice machine WARNING A fused disconnect must be provided near the Tube Ice machine The control panel and compressor motor starter are attached to the structurals on the front of the Tube Ice machine see FIGURE 3 8 Incoming 3 phase power will be connected at the compressor
63. able gas effects are 1 Higher condensing pressure than desired 2 Greater electrical power consumption 3 Reduced refrigeration capacity 4 Longer than normal compressor running time Slow ice release and long thaw cycle Air collects mostly in high pressure condensers receivers and other high pressure components It collects mostly in the coolest lowest velocity area of these components Water Contamination of R 22 R404a Refrigerant Water in the refrigerant can cause a slow ice discharge erratic operation and dilution of the oil This can result in freeze up refrigerant carry over and compressor failure This condition should not go uncorrected and the water should be immediately removed There are two options for water removal from the refrigeration system The first and best alternative is removal of all refrigerant and oil from the system followed by vacuuming and recharging according to the procedure outlined in Section 5 The second is reclaiming and reconditioning the refrigerant and oil Circulating Water Pump Motor The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water level above the impe housing The pump is equipped with a mechanical seal that is self adjusting and requires no lubrication However the pump should not be operated without any water in the water tank The pump manufacturer recommends that a mechanical seal be kept as a spare
64. aight edge long enough to reach across the top flange of the water tank 30 for P24 and 40 for P34 the top of the cutter rim and blade should be 1 8 1 16 below the top of the water tank flange Keep one end of the straight edge at the same point and swing the other end across the tank at various points to check the clearance Also rotate the cutter to check all points If adjustment is necessary loosen the four side bolts and raise or lower each arm as needed Tighten the bolts securely to approximately 90 ft Ib Water Tank Installation 1 Place the 3 16 thick gum rubber gasket on the top of the tank flange It can be held in place with narrow strips of tape through the bolt holes 2 Push the water tank in and under the freezer aligning the bolt holes and installing the mounting bolts around the flange and tightening the nuts securely 3 Reconnect the discharge chute or hopper to the ice discharge opening 4 Mount the water pump P34 only and attach the circulating water tubing and overflow tubing 5 Reconnect all water piping such as drain overflow and make up water lines Turn water on and check for leaks 6 Fill the water tank with water and make sure the drain valve is closed When ready turn the power On to the machine but don t operate the compressor until the oil is warm and there is no liquid refrigerant in the crankcase 11 19 12 P34F Service Manual 9 19 11 19 12 SERVICING OPERATIONS Cut
65. al setting indicator is fully down Turn the high signal adjustment nut until high signal setting indicator is slightly beyond the actuation setting of 55 psig for R 22 70 psig for R 404A 2 Starting with the pressure above the actuation pressure reduce the pressure to desired actuation pressure of 55 psig for R 22 70 psig for R 404A contact opens 3 Advance the low signal adjusting nut until the switch actuates and contact closes High Signal Adjusting nut Open Contacts set to 55 psig R 22 70 psig R 404A CW Raises pressure setting Low Signal Adjusting Nut Set for desired ice thickness CW Raises pressure setting to make ice thinner Note When installing a new control be sure to remove paper from transducer surfaces so there will be nothing between the switch and transducer FIGURE 9 2 ASCO Freezer Pressure Switch 2PS It is preferable that the freezing cycle be such that a small diameter hole remain in the center of the ice cylinder 1 16 diameter for 7 8 diameter ice 1 8 diameter for 1 1 8 diameter ice 1 4 diameter for 1 3 8 diameter ice This insures that the freezing cycle is not extended unnecessarily and eliminates a possible opaque core in the center of the ice as well as a loss of production P34F Service Manual 11 19 12 9 7 SERVICING OPERATIONS High Low Pressure Switch The high low pressure switch 1PS Figure 9 3 is a two pole dual function switch mounted to the frame ne
66. an be disassembled and cleaned then reassembled Cleaning Ice Making Section Refer to Section 7 Maintenance for instructions for cleaning the circulating water tubes water distributors and water tank Float valve make up water The make up water float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank during the freezing period so that there will be a quantity of blowdown only during the thaw mode The water level during the freeze cycle should always be below the overflow piping to prevent excessive waste of cold water resulting in loss of ice capacity If it should become necessary to clean the float valve close the stop valve in the make up water line to the machine and remove the float valve After the valve has been cleaned and reinstalled check to ascertain if the proper water level is being maintained After the machine is stopped and the water in the tank seeks its normal level there should be no water flow through the float valve or out the overflow It is advisable to install a large area strainer in the water supply line to protect the float valve from dirt or solids in the water that would necessitate frequent cleaning A strainer of 40 mesh screen is usually satisfactory Capacitive Level Control The control unit houses the brains of the Vari Level its digital readout knobs for adjusting set points and differentials
67. apacity shown is the average for model Individual machines may vary up to 5 above or below depending on field conditions TABLE 2 1 P34F Specifications Storage prior to installation or start up The machine must not be stored or installed in an area that is subject to reach temperatures at or above 110 F 43 3 C Temperatures above this may cause the relief valves to open and result in the loss of refrigerant 2 4 P34F Service Manual RECEIPT OF YOUR TUBE ICE MACHINE This page is blank 11 19 12 2 9 12 P34F Service Manual 3 1 INSTALLING YOUR TUBE ICE MACHINE 3 Installing Your Tube Ice Machine Your machine will be shipped to you as one package You will need to arrange for the handling of the package as soon as it arrives see the machine specifications Table 2 1 for shipping and operating weight Before you remove the unit from the truck be certain that any sign of damage however slight is noted on the carrier s papers Note See Lifting Procedure drawing furnished with this manual Figure 3 3 Machine Room The machine must be located inside a suitable building and must not be subjected to ambient temperatures below 50 F 10 C or above 110 F 43 3 C Heat radiation from other sources sunlight furnaces condenser etc and unusual air current may affect the operation of the machine and should be avoided The electrical components of the Tube Ice machine are rated IEC Therefore the machine should not be located
68. ar the compressor It protects the machine from possible damage due to abnormal pressure during operation CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming normal operation CAUTION The LOW pressure cut in should be set at 40 psig R 22 R 404a and the cut out set at 20 psig R 22 1 R 404a After tripping at the cut out setting the switch will reset automatically when the pressure rises to the cut in setting Loss of water pressure will cause frequent cut out also check freezer pressure switch operation The HIGH pressure cut out should be set at 300 psig R 22 R 404a After tripping the switch must be reset manually Lack of condenser water pressure or fouled condenser is generally the cause of a high pressure trip Note Do not rely on the switch calibration for accuracy For accurate adjustment check settings with a test gage Range Adjusting Screw Set at 40 PSIG R 22 amp R 404A CW Raises Setting Differential Adjusting Screw Set at 20 PSIG SA CW Raises Setting Vogt Part 1242117002 Part 12A21 Vogt Part 1242117002 Reset Button High Pressure Adjustment Set at 300 PSIG R 22 amp R 404A CW Raises Setting Differential Factory Set not adjustable Low Pressure ee Connection High Pressure Connection FIGURE 9 3 High Low Pressure Switch 1PS Compressor Crankcase Heater When elect
69. ault TABLE 10 1 Phase Protector Troubleshooting P34F Service Manual Check control input Parameters are locked out See Locking Out Setup Menu Line voltage too low and or phase missing Control input is very sensitive Insure control voltage 2 volts for off condition Check normal line voltage using READ feature Re adjust voltage range as required Control Mode setting is OFF Press setup to get to Control Mode then use arrow keys to set mode to EXTERNAL Some sound coming from the unit is normal and may vary with input voltage P34FService Manual 11 1 TABLES amp CHARTS 11 Tables amp Charts 2 9 12 11 2 P34F Service Manual TABLES amp CHARTS P34F SPECIFICATIONS 400 460 Volt 3 Phase 50 60Hz Tube Size inches cm 11 4 3 17 112 380 Nominal Nominal Capacity Nominal Capacity 55 5 555 3 512 57218 8 52 8 58609 9 ons day Overall Dimensions LxWxH Feet meters 3 0x2 4x4 8 3 0x2 4x4 8 3 0x2 4x4 8 Total FLA Water Cooled 3a O Maximum Fuse ______ w 49 k Minimum Ampacity 238 Water Requirements o _ NAT T um RU mm DENS UT CE NA ondene vater oote ss dim LxWxH ft meters 9 9x6 5x9 7 9 9 6 5 9 7 9 9 6 5 9 7 3 0 1 9 2 9 3 0 1 9 2 9 3 0x1 9x2 9
70. cement The cutter blades are designed to give many years of satisfactory service and rarely need to be replaced If they become damaged they can be replaced by the following procedure l Disconnect and lock out all power and remove the water tank assembly so the cutter assembly is accessible See water tank removal Remove the 3 8 cap screws holding the blades to the cutter plate and remove the blades 3 Set the new blades in place and install the cap screws and washers but do not tighten Refer to FIGURE 9 8 adjust each blade to dimension A and lock the blade in position by tightening the 3 8 cap screws Note Use a 90 square as illustrated to obtain the proper blade clearance required for satisfactory ice discharge Dimension A is critical and should be measured at both ends of the blade Note 3 8 x 1 cap screw must be flush with cutter blade Make sure all bolts and nuts are tightened securely then reinstall the tank assembly 9 20 P34F Service Manual SERVICING OPERATIONS CHECK DIMENSION A AT BOTH ENDS OF BLADE PROJECT UP 90 OM EDGE OF THE ADAPTER PLATE CUTTER BLADE ADAPTER PLATE LOCK WASHER i 3 8 X 1 CAP SCREW TUBE ICE SIZE DIA CUTTER CUTTER PLATE 144 1 178 1 8 1 2 1 378 3 8 Figure 9 8 Cutter Blade and Adapter Plate Adjustment Cutter Adapter Plate Installation 1 Disconnect and lock out all power to the
71. corded so the full width of the gear teeth will engage when assembled and tightened 10 Tighten the cap screws three or four progressively and uniformly around the hub and recheck the location measurement If it is not correct loosen the cap screws hub and gear assembly and make correction Then retighten the cap screws 11 Install the reducer and mounting plate assembly on the water tank bracket and fasten in place with the side and top cap screws 12 Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount of backlash between the gear teeth NOTE There should be only a slight amount of backlash more specifically tooth tip clearance Too much clearance will cause premature wear and possible tooth damage When the cutter runs under a no load condition it should have a smooth uniform sound For lubrication see Section 7 Maintenance 13 If the tooth tip clearance needs adjusting loosen the four hex nuts holding the reducer to the mounting plate and move the reducer as required for proper tooth engagement Tighten the hex nuts securely and recheck backlash 9 14 P34F Service Manual SERVICING OPERATIONS Gear Reducer Replacement 1 Disconnect and lock out all power to the machine 2 Disconnect electrical wires and conduit from the motor 3 Remove the top and side bolts holding the mounting plate to the support bracket and lift the plate and gear reducer assembly from the tank brack
72. ctors 11 8 Cooling Tower 3 7 12 1 INDEX Cooling Tower 7 5 Cooling Tower Maintenance Schedule 7 5 Cooling Tower Piping Diagram Crushed Ice Production Current Unbalance Cutter Adapter Plate Installation Adjustment 9 19 Cutter Assembly 9 10 Parts list Cutter Assembly Removal and Installation 9 14 Cutter Blade Replacement 9 18 Adjustment Cutter Gear Reducer Drive gear replacement Gear reducer replacement Cutter Height Adjustment Cutter Ring Gear Replacement Cutter Parts Weights Cutter Shaft amp Bearing Removal Installation 9 15 D Description Of Machine 2 1 Discharge Stop Valve 35 1 7 Discharge Line Stop Valve 55 Drive Gear Replacement 9 12 E Electrical Schematic
73. defective Check solenoid valves 420A and 20B to make sure they are not leaking through Repair or replace if defective Refrigerant contaminated with water Test refrigerant or oil for water contamination Completely pump the freezer out pump down and pull vacuum on freezer Refer to Service Section 9 Removing Water 2 9 12 P34F Service Manual 11 19 12 9 1 SERVICING OPERATIONS 9 Servicing Operations Automatic Blowdown harvest cycle A feature of this machine is a solenoid activated flushing valve 63 which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water tank This flushing during the harvest cycle helps to remove salts or solids accumulated in the water as a result of the freezing action It also helps melt ice chips that fall into the water tank during harvest The flushing valve is opened energized during each thaw cycle when the water pump stops and the water in the freezer tubes returns to the water tank If water quality is superior the blowdown can be reduced by installing a smaller reducer bushing in the outlet elbow The flushing action carries accumulated salts solids and ice chips fines out through the water tank overflow pipe This overflow should be kept open at all times to allow the water to drain freely and keep the water level below the cutter disc and ice discharge opening If the flushing solenoid valve leaks through during the freeze cycle it c
74. drained new oil of the required specifications can be pumped into the crankcase to the proper level 4 Turn the power on and allow the crankcase heater to warm the oil prior to start up Be sure to confirm sufficient oil pressure at start up 5 Restore power to the crankcase heater allowing time to warm the oil Be sure to confirm sufficient oil pressure at start up Compressor Inspection 1 Close the compressor suction valve and allow the machine to stop by low pressure cut out 2 Close the compressor discharge valve and oil return stop valve Disconnect and lock out all power to the machine 3 Drain the oil through the oil drain valve located at the base of the compressor and reclaim the compressor until all pressure is relieved 4 Remove the compressor side cover handhold cover being careful to protect the gasket and surface from damage 5 Inspect the crankcase inside for foreign material such as sludge metal flakes burrs or anything that may look unusual indicating excessive wear or damage 6 Remove all remaining oil and wipe out the compressor with a lint free cloth The extent of internal inspection should be dependent on the degree of evidence of wear 7 Inspect and clean the oil strainer Cleaning can be accomplished with light oil diesel fuel or mineral spirits Make sure excess cleaning agents are removed prior to closing the crankcase 8 Clean the oil sight glass and install the side cover plate using a ne
75. e Refrigerant feed light is not illuminated open the charging valve 28 and refrigerant will flow from the cylinder to the freezer 4 Close the cylinder valve immediately when the refrigerant feed light comes on and reopen it when the light goes out Repeat until properly charged As the machine is being charged continually observe the following operating characteristics a Discharge pressure 200 psi to 210 psi maximum R22 240 psi to 250 psi maximum R404a b Compressor oil pressure 17 28 psi above suction c Liquid level in receiver marked on gage glass guard d Compressor oil level approximately 1 2 glass CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant CAUTION 11 19 12 P34F Service Manual 5 5 START UP amp OPERATION Operating Tips e Make sure the machine is left running in the Auto position This will assure a complete shutdown if a safety or overload is tripped e To initiate a harvest cycle simply push the Manual Harvest push button 3PB e To interrupt the harve
76. e below Cleaning Procedure Perform pump down procedure to avoid refrigerant migration Shut off make up water supply Drain the water tank flushing out any loose sediment Close the drain valve and fill the tank with warm water Warm water promotes faster cleaning Cover the ice discharge opening to prevent contaminating any stored ice by splashing water out Add sufficient ice machine cleaner to the water tank P34 tank 4 7 gallons water per inch of water height in tank 13 60 6 gallons Mix cleaning solution according to manufacturer s recommendations 7 Remove top water box cover inspect distributors remove any hard particles from orifices and make sure all distributors are in place Replace cover 8 Turn Hand Auto switch to Hand position and circulate the cleaning solution until deposits are dissolved or the solution is neutralized After draining the pump may have to be stopped and restarted to dispel air 9 Turn switch to Auto position to stop the pump Drain and flush the water tank Repeat cleaning as necessary 10 After cleaning fill the tank with fresh water start the pump again and circulate for 15 minutes 11 Stop the pump drain and flush the tank and again refill with fresh water 12 Remove the cover from the ice discharge opening and clean any area that may have been splashed with solution during cleaning 13 Make sure the make up water float valve is adjusted properly and the drain valve
77. e cutter lower it down onto the shaft allowing the ring gear to mesh with the drive Lift the cutter straight up and off the shaft taking care to catch the shaft key as it is removed gear Rotate the cutter aligning the shaft and hub key way and inserting the key to its full depth 6 Install the gasket retainer and socket head cap screw and tighten to approx 15 ft Ib torque 7 Check and adjust the cutter height per Cutter Height Adjustment instructions 9 16 P34F Service Manual SERVICING OPERATIONS Bearing Bracket and Cutter Disc Removal 1 Remove the cutter assembly per instructions 2 Match mark the bearing bracket support arms with the water tank for reassembly reference 3 Remove the splash shield and ice deflector plate from the ice discharge opening 4 Support the bearing bracket to keep it from falling in the tank Loosen and remove the four cap screws and lock washers from the ends of the bearing bracket support arms 5 Lift the bracket and cutter disc from the tank Be sure the support arms are match marked for reassembly You may have to gently drive the support arms up or down to release them from the tank walls 6 With the bracket and disc assembly turned upside down remove the cotter pin from the shaft 7 Loosen and remove the slotted hex nut spring washer and spacer 8 Lift the cutter disc from the keyed shaft being careful not to loose the shaft key The cutter shaft and bearings are sea
78. e up and flushing water lines to trap dirt sand rust or other solid particles prior to entering the water tank and contaminating the ice Be sure to size the filter large enough to meet the water demands of 15 GPM peak flow allowing for a restriction through the filter as it traps these particles The inlet water pressure should be a minimum of 40 psi Refer to TABLE 3 1 for line size and TABLE 2 1 for average flow rate at various water temperatures Flushing Water In Flushing water blowdown is necessary to melt ice fines and flush dissolved solids from the water tank during the thawing harvest cycle This function is important and helps to maintain good ice quality If water quality is superior installing a smaller orifice in the flushing outlet elbow can reduce this blowdown Make sure there is enough flushing water to prevent the accumulation of excessive ice fines in the tank If make up and flushing water are from the same source a common line to the machine can connect them Water Tank Drain This valve and connection located at the bottom of the water tank is for the purpose of flushing and draining the water tank of impurities foreign material and cleaning chemicals used during servicing It should be piped to an open drain or sump for visible discharge It can be tied in with the overflow line but no others Water Tank Overflow A 3 FPT connection on the side of the water tank is provided to carry away overflow water durin
79. ed 2 Strainer The pan or sump strainer is located in the bottom of the sump at the suction connection to the pump The strainer should be inspected monthly and kept clean Do not operate the unit without the strainer in place 3 Make up water float valve This valve should be checked monthly for proper operation and adjustment It should be adjusted to maintain a water level below the overflow and high enough to prevent the pump from cavitating when the system is in operation 4 Spray nozzles The spray nozzles should be checked monthly to make sure none are restricted and the spray pattern is complete and even 5 Pump motor and fan motor The motors should be checked and or lubricated every six months according to the motor manufacturer s recommendations 6 Fan bearings The fan bearings should be lubricated every six months Make sure the proper grade of grease is used normally conforms to NLCI Grade 2 It is best to use a hand grease gun 7 Fan belts The fan belt tension should be checked weekly for the first two weeks of operation then monthly during continuous use The best tension for a V belt is the lowest tension at which the belt will not slip under its full load Never use dressing on V belts Keep belts and grooves clean and free of oil grease and foreign material Clean with non flammable non toxic degreasing agent or commercial detergent and water CAUTION Follow all lock out and tag out procedures before ser
80. ee Freeze Cycle 11 19 12 5 4 P34F Service Manual START UP amp OPERATION As the machine continues its freezing cycle the liquid refrigerant will feed into the freezer until the level float switch 10 is satisfied The float switch will open and close the liquid line solenoid valve 20 to maintain that level of refrigerant in the freezer during the freeze cycle When the suction pressure pulls down to the setting of the freezer pressure switch 2PS the switch will close and initiate the harvest cycle See Harvest Period Be sure to observe several complete cycles of ice production to confirm the satisfactory operation of the machine IMPORTANT Complete the remaining part of the Warranty Registration Start Up Report and return it to Tube Ice LLC IMPORTANT Check the refrigerant level at the receiver liquid gage glass to make sure it is near the operating level mark Adding Refrigerant Add refrigerant while the machine is running by the following procedure 1 With a cylinder of refrigerant laying on its side cylinder valve outlet pointing up and bottom end raised two inches higher than the valve end connect an approved for R 22 charging hose between the freezer charging valve 28 and the cylinder valve 2 Purge all air from the charging hose and open the cylinder valve gradually to check for possible leaks around the packing nut or hose fittings Then open the cylinder valve fully 3 While th
81. essor 3 The suction gas is then compressed and discharged once again completing the cycle As ice continues to form in the freezer tubes the suction pressure steadily decreases until the freezer pressure switch not shown is satisfied and the contact closes initiating the thaw harvest cycle Note Freezing time will vary depending on make up water temperature and thickness of ice produced During the harvest period the D thawing gas valve 18 opens and the compressor unloads allowing the warm high pressure gas from the receiver to enter the freezer As the tubes warm up to slightly above freezing the ice inside the tubes releases and falls down onto the rotating cutter in the water tank for sizing and discharging Harvesting requires about three minutes but can vary depending on ice thickness suction pressure and discharge pressure thawing gas temperature IMPORTANT It is a good idea and will be profitable for you to observe and become familiar with the proper operating characteristics of your Tube Ice machine It will help you to recognize and correct minor irregularities as they occur in order to help prevent major problems ounce of prevention is worth a pound of cure IMPORTANT 11 19 12 5 2 P34F Service Manual START UP amp OPERATION Start up Checklist Be sure to complete and return the Warranty Registration Start up Report located in the front of the manual 1 See that the
82. et 4 Inspect the drive gear teeth for proper vertical alignment and wear pattern If the wear pattern indicates less than a full width of tooth engagement measure the distance so correction can be made at the time of reassembly 5 Measure and record either the distance of the drive gear from the mounting plate or the split hub from the shaft end for future reference when reassembling 6 Remove the three or four cap screws from the split taper bushing 7 Usetwo of the cap screws in the threaded holes of the bushing as jacking screws for pushing the drive gear from the hub 8 Drive a wedge in the split of the hub bushing and slide both the hub and gear from the shaft 9 Remove the four hex nuts and lock washers from the carriage bolts around the reducer base and mounting plate and separate the plate and reducer 10 Install the replacement gear reducer and motor onto the mounting plate using the carriage bolts lock washers and hex nuts Tighten the nuts snug only for later adjustment 11 Clean the split hub and drive gear insert the hub into the gear making sure the tapers of the two match and slide the hub and gear onto the shaft 12 Position the hub on the shaft note measurements previously taken so the full width of the gear teeth will engage when assembled and tightened 13 Tighten the cap screws three or four progressively and uniformly around the hub checking the measurements and adjusting as necessary 14 I
83. evel is indicated by the pipe plug in the side of the gear housing The oil should run out of the hole when the plug is taken out If low add oil through one of the top plugged holes A high grade lubricant such as Mobil 600W or SAE 140 gear oil should be used The oil should be changed annually Drain the oil and flush the gear case with mineral spirits Drain the mineral spirits completely and refill with the proper oil Note If a USDA high food grade lubricant is desired use Chevron FM Lubricating Oil 460X CAUTION Follow all lock out and tag out procedures before servicing any electrical equipment CAUTION V Belt Maintenance Belts should be kept clean free of oil and protected from sunlight as much as possible To clean belts wipe with a dry cloth The safest way to remove dirt and grime is to wash the belt with soap and water and rinse well BELT DRESSING SHOULD NEVER BE USED ON A V BELT DRIVE The tension on a5 rib banded V belt can be checked as follows 1 Apply 50 75 pounds of deflection force uniformly across the belt midway between the pulley centers Lay a straight edge across the sheaves to measure the deflection The deflection should be 5 8 to 3 4 2 When installing a new belt move the sheaves together to allow the belt to slide across the sheaves Rotate the belt and sheaves to obtain proper seating Remove the slack from the belt and measure the outside circumference to the nearest 1 4 Multiply th
84. f necessary Restriction strainer oil filter pick up tube or oil replace filter Symptom Compressor loosing oil excessively Possible Cause Possible Remedy Non effective oil separator or float The oil separator will normally return a good portion of oil leaving the compressor if it is working properly Check the oil float and return line to see it is not restricted Liquid refrigerant in crankcase Check liquid feed to make sure it is not overfeeding and that the solenoid valves 420A and 20B are not leaking through when the machine is stopped seized or broken replace defective parts A few drops per minute is okay If refrigerant is leaking replace the seal 2 9 12 2 9 12 P34F Service Manual Symptom Machine short cycles Possible Cause Possible Remedy Freezer pressure switch 2 5 set too low or Adjust switch or replace if defective See defective FIGURE 9 2 Clogged water distributors sid water distributors Lack of water for making ice Lack of sufficient liquid refrigerant feed Water pump rotation incorrect or pump defective Symptom Shut down by oil pressure switch Possible Cause Possible Remedy Switch adjusted too high or defective 8 11 TROUBLESHOOTING See Freeze up due to extended freezer period and OT RCM due to ice failing to discharge Clean water distributors water distributors Check water tank for sufficient water level Checks for restriction in water line de
85. fective float valve open drain valve excessive ice chips or low water pressure and correct Check liquid level controller solenoid valves and coils 420A and 20B in liquid line filter drier and refrigerant level in receiver Check pump motor rotation Check for leaking pump seal or defective motor and repair or replace as needed Check switch adjustment and cutout pressure activation against an accurate gage Replace switch if defective See Figure 9 5 Oil pressure low See Compressor oil pressure low Low oil level Add oil Defective thawing timer causing long harvest Replace defective timer cycle and oil dilution Symptom High compressor discharge temperature Possible Cause Possible Remedy High head pressure Defective suction or discharge valves Restriction in the discharge gas line Internal relief valve leaking Check gage accuracy and High discharge pressure Feel the compressor heads for hot spots or one head running hot Replace worn or leaking valves Check all hand and check valves to make sure they are fully opened and not stuck Repair or replace as needed Check the compressor manual to see if your compressor is so equipped Replace accordingly 8 12 P34F Service Manual TROUBLESHOOTING Symptom Suction line frosting to compressor Possible Cause Possible Remedy Liquid refrigerant overfeed Check liquid level controller to make sure it is functioning properly Replace if
86. firmly in each tube with a vent tube in each distributor CAUTION The crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compressor CAUTION 2 9 12 2 9 12 P34F Service Manual 4 1 HOW YOUR TUBE ICE MACHINE WORKS 4 How Your Tube Ice Machine Works Operating Features Your package Tube Ice machine is an efficient ice producing plant If installed and maintained properly it will give many years of operation with a minimum amount of repairs Refer to piping schematic FIGURE 4 1 to identify component parts while following the information and instructions in this manual The machine is manually started and stopped by the START and STOP push buttons The machine will automatically stop by safeties such as compressor cutter and pump overloads as well as other auxiliary motor overloads It will also stop automatically by high head pressure low suction pressure or low compressor oil pressure The circulating water pump can be operated independently for cleaning the freezer tubes and water tank by putting the HAND AUTO selector switch in the HAND position The machine can be manually forced into a harvest cycle with the manual harvest push button Principle of Operation The freezer 2 is a shell and tube type vessel During the freezing period cycle water is constantly recirculated through the vertical tubes of the freezer by a
87. frigerant in the crankcase before restarting the machine When ready to restart the machine depress the Start button As usual initiate a harvest cycle if there is ice remaining in the freezer Check Amp draw through the breaker for excessive load or unbalance Thawing Timer The thawing timer 2TR Figure 9 6 governs the ice thawing period It is located inside the control panel FIGURE 6 1 It is started by action of the freezer pressure switch 2PS which energizes the ICR relay This timer is set prior to shipment for approximately a three minute period To replace the timer simply pull the timer from its base and plug in another set to 0 to12 and Min and set the thawing period for at least 30 seconds longer than the time required to harvest the entire discharge of ice If it should be necessary to change the setting of the timer turn the adjustment dial clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment Note Thicker ice may require a longer thaw period due to slower ice release time Allen Bradley Timer Power Light green Light blinks while timing Light solid when timed out Up Light red Light off while timing Light solid when timed out nits Set to min Range Set to i Unit adjustment 0 to 12 m a
88. g the thawing harvest cycle This water contains ice fines accumulated during harvesting and dissolved solids accumulated during the freezing cycle Do not reduce the size of this line Three inches is needed to provide sufficient area for ice fines to be flushed out especially if the incoming flushing water is 55 F 13 C or below _ This overflow line should not tie in with any other drain line except the water tank drain 2 9 12 2 9 12 P34F Service Manual 3 7 INSTALLING YOUR TUBE ICE MACHINE Condenser Water In and Out One end of the condenser has two water connections The lower connection is the inlet and the upper connection is the outlet See TABLE 3 2 for condenser water requirements and machine total heat rejection The condenser water outlet must be extended to an open drain or sump for visible discharge CAUTION The condenser water outlet must not be connected onto a pressure tight common header with the water tank due to the possibility that contaminated condenser water may back up into the water tank The condenser water outlet must be piped separate from the drain or sump CAUTION Cooling Tower When selecting a cooling tower careful attention must be given to operating wet bulb conditions It is advisable to check with your local cooling tower distributor for their recommendations based on actual operating conditions in your area An average wet bulb of 78 F is typical in the U S but many locali
89. gt sec Time Range hrs adjustment 10h 0 1 2 0 3 0 12 0 30 FIGURE 9 6 Thawing Timer 2TR 9 10 P34F Service Manual SERVICING OPERATIONS Condenser Cleaning There are 124 1 1 4 OD x 84 long steel tubes in the P34F condenser receiver These tubes are approximately 1 1 32 inside diameter Any brush or cleaning tool should be sized accordingly so as not to damage the tubes during cleaning The cleaning tools should be rotated at the specified speed for the particular tool used The tubes should be kept wet during cleaning After cleaning the tubes should be flushed thoroughly and all foreign material removed Contact your distributor or the Vogt Service Department to obtain the proper cleaning tools The following is the condenser cleaning procedure 1 Refer to the space diagrams Section 2 to make sure ample room is provided for removing the condenser heads and using the mechanical cleaning equipment 2 Order replacement cover gaskets for use at the time of reassembly 3 Disconnect and lock out power to the ice machine and auxiliary equipment 4 Disconnect water piping and drain the condenser Loosening the cover heads hex nuts and separating the covers from the condenser end will drain additional water 5 Remove the heads stud bolts and gasket completely 6 Inspect the tubes for excessive corrosion and possible refrigerant leaks Determine whether or
90. handle R 22 refrigerant WARNING It is not recommended that refrigerant to be transferred from a refrigeration system directly into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer of any applicable code requirements WARNING Note Observe all local codes when handling R 22 refrigerant 9 22 P34F Service Manual SERVICING OPERATIONS 11 19 12 Refrigerant Leaks Refrigerant leaks can be detected by an electronic leak detector Apply a solution of soap and water with a narrow brush or spray bottle to all joints welds or areas of suspicion The solution will form bubbles if there is a leak Note During long shut down periods 3 days or more machine should be pumped down to prevent leaks at compressor shaft seal at start up Non condensable Gasses Satisfactory operation of the machine is not possible if non condensable gases usually air are present in the system Excessive condensing pressure is an indication of such gases Excessive condensing pressure in water cooled condensers may also be due to the accumulation of scale in the cooling coil or due to insufficient cooling water or excessive water temperature See Water Cooled Condensers Section 7 and Section 9 Condenser Cleaning Non condens
91. heat due to non condensables usually air in the system Insufficient heat due to water in the refrigeration system Insufficient heat due to low refrigerant charge Cutter or cutter disc does not turn Compressor not running unloaded during thaw cycle Check freezer pressure switch 2 5 adjustment See FIGURE 9 1 for adjustment and TABLE 7 2 for average hole size Make sure all water distributors are in place one in each tube Adjust thaw timer 2TR to allow all ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Replace defective timer The head pressure should be maintained from 195 210 psi for R 22 or 240 250psi for R404a usually by a water regulating valve or fan cycling switch Check to make sure these controls are working properly Cold prevailing wind can also be a factor If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver and the refrigerant will be cooler although pressure will be high Air can be purged from the system by following the procedure in the Section 9 Purging Non Condensables If water is present in the refrigeration system the ice will release but discharge very slowly Check the refrigerant for water content purchased kit or freezer pump down Remove all water by following the procedure in Section 9 Removing water The refrigerant level in the receiver should be
92. ial detergent 4 Install new belts by rotating the belt and sheaves to obtain seating in the grooves Note on drives having more belt grooves in the sheaves than needed use the grooves closest to the motor and compressor Make sure that the belts are all slack on the same side of the drive preferably the bottom prior to tightening Move the sheaves apart until the belts are snug 6 Check the motor and compressor shafts to make sure they are parallel and check the flywheel and motor sheave with a straight edge string or wire to make sure they are parallel and in the same plain Make adjustment as required 7 Adjust tension following these guidelines a Best tension is the lowest tension at which the belts will not slip under the highest load condition b Check tension after the first two to four hours and again after 24 to 48 hours of operation then periodically thereafter c Ifa belt slips tighten it 8 Retighten motor hold down bolts after each adjustment Compressor Servicing Refer to your compressor manual for specific instructions regarding repair and servicing of internal parts It is important to be familiar with the operation and function of your equipment so you can provide the best possible service 11 19 12 2 9 12 P34F Service Manual 10 1 OPTIONS AND ACCESSORIES 10 Options and Accessories Crushed Ice Production Your P34F Tube Ice machine is capable of producing crushed ice with no loss of capacity
93. ine Total refrigerant charge required is approximately P34F 2400 lbs of R22 amp R404a 11 19 12 P34F Service Manual 5 3 START UP amp OPERATION FREEZING LIQUID START SWITCH STOP SWITCH FIGURE 5 1 Control Panel Start Up Starting the machine in a freezing cycle can be accomplished as follows 1 Make sure the crankcase oil temperature is approximately 100 F and there is no liquid refrigerant in the compressor crankcase 2 Turn the Hand Auto switch 1SS to the Hand position and allow the water tank to refill MAKE SURE THE DRAIN VALVE IS CLOSED 3 Push the green Start push button to start the compressor and immediately observe the oil pressure the oil level the discharge pressure and listen for any unusual sounds The compressor starts unloaded and will load automatically after several seconds by action of the delay timer DT 4 Turn the Hand Auto switch to the Auto position 5 When the discharge pressure increases to about 170 psi R 22 206psi R404a push the Manual Harvest button to initiate the harvest cycle See Harvest Period 6 When the suction pressure raises to 65 70 psig R 22 80 85 psi R404a any ice made should release and discharge After all of the ice clears the cutter and auger turn the Hand Auto switch to Hand and back to Auto This will interrupt the harvest cycle and start another freeze cycle S
94. ing during the set thawing time Adjust timer accordingly CAUTION 10 2 P34F Service Manual OPTIONS AND ACCESSORIES Power Monitor Several Vogt Tube Ice machine models are available from the factory with a three phase line voltage power monitor with LCD display The units are also available for after market or retrofit installation These units monitor line voltage inputs from 190 to 610 volts and provide protection against line voltage variances which can damage or destroy the compressor motor Features include automatic system shutdown and restart based on current line conditions a voltmeter and a non volatile system memory so settings are retained even if power is lost If machine is ordered with this option the power monitor can be factory set to customer specifications Operation Parameters Press Setup Key to enter Setup Mode Holding the Setup key down for 2 seconds will place all settings at their defaults To change settings press the Setup Key repeatedly to step through each menu item changing settings where required As you step through the Setup Menu the unit will remain on line monitoring your system and logging any faults in memory for you to review after you leave the setup mode The Setup LED will stay on during setup operations When you have passed the last parameter in the setup menu the setup LED will extinguish and you will be returned to the SYSTEM ON LINE display NOTE The power monitor has no on and off
95. ion of all controls high and low pressure switches oil pressure switch etc Check cooling tower spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures Check water distributors in freezer for scale accumulation Check water tank for solids to be removed Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc for abnormal noise and or vibrations Check oil level in gear reducer Check one complete freeze thaw cycle record data and compare with production check of Registration Start up Report D Yearly in addition to weekly and monthly 1 2 3 4 5 6 7 8 9 Check entire system for leaks Drain water from condenser and cooling tower and check condenser tubes Check closely for damage by corrosion or scale Remove all rust from all equipment clean and paint Check all motors for shaft wear and end play Check operation and general condition of all electrical controls relays motor starters and solenoid valves Check freezing time ice release time and ice out time Change oil in gear reducer box once a year Lubricate compressor motor bearings Drain compressor oil open compressor inspect and clean inside crankcase Change oil filter and add new oil Inspect compressor suction strainer 7 2 P34F Service Manual MAINTENANCE PREVENTATIVE MAINTENANCE FORM This form can be removed and duplicated
96. is closed 14 Start and stop the pump again to make sure it is circulating water and it is not air bound De a You are now ready to produce ice Water Distributors The water distributors are located under the top freezer cover These distributors are similar in design to those used in mid size and small machines i e P18F P118 etc except they have a small vent tube It is important that this plastic vent tube remain in place in each distributor The distributors may require occasional or periodic cleaning to remove solids foreign particles or mineral deposit accumulated from the circulating make up ice making water The frequency of cleaning operation will depend on the characteristics of the water supply The distributors need inspection when the inside diameter of a large portion of the ice becomes irregular due to channeling of water if some of the ice is opaque or if there is a noticeable decrease in ice capacity and quality TABLE 7 1 Water Distributors You may look through the plastic freezer cover to inspect the water distributors if the view is clear For a closer inspection you should stop the unit remove the nuts and retaining ring sections and lift off the top cover Make sure the two orifices in the side of each distributor are open the vent tubes are in place and a distributor and vent tube assembly is installed firmly in each tube 7 4 P34F Service Manual MAINTENANCE To remove the water distributors for cleani
97. is reading by 0075 and 001 add these amounts to the circumference reading Elongate the belt to the new length Example 105 x 0075 7875 105 7875 105 7875 105 3 4 min 105 x 001 1 05 105 1 05 106 05 106 1 16 max 3 Check Compressor sheave and motor sheave with a straight edge to be sure they are parallel and in the same plane 4 The tension should be checked after 24 to 48 hours of operation to compensate for initial stretch and wear in Periodic checks should be made and tension restored as necessary General Rules 1 The best tension for a V belt drive is the lowest tension at which the belt will not slip under the highest load Too much tension shortens belt and bearing life 2 Check tension often during the first 48 hours of operation and periodically afterwards 3 Keep belts and sheaves free of any foreign material which may cause slippage 4 If a belt slips tighten it 7 8 P34F Service Manual MAINTENANCE This page in blank 11 19 2012 P34F Service Manual 8 1 TROUBLESHOOTING 8 Troubleshooting Note Your machine s electrical system has several built in safety and overload protection features to stop operation when a single component fails or there is a problem from an outside source such a power supply Make sure all auxiliary equipment is connected to incorporate safety and overload circuits and protect all related equipment When the machine stops it must be manually restarted by pushi
98. justment Delay On Fault is energized when any line fault occurs The fault must be present set time in order to be registered or acted upon Default is 2 0 seconds Contactor Test Selectable number of Contactor Retries 1 to 10 or OFF on Contactor Fault Use the arrow keys to adjust the number of times the contactor will be operated in order to seal the contacts Setting retries to OFF means do not check load side Any input to the load inputs will be ignored Default is off Reset Mode Manual Automatic Choose whether to let the unit automatically reset or to wait for you to manually reset it The recommended setting is automatic because faults must be cleared in order to reset from the manual mode To reset from a fault condition in the manual mode press and hold the fault button for two seconds Default is manual reset Control Mode This setting allows you to select the control source Pressing the arrow keys in this setup mode takes you through ON OFF and EXTERNAL The normal setting would be EXTERNAL With the control set to EXTERNAL the unit will respond to the signal connected to the CONTROL input With the control mode set to ON the unit will turn on its output relay if line parameters are within setup parameters Setting the control mode to OFF causes the unit to ignore the control input and keep it s output relay off Default is external Read Mode For reading individual phase to phase voltages Pressing the read key will en
99. led in the bearing bracket assembly The cavity between the bearings has been filled with a food grade grease to prevent the presence of moisture and prolong the life of the unit If there is any vertical or side movement of the shaft or if the bearings feel rough or tight when turning the shaft the assembly should be dismantled and rebuilt Refer to the cutter tank assembly drawing Figure 9 5B for parts location and identification Cutter Shaft and Bearing Removal Note Use only a soft mallet or other soft tool for fitting all parts into place 1 With the bearing bracket assembly removed from the tank press the shaft out of the housing from the bottom up Note The two top bearings may come out with the shaft along with the upper seal and excluder 2 Turn the bracket over and press the bottom bearing out the bottom along with the lower seal 3 There are three spacers on the shaft that should be removed and labeled as to their location Remove them as they are made accessible 4 Clean and inspect all parts for wear or damage Discard all parts showing any indication of damage 11 19 12 P34F Service Manual 9 17 11 19 12 SERVICING OPERATIONS Cutter Shaft and Bearing Installation 1 Clean the inside of the bearing housing of grease or foreign matter Further clean the top bearing housing with pro lock cleaner and primer or a suitable substitute and remove the pipe plugs from the side of the housing Apply a thin coat
100. maximum vertical tooth engagement and the reducer assembly can be moved in or out horizontally to obtain the proper tooth depth for maximum gear life Note The motor and gear reducer are an integral unit Only qualified personnel should attempt to disassemble and repair this unit Drive Gear Replacement Disconnect and lock out all power to the machine 2 Remove the top and side bolts holding the mounting plate to the support bracket Lift the plate and gear reducer from the bracket and rest the assembly on a stable work table sitting next to the tank Leave the electrical conduit connected to the gear reducer motor 3 Inspect the drive gear teeth for proper vertical alignment and wear pattern 4 Ifthe wear pattern indicates less than a full width of tooth engagement measure the difference and make a note to correct at the time of reassembly 5 Measure and record the dimension from the drive gear to the bottom side of the mounting plate 6 Remove the three or four cap screws holding the drive gear to the split taper bushing 7 Using two of the same cap screws in the threaded holes of the bushing jack the gear off the bushing and remove both from the gear reducer shaft 8 Clean the split bushing and tapered hole of the new drive gear and insert the bushing into the drive gear making sure the tapers match 9 Slide the split hub and gear onto the keyed shaft with the key in place positioning the hub by measurement previously re
101. n need of Check fan motor and fan belts for proper maintenance operation and tension Check spray nozzles tubes sump and sump screen for accumulation of mineral deposit and clean as required Check tower blowdown and chemical treatment if applicable Dirty condenser tubes Visually inspect the condenser tubes to see if there is any build up of mineral deposits which would reduce the cooling effect of the tubes and water Clean chemically or mechanically as applicable Too much liquid in condenser receiver Remove refrigerant so all tubes will be above covering tubes causing inefficienc liquid refrigerant level 2 9 12 P34F Service Manual 8 9 TROUBLESHOOTING Symptom Low discharge pressure check gage accuracy Possible Cause Possible Remedy Fan cycling switch out of adjustment or Check adjustment Refer to FIGURE 9 4 Fan defective Control Replace if defective Compressor running unloaded or not pumping Check compressor motor amp If the efficiently compressor is running unloaded the amperage will only be approximately 60 of normal amp draw FLA Refer to the compressor manual Shield tower from prevailing winds to prevent blowing through tower excessive cooling Install an indoor sump Too much cold water circulating through Install a water regulating valve in the water condenser line form the condenser and control flow by receiver pressure Thaw gas valve 18 leaking through Make sure manual opening stem is i
102. n the automatic screwed in position Repair or replace defective parts Symptom High suction pressure check gage accuracy Possible Cause Possible Remedy Compressor running unloaded or not pumping Check compressor motor amp If the efficiently compressor is running unloaded the amperage will only be approximately 60 of normal amp draw Refer to the compressor manual Thaw gas valve 18 leaking through Make sure manual opening stem is in the automatic screwed in position Repair or replace defective parts Defective gage Check pressure with accurate gage and replace as necessary Symptom Compressor running unloaded during freeze Possible Cause Possible Remedy Low oil pressure Check compressor net oil pressure Net oil pressure oil pressure gage reading less suction pressure 17 28 psi Refer to the compressor manual for Oil Pressure Adjustment Unloader solenoid valve open Check solenoid coil to make sure it is not energized If valve is stuck open replace valve Unloader mechanism not working properly Refer to compressor manual for unloader information 2 9 12 8 10 P34F Service Manual TROUBLESHOOTING Symptom Compressor oil pressure low check gages See Section 7 for compressor oil pressure requirements Oil will be very foamy Check liquid feed control for overfeed problem Adjust valve to increase oil pressure Turn stem in to increase out to decrease Reverse rotation i
103. nd the pressure does not increase at least 5 psi above the setting during that 60 seconds the switch contact will open and stop the machine After a period of time as the delay heater cools the switch can be manually reset and the machine restarted The compressor should not be operated under low oil pressure or low oil level conditions If oil is added to the compressor crankcase to resume operation after a loss of oil be sure to observe several cycles to make sure the oil level remains stable See Troubleshooting Low Oil Pressure Switch Tripped CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming operation CAUTION ADJUSTING WHEEL SET AT 5 PSIG CW TO RAISE SETTING CRANKCASE PRESSURE CALIBRATION POINTER MANUAL RESET BUTTON OIL PRESSURE 1 4 FIGURE 9 5 Oil Pressure Switch 11 19 12 P34F Service Manual 11 19 12 9 9 SERVICING OPERATIONS Control Circuit Protection The electrical control circuit of the machine is protected by a 6 amp circuit breaker CB4 If this breaker trips the machine will immediately stop Before resetting the circuit breaker open the disconnect switch and lock out all power to the control panel Reset CB4 and restore power Check circuitry with a voltmeter If the machine was off for an extended time the crankcase heater must be energized for a minimum of four 4 hours and no liquid re
104. near the operating mark at the end of a freezing cycle to provide enough volume of warm gas for harvesting DO NOT OVERFILL RECEIVER Check cutter gear reducer and drive gear for proper operation and alignment Check for broken gear teeth or sheared shaft key Replace defective parts Check compressor motor Amp draw During the thaw cycle the compressor motor Amp draw should be 60 7096 of normal amp draw during the freeze cycle Check compressor unloader solenoid coil UR to make sure it is energized and the valve opening during the thaw cycle Check oil pressure 8 6 P34F Service Manual TROUBLESHOOTING Symptom Low ice capacity Suspicions of low ice capacity should be confirmed by accurate calculations of actual ice produced Much weight can be lost by melting and fall off through augers and other ice handling equipment 1 Time the total freeze and thaw cycle for the cycle which is to be caught and weighed 2 Catch all the ice at the ice discharge opening of the machine 3 Weight the total amount of ice caught Lbs ice per cycle Cycle time minutes X 1440 Ibs production per 24 hours More than one cycle should be caught and weighed to get an accurate average Possible Cause Possible Remedy Inadequate water for ice making Water pressure of 40 psig minimum is required to assure proper water supply Check water pressure Check for a restriction in the incoming line or at the make up water float valve Freezer pressure
105. ng 1 Grip the top of the distributor body not at the vent tube with adjustable pliers 2 Hold and twist the distributor while pulling upward 3 Lift the distributor out of the hole To install the distributors 1 Insert one in each tube hole and seat firmly by using a short piece of pipe or conduit 2 Slide the pipe or conduit down over the vent tube and gently tap the distributor in place 3 Do not allow the distributor to be recessed below the top of the tube sheet To replace the cover 1 Replace water distributor box cover gasket Install the cover over the bolt studs Install the four 4 cover retaining rings sections and nuts Tighten the wing nuts firmly to prevent foreign materials from entering the water box Note The freezer cover and gasket are not intended to hold pressure of circulating water in the event of a freeze up Therefore every effort should be made to prevent the Tube Ice from freezing solid with no hole 1 1 2 1147 1 4 3 8 Avg 1 87 3 167 Avg 1 16 1 8 Avg TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank contains a concentrated amount of solids or salts See Troubleshooting Poor Ice Quality To clean the water tank 1 Stop the machine at the end of harvest Shut off the make up water supply Open the drain valve and drain the tank Remove the water box cover and flush o
106. ng the Start button If it stopped while in a freeze cycle it should be manually harvested to remove all ice from the freezer This is done by pushing the white Manual Harvest button Always check the machine operation thoroughly after remedying the problem Be sure to correct the source or cause of the problem to prevent the problem from occurring again Symptom Page Machine stopped 8 2 Freeze up due to extended freeze period 8 4 Freeze up due to ice failing to discharge 8 5 Low ice capacity 8 6 Poor ice quality 8 7 High discharge pressure 8 8 Low discharge pressure 8 9 High suction pressure 8 0 Compressor running unloaded during freeze 8 9 Compressor oil pressure low 8 10 Compressor loosing oil excessively 8 10 Machine short cycles 8 11 Shut down by oil pressure switch 8 11 High compressor discharge temperature 8 11 Suction line frosting to compressor 8 12 Notice Opening the compressor for observation or determination of failure does NOT void the warranty Contact your distributor first for technical service assistance about operation problems not covered in this manual 2 9 12 8 2 P34F Service Manual TROUBLESHOOTING Symptom Machine Stopped Possible Cause Possible Remedy Power failure or interruption Check fused disconnect or circuit breaker supplying power to the machine If power has been off make sure the crankcase heater is energized and there is no liquid refrigerant in the compressor crankcase prior to
107. nstall the reducer and mounting plate assembly on the water tank bracket and fasten in place with the side and top cap screws 15 Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount of backlash between the gear teeth 16 If the gear tooth tip clearance needs adjusting loosen the four hex nuts around the reducer base and move the reducer as required for proper tooth clearance Tighten the hex nuts securely and recheck for backlash 17 Reconnect the electrical wires and conduit to the motor 18 Check cutter rotation and correct as necessary NOTE When the cutter runs under a no load condition it should have a smooth uniform sound The weights listed in TABLE 9 1 will give you an idea of manpower or equipment needed when servicing and handling the various parts of the water tank and cutter Be sure to use safe lifting and handling practices to prevent bodily injury and or damage to parts If additional information is needed you should contact your distributor or the factory 11 19 12 P34F Service Manual 9 15 11 19 12 SERVICING OPERATIONS To inspect the cutter assembly and make repairs or replace parts it will be necessary to lower and remove the water tank from its mounting to the bottom of the freezer The water tank has metal casters allowing it to be rolled out from under the freezer for inspection and servicing Description P34 Weight Ibs Water tank ba
108. nstallations throughout the world Furnished with your machine is the Certificate of Test the report of operating data which is a record of the unit s satisfactory operation at our factory test floor It is evidence of our desire to deliver to you finest ice making unit ever made This manual is designed to assist you in the installation start up and maintenance of your unit Your Tube Ice machine will give you a lifetime of service provided you install maintain and service it properly Please read your manual carefully before attempting installation operation or servicing of this professionally designed piece of equipment Also make sure the Warranty Registration Start up Report is completed and returned If you have additional questions please call your distributor Also feel free to phone the factory direct at 502 635 3000 Important Safety Notice This information is intended for use by individuals possessing adequate backgrounds in electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in personal injury and or property damage The manufacturer or seller cannot be responsible for the interpretation of this information nor can it assume any liability in connection with its use It is important that personnel understand the properties of these refrigerants and that they be thoroughly trained in safe practices for their use and handling Refer to the enclosed Freon Compo
109. o prevent abnormal mechanical shocks Also transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended CAUTION It is not recommended that refrigerant be transferred from a refrigeration system directly into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements CAUTION 1 4 P34F Service Manual INTRODUCTION LA FREEZER SAFETY VALVE v 5 GLASS STOP VALVE WAY LVE LEVEL GAGE GL ONDENSER SAFETY V WAY VALVE STOP VALVI CTION STOP VALVE FILTER DRYER LTER DRYER COMP R SUCTION AC LEVEL PROBE CONTROLLER CHECK VALVE __ SUCTION PRESSURE GAGE 2 DISCHARGE GAGE STOP VA DISCHARGE PRESSURE GAGE CONTROL PANE CONDENSER PRESSURE CONTROL JR COOLING SOLENOID OIL DRAIN VALVE EZER OIL DRAIN HI LO PRESSURE SWITCH TANK
110. oading and lifting the P34F Tube Ice machine Tube Ice LLC is not responsible for product damage or personnel injury or loss of life during the loading or lifting procedure 3 2 INSTALLING YOUR TUBE ICE MACHINE 2 9 12 40 NOTE E 2 ICE DISCHARGE AS REQ D NOTE 7 10 0 NOT NOTES A REQUIRED TO SERVICE CUTTER ASSEMBLY B REQUIRED TO REMOVE COMPRESSOR CRANKSHAFT C REQUIRED MINIMUM FOR SERVICING D REQUIRED TO CLEAN OR REPLACE CONDENSER TUBES EITHER END 36 SQUARE OPENING NOT REQUIRED IF THERE 15 AT LEAST 8 0 CLEARANCE BETWEEN END DENSER AND WALL EITHER END D ABOVE FREEZER TO SERVICE FREEZER TUBES E SHOWN WITH STANDARD SUPPORTS INCREASE UIRED TO ACCOMODATE EXTENDED BASE IF USED D FOR ICE HANDLING EQUIPMENT CUSTOMER NOTES THIS DRAWING IS INTENDED TO BE USED AS A GUIDE ONLY FOR MINIMUM SPACE REQUIREMENT SERVICING AND OPERATING A P34F VOGT TUBE ICE MACHINE SPACE REQUIREMENTS FOR OTHER EQUIPMENT SUCH AS CONVEYERS AUGERS BAGGERS ETC MUST BE CONSIDERED FIGURE 3 1A P34F Space Diagram Side View E B P34F Service Manual P34F Service Manual 3 3 INSTALLING YOUR TUBE ICE MACHINE 8 5 40 tS NOTE E
111. pen probe housing cover and check connection of probe wire single wire lead from probe center to terminal connection Solenoid valve 220A Blown fuse in control unit Fuses located just Find reason for electrical fault and correct does not respond above quick disconnect terminal strip Replace blown fuses Digital readout 1 Control unit and probe serial numbers do 1 Contact factory if mate is not available indicates too low a not match 2 See Note 2 below level compared to 2 Fault in control cable 3 See Note below sight glass 3 Moisture in control unit or probe housing 4 See re calibration instructions 4 Calibration not correct 5 Contact factory for replacement 5 Calibrated for different refrigerant 6 See Note 3 below 6 Insulating resistance of teflon enclosed probe rod is too low Digital readout 1 Control unit and probe serial numbers do 1 Contact factory if mate is not available indicates too high a not match 2 See Note 2 below level compared to 2 Fault in control cable 3 See Note 1 below sight glass 3 Moisture in control unit or probe housing 4 re calibration instructions 4 Calibration not correct 5 Contact factory for replacement 5 Calibrated for different refrigerant 6 Check for excessive oil carry over from 6 Oil rich mixture in level column compressor Intermittent high level 1 Rapid suction pressure pull down results in 1 Check time delay timer DT for p
112. ptable Important If the supply voltage phase unbalance is more the 2 contact your local electric utility company Current Unbalance Voltage unbalance will cause a current unbalance but a current unbalance does not necessarily mean that a voltage unbalance exists A loose terminal connection or a buildup of dirt or carbon on one set of contacts would cause a higher resistance on that leg than on the other 2 9 12 2 9 12 P34F Service Manual 3 13 INSTALLING YOUR TUBE ICE MACHINE two legs Current follows the path of least resistance therefore if terminal connection L1 is loose or dirty L2 and or L3 will have higher current Higher current causes more heat to be generated in the motor windings The maximum acceptable current unbalance is 10 Example Current Readings Ll 96 Amps 12 91 Amps Average 96 91 98 3 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation L3 98 95 3 Amps Current Unbalance 100 x 4 95 4 2 Acceptable Rotation Check The compressor cutter and pump motor rotation are factory synchronized but must be checked at installation For cylinder ice production the cutter disc as viewed at the ice discharge opening should turn from left to right Check rotation by the following procedure 1 Turn the power to the machine on and check voltages 2 Make sure the water tank is full of clean water 3 Turn the Hand Auto switch ISS to HAND po
113. r R 22 or the compressor discharge pressure goes too high 300 psi for R 22 See High Low Pressure Switch Oil failure pressure switch OPS to stop the machine if the compressor oil pressure drops to 11 15 psi net suction pressure minus oil pressure gage reading See Oil Pressure Switch 2 16 12 6 2 2 16 12 ELECTRICAL CONTROLS 2M 2PS 2TR CB4 Lowside Control Panel Door Opened 1M Compressor Motor Starter Not shown Pump Motor Starter Contactor amp manual motor starter FIGURE 6 1 Provides power to the compressor motor freezing and thawing with auxiliary hold contact and auxiliary contact to de energize the compressor crankcase heater when the motor is running Provides power to the circulating water pump during the freezer period or when the Hand Auto switch is in the Hand position to circulate water or ice machine cleaner etc Manual motor starter provides motor over current and short circuit protection P34F Service Manual Continuously energized during Cutter Motor Starter Provides power to the cutter during the harvest period Manual motor starter Contactor amp manual motor starter provides motor over current and short circuit protection Pneumatic Timer Control Relay De Control Relay With For making and breaking various circuits d
114. r unloads the cutter motor starts the thaw timer 2TR is energized the red thawing gas light illuminates and auxiliary equipment such as conveyors etc start When the refrigerant in the freezer is warmed sufficiently to allow the ice in the tubes to release and be sized the ice is discharged into the customers ice handling equipment See Ice Handling for more information on this subject The thaw timer 2TR is adjustable and should be set for the time required for all the ice to clear the freezer plus 30 seconds more CAUTION Make sure all the ice clears the freezer with at least 30 seconds to spare before the next freezer period begins This is to prevent refreezing and to allow the ice moving augers etc to clear CAUTION 1 Control Panel Condenser Pressure Control 4 4 G Discharge Pressure Gauge Receiver Drain Valve R Gear Reducer 3 Way Valve Water Tank includes cutter assembly Discharge Line Stop Valve Water Distributing Chamber Freezer Pressure Switch 2PS Water Tank Overflow 3 FPT Liquid Outlet Valve King Valve Make Up Water Float Valve Condenser Receiver Access Valve 13 Heat Exchanger Freezer Oil Drain Valve 14 Oil Separator Make up Water Inlet Valve 16 Thawing Chamber Capacitive Level Probe 17 Hand Expansion Valve Level Column Sightglass 8R Thawing Gas Solenoid Valve 69 Low Suction Pressure Stop Valve OA Liquid Feed Solenoid Valve A Oil Return Stop Valve 20B Constant
115. re 428 Bearing bracket assembly and cutter disc 150 Cutter assembly and ring gear 164 Water tank and cutter assembly 742 Cutter disc 97 Cutter drive gear 14 Gear reducer and motor 96 Water pump 85 TABLE 9 1 Water Tank and Cutter Parts Weights Water Tank Removal 1 Disconnect and lock out all power to the machine There should be ample space to roll the water tank from under the machine It may be necessary to provide a flat level surface such as a sheet of plywood sufficiently supported to hold the weight of the tank and cutter assembly See TABLE 9 1 Turn off water supply drain water and disconnect water and drain lines from the tank 3 Remove the overflow tubing from the water tank and remove the circulating water tubing from the pump Disconnect the ice discharge chute or hopper from the ice discharge opening of the water tank making sure the tank is free to be moved Remove the mounting bolts from around the flange of the tank and water pump allowing the tank to be lowered to rest on its casters Roll the water tank from under the freezer turning it as you go to clear the gear reducer and motor It is now accessible for inspecting and or repair of the cutter assembly Cutter Assembly Removal and Installation e 1 Follow water tank removal instructions Steps 1 7 See Figure 9 7B 2 Remove the socket head cap screw from the center of the cutter shaft and lift out retainer and gasket 3 4 To install th
116. relay level set points and differentials are properly set return the simulated level to a percentage value between the control and high level settings This prevents the unexpected operation of relays during the next simulation Simply release the simulation button to return to normal operation the operation mode light green will come on The value displayed on the readout will now become that of the actual liquid level in the level column and the relay positions will respond to this level RECALIBRATION Control units are accurately factory precalibrated to a 3 level column for the specified refrigerant and the supplied probe Recalibration may be necessary when a replacement probe or control unit is installed especially if not factory matched by serial number However the zero point and at least one other point should be checked at the operating refrigerant temperature for the highest level of accuracy It is ultimately the responsibility of the installer to ensure proper calibration for the specific application If the control unit appears to be out of calibration check for possible causes in the trouble shooting guide on before attempting to change the calibration If recalibration is ever required only two points need to be checked typically the 096 and sight glass at 50 level point Recalibration must be done in the order specified below To check the proper calibration at the 0 level the level column should be free of liquid to belo
117. restarting the compressor If ice is in the freezer initiate a manual harvest Circuit breaker CB4 for control circuit Check compressor crankcase heater coils of tripped relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and reset circuit breaker Make sure there is no liquid refrigerant in the compressor crankcase prior to restarting the machine Compressor motor starter overload 1MOL Check for a loose connection on all motor tripped starter and motor terminals which could cause excessive amp draw Reset overload and restart the machine check amperage power supply and head pressure Check TR in part wind starts only Water pump cutter motor tower fan tower Check for loose connection on all terminals pump conveyor motor overload tripped which could cause excessive amp draw Reset the overload and manually run that particular motor to check actual voltage and amperage against motor rating Freezer water pump motor overload 2MOL Check for loose terminal connections and or tripped defective breaker CB2 reset the overload and start the pump by turning the selector switch 1SS to Hand Check voltage and amperage against motor rating Confirm proper rotation Cutter motor overload 3MOL tripped Check for loose terminal connections and blown fuse reset the overload Clear all ice that may have jammed cutter Turn the selector switch 1SS to Hand
118. rical power is supplied to terminals 12 and 22 of the control panel see Figure 6 3 the crankcase heater is energized when the compressor is not running It is deenergized when the compressor is operating The heater is designed to maintain a temperature of the oil in the crankcase at 100 110 F 38 43 C when the compressor is not running This will prevent the migration of refrigerant to the compressor during off periods 9 8 P34F Service Manual SERVICING OPERATIONS Fan Control cooling tower The fan control switch is used to cycle the cooling tower fan on and off thereby maintaining the proper operating head pressure This switch is mounted on the frame of your machine and should be adjusted to maintain a head pressure between 190 210 psig R 22 or 240 250psig R 404a The fan control supplies power to the starter coil for the tower fan motor s 6M not furnished by Vogt See FIGURE 9 3 for adjustment instructions Cut In Adjusting Screw Set at 210 psig R 22 Set at 250 psig R 404a Cut Out Adjusting Screw Set at 190 psig R 22 Set at 240 psig R 404a Vogt Part 12A2117F05 FIGURE 9 4 Fan Control Switch Oil Pressure Switch The compressor is protected by a manual reset type low oil pressure safety switch which is set at 15 psig The oil pressure switch has a built in 60 second time delay If the net oil pressure pump pressure minus suction pressure falls below the switch setting for a time period of 60 seconds a
119. roper excessive boiling and liquid surging operation 2 High level alarm point has been positioned 2 Lower operating set point or raise high too close to operating set point level set point 3 Moisture in control unit or probe housing 3 See Note below Occasional erratic 1 Moisture in control unit or probe housing 1 See Note 1 below level displayed on 2 Radio Frequency Interference RFI 2 Find source of interference such as digital readout without mobile radios or transmitters and actual changes in level disable If unable contact factory for arrestor device Note 1 MOISTURE IN CONTROL UNIT OR PROBE HOUSING Dry out control unit or probe housing If appearance is dry look for signs of moisture damage such as white residue Check cover gaskets watertight cable connectors and other water sealing joints replace if worn If a conduit connection is on top of the probe carefully seal the inside to prevent condensation migration into the housing Relocate any conduit connections on top of the control unit to the bottom or seal the connections Note 2 FAULT IN CONTROL CABLE A symptom can be the digital readout display above 100 or below 0 Check wires and matching color dots on quick disconnect plugs at the probe and control unit for proper connection See page 9 for probe wiring diagram Wires should be securely fastened and not frayed Also check for continuity in the wiring Note 3 INSULATION VALUE OF
120. rtant information necessary for safe and efficient operation of your equipment 11 19 12 2 2 RECEIPT OF YOUR TUBE ICE MACHINE P34F Service Manual The machine is available in three different tube sizes for producing ice 7 8 OD x 1 long 1 1 8 OD x 1 long or 1 3 8 OD x 1 long 1 long ice is standard length The ice is cut to length by a rotating breaker type cutter Ice can be produced up to 1 1 2 long by modifying the spacers under the adapter plates see Chapter 10 Ice Length for modifying instructions Crushed ice is also available by modifying the cutter and making minor adjustments to the machine see Chapter 10 Crushed Ice Nominal Capacity T z tons day 25T 25 tons day 50 50 tons day 80T 80 tons day Model Variation A letter assigned to indicate major variations within any one family series Basic Configuration Package L Lowside Refrigerant F R 22 A Ammonia R 404a Type of Ice B Cylinder K Crushed L 1 Long Ice FIGURE 2 1 Product Variation Code A number or letter designator assigned to specific variations within a family series 000 or Blank Standard Product Consult factory for specific code interpretation Condenser Type WC Water Cooled NC No Condenser Electrical Codes 26 208 230 3 60 46 460
121. sition The water pump will start and the freezing and the liquid feed 2LT pilot lights will illuminate Check pump rotation 4 Push the MANUAL HARVEST button The water pump will stop the Freezing and Liquid Feed lights will go out and after 20 30 seconds the cutter motor will start The thawing gas solenoid valve will open and the Thawing pilot light 3LT will illuminate 5 Check the cutter disc rotation It should be turning from left to right CCW looking from the top 6 Turn the HAND AUTO switch to AUTO to stop the cutter To change rotation follow this procedure Disconnect power to the machine and lock it out to make sure it can t be turned back on Check for power at L1 L2 L3 with a voltmeter to make sure it is off At the compressor motor starter 1M or at the power disconnect reverse wires L1 and L2 Make sure these terminals are tight and restore power to the machine Perform rotation check again to confirm that it is correct ee Pores CAUTION Do not attempt to start the compressor motor until first making sure all conditions listed in the Installation Review Checklist and all necessary valves have been opened for operation CAUTION Auxiliary Controls or Equipment When connecting other equipment such as tower fan condenser pump conveyor motors bin level control etc refer to the control panel wiring drawing for the proper connecting terminals and instructions See Figure
122. st cycle and revert to a freeze cycle turn the Hand Auto switch to Hand and back to Auto Too much refrigerant in condenser receiver can contribute to high discharge pressure Do not go above 15 inches from the center of the lower gage glass cock while in normal operation A higher level can begin to cover the condenser tubes and reduce condenser efficiency e The circulating water overflow tubing will show that water is being slightly lifted up the tubing near the end of the freezing cycle If this action ceases and water begins overflowing from the top water box it is an indication that the tubes are freezing solid and the machine should begin a harvest cycle It is best not to freeze the ice solid with no hole e To cease ice production manually allow the machine to complete the harvest period and start the freeze period When the liquid feed light comes on at the beginning of the freeze period push the Stop button to cease ice production approximately 3 4 minutes e For proper oil return check position of oil drain valve located on accumulator Adjust valve for proper return of oil without sweat appearing on return line 11 19 12 5 6 P34F Service Manual START UP amp OPERATION This page is blank 11 19 12 P34F Service Manual 6 1 ELECTRICAL CONTROLS 6 Electrical Controls Your packaged Tube Ice machine is equipped with a compressor motor starter 1M as required for your particular vol
123. st period Green Push Button Start For starting the compressor motor and ice production NO Red Push Button Stop For stopping the compressor motor and ice production NC White Push Button Manual Harvest For manually initiating a harvest cycle NO 1SS Selector Switch Hand Auto Hand position for running the circulating water pump independently at start up or for cleaning the freezer tubes and water tank Auto position for provision of automatic system shutdown if there is a control circuit power interruption TABLE 6 2 Description of Control Panel Parts Outer Door 2 16 12 6 4 P34F Service Manual ELECTRICAL CONTROLS 5M OL TCHES H j MRING BY CUSTOMER TO TOWER FAN pf 460V 5A 230V 6A CIRCUIT BREAKER Lia 4 OR MOTOR STARTER 2 TRANSFORMER USED ON A00 450V ONLY THE LINE START E 22 RESSOR MOTOR STARTER PUMP MOTOR CUTTER NOTE SEE COMPR MOTOR STARTER PANEL FOR SOMPRESSOR MOTORING HIGH LEVEL CUTOUT 22 REMOVE JUMPER 12 13 WHEN 2 HEATER UNLOADI ING CONVEYOR MOTOR STARTUP
124. stall the two pipe plugs Install the largest excluder on the bracket as illustrated by the assembly drawing Install the tines disc the 1 4 x 1 4 key spacer spring washer castle nut and cotter pin Turn the assembly right side up and install it in the water tank locating the support arms as they were match marked when removed and secure in place using the 5 8 stainless steel cap screw and lock washer maximum torque should be 90 ft Ibs Install the top seal open side facing out tapping it uniformly into the housing until it seats Install the top water excluder Install the splash shield and ice deflector plate in the ice discharge opening Install the cutter assembly using the 1 4 X 1 4 X 3 3 16 Ig stainless steel key to align the key ways and lock the cutter and shaft together Install the red rubber gasket retainer and 3 8 stainless steel socket head cap screw Tighten to approximately 15 ft Ibs Check and adjust the cutter height per Cutter Height Adjustment instructions 9 18 P34F Service Manual SERVICING OPERATIONS Cutter Height Adjustment The height of the cutter can be adjusted by the four bolts holding the bearing bracket assembly in place These bolts are threaded into holes in the end of each arm through holes in the water tank The current design has these washers welded in place after the cutter height is properly adjusted This helps to insure proper adjustment during servicing Using a true str
125. tage and a transformer if required for the control circuit power The motor starter and transformer are mounted on the machine front side see Figure 1 1 The control panel wiring schematic FIGURE 6 3 illustrates these components as well as provisions for auxiliary equipment which may be incorporated by the customer such as FU1 Main power disconnect 5M Conveyor motor starter and overload SMOL 6M Tower fan starter and overload 6MOL 7M Condenser pump starter and overload 7MOL When adding motor starters for auxiliary equipment be sure to incorporate the overload protection as indicated between terminals 12 13 and remove the jumper wire This will assure that the machine will shutdown when any auxiliary equipment fails Bin Level Control Included in the wiring schematic is provision for a bin level control BLC The NC contacts of your control should be wired between terminals 8 9 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown However the machine will still need to be manually started to resume production Safety Switches The machine is also equipped with the following safeties and control switches which are mounted to the frame near the compressor Refer to the wiring schematic FIGURE 6 3 for their circuitry High Low dual pressure switch 1PS to stop the machine if the compressor suction pressure goes too low 15 psi fo
126. tals 11 5 Operating Weight 2 3 P 24 Capacity ratings 2 3 11 3 Condenser water 1144 Make up water 11 4 Normal operating vitals 11 5 Specifications 112 Part Wind Start Compressor 6 6 Phase Protector wiring schematic 10 5 Piping and Drain Connections 3 6 Piping Nomenclature 4 2 Piping Schematic 4 3 Poor Ice Quality 8 7 Power Supply Connection 3 12 Power Monitor 10 2 Contactor test 10 3 Contrast adjustment 10 4 Control 10 3 Delay on 10 2 Delay on fault 10 3 Delay on
127. ter Ring Gear Replacement 1 Remove the water tank assembly see water tank removal 2 Remove the cutter assembly from the cutter shaft 3 4 The ring gear is a shrink fit onto the cutter bank and therefore will have to be driven off It should Remove the 6 3 16 drive pins that hold the ring gear to the cutter bank be driven off progressively and uniformly around its circumference to avoid binding Inspect and clean the cutter band removing any burrs scale or dirt 6 Attempt to put the new gear onto the cutter and check for fit If it will not fit it will have to be expanded by heat Move the ring gear away from the cutter and heat the gear uniformly to 300 400 F 150 205 C This can be done by passing a hand held oxy acetylene torch uniformly over the entire ring gear DO NOT HEAT THE CUTTER Align the valley of the ring gear teeth with the existing drive pin holes and carefully set the ring gear onto the cutter Make sure it is fully seated all the way against the machined shoulder of the cutter bank After the gear has cooled drill 3 16 holes in the valley between the teeth of the ring gear and install the drive pins Make sure the drive pins do not protrude and interfere with the engagement of the drive gear 10 Install the cutter assembly onto the shaft 11 Check and adjust cutter height and meshing of the gear teeth 12 Install the water tank assembly Cutter Blade Repla
128. ter read mode Press the read key to step through the voltages Read voltages in the following order Voltage A to B Voltage A to C Voltage B to C Pressing the read key again will exit read mode Fault Mode Recalls faults from most recent to the oldest in order Press the FAULT key to enter fault mode FAULT 1 is most recent fault Press the fault key again to step to the next fault Pressing fault key at the last fault will exit fault mode Press and hold fault key down for two seconds to clear fault from memory and reset the unit 10 4 P34F Service Manual OPTIONS AND ACCESSORIES Contrast Adjustment When the SETUP READ and FAULT LED s are all off the unit is in the monitor mode While in the monitor mode the UP and DOWN arrow keys will control the display contrast NOTE LCD display contrast will vary with changes in ambient temperature and under extreme temperature conditions the LCD display may be dark or clear If this occurs simply use the arrow keys as described above to adjust the display to a visible condition LCD contrast adjustments are stored in the permanent memory and will remain constant once set Locking Out Setup Menu In some field installations it may be desirable to lock out unwanted changes from being made to the programmed parameters This can be achieved by using the lock feature The setup menu can be viewed but not changed when the lock is on TO LOCK out operator adjustments Hold
129. th 50 feet of shielded control cable If the control unit is located less than 50 feet from probe trim the control unit end of the cable as necessary Securely place the control cable quick disconnect plug into the appropriate marked socket inside the control unit Setpoint and Operation The level set point adjustment control is a slide knob with a scale in percentage of active probe length The percentage relates to the liquid level in the column between the 3 level point and the 100 level point as measured from the probe bottom end The level set point has a level differential adjustment control which is a rotating knob scaled in percentage of active probe length from 296 to 20 These percentages relate to the number of percentage points above or below the set point at which the particular relay position will change as detailed in the next three paragraphs LOW LEVEL ADJUSTMENT Not used on the P34F CONTROL LEVEL ADJUSTMENT This set point is intended to maintain the level inside the vessel via a liquid refrigerant supply solenoid valve 1 The control level set point is the level at which make up liquid will start to feed into the vessel The level in the P34F should be between 20 and 40 and is dependent on make up water and ambient temperatures The differential adjustment control should be set at 2 The filling indicator light green will be on when the relay is energized HIGH LEVEL ADJUSTMENT This set point is intended
130. the FAULT key down until FAULTS CLEARED appears on the Display While holding the FAULT key down press the ARROW UP key once This will turn the Setup Lock on TO UNLOCK the panel and allow operator adjustments Hold the FAULT key down until FAULTS CLEARED appears on the Display While holding the FAULT key down press the ARROW DOWN key once This will turn the Setup Lock off When the operator adjustments are locked out the ability to load default parameters is also locked To use the press and hold the setup key to load default values function you must first unlock the setup menu as explained above Wiring The power monitor should be wired to the line and load side of the compressor contactor with 1 amp fused connections The connections labeled control should be wired to a 230 volt power source Com and Run connections should be wired in series with the system control circuit Note that specified connections are for PI8XT models only Consult factory for other models 2 9 12 P34F Service Manual 10 5 OPTIONS AND ACCESSORIES Power Monitor Kit Vogt 12A7700K01 Fuses Vogt 12A7504E20 200 230V Machines Fuses Vogt 12A7504E29 400 460V Machines Wiring Instructions i POWER MONITOR
131. ties have designed wet bulbs as low as 72 F or as high as 82 F The cooling tower water pump must be capable of delivering the required volume of water through the condenser Due to cooling tower location and pressure drop through water lines and regulating valves the water pump must be sized for each installation Refer to TABLE 3 2 for condenser water requirements The water piping for the cooling tower and the installation of the pump must be in accordance with the manufacturer s instructions Caution must be used to prevent the condenser water pump from losing its prime during off cycles Proper water treatment for the prevention of mineral and foreign matter accumulation in the condenser or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use The use of a 40 mesh strainer in the condenser water supply line is also recommended Condenser water flow is based on pull down of 30 F SST and 105 F SDT Condenser water pressure drop does not include water regulating valve Consult factory for sizing if desired 3 8 P34F Service Manual INSTALLING YOUR TUBE ICE MACHINE Water GPM PSID 1 220 JN Total Heat Rejection THR 2 033 590 BTUH TABLE 3 2 Condenser Water Requirements Contact your local distributor for cooling tower sizing requirements Tower nozzles will be selected based on GPM required for condenser The condenser water pump should be sized on GPM required
132. unds and Safety in Appendix A 2 9 12 1 2 P34F Service Manual INTRODUCTION Safety Symbols amp What They Mean Prior to installation or operation of the Tube Ice machine please read this manual Are you familiar with the installation start up and operation of a Tube Ice machine Before you operate adjust or service this machine you should read this manual understand the operation of this machine and be aware of possible dangers These safety symbols will alert you when special care is needed Please heed them DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates a strong possibility of a hazard and that an unsafe practice could result in severe personal injury WARNING CAUTION Means hazards or unsafe practices could result in personal injury or product or property damage CAUTION 2 9 12 2 9 12 P34F Service Manual 1 3 INTRODUCTION Special Precautions To Be Observed When Charging Refrigeration Systems Only technically qualified persons experienced and knowledgeable in the handling of R 22 R404a refrigerant and the operation of refrigeration systems should perform the operations described in this manual All local federal and EPA regulations must be strictly adhered to when handling R 22 R404A refrigerant See Material Safety Data Sheet MSDS Code No 00000025
133. uring freezing and thawing period with pneumatic timer to delay the actual thawing process thawing For making and breaking circuits during freezing and thawing Energized during freezing thawing and hand Momentarily de energized at the end of the harvest Energized during Timer Controls the time of the harvest thawing period Energized during the harvest period HE Allows the compressor to start unloaded by delaying the energizing of the UR SOL unloader solenoid valve helps prevent belt slippage at start up This gives lower in rush amps and pressure and initiating the harvest period is running circuit Terminal Block Numbered for multiple wire connections and ease of troubleshooting panel Lowside Disconnect Used to disconnect power from panel when panel door opened not shown TABLE 6 1 Description of Control Panel Parts Inside P34F Service Manual 6 3 ELECTRICAL CONTROLS p FREEZING oa START SWITCH FIGURE 6 2 Lowside Control Panel Hinged Door 1LT Amber Pilot Light Freezing Illuminated during the freeze period or whenever the circulating water pump is running Clear Pilot Light Liquid Feed Illuminated when the circulating water pump is running and the float switch 10 is closed Indicates that the liquid line solenoid valve 20A is opened Red Pilot Light Thawing Illuminated when the machine is in a harve
134. ut any loose sediment from the tank The wire mesh screen can be removed if necessary If further cleaning is needed follow Cleaning Procedure If further cleaning is not needed close the drain valve and refill the tank with fresh water Make sure the float valve is adjusted properly and install the water box cover Start and stop the pump again to make sure it is circulating water and is not air bound up o ud Water Cooled Condenser Cleaning As water evaporates from a cooling tower the solid impurities remain and must be flushed from the system to prevent a scale build up in the condenser and cooling tower This can be accomplished by a continuous bleed off valve located in the pump discharge line The valve should be adjusted to bleed off an equal amount of water that is evaporated If water hardness is very high a higher bleed off rate or chemical treatment may be required Consult you local water treatment company for recommendations If after a period of time scale has formed inside the tubes mechanical cleaning may be necessary See Servicing Section Condenser 2 9 2012 P34F Service Manual 2 9 2012 MAINTENANCE Cooling Tower Evap Condenser See Figure 3 4 for parts location 1 Bleed off valve The bleed off valve should be checked monthly to assure that it is not blocked and that water is flowing as required If the unit is controlled by a water treatment system the bleed off valve may not be requir
135. ve 3 4 5 6 Reclaim the remaining refrigerant from this line through the charging valve 28 Repair or replace the valve as needed making sure all connections are tight Evacuate air from this isolated part of the liquid line through the charging valve 28 After evacuating manually close screw stem out the solenoid valve and open stop valves 29 and 58 check for leaks a 12A4200C1202 124420041404 H 12 4200 0604 12 4200 0604 FIGURE 9 10 Liquid Line Solenoid Valve P34F Service Manual 9 25 11 19 12 SERVICING OPERATIONS Water Flush Solenoid Valve 63 is opened during the thaw harvest cycle to flush out impurities from the water in the tank thereby improving the ice quality Repair or replace as follows 1 Turn off the water supply to this valve 2 Dismantle the valve and inspect for dirt and wear Reverse osmosis water can cause premature wear and erosion of the brass parts of this valve You may want to consider replacing it with a stainless steel valve 3 Repair or replace the valve as needed Turn on the water supply and check for leaks Compressor Oil Changing See Table 7 4 for frequency recommendations 1 Turn off power to the machine and make sure the compressor crankcase heater is not energized Drain the oil through the oil drain valve located at the base of the compressor 3 When all oil is
136. vicing any electrical equipment CAUTION X X X Drain sump and piping Check for noise vibration X X X TABLE 7 3 Cooling Tower Maintenance Schedule Compressor In starting and charging the unit the oil sight glass should be continually checked to make sure an adequate oil level is maintained The oil level should be 1 4 3 4 of the sight glass If 7 5 7 6 P34F Service Manual MAINTENANCE 2 9 2012 the oil level drops below 1 4 of the glass add refrigeration oil Suniso 4G or equivalent Class No 300 compressor oil for R22 or 68 weight POE oil for R404a as per the compressor manufacturer recommendations Never allow the oil level to be out of sight above or below the sight glass when the compressor is operating The compressor contains approximately 6 8gallons 26 liters of refrigeration oil CAUTION The crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compressor CAUTION During operation the specified net oil pressure should be maintained for proper lubrication and operation of the cylinder unloader mechanism Net oil pressure 17 28 psig Note Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pressure gage reading while the compressor is running Example Oil pressure gage reading 65 psig Suction pressure gage reading 40 psig Net Oil Pressure 25 psig
137. w the probe bottom end This can be accomplished by pumping the P34F down With the probe end free of liquid the control unit s digital readout should display 00 If not remove the seal on the low level calibration screw and adjust with a small screwdriver until the readout indicates 00 replace seal The level column standard sight glass location is at 50 Raise or lower the liquid level so that it is centered in the sight glass The digital readout on the Vari Level control unit should display the same level as the sight glass 50 level If not remove the seal on the high level calibration screw and adjust until the digital readout displays the calculated sight glass 5096 level replace seal For greatest accuracy recheck 046 calibration and readjust if necessary 11 19 12 P34F Service Manual 11 19 12 9 5 SERVICING OPERATIONS Problem Cause Action Digital readout and 1 No power to control unit or wrong voltage 1 Check Voltage at terminals 1 and 2 in indicator lights do not 2 Moisture in control unit or probe housing the control unit display 2 See Note below Digital readout does 1 Fault in control cable 1 See Note 2 below not indicate level 2 No continuity between probe and level 2 Check for Teflon tape or other non changes column conductive pipe sealant at probe to 3 Moisture in control unit or probe housing column connection replace sealant 4 Probe wire loose 3 See Note below 4 O
138. w gasket if necessary Torque down bolts to the correct specification 9 Evacuate the compressor and add new oil to the crankcase 10 Restore power to the crankcase heater allowing time to warm the oil 11 Open the suction valve discharge valve oil return valve and any other valves which may have been closed for servicing and check for leaks 12 Check and confirm sufficient oil pressure as you witness at least one complete cycle when operation is resumed 9 26 P34F Service Manual SERVICING OPERATIONS Belt Tension New belts should be checked after the first day running after the first week for tension then at regular intervals for tension alignment and wear 1 Always use matched sets or banded belts for multiple belt applications 2 Too much tension shortens belt life and motor bearing life 3 Never use a petroleum base belt dressing 4 The proper tension is just enough to prevent slipping Reasons for premature wear 1 Pulley misalignment 2 Belts not matched 3 Dirt or foreign material present 4 Excessive slipping loose tension Belt Replacement Belts which are worn cracked frayed or over stretched should be replaced 1 Remove the belt guard and loosen motor hold down bolts 2 Move the motor and sheave closer to the compressor until there is enough slack to remove the old belts 3 Remove the old belts and clean the sheave grove is necessary with non flammable non toxic degreasing agent or commerc
139. water tank drain valve 2 9 12 2 9 12 P34F Service Manual Symptom Low ice capacity cont Possible Cause Possible Remedy Excessively high head pressure Thawing gas solenoid valve 18 leaking through during freeze cycle Symptom Poor ice quality Possible Cause Possible Remedy Excessive concentration of solids in the water tank usually indicated by a build up of mineral deposit on the sides and bottom of the tank and opaque ice production Also water distributors restricted Insufficient water supply indicated by a low level in the tank Water pump rotation wrong direction Low refrigerant charge causing an ice out problem and re freeze Restriction in liquid line causing short freeze cycle 8 7 TROUBLESHOOTING Check cooling tower or evap condenser to make sure sufficient water is provided for cooling and the equipment is operational to cool the water Also see Symptom High Head Pressure Check the manual opening stem to make sure it is in the automatic position stem screwed in Check for leak by sound temperature difference and frost during a freeze cycle Close the stop valve 90 to confirm suspicion of leakage Repair or replace the valve Performing a cleaning procedure as well as removing the freezer cover and cleaning the water distributors Make sure the flushing valve 63 is functioning and the tank overflow piping is not restricted Check water pressure 40 psig is recommended

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