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10TA (P18XT) Service Manual

1. FOR COMMON REFRIGERANTS R502 R 134a MP 39 404 R 12 R 22 502 R 134a MP 39 R 404a 0 2 9 0 9 1 0 0 7 0 50 46 7 84 0 97 4 45 5 45 3 102 9 742 0 7 8
2. Float switch assembly Part No 12A7500E22 R Springs Float calling for refrigerant Float satisfied Not calling for refrigerant FIGURE 9 2 Hansen Refrigerant Float Switch 4 28 14 4 28 14 10TA Service Manual 9 3 SERVICE OPERATIONS Hand Expansion Valve Part No 12A4200C0605 The hand expansion valve is located after the liquid feed solenoid valve A1 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 The factory setting is about 2 turns from full open Freezer Pressure Switch Part No 12A2117E04 The freezer pressure switch FPS located inside the control panel controls the freezing time period for the production of cylinder or crushed ice This 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 6 Operating Vitals for typical settings Do not make adjustments until several ice discharging cycles have been completed B An N Qj FIXED POINTER Part No 12A2117E04 DIAL DIVISIONS 1 2 PSIG PER DIVISION RANGE ADJUSTMENT SCREW CLOCKWISE RAISES PRESSURE VALLEY OF CAM DIFFERENTIAL ADJUSTM
3. 821 HGIS LHOT3I NO GA LVOO I ES 7 1 LATLNO YASNACNOD Ld INI YaLVM IHSNHGNOO VT 11 iS ae 77 ONINVATO YHSNAGNOD 404 INCUNINIIN FIGURE 3 28 Connections and Space Diagram Water Cooled Machine 4 14 14 10TA Service Manual 3 5 INSTALLING YOUR TUBE ICE MACHINE Wiring and Electrical Connection WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on the Tube Ice machine WARNING Refer to TABLE 3 2 below to properly size wiring connections A fused disconnect must be provided near the Tube Ice machine Connect 3 phase power to terminals L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of cutter motor and water pump is required see following section 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 lug provided MAIN MACHINE POWER In
4. 6 1 6 3 6 4 Cleaning Procedure 7 1 7 6 Compressor Crankcase Heater 9 11 Compressor Lubrication 7 6 Compressor Motor Burnout Compressor Unloader 9 16 Compressor Contactor 6 2 6 4 6 5 6 6 Compressor Motor Protection 9 6 Condenser Cleaning 9 5 Condenser Fan Contactor FC 6 2 6 4 6 5 6 6 Condenser Fan Switch 9 5 Condenser Piping Cold Weather Valve Kit 3 9 Condenser Water Usage 11 4 Condenser Air cooled Cleaning 9 5 Condenser Air cooled Heat Rejection 3 8 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled 3 2 7 4 Control Circuit Protection 9 11 Control Panel Parts 6 5 6 6 12 1 INDEX Control Relay CR 6 2 6 4 6 5 6 6 Cooling Tower
5. 7 2 Shipping Papers 2 1 Solenoid Valve Space Diagram Air Cooled Machine Space Diagram Water Cooled Machine 3 4 Special Precautions 1 2 Start Push Button PB1 5 2 5 3 6 3 6 4 6 5 5 2 Start Up Checklist 3 15 Storage prior to installation and start up 2 2 Suction Cut Off Unloader 9 16 Symptoms Troubleshooting 8 2 Telephone Number 1 1 Temperature Pressure Chart Thawing Chamber Thawing Timer 6 2 6 4 6 5 6 6 9 12 Thermostat Bin Installation 3 13 Thermostat Setup 3 14 Timer Thawing 6 2 6 4 6 5 6 6 9 12 Trap AC Piping Troubleshooting 8 1 U Unloader Loaded Operation Freeze Period 9 16 Unloader Unloaded Operation Harvest Period 9 16 10TA Service Manual Vitals Operatio
6. 3 2 CoreSense 6 9 9 10 9 11 Crankcase Heater 7 6 9 11 Crushed Ice 9 22 Cutter amp Bearing Removal Installation Cutter Drive Parts Cutter Gear Reducer 7 7 9 16 9 17 Cutter Motor 9 18 Cutter Assembly 9 20 Cutter Bearing 9 19 Cutter Bearing Support Cutter Disc Assembly 9 20 Cutter Drive Parts 9 21 Cutter Gear Reducer 9 17 9 18 Cutter Motor 9 18 Cutter Assembly 9 20 Cutter Parts crushed 9 22 Cutter Parts cylinder 9 20 D D Valve Thawing Gas 4 1 9 15 Drive gear 9 21 E Electrical Connection 3 5 Electrical Schematic All Voltages 50 60 Hz 6 7 Electrica
7. 8 2 8 3 Maintenance 7 1 Maintenance Program 7 1 Make Up Water 3 1 Manual Harvest Push Button Metric Conversion Mechanical Cleaning 7 5 7 6 N NEMA 2 1 Nomenclature Piping 4 2 Non Condensable Gases 9 14 Normal Operating Vitals 11 4 Oil Pressure Safety Control 9 9 Operating Tips 5 3 Operation Vitals Optional Equipment Power Monitor Overload Protection Cutter Motor Starter 6 2 6 4 6 5 6 6 Overload Protection Pump Motor Starter 6 2 6 4 6 5 6 6 Pin for Cutter Bearing 9 20 Piping and Drain Connections 3 1 Piping Schematic Air cooled 4 4 Piping Schematic Nomenclature 4 2 5 30 14 10TA Service Manual Piping Schematic Water cooled 4 3 PLC Programmable Logic Controller Poor Ice Quality Power Connection
8. i eaa taa trennt netten trie nhe nnb au us 11 4 Make up Water Usage gpm TABLE II 11 4 10TA Service Manual TABLE OF CONTENTS Page No 11 TABLES AND CHARTS cont Normal Operating Vitals TABLE 11 6 11 4 Recommended Spare Parts Lt am o pete ad Rene 11 5 Temperature Pressure Chart for Common Refrigerants TABLE II 11 6 Conversion Factors English to Metric TABLE 11 8 11 7 Constants TABLE 11592 i RAEN EE AEN EAR LEN RENE RSE 11 7 12 INDEX TABLE OF CONTENTS BLANK 10TA Service Manual 4 14 14 10TA Service Manual 1 1 INTRODUCTION 1 Introduction VOGT ICE LLC A Brief History Of Our Company Henry Vogt Machine Co was founded as a small machine shop in Louisville Kentucky in 1880 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 much hard labor and large amounts of floor space for freezing cutting and crushing ice by hand Today VOGT ICE LLC carries on the tradition as one of the world s leading producers of ice making equipment 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 a
9. Note Condenser return lines supplied by customer check valve supplied by Vogt FIGURE 3 5 Condenser Field Piping Cold Weather Valve Kit 4 14 14 3 12 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE CONDENSER EQUIVALENT LINE SIZE WORKSHEET Discharge Gas Line O D Fitting Type Number Used Factor Total Globe Valve open Angle Valve open 90 Elbow 45 Elbow Tee Feet of Straight Copper Used Total Fitting Factor Total Equivalent Feet Copper Tubing L 11 8 1 3 8 O D 1 5 8 2 1 8 Globe valve open 28 36 42 57 Angle valve open 15 18 21 28 90 Elbow 3 4 4 5 45 Elbow 1 5 2 2 2 5 Tee 90 turn through 6 8 9 12 Tee straight through 2 2 5 2 8 3 5 TABLE 3 5 Equivalent Feet Due To Friction BEST BETTER AVOID FIGURE 3 6 Minimum Traps For Discharge Lines Note Each recommended line size is based on use of Type L copper tubing at a maximum equivalent distance of 150 feet See TABLE 3 5 for equivalent feet of valves and fittings 4 14 14 10TA Service Manual 3 13 INSTALLING YOUR TUBE ICE MACHINE Air Cooled Condenser Wiring ICE MACHINE CONTROL PANEL FIELD DISCONNECT FIELD DISCONNECT SUPPLIED BY CUSTOMER SUPPLIED BY CUSTOMER CONDENSER CONTROL
10. 12 1 Electronic Motor Protector Module T2 Ti M2 1 COMPRESSOR JUNCTION BOX COMP MOTOR NOTE ELECTRONIC OVERLOAD PROTECTOR MODULE USED ON 4D amp 6D COPELAND DISCUS COMPRESSORS THAT DO NOT HAVE CORESENSE PROTECTION Compressor with CoreSense Motor Protection amp 6D COMPRESSOR TERMINAL BOARD CONN DN BLACK WIRE INTERNAL TEMPERATURE SENSORS 515254 CORANGE WIRES TO CORESENSE PROTECTION MODULE WIRE HARNESS CURRENT LOOP CY BLACK amp RED WRE COMPRESSOR JUNCTION BOX CURRENT LOOP USED ON ALL DISCUS CDMPRESSDRS TO DETECT WHEN IS RUNNING AND START MONITORING OL PRESSURE NOTE ON 4D amp 6D COPELAND DISCUS COMPRESSOR INTERNAL TEMPERATURE SENSORS SEND SIGNAL CORESENSE PROTECTION MODULE TO PROVIDE OVER CURREN Y PROTECTION NOTE 20 amp 3D COPELAND DISCUS COMPRESSORS HAVE INTERNAL LINE BREAK CURRENT PROTECTION FIGURE 9 6 Compressor Protection Wiring 9 8 10TA Service Manual SERVICE OPERATIONS Electronic Motor Protector Field Trouble Shooting 4D amp 6D compressors before March 2011 In the event the motor compressor is inoperable or is not operating properly the solid state control circuit may be checked as follows 1 If the compressor has been operating and tripped on the protector allow the compressor to for at least one hour before checking This
11. Wiring For Bohn BNHS04A029 Condenser 3 phase motors FIGURE 3 7 eee Ice Bir lte groen Typical Bin Sensor Mounting FIGURE 30 Programming Electronic Bin Thermostat Installation Review A Checklist e EE Rr RS EET MONI FEE ERA TABLE OF CONTENTS EA 1 4 1 5 1 6 1 7 1 8 1 9 10TA Service Manual TABLE OF CONTENTS Page No 4 HOW YOUR TUBE ICE MACHINE WORKS Principle Of re enn erben ee cues od anat b a m adt 4 1 Freeze Period z ted reme beer hte de tier t bant eb eva d ds 4 2 Harvest Period ees GE UI CEU EU Uk 4 2 Piping Normencl ture een t RP ER s e E 4 2 Water Cooled Piping Schematic FIGURE 4 1 22222 0 00000000000000000000000000000 4 3 Air Cooled Piping Schematic FIGURE A 4 4 5 START UP AND OPERATION R frigeration System Review oii t pier eem td breit b m Leben 5 1 Refrigerant Charge 225 1 Start up Procedure 5 3 Control Panel Switch Layout FIGURE 5 1 5 3 Shut down Procedure Operanne Tips herut 5 4 Entrar 5 5 6 ELECTRICAL CONTROLS amp THEIR FUNCTIONS Control On FIGURE 6 1 A etin t e
12. Automatic Blowdown Water Pump rn ol FIGURE 9 1 Water Pump Blowdown Assembly Automatic Blowdown Harvest Cycle A feature of this machine is the automatic blowdown 40 which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water tank 7 and to remove accumulated salts or solids in the water as a result of the freezing action During the harvest water returning from the freezer raises the tank level and causes an overflow of water which creates a siphon to remove a fixed amount of water from the tank Make up Water Float Valve Part No 12A4200H0402P The make up 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 by pass or blowdown only during the thaw mode The water level during the freeze mode should always be below the by pass 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 drain by pass
13. O O 15261 SLUIS LIS LUIS MISLIS 2 2 H z lo Li LLL S L FUI amp FU2 CIRCUIT BREAKER USED ON 400 460 575 MACHINES ONLY FIGURE 6 2 Control Panel Components Standard 44 14 6 3 10TA Service Manual ELECTRICAL CONTROLS OPTIONAL POWER MONITOR LOCATED ON BACK OF ENCLOSURE DOOR FU10 FU60 2 28 82 BE lt Z OU an n 02 55 nO PANEL DOOR FIGURE 6 2A Control Panel Door Standard and Optional Power Monitor 4 14 14 6 4 10TA Service Manual ELECTRICAL CONTROLS 051 200A DISCONNECT 2207 MACHINES 2 DL 29 SI 5 5 5 124 SI START CLEAN ICE OFF STOP HARVEST ss 1 2 ON CONTROL PANEL DOOR FIGURE 6 2B Control Panel Components CE amp Australian Approved 4 14 14 4 14 14 Approval TABLE 6 1 Control Panel Components and Part Numbers See FIGURE 6 1 6 2 6 2A amp 6 2B 6 5 10TA Service Manual ELECTRICAL CONTROLS Item No Vogt Part No Description AX 12A7518E33UL Aux Trip Indicator INO INC BT 12A2117G09 Bin Thermostat Optional CB2 12A7515E22 GE Circuit Breaker 6 Amp 2 Pole 400V amp 460V machines 12A7516E30 Compressor Motor Contactor 72 Amp 3 Pole 12A7518E30 Au
14. Press the SET button to set the Set point S1 will be blinking Use the up T or down J key to set the temperature at 38 F Press the SET button to set the Differential DIF 1 will be blinking Use the up or down J key to set the differential at 2 F Select between 1 Cooling mode and Heating mode Use the up or down J key to select C1 Machine will shut off when temperature drops to 38 F and come on when temperature reaches 40 F Note The sensor will automatically exit the programming mode if no keys are depressed for a period of thirty seconds Any settings that have been input to the control will be accepted at that point DIGITAL TEMPERATURE A READING 38 F 2 Sao SENSOR 525 L 120 COM SENSOR POWER CONNECTION SOS contro orcu EE CONNECTION amp a FIGURE 3 9 Electronic Thermostat Note If damaged the sensor can be replaced without replacing entire unit Replacement sensor part 12A 211760901 Electronic temperature control part 12 2117G09 Sensor cable can be extended up to 400 feet For more information consult Tube Ice Technical Service Department 10TA Service Manual 3 17 INSTALLING YOUR TUBE ICE MACHINE IMPORTANT Be sure to follow the wiring schematic and electrical specification table when incorporati
15. Float Valve Make Up Water 9 1 Float Switch 9 2 Hansen Float FIGURE 9 2 Hand Expansion Valve Freezer Pressi e S witch seis Moe Lik alee eee lat hie i ES 9 3 Freezer Pressure Switch Allen Bradley FIGURE 9 3 9 3 Capillary BypaSS M 9 4 High Low Pressure oe peti e Rete pe Ox gp e o ERR e RAS e eR ERE IRR UE REIR det 9 4 High Low Pressure Switch 94 eene nnne 9 4 Head Pressute eege toe elu dantem Missa t iei ots ve 9 5 Water 010 lere N 01116 255528 EE 9 5 Aur Cooled Umso dn eed a red ae dus 9 5 Water Regulating Valve FIGURE 925A dee be e deett b a eb tenes 9 5 Condenser Fan Switch FIGURE IN EDEN RERO REGENS 9 5 eom amem 9 5 Air Cooled Condenser da uses 9 5 Compressor Motor Protection 9 6 High Potential Testing ameet E e e D E pene dE Ree 9 7 Field Troubleshooting u u eere Re esas EET ees Or E ER Oe ERR 9 7 Electronic Module and Compressor Terminal Board Connections FIGURE 9 6 9 8 Oil Pressure Safety Control Sentronic Oil Safety FIGURE 9 7
16. ee Storage prior to installation and start up Vogt Model Nomenclature FIGURE 2 1 essent 3 INSTALLING YOUR TUBE ICE MACHINE Piping and Drain Connections TABLE 3 1 terio ete e Ee Pre HL Water Cooled Condenser Connections FIGURE 3 1 0 1 2 0000001000 Cooling e Space Diagram Air Cooled Machine FIGURE 3 2A Space Diagram Water Cooled Machine FIGURE 3 2B sse ener Wiring and Electrical Connection FIGURE 33 Electrical Specifications TABLE 322 14 dece t dae deer tds i aere ces eene Phase Check Voltage and Current unbalance eese nennen nennen Rotation Check eee NR REUTERS Air Cooled Condenser Installation Instructions esee Pounds of R 22 to Add Vs Liquid Line Length TABLE 3 3 Air Cooled Condenser Data TABLE3A waska iq aha spa Condenser Dimensions FIGURE 3 4 Condenser Field Piping Cold Weather Valve Kit 5 Equivalent Feet Due To Friction TABLE 3 5 2 0 00000000000 00000 Minimum Traps For Discharge Lines 6 00 0 00
17. ER 6 1 Control Panel Cover Removed FIGURE 6 2 ccccccscccssssssscesscsssccsseeessecseecsseeeeecnseceseecssesesseceseeceseceseeseseseeeeeseeeseeens 6 2 Control Panel Cover Removed and Optional Power Monitor FIGURE 6 2 6 3 Control Panel Components amp Australian Approved FIGURE 6 2B 6 4 Control Panel Components and Part Numbers TABLE 6 1 6 5 Control Panel Part Descriptions TABLE OI 6 6 Electrical Schematic Voltages 50 60 Hz Across Line Start FIGURE 6 3 6 7 3 Phase Power Electrical Schematic Voltages 50 60 Hz FIGURE 6 6 8 Compressor Schematic Detail All Voltages 50 60 Hz FIGURE OAI 6 9 7 MAINTENANCE 7 1 Cleaning Procedure PER Se casein ea eve anata Seana ape nena eater 7 1 Sanitizing Procedure urea due uuu 7 2 KE OR Ee CEET 7 3 Number of Water Distributors Per Tube Size TABLE 7 1 0000000 2 7 3 Average Hole Size In Tube Ice TABLE 23 7 3 Water aaa Uere e bee eire m eda eit 7 3 Freezer Cover 7 3 Water Cooled Condensers 7 4 Checking Operation gt 7 4 Chemical ee gg RE HEB ERREUR eege 7 5 Mechanical Cleaning untere RR p
18. FIGURE 1 5 Right Side View 10TA Service Manual 1 9 INTRODUCTION CONDENSER WATER REGULATING VALVE 41 SAFETY RELIEF VALVE 50 RECEIVER 15R OIL p SEPARATOR 14 RECEIVER SIGHT GLASS 30 THAWINGGAS SOLENOID VALVE D VALVE 18 CUTTER MOTOR SM RECEIVER DRAIN VALVE 44 k GEAR REDUCER ___ Fa SR V2 MAKE UP WATER CONNECTION MAKE UP WATER FLOAT VALVE 12 FIGURE 1 6 Assembly Water Cooled Left Side View 4 14 14 1 10 10TA Service Manual INTRODUCTION BLANK 4 14 14 4 14 14 10TA Service Manual 2 1 RECEIPT OF YOUR TUBE ICE MACHINE 2 Receipt Of Your Tube Ice Machine Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on this Tube Ice machine WARNING 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 Vogt Ice LLC can void the machine s warranty The machine was shipped with
19. 3 5 Power Monitor 10 1 Preventive Maintenance 7 8 Preventive Maintenance Program 7 8 Preview 1 1 Principle of Operation 4 1 Pump DOWn 9 12 Pump Overload Protection 6 2 6 4 6 5 6 6 Pump Contactor 6 2 6 4 6 5 6 6 Q R 22 22 1 2 2 1 5 1 404 5 1 Receipt of Machine 2 1 Receiver 4 1 Refrigerant Charge Refrigerant Leaks 5 1 9 14 Refrigerant Removal 9 13 Refrigeration System Review 5 1 Rotation Check 3 6 Safety Notice 1 2 Safety Symbols and What They Mean 1 3 Safety Valves 2 1 Sanitizing Procedure
20. 70 x 1 FPT WATER TANK DRAIN 4 14 14 10TA Service Manual 46 N E RUN NN NON NUN NUN NN ki NC c MX NC weg SSC M X NC NN NON N x Wi 3 edF Koco AAAI E ah 524 gt _ FREEZER 2 FREEZER PRESSURE STOP VALVE 69 _ SUCTION d ACCUMULATOR 88 FLOAT SWITCH 22 _ LIQUID FEED I SOLENOID VALVE A1 VALVE 20 2 4 HAND EXPANSION VALVE 17 _ FREEZER REFRIGERANT CHARGING VALVE 28 7 2 LIQUID FEED SOLENOID VALVE A2 VALVE 21 7 FILTER DRIER 46 Assembly Water Cooled
21. CAUTION Start Manual Harvest J Clean Ice CONTROL PANEL DOOR FIGURE 5 1 Control Panel Switch Layout Starting Procedure Initial Start Up NOTE The machine will start in the harvest mode when set to Ice 1 Set the Clean Off Ice selector switch to the Clean position 2 Push the Start button PB2 to start the water pump 3 The pump can be stopped and started by the Stop and Start push buttons Water should be circulated for a minimum of five 5 minutes to prime the pump purge the tubing of air and lubricate the cutter bearing Note If pump is already primed skip steps 1 3 4 When there is good water flow turn the Clean Off Ice selector switch to Ice The machine will then start in a harvest thaw period with the compressor running 5 Atthe termination of the harvest thaw period the machine will begin the freeze period 6 Be sure to observe a minimum of four 4 cycles of ice production to confirm the satisfactory operation of the machine approximate time for four cycles is 60 80 minutes Complete the remaining part of the Warranty Registration Start Up Report upon initial machine start up and return it to Vogt Ice LLC 4 14 14 5 4 4 14 14 10TA Service Manual START UP AND OPERATION Shut down CAUTION The red Stop button should only be used for emergency shutdown For normal shutdown use the Clean Off
22. Note The probe should also be mounted on the back side of the bracket opposite of the front of the bin to reduce the possibility of damage from ice removal equipment The control panel is electrically connected so that the bin thermostat will stop the machine only upon the completion of a harvest period Bin Opening 27 NOTE Use front of angle to protect probe STAINLESS STEEL ANGLE TYPICAL BIN SENSOR MOUNTING BRACKET FIGURE 3 8 Typical Bin Sensor Mounting Note Actual location of sensor will vary based on bin layout and ice distribution system 4 14 14 3 16 INSTALLING YOUR TUBE ICE MACHINE 4 14 14 10TA Service Manual Programming the Electronic Bin Thermostat The electronic bin thermostat has an LCD readout that displays the temperature in the bin at the sensor The control has been preset and locked out at the factory to shut the machine down at 38 F and to re start at 40 F The control retains the program even if power is cut to the machine Under special conditions the settings may need to be changed The lockout switch is located on the inside of the control Removal of the four screws on the face of the control will reveal the lock switch Follow the instructions below to reset the switch 1 2 5 Press the SET button to enter the sensors setup mode Select between Celsius and F Fahrenheit Use the up T or down 1 key to select
23. Vogt 10TA TUBE ICE MACHINE Includes model P18FXT Manual Part Number 12A4171M08 evision Service Manual 50 NOTICE This manual is the property of the owner of this particular Tube Ice machine __________ It is to be left on the premises with this machine at all times After start up it should be stored in a safe place where it can be readily available when needed for future reference in maintaining troubleshooting or servicing Failure to comply with this notice will result in unnecessary inconvenience and possible additional expenses This manual is intended as an informational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 502 635 3024 IMPORTANT To activate the machine warranty the Product Registration Form MUST be completed and returned to the factory promptly after the official start up Product Registration Form is located in the Owners Packet or can be found online at www vogtice com registration htm Please return to VOGT LLC Suite 19 1000 W Ormsby Ave Louisville KY 40210 5555 SSSR d S Oss A ANER AN f de 2 55 52555556 555555555
24. 0 68 condenser gpm Hr 70 15 9 70 159 70 5 9 3 4 3 4 3 4 tank drain FPT 3 4 3 4 3 4 condenser water inlet FPT 2 2 2 27 27 2 218 21 8 21 8 AC condenser outlet ODC 13 8 1 3 8 1 3 8 21 15 7 105 21 15 7 105 21 15 7 105 1 5 2 1 48 1 5 2 48 1 5 2 4 48 0 5 0 7 2 2 05 07 22 05 07 22 275000 035 275000 033 275000 033 4822 4822 4822 4 x 5 x 6 5 1 2 1 5 2 0 4 x 5 x 6 5 1 2 1 5 2 0 4x 5 x 6 5 12x1 5x2 0 650 095 650 95 650 95 1260 1260 57 1260 571 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 78 78 77 78 77 80 044 80 044 80 044 3 2 219 6 3 2 219 6 3 2 219 6 4 x 3 4 x 3 4 x 3 65 095 65 095 65 055 Bohn Air Cooled Condenser BNHS04A029 BNHS04A029 BNHS04A029 4115 4115 4115 4 5 28 45 28 45 28 21 8 21 8 21 8 outlet connection ODC 13 8 13 8 13 8 1520 690 1520 690 1520 690 1265 eu 1265 1265 79 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F amb and 0 blowdown 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 2 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower 5 Tower sized for 80 F wet bulb temperature 3 Makeup water is maximum value and includes 10 gallons per cycle blowdown 6 Recommended air cooled condenser is based on 15 F TD Vogt reserves
25. 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation Current Unbalance 100 x 4 95 4 2 Acceptable L3 98 95 3 Amps 4 14 14 10TA Service Manual 3 7 INSTALLING YOUR TUBE ICE MACHINE Air Cooled Condenser Installation Instructions WARNING These installation guidelines must be followed to obtain reliable operation from air cooled ice machines IF THESE GUIDELINES ARE NOT FOLLOWED THE COMPRESSOR WARRANTY WILL NOT BE HONORED WARNING 10 11 12 13 Use only Vogt approved condensers Any exceptions to this policy must be obtained in writing from Vogt prior to installation and operation of the ice machine Outdoor condensers must be installed with vertical air flow Indoor condensers used for heat recovery may be installed with either horizontal or vertical air flow NOTE Condenser must be ordered for horizontal air flow The condenser must be mounted above the ice machine Horizontal runs in the liquid return line should slope 1 4 per foot with liquid refrigerant draining freely in the direction of normal operating flow back to the ice machine with no traps in the liquid line Horizontal runs in the discharge line should slope 1 4 per foot in the normal direction of flow away from the ice machine Traps must be installed in discharge lines at the base of all vertical risers There should be no intentional traps in liquid lines Trap volum
26. If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant level in the receiver should be near the operating mark at the end of a freezing cycle to provide enough volume for harvesting 1 approx 11 165 of R22 or R404a Check the thaw timer T which should be adjusted to allow all the ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Check cutter reducer and drive gear for proper operation and alignment Check for broken cutter disc or drive pin and replace as necessary Ice mushy due to concentration of solids in the water tank Perform Cleaning Procedure and check automatic and adjustable blowdown If the machine discharges ice into a chute it should slope at an angle of 30 degrees for cylinder ice and 45 degrees for crushed ice Check bin stat or level control to make sure it will stop the machine before ice backs up into the cutter Check freezer pressure switch adjustment see FIGURE 9 3 Section 9 Freezer Pressure Switch and TABLE 11 6 Section 11 Operating Vitals Check compressor amps during harvest noticeable drop in amperage should occur Check unloader solenoid coil If coil is okay replace unloader head assembly 8 6 10TA Service Manual TROUBLESHOOTING SYMPTOM Poor ice quality POSSIBLE CAUSE POSSIBLE REMEDY Excessive concentration of solids in the Perform a cleaning
27. 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 which would necessitate frequent cleaning A strainer of 40 mesh screen is usually satisfactory 9 2 10TA Service Manual SERVICE OPERATIONS Float Switch Part No 12A7500E22 The float switch is installed on a header assembly that is attached to the freezer shell Valves are provided for isolation of the float switch assembly if replacement or servicing is necessary The float switch closes as the level of refrigerant in the freezer rises and opens as the level falls The float switch is connected to the liquid feed solenoid valve A valve coil This is the solenoid valve directly before the hand expansion valve Therefore when the refrigerant level in the freezer drops the float switch opens thereby de energizing the normally open liquid feed solenoid until sufficient level has been reached to close the float switch The float switch has a fixed 1 2 differential The float switch is installed at the correct height at the factory and should not need to be adjusted The float switch is installed at the position that provides highest capacity The correct height will produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30 F gt Attractor Switch assembly only Part No 12A7500E24
28. Table 11 3 50Hz 1 1 2 1 17600 22568 17580 22526 17560 22485 17540 22443 17520 22402 17500 22360 17460 22298 17420 22235 17380 22173 17340 22110 17300 22048 17260 21986 17220 21923 17180 21861 17140 21798 17100 21736 17060 21674 17020 21611 16980 21549 16940 21486 16900 21424 16860 21362 16820 21299 16780 21237 16740 21174 16700 21112 16660 21050 16620 20987 16580 20925 16540 20862 16500 20800 16350 20623 16200 20446 16050 20270 15900 20093 15750 19916 15600 19739 15450 19562 15300 19386 15150 19209 15000 19032 14850 18855 14700 18678 14550 18502 14400 18325 14250 18148 14100 17971 13950 17794 13800 17618 13650 17441 13500 17264 Crushed 11 4 TABLES amp CHARTS Condensing Temp F Includes 10 gallons per cycle blowdown Entering Water Temp F Make Up Water Temp F 1 40 2 56 50 2 49 60 2 42 70 2 35 80 2 14 90 1 93 Leaving Water Temp F Table 11 4 Condenser Water Usage Cylinder Ice _ Size 11 4 1 1 2 2 25 2 19 2 21 2 14 2 16 2 09 2 12 2 04 1 93 1 86 1 74 1 68 Table 11 5 Make Up Water Usage gpm 5 27 14 Normal Operating Vitals Water Flow gpm Pressure Average Drop Total Heat of Rejection 2
29. amp 6D compressors without contactor and compressor terminals which could Coresense All 3D compressor have have caused excessive amp draw Check Internal Line Break for overcurrent amperage power supply and head pressure protection Excessive temperature may be caused by gas Coresense on 4D amp 6D compressors leakage between suction and discharge port of combines overcurrent amp oil pressure the compressor Check for broken cylinder head protection after March 2011 gasket or valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body Note Switch on 4D amp 6D compressors without Coresense and 3D compressors with line break protection will reset automatically after the motor has cooled sufficiently Compressor cylinder head temperature switch The thermal switch will reset automatically after trips the motor has cooled sufficiently Excessive temperature may be caused by gas leakage between suction and discharge port of the compressor Check for broken cylinder head gasket or valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body 3 0 amp circuit breaker CB in the control Check compressor crankcase heater coils of panel tripped relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and replace fuse Make sure ther
30. motor contactor or the control circuit transformer as required The control circuit is to be connected to the two terminals marked control circuit When the proper voltage is present and the motor temperature is within limits the M1 M2 circuit is closed and the pilot circuit is energized after the two minute off cycle time delay If the motor temperature rises beyond safe limits the resistance of the motor sensors rises causing the control circuit to open The solid state module cannot be repaired in the field and if the cover is opened or the module physically damaged the warranty on the module is voided No attempt should be made to adjust or repair this module and if it becomes defective it must be returned intact for replacement 4 28 14 4 28 14 10TA Service Manual 9 7 SERVICE OPERATIONS Electronic Motor Protector CoreSense Protection High Potential Testing The solid state sensors and the electronic components in the solid state module are delicate and can be damaged by exposure to high voltage Under no circumstances should a high potential test be made at the sensor terminals with the sensor leads connected to the solid state module Even though the power and pilot circuit leads are not connected the module can be damaged Note 4D amp 6D Compressors manufactured before March 2011 have Electronic Motor Protector Compressor with Electronic Motor Protection CM OL COMPRESOR TERMINAL BOARD 2 TB
31. the gas pressures across the plunger are equalized and the plunger is held in the open position by the spring When the solenoid valve is energized the needle valve is seated on the upper port and the unloading plunger chamber is exposed to discharge pressure through the discharge pressure port The differential between discharge and suction pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may be used with the valve either energized or de energized without excessive compressor cycling Nm Part No 12A2110P0907 Unloader Valve amp 240V Coil NEEDLE VALVE PORT TO DISCHARGE PRESSURE PORT TO SUCTION PRESSURE SEAL UNLOADING PLUNGER SUCTION CHAMBER IN COMPRESSOR HEAD SPRING SUCTION PORT IN VALVE PLATE NORMAL OPERATING CONDITIONS UNLOADED OPERATION VALVE DE ENERGIZED VALVE ENERGIZED SUCTION PORT OPEN SUCTION PORT CLOSED FULL CAPACITY REDUCED CAPACITY SCHEMATIC OPERATION OF INTERNAL UNLOADER VALVE FIGURE 9 11 Copeland Compressor Unloader Valve Loaded Operation during freeze This capacity control valve is controlled by an electric solenoid When the solenoid is de energized the valve loads the cylinder bank 2 cylinders as shown in the above figure Unloaded Operation during thaw only
32. union in the refrigerant charging line carefully to avoid unnecessary and 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 CAUTION Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 125 F and should be stored in a manner to 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 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 connected to an approved recovery mechanism with a safety shutoff sensor to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements CAUTION 4 14 14 10TA Service Manual 1 3 INTR
33. 0 424 00 00 000000000000 9 9 Oil Press re MM EE eS 9 9 Oil Pressure SIRE ERR 9 10 10TA Service Manual TABLE OF CONTENTS Page No 9 SERVICE OPERATIONS cont Coresense Protection uocem hare E u ett 9 10 Oil Separator FIGURE 9 8 eben eegend eben EE rdg e ee deefe baad 9 11 Compressor Crankcase Heater 5 enter enter tne tr eene Pre er eie 9 11 Control Circuit Protection e EROR DN Rer DI ON RR tue Ceca eran C Eee iae 9 11 Thawinge Timer Ra EENS 9 12 eto dae Madden stemmate et 9 12 Pump DOMN 9 13 Removal Of Refrigerant From Machine 9 13 Refrigerant EE 9 14 Non Condenisabl Pret beer tct dee LU reet eb va e bleed 9 14 Compressor Motor BUIMOUt iin 9 14 Nee escono e e EE 9 15 Thawing Gas Solenoid Valve D Valve FIGURE 9 10A 9 15 Liquid Feed Solenoid Valve 1 amp A2 Valve FIGURE 9 10 n nnsnsnsssssssssssss 9 15 Capacity Control Valve Compressor Unloader neret enne 9 16 Copeland Compressor Unloader Valve FIGURE OI 9 16 Loaded Operation Freeze Period a teet ee cente conan e eae ea eine ee ea nei e RAE Cine eno 9 16 Unloaded Operation During Thaw
34. 12 To sanitize inside the ice storage area flood the area with sanitizing solution making sure to wet all surfaces completely for at least 60 seconds Note Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm 13 Drain flush tank and refill with fresh water Return machine to ice making operation 1 Make sure the water tank drain valve is closed and the Selector switch is in the Off position 2 Turnon the water supply and refill tank with clean water 3 Manually open the thaw gas solenoid valve D valve 18 by running the stem in This will allow the pressure to rise in the evaporator and allow the machine to operate After approximately 1 minute put D valve back into the automatic position 4 When tank is full turn the selector button to the Ice position and push the Start button for immediate start up in the ice production mode 5 Make use the adjustable blow down petcock is adjusted properly NOTE The petcock should be adjusted to the minimum rate required to maintain production of clear ice Should be no more than 1 gallon 5 minutes 4 15 14 10TA Service Manual 4 15 14 7 3 MAINTENANCE Water Distributors The water distributors are located under the freezer cover at the top of the freezer These distributors may require occasional or periodic cleaning to remove solids and foreign particles accum
35. 14 10TA Service Manual 7 1 2014 4 1 HOW YOUR MACHINE WORKS 4 How Your Tube Ice Machine Works Principle Of Operation For a detailed description of the functions of each control panel components see Section 6 Operation of the machine is controlled by Clean Off Ice Start and Stop switches located in the control panel of the freezing unit Automatic operation can be controlled by optional ice bin thermostats which will automatically stop and start the ice maker by the level of the ice in the storage bin NOTE See Ice Bin Thermostat Typical Installation for instructions on installation of the control bulb of the ice bin thermostat FIGURE 3 8 The type ice produced cylinder or crushed is determined by how the machine cutter is set up cylinder is standard crushed is optional The control wiring is arranged so that the unit will stop only upon the completion of a thawing period whether by action of the Clean Off Ice switch or the ice bin thermostat The Clean Off Ice switch must always be set in the Ice position during normal ice making operation It is set in the Clean position only when the equipment is to be cleaned as outlined in the Cleaning Procedure Section 7 and instructions attached to the machine If it should become necessary to instantly stop the machine push the Stop button To restart the machine push the Start button FIGURES 4 1 amp 4 2 illus
36. 3A 208 230V 60hz 12A7530E57UL Pump Manual Motor Starter 6 5 10 0A 200V only 12A7500E57 Stop Push Button Red 12A7500E76 Contact Block Mounting Latch 1 N C PB 12A7500E56 Start Push Button Green 12A7500E73 Contact Block Mounting Latch 2 N O PM 12 7700 1 Power Monitor Universal Phase Protector Optional PF Power Failure Contactor 9 Amp 3 Pole 1 N O Aux Contact 205 240 Coil SS 12A7500E61 Selector Switch 3 Position 12A7500E77 Contact Block Mounting Latch 2 N O 1 N C T 12A7503E22 Thawing Timer Delay On Make 100 240V 12A7503E39 Timer Base 8 Pin Guarded Terminal amp TB N A Main Terminal Block Assembly TB2 N A Terminal Block Connections for Customer CE amp Australian 6 6 10TA Service Manual ELECTRICAL CONTROLS Description of Component Function AX Auxiliary trip indicator for manual motor starters Switches when cutter or pump motor starter trips CB2 Overload and short circuit protection for control circuit and crankcase heater 400 460V machines only Provides power to the compressor motor Continuously energized during freezing and thawing Auxiliary contacts control main power for control circuit components crankcase heater control relay and harvest timer CR Controls sequencing of Freezing and Thawing circuits Energized during thawing period CU Cutter Motor Starter Manual motor starter and contactor Starts and stops cutter
37. 4 14 14 10TA Service Manual SAFETY RELIEF _ VALVE 51 CHECK VALVE 101 CONDENSER SERVICE CONNECTION 32 LIQUIDRETURN STOP VALVE 91 OIL RETURN STOP VALVE 70 1 WATER TANK DRAIN 1 5 INTRODUCTION FREEZER 2 FREEZER PRESSURE STOP VALVE 69 _ SUCTION ACCUMULATOR 88 FLOAT SWITCH 22 LIQUID FEED SOLENOID VALVE VALVE 20 HAND EXPANSION VALVE 17 FREEZER REFRIGERANT CHARGING VALVE 28 LIQUID FEED SOLENOID VALVE A2 VALVE 21 FILTER DRIER 46 FIGURE 1 2 Assembly Air Cooled Right Sid
38. 66 20240 18160 16660 21050 18886 17326 20240 18160 18845 17285 20180 18120 68 20120 18080 16580 20925 18803 17243 20120 18080 69 20060 18040 16540 20862 18762 17202 20060 18040 18720 17160 20000 18000 18564 17004 19830 17850 18408 16848 19660 17700 18252 16692 19490 17550 18096 16536 19320 17400 17940 16380 19150 17250 17784 16224 18980 17100 17628 16068 18810 16950 17472 15912 18640 16800 17316 15756 18470 16650 80 18300 16500 15000 19032 17160 15600 18300 16500 16994 15444 18130 16340 82 17960 16180 14700 18678 16827 15288 17960 16180 83 17790 16020 14550 18502 16661 15132 17790 16020 84 17620 15860 14400 18325 16494 14976 17620 15860 85 17450 15700 14250 18148 16328 14820 17450 15700 86 17280 15540 14100 17971 16162 14664 17280 15540 15995 14508 17110 15380 15829 14352 16940 15220 89 16770 15060 13650 17441 15662 14196 16770 15060 90 16600 14900 13500 17264 15496 14040 16600 14900 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
39. 7 8 7 0 8 6 5 52 48 8 87 3 101 0 477 60 0 109 0 77 7 1 5 8 3 8 3 1 6 6 0 54 51 0 90 8 104 8 50 1 62 0 113 0 81 3 2 3 8 0 7 9 2 5 5 4 56 53 2 94 3 108 6 52 3 65 0 117 0 84 9 3 2 7 6 7 4 3 4 4 9 58 55 4 97 9 112 4 55 0 68 0 121 0 88 7 4 1 7 1 7 1 5 5 4 3 60 57 7 101 6 116 4 57 5 70 0 125 0 92 6 5 0 6 7 6 6 6 5 3 6 62 60 1 105 4 120 4 60 1 73 0 130 0 96 6 6 0 6 3 6 1 149 3 0 64 62 5 109 3 124 6 62 7 76 0 134 0 100 7 7 0 5 8 5 6 8 6 2 3 66 65 0 113 2 128 8 65 5 79 0 139 0 104 9 8 1 5 3 5 2 9 7 1 6 68 67 6 117 3 133 2 68 3 82 0 144 0 109 3 9 2 4 8 4 4 10 8 0 8 70 70 2 121 4 137 6 71 2 85 0 148 0 113 7 10 3 4 2 4 1 12 0 0 0 72 72 9 125 7 142 2 74 2 89 0 153 0 118 3 11 5 3 8 3 4 13 2 0 8 74 75 6 130 0 146 8 77 2 92 0 158 0 123 1 12 7 3 0 2 9 14 5 1 7 76 78 4 134 5 151 5 80 3 95 0 164 0 127 9 14 0 2 4 2 2 15 8 2 6 78 81 3 139 0 156 3 83 5 99 0 169 0 132 8 15 3 1 8 1 7 17 1 S5 80 84 2 143 6 161 2 86 8 102 0 174 0 137 9 16 7 1 1 1 0 18 5 4 5 82 87 2 148 4 166 2 90 2 106 0 180 0 143 2 18 1 0 4 0 2 20 0 5 6 84 90 2 153 2 171 4 93 6 109 0 185 0 148 5 19 5 0 3 0 4 21 5 6 7 86 93 3 158 2 176 6 97 1 113 0 191 0 154 1 21 0 1 1 1 4 23 0 7 8 88 96 5 163 2 181 9 100 7 117 0 197 0 159 7 22 6 1 9 2 2 24 6 8 9 90 99 8 168 4
40. Cooled Connections Note Water regulator valve is not installed on condenser when shipped from the factory Installed water regulator valve on condenser water inlet connection bottom connection on condenser Connect the condenser water out line to the top connection on the condenser 2 1 2 Condenser Water Outlet 2 Condenser Water Inlet FIGURE 3 1 Water Cooled Condenser Connections Cooling Tower For water cooled machines only 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 localities have design 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 water regulating valves the pump must be sized for each installation Refer to TABLE 11 4 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 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 pr
41. Elapsed Timer 4 Selector Switch Ice position in series w Bin control 4 Water Pump motor starter 5 Freezer Pressure switch 5 Alarm 6 Compressor overload for 4D amp 6D without CoreSense 6 D sol defrost solenoid valve 7 Cutter Motor overload 7 Not used 10 Pump Motor overload 10 Float switch A sol liquid feed valve s 11 s press safety for comp without 11 Cutter motor starter 12 High Low pressure safety 13 Not used 14 Not used 15 Not used Expansion Module 20 Not used 20 UN sol compressor unloader 21 Not used 21 Not used 22 Not used 22 Not used 23 Not used 23 Not used TABLE 10 2 PLC Input Output Table 10 7 OPTIONS AND ACCESSORIES 10TA Service Manual CATER rang TOI Rox roe FIGURE 10 4 Wiring Schematic Mid Size Machine P112 P118 amp P18XT 10 8 10TA Service Manual OPTIONS AND ACCESSORIES BLANK 5 27 14 10TA Service Manual 11 1 TABLES amp CHARTS 11 Tables amp Charts P18FXT SPECIFICATIONS 208 230 Volt 3 Phase 60Hz 1 059 114 317 112 018 Nominal Capacity Ibs day Kg day 20 000 9072 18 000 8 165 16 500 7 484 48 60 129 1 2 1 5 3 3 48x 60x 129 1 2x1 5x3 3 48x 60 x 129 1 2x1 5x3 3 4800 2177 4800 2177 4800 2177 Operating Weight lbs Kg 4900 222 4900 2222 4900 2222 500 vn 500 258 500 238 122 122 122 139 139 139 220 250 220 250 220 250 125 153 125 153 125 153 3 0 0 68 3 0 0 68 3 0
42. FLA 1 0 8 3 6 1 0 8 3 6 Tower Pump C flow gpm m Hr 78 1727 78 17 TDH minimum ft m 80 044 80 244 HP KW FLA 3 2 219 6 3 2 219 6 connections inlet x outlet FPT 4 x 3 4 x 3 shipping weight lbs Kg 65 29 5 65 29 5 Bohn Air Cooled Condenser BNHS04A029 BNHS04A029 of Fans HP 4 1 5 4 15 total KW FLA 4 5114 4 5114 inlet connection 2 1 8 2 1 8 outlet connection 13 8 13 8 shipping weight Ibs Kg 1520 690 1520 69 operating weight Ibs Kg 1265 574 1265 574 1 Nominal capacity is based on 70 F makeup water 100 F condensing temp 70 F amb and 0 blowdown 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 2 FLA for 200 volt models is approximately 2 times that of 380 volt models Total FLA does not include cooling tower 5 Tower sized for 80 F wet bulb temperature 3 Makeup water is maximum value and includes 10 gallons per cycle blowdown 6 Recommended air cooled condenser is based on 15 F TD Vogt reserves the right to change designs and specifications without notice Table 11 2 5 27 14 5 27 14 10TA Service Manual P18FXT Capacity Ratings 11 3 TABLES amp CHARTS Makeup Rated Capacity Ibs day Water 60Hz Temp Crushed Cylinder Deg F 1 11 4 11 2 1 114 11 72 1 11 4 40 21700 19100 17600 22568 19864 18304 21700 19100 19843 18283 21660 19080 42 21620
43. I rt e PERI SE c o EE 7 5 RTE iere ter cepere e ate aens eaten eaters 7 6 Lubrication Cor pressor 2 5 neuste ene ana ae acea aee i aee e ttv 7 6 Compressor Recommended Lubricants TABLE ID 7 6 10TA Service Manual TABLE OF CONTENTS Page No 7 MAINTENANCE cont Cutter Gear Reducers ou bric ation Z ee ee cds yest anat b 7 7 Preventive bev a aei entera dont Ae nett bab hte tds 7 8 For The Manager a RHEINE OIN ERE I REINO ES 7 9 Preventive Maintenance menda eno end E 7 10 8 TROUBLESHOOTING Last OP Symptoms ee RE ERR te ROT HUE RR ERR ERN EDI DDR EUREN e 8 1 Machine Won t iet eer REGI dE e Ra DER 8 2 8 3 Freeze Up Due To Extended Freezing Period anna EE A net enne 8 4 Freeze Up Due To Ice Failing To Discharge AA 8 5 Poor ce Qualityz uereg TU dis e IM dr e 8 6 LOW ACE Capacity EE 8 7 Low Compressor Oil Eeyel nineteenth te cde ats 8 8 High Head Pressure Water Cooled eerte netter rn pae keen eee eee ee een knee ena eee ene eR EE 8 9 High Head Pressure Air Cooled ye e roe e a RE e CH EE 8 10 9 SERVICE OPERATIONS Adjustable Blowdown For Clearer Jee 9 1 Water pump Blowdown Assembly FIGURE OI 9 1 Automatic Blowdown Harvest e dee ete teret pee E t dete Eee ue pg 9 1
44. PANEL ep eg J phase Motors CONDENSER FAN MOTOR 4 AMBIENT THERMOSTAT CLOSE AT 20 F N O SOLENOID VALVE A P SHUTS OFF 50 OF COIL AMBIENT THERMOSTAT CLOSE AT 60 F FAN CONTACTOR 152 ITN y a gt B en CU CONDENSER CONDENSER FAN MOTOR sn MOTOR 3 AMBIENT THERMOSTAT CLOSE AT 40 FAN CONTACTOR TS3 pe Oc A 2 CONDENSER d FAN MOTOR 1 FIGURE 3 7 Wiring For BOHN BNHS04A029 with Cold Weather Valve and Four Fans 50 50 Condenser Split 4 4 14 3 14 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE Air Cooled Connections See FIGURE 3 2A for connection sizes Follow these procedures to make a tight joint 1 Silver solder or braze condenser tubing ends to the female Rota lock connectors Remove dust caps if used making sure that component plastic seals are intact 3 Wipe off connector and spud threaded surfaces with a clean cloth to prevent the inclusion of dirt or any foreign material in the system 4 Connector coupling nut should be screwed onto Rota lock spud using the proper amount of torque Spud Size Amount of Torque 7 8 1 1 8 13 87 TABLE 3 6 Rota lock Connector Torque Ratings Pressure Relief Valves Pressure relief valves are installed on the freezer receiver and the water cooled condenser These valves are designed to vent
45. eret nennen teer 9 16 Circulating Water Pump Motor FIGURE OU 9 17 C tter Gear Reducer FIGURE 9 13 SE geed 9 17 Component Removal and Replacement Operatons eese enne 9 18 Cutter Gear Redu cer ee 9 18 Water Tank Removal 9 19 Cutter amp Bearing Removal Installation Cutter Assembly FIGURE 9 14 9 20 Cutter Parts Cylinder Ice FIGURE 0 15 J ukanaka saan 9 20 Cutter Drive Parts FIGURE 9 16 5 sn Re RO ee EEG ERR REE 9 21 Ice Prod ction FIGURE O EES 9 22 Defrost Pressure Switch DPS R404A Machines only 9 23 Pressure Rehlet Valve na ier natant eae eter a tta ee antea ta tema e aue 9 23 Technical Service Bulletin Water quality U u tenente enne 9 24 10 OPTIONS AND ACCESSORIES Power Monitor FIGURE u X ER NESCIT BERNER NER ERE awaqpa ee 10 1 Power Monitor Parameters TABLE 10 1 10 2 PLC Programmable Logic Controller na EN AE E s 10 4 11 TABLES AND CHARTS Ratings 60 Hz TABLE nhe En oe pen de 11 1 PISFXT Ratings 50 HZ TABLE TI 5 u a sS Itc tap e ere EO RUP Pipe 112 PISEXI Capacity Ratings TAB E tastes dee eran ie et etu e P e t ets 11 3 Condenser Water Usage TABLE PIA aa
46. in emergency conditions This ensures vessel internal pressure does not exceed maximum allowable pressures Vent the relief valve outlet to a safe outdoor location in the approved manner away from people and building openings Vent line piping must have drain line at low point to drain condensate from line per ASME Boiler and Pressure Code Section Division 1 PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE BEFORE REPLACING RELIEF VALVE REVIEW REQUIREMENTS PER CURRENT LOCAL AND NATIONAL CODE VALVE REPLACEMENT SHOULD BE MADE BY PROPERLY TRAINED PERSONNEL ONLY NOTE IF RELIEF VALVE DISCHARGES VALVE MUST BE REPLACED AFTER DISCHARGING BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES PHONE 502 635 3000 4 14 14 10TA Service Manual 3 15 INSTALLING YOUR TUBE ICE MACHINE Ice Bin Thermostat Sensor Optional An electronic ice bin thermostat may be added to automatically cycle machine operation To assure proper protection for the machine or auxiliary equipment the sensor of the ice bin thermostat must be located so that ice will contact it when the bin is full See FIGURE 3 8 for typical mounting bracket The distance between the top of the ice bin and the sensor allows space for the machine to make an additional discharge of ice AFTER the ice contacts the probe This will vary based on the size of the bin and the ice distribution system employed
47. location of the bearing support on the side of tank 10 11 13 14 15 16 17 18 Loosen and remove the three cap screws from the bearing support ends and lift the support out of the water tank Drive the 3 16 x 1 2 pin located in the side of the support hub in and through the bearing wall Now the bearing can be pressed or driven out of the support hub Try the new bearing on the cutter shaft to make sure it turns easily 12 Press or drive the new bearing into the hub Be careful not damage the bearing surfaces the old bearing may be used as a driver Drill a 3 16 hole through the bearing wall using the original hub hole as a pilot Insert and drive the 3 16 pin flush with the outside of the hub making sure the pin doesn t extend beyond the inner surface of the bearing Slide the new bearing and support onto the cutter shaft to make sure it spins freely If it is tight ream the bearing inner surface slightly until it turns free Install the bearing support in the tank using the reference marks as a guide Slide the cutter and shaft into the bearing and check the cutter alignment By laying a straight edge across the tank top flange there should be 0 to 1 16 clearance between the rim of the cutter and the top of the tank flange Loosen the bearing support cap screws and drive the support arms up or down for the proper alignment Tighten the support screws securely and finish assembly of the cutte
48. n ato Hd sl e ZS gt 00 Lh FIGURE 4 2 Air Cooled Piping Schematic 4 14 2014 4 14 14 10TA Service Manual 5 1 START UP AND OPERATION Start Up and Operation Refrigeration System Review refrigeration system uses R 22 or R 404a refrigerant a compressor a refrigerant float switch expansion valve a flooded evaporator freezer and warm gas defrost Following the schematic you see that during the freeze period of the machine s cycle the condenser discharge gas leaves the compressor and goes to the condenser where it is condensed into liquid by the removal of heat by either air or water passing through the condenser A reservoir of liquid is accumulated in the receiver and flows as required passing through the thawing chamber a lower separate section of the freezer then the filter drier The liquid feed solenoid valves A1 and A2 being open during the freeze cycle allows the liquid to be metered by the float switch as the valve opens and closes in response to the refrigerant level in the freezer Wet refrigerant floods the ev
49. pressure Note Wire T1 passes through CT before connecting to compressor terminal The CoreSense module has power applied at all times to allow for more detailed fault notification An LED will flash when a fault occurs The number of flashes will identify the fault condition of Flashes Condition Oil Pressure Motor Protection Trip Discharge Temperature optional add on Current Sensor Fault Communication Error CORESENSE PROTECTION 220N OR nov 2 M Q CO Po L A for Copeland Discus Compressors WIRES COMPRESSOR CURRENT LOOP CT 1 RED amp 1 BLACK WIRFS IN HARNESS WIRES TO COMPRESSOR SS ge MOTOR SENSORS 3 ORANGE amp 1 BLACK WIRE ov COMPRESSORS IN HARNESS 1 I CoreSense Protection I I FIGURE 9 7B CoreSense Protection 4 28 14 10TA Service Manual 4 28 14 9 11 SERVICE OPERATIONS Description Vogt Copeland Crankcase Heater 100 W insert type 12A7509E12 518 0028 01 Oil Pressure safety switch Sentronics 12A2117A05 585 1076 02 Module and Sensor CoreSense Protection Module and Sensor 12A2117A07 943 0109 00 Oil safety sensor only For Semone Senones Lasso d NOB 998 0162 00 or CoreSense Oil Separator A helical oil separator is used to separate the oil from the discharge gas and return it to the compressor Oil may be drained from the separator through the angl
50. the right to change designs and specifications without notice Table 11 1 11 2 10TA Service Manual TABLES amp CHARTS P18FXT SPECIFICATIONS 380 Volt 3 Phase 50Hz Tube Size inches cm 1 Gan 11 4 317 Nominal Capacity Ibsiday Kg day 20 000 072 18 000 _ 8 165 Overall Dimensions LxWxH inches meters 48 60 129 1 2x1 5x3 3 48 x 60 x 129 1 2x1 5x3 3 Shipping Weight Ibs Kg 4800 2177 4800 2177 Operating Weight Is Kg 4900 2222 4900 2222 Refrigerant Charge R404A Ibs 500 238 500 238 Total FLA Water Cooled 66 5 66 5 Total FLA Air Cooled 75 75 Maximum Fuse WC AC 150 160 150 160 Minimum Ampacity WC AC 83 97 83 97 Water Requirements makeup Hr 3 0 068 3 0 0 68 condenser Hr 70 15 9 70 15 9 Connection Sizes ee makeup water 3 4 3 4 tank drain FPT 3 4 3 4 condenser water inlet FPT 2 2 2 condenser water outlet MPT 2 2 2 AC condenser inlet 21 8 21 8 condenser outlet ODC 1 3 8 1 3 8 Compressor HP KW FLA 241 17 9 62 5 241 17 9 62 5 Water Pump HP KW FLA 2 1 5 3 6 2 1 5 3 6 Cutter Motor HP KW FLA 05 04 11 0 5 0 4 1 1 THR Btwhr kW 275 000 73 3 275 000 Marley Cooling Tower 4822 4822 dim LxWxH ft meters 4x5x 6 5 12 1 5 2 0 4 5 x 6 5 12 1 5 2 0 shipping weight lbs Kg 650 295 650 295 operating weight Is 1260 571 1260 571 fan HP KW
51. to 3 GPH bleed depending on water quality the resulting mineral concentration in the water can cause rapid and heavy fouling inside the condenser tubes requiring excessively frequent cleaning Also these conditions often lead to severe corrosion Chemical additives including those to stop algae and related growths should be obtained only from a reputable established supplier and used specifically according to directions Excessive treatment of the water can cause more harm than good and the condensers pumps piping and the towers themselves may be damaged It is advisable to double check the system to make sure that fouling is actually causing the trouble High head pressure alone does not mean a fouled condenser The following possibilities should always be checked before cleaning is undertaken 1 Non condensables in system or faulty head pressure gauge Check standby pressures against refrigerant tables 2 Incorrectly set or defective water regulator valve Check its setting and operation 3 Partly closed compressor discharge service valve Check its setting Stem should be backseated 4 High water temperatures entering condenser Check tower fan and system After the above possibilities have been eliminated determine the temperature difference between the water leaving the condenser and the refrigerant condensing temperature saturation temperature from pressure temperature chart corresponding to head pressure If this diffe
52. valve on cylinder and purge air out of charging line at the charging valve connections 3 Open charging valve 4 Refrigerant can be added only during the freeze cycle The charging valve must be closed when the freezer is in a harvest In order to check the total charge in the system it is necessary to transfer all of the refrigerant to the receiver A total pump down procedure should be performed See the name plate for the approximate refrigerant charge for the machine Remember the total charge will vary for air cooled machines with remote air cooled condensers DANGER 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 overfilling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant DANGER 5 6 10TA Service Manual START UP AND OPERATION BLANK 4 14 14 6 1 10TA Service Manual ELECTRICAL CONTROLS 6 Electrical Controls PB2 ea e 27 7 FIGURE 6 1 Control Panel 4 14 14 6 2 10TA Service Manual ELECTRICAL CONTROLS OOO oXeXe eXeXe O O Q
53. various parameters To prevent tripping on a 1 volt change the DTP 3 automatically calculates cut in voltages for the return from undervoltage conditions The cut out voltage is always based on user voltage and tolerance settings while the cut in voltage is 3 closer to the nominal voltage setting This quality is sometimes referred to as hysterisis This is to help reduce oscillation that may occur on weak power distribution system When the load is switched off due to undervoltage the line voltage will increase Without the hystersis the monitor would switch the load back on the line voltage would again drop and cause a continuous on off on cycling 10 4 10TA Service Manual OPTIONS AND ACCESSORIES PLC Programmable Logic Controller Tube Ice machines are available with a Mitsubishi Fx n 24MR programmable controller expansion module and a Mitsubishi E1012 Operator interface The E1012 interface contains a real time clock and 6 programmable function keys that allow for easy screen navigation and enhanced machine operation over the standard Tube Ice machine mechanical controls Note The E1012 interface replaces the E150 and requires a 24VDC power supply to power the unit where the E150 was power by the plc The PLC Interface add features such as selectable Automatic Restart after a power failure choice of timed or pressure switch controlled freeze cycles and Freezer pumpdown For package units the machine wil
54. 0 288 0 60 1 22 9 23 0 63 6 40 0 126 171 4 281 6 305 2 187 5 207 0 336 0 296 7 62 8 24 5 246 66 5 42 4 128 176 2 289 1 312 9 193 1 213 0 345 0 305 7 65 6 26 1 26 2 69 4 44 8 130 181 0 296 8 320 8 198 9 219 0 354 0 314 8 68 4 27 8 27 9 72 3 47 4 132 185 9 304 6 328 9 204 7 225 0 364 0 324 2 71 3 29 5 29 6 75 4 50 0 134 191 0 312 5 337 1 210 7 231 0 373 0 333 7 74 3 31 3 31 3 78 5 52 7 136 196 2 320 6 345 4 216 8 237 0 383 0 343 4 77 4 33 2 33 2 81 8 55 5 138 201 3 328 9 353 9 223 0 243 0 392 0 353 4 80 5 35 1 35 0 85 1 58 4 140 206 6 337 3 362 6 229 4 250 0 402 0 363 5 83 8 37 0 37 0 88 5 61 3 142 212 0 345 8 371 4 235 8 256 0 412 0 373 8 87 0 39 1 39 0 91 9 64 4 144 217 5 354 5 380 4 242 4 263 0 423 0 384 4 90 4 42 0 41 0 95 5 67 6 146 223 1 363 4 389 5 249 2 269 0 434 0 395 2 93 9 43 3 43 1 99 2 70 8 148 228 8 372 3 398 9 256 0 277 0 444 0 406 1 974 455 45 3 102 9 74 2 150 2346 381 5 408 4 263 0 283 0 449 0 432 0 TABLE 11 7 All pressures are in Ibs in gage psig 5 27 14 10TA Service Manual REFERENCE INFORMATION CONVERSION FACTORS English to Metric To Convert Multiply by Area ft m 9 2903 2 m 6 416 e 4 Energy BTU Joule J 1
55. 054 48 hp BTU Hr 2546 2 kW hp 1 34 Length ft m 0 3048 in m 0 0254 Pressure Ibf ft Paschals 47 88 Ibf in psi Paschals 6894 76 in Hg psi 0 491 in psi 0 03612 Temperature C Tc 5 9 Tr 32 F 9 5 32 Volume f m 2 8317e 2 gal U S m 3 7854e 3 EE TABLE 11 8 CONSTANTS Specific heat of Water Specific heat of Air Tube Ice Density Ice Latent Heat Water Sensible Heat 1 Ton Refrigeration Atmospheric pressure Weight of Water 1 gpm water Weight of air 1 Horsepower 1 Kilowatt Gravitational accel Ice Melting Effect IME 1 BTU Ibm F 4 19 kI 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 Ibs ft 8 33 Ibs 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 9 11 7 TABLES amp CHARTS 11 8 10TA Service Manual TABLES amp CHARTS BLANK 7 2 14 5 30 14 10TA Service Manual 12 Index A A Valves 4 1 5 1 Accumulator 4 1 5 1 Adding Refrigerant 5 4 Air cooled Condenser Wiring 3 phase 3 12 Air Cooled Condenser 9 5 Air Cooled Condenser Data Air Cooled Condenser I
56. 187 4 104 4 121 0 203 0 165 5 24 2 2 8 3 1 26 3 10 2 92 103 1 173 7 192 9 108 2 125 0 209 9 171 4 25 8 3 6 3 9 28 0 11 4 94 106 5 179 1 198 6 112 1 129 0 215 0 177 5 27 5 4 5 4 8 29 8 12 8 96 110 0 184 6 204 3 116 1 133 0 222 0 183 7 29 3 5 5 5 7 31 6 14 2 98 113 5 190 2 210 2 120 1 138 0 229 0 190 1 31 1 6 5 6 7 33 5 15 6 100 117 2 195 9 216 2 124 3 142 0 235 0 196 1 32 9 7 5 7 7 35 6 17 1 102 120 9 201 8 222 3 128 5 146 0 242 0 203 3 34 9 8 5 8 8 37 4 18 6 104 124 7 207 7 228 5 132 9 151 0 249 0 210 2 36 9 9 6 9 9 39 4 20 3 106 128 5 213 8 234 9 137 3 156 0 256 0 217 2 38 9 10 8 11 0 41 6 21 9 108 132 4 220 0 241 3 142 8 160 0 264 0 224 4 41 0 12 0 12 2 43 9 23 7 110 136 4 226 4 247 9 146 5 165 0 271 0 231 7 43 2 13 1 13 4 46 0 25 4 112 140 5 232 8 254 6 151 3 170 0 279 0 239 2 45 4 14 4 14 6 48 3 27 4 114 144 7 239 4 261 5 156 1 175 0 286 0 246 9 47 7 15 7 15 9 50 7 29 3 116 148 9 246 1 268 4 161 1 180 0 294 0 254 8 50 0 17 0 17 2 53 1 31 3 118 153 2 252 9 275 5 166 1 185 0 302 0 262 8 52 5 18 4 18 6 55 6 33 3 120 157 7 259 9 282 7 171 3 191 0 311 0 271 0 54 9 19 9 20 0 58 2 35 5 122 162 2 267 0 290 1 176 6 196 0 319 0 279 4 57 5 21 4 21 5 59 9 37 7 124 166 7 274 3 297 6 182 0 202 0 328
57. 19060 17560 22485 19822 18262 21620 19060 43 21580 19040 17540 22443 19802 18242 21580 19040 44 21540 19020 17520 22402 19781 18221 21540 19020 45 21500 19000 17500 22360 19760 18200 21500 19000 46 21440 18960 17460 22298 19718 18158 21440 18960 19677 18117 21380 18920 48 21320 18880 17380 22173 19635 18075 21320 18880 49 21260 18840 17340 22110 19594 18034 21260 18840 50 21200 18800 17300 22048 19552 17992 21200 18800 19510 17950 21140 18760 52 21080 18720 17220 21923 19469 17909 21080 18720 53 21020 18680 17180 21861 19427 17867 21020 18680 54 20960 18640 17140 21798 19386 17826 20960 18640 55 20900 18600 17100 21736 19344 17784 20900 18600 56 20840 18560 17060 21674 19302 17742 20840 18560 19261 17701 20780 18520 58 20720 18480 16980 21549 19219 17659 20720 18480 59 20660 18440 16940 21486 19178 17618 20660 18440 60 20600 18400 16900 21424 19136 17576 20600 18400 19094 17534 20540 18360 62 20480 18320 16820 21299 19053 17493 20480 18320 63 20420 18280 16780 21237 19011 17451 20420 18280 64 20360 18240 16740 21174 18970 17410 20360 18240 65 20300 18200 16700 21112 18928 17368 20300 18200
58. 4
59. 4D amp 6D compressors before March 2011 The same oil pressure sensor is used for all Sentronic Oil Pressure Controls It mounts directly into the oil pump The sensor measures oil pump differential pressure It has an internal contact that opens on low oil pressure and signals the Sentronic electronic control module to begin time out The same contact closes when proper oil pressure is present and stops the module time out Should oil pressure fall below 7 9 PSID for a period of two minutes the Sentronic module will open the control circuit using its Normally Closed N contact and shut the compressor off Approximate oil pressure can be measured in the field Oil pumps are furnished with a Schrader valve mounted on the oil pump discharge port To measure oil pressure subtract crankcase pressure from discharge oil pressure Tripping of the oil pressure safety switch is a warning that the system has been without proper lubrication for too long a time Repeated trips of the oil pressure safety control are a clear indication that something in the system requires immediate remedial action 9 10 10TA Service Manual SERVICE OPERATIONS Sentronic Module 2D 3D 4D amp 6D compressors before March 2011 The Sentronic has in addition to the N contact used for compressor shutdown a Normally Open N O contact that can be used in an alarm circuit The Single Pole Double Throw S P D T contact of Sentronic can be electrically isolated from
60. 55 55555 5555 EOS NS 5255 SSO VOGT ICE LLC located in Louisville Kentucky since 1880 Sales 800 959 8648 Service 502 635 3000 Parts Your Local Distributor Call your local distributor first for all of your parts and service needs Since 1880 Manufacturers of Quality Tube Ice Machines Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M08 10TA Model 10TA Service Manual TABLE OF CONTENTS Vogt TUBE ICE MACHINES Model 10TA Includes P18FXT 1 INTRODUCTION A Brief History Of Our Company Vogt Energy Savings Tube Ice Machines eese enne enne PREVIEW Timportant Safety Notice s gs a EE MON etre ea bcne epe n pet epe Special Precautions To Be Observed When Charging Refrigeration Systems Safety Symbols and What They Mean uu lq s nha eene tenente Assembly Drawing Model 10TA P18FXT Air Cooled FIGURES 1 1 1 2 461 3 2 2 Assembly Drawing Model 10TA P18FXT Water Cooled FIGURES 1 4 1 5 amp 1 6 2 RECEIPT OF YOUR TUBE ICE MACHINE SPetr MR Safety Valves ettet ea RATER RI IRR ER ERR Machine Room temi am ete
61. 60hz coil CU P Starter 208 230v 50 60hz coil Compressor Contactor 208 230v 50 60hz Cutter motor 1 2 HP 3 ph Make up water float valve Lead Free Plastic Cutter bearing Gasket for freezer cover Gasket for water tank Crankcase heater 100W Insert type Copeland Discus Compressor Suction pressure gage R22 Discharge pressure gage R22 Suction pressure gage R404A Discharge pressure gage R404A Float Switch Assembly Coil for Hansen solenoid valve 208 240V 50 60HZ TO ORDER SPARE PARTS PLEASE CONTACT YOUR DISTRIBUTOR 11 6 TABLES amp CHARTS 5 27 14 DegF R 12 50 7 6 34 7 36 7 38 7 40 9 43 0 45 3 47 6 49 9 52 4 54 9 5 5 60 1 62 8 65 6 68 5 71 5 74 5 77 6 80 7 84 0 10TA Service Manual TEMPERATURE PRESSURE CHART
62. 75000 275000 275000 275000 275000 275000 275000 275000 275000 275000 Crushed Ice _ Size 1 1 1 4 1 1 2 3 00 2 62 2 54 2 92 2 58 2 49 2 84 2 53 2 43 2 74 2 47 2 38 2 49 2 25 2 16 2 25 2 02 1 94 Ice per cycle Average Ibs Suction Pressure Discharge Pressure Harvest Times psig psig secs End of Freeze Average during Freeze First Ice 15 15 20 15 105 15 105 15 105 15 120 15 120 20 120 240 15 105 240 15 105 200 20 105 Table 11 6 10TA Service Manual Freeze Time minutes 90 70 50 179 144 139 135 21 0 17 0 16 6 16 2 19 8 16 0 15 6 117 93 89 15 2 8 6 13 7 10 9 10 6 10 3 13 3 10 6 10 3 10 0 RES 16 2 144 13 9 21 0 17 0 16 6 17 9 16 0 19 8 16 0 15 6 15 2 11 7 93 89 8 6 13 7 10 9 10 6 11 8 10 3 10 0 10TA Service Manual QTY PART NUMBER 1 1 5 27 14 12A2117E04 12A7503E22 12A7517E27 12A7516E23 See Page 6 5 See Page 6 5 12A2900M0508 12A4200H0402P 12 2020 01 12A2600G15 12A2600G05 12A7509E12 12C2590G08 12C2590G09 12C2590G1 12C2590G11 12A7500E22 12 6229 11 5 TABLES amp CHARTS RECOMMENDED SPARE PARTS LIST Vogt Model P18FXT Tube Ice Machine DESCRIPTION Freezer pressure switch Thawing timer CR Relay 208 230v 50 60hz coil PF Contactor 208 230v 50
63. AI323M f Me T nae 69 3323393 90135 1 10TA Service Manual FIGURE 4 1 Water Cooled Piping Schematic 4 14 2014 4 4 10TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS GE 1 1 ISCHARGE OIL RETURN DISCHA ECEIVER 1 L Ne D lt 2 i e 2 M 00 ao J p LV 1 r Ny 1 E Es lt 5 Ba aay lt gt a gt m o m S 5 x gt v b 2 n e m 2 52 I 5 lt amp sit Ee MER s E 9 a N D DC M o E Ga v N 5 2
64. Condensers Maintenance Section 7 Air Cooled Condenser Visual inspection will indicate if dirt is accumulating and clogging the fin face of the condenser A vacuum cleaner compressed air or a brush may be used to remove an accumulation of dirt from the fin section of the condenser 9 6 10TA Service Manual SERVICE OPERATIONS Compressor Motor Protector Electronic Copeland compressors using solid state protection have PTC Positive Temperature Coefficient internal sensors with an avalanching resistance in the event of high temperatures The sensors are calibrated for proper motor protection The solid state sensor protectors provide excellent protection against high motor temperatures resulting from locked rotor loss of charge or motor overload The combination of low voltage sensing and time delay provide positive protection against low voltage conditions which can occur in the pilot circuit in the event of a single phase condition on a three phase circuit The low voltage protection feature removes the compressor from the line in the event of low voltage brown out conditions The module locks the compressor off the line until the voltage rises to the cut in setting The time delay provides a two minute delay before restarting each time the power circuit is opened Pressing the start button before the two minute delay will have no effect Service and test personnel must be alert to this feature since it is possible in checking th
65. During the thaw cycle the solenoid coil is energized The needle valve is seated on the upper port and the unloading plunger chamber is exposed to discharge pressure through the discharge pressure port The differential between discharge and suction pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders 4 28 14 4 28 14 10TA Service Manual 9 17 SERVICE OPERATIONS Circulating Water Pump Motor Part No 12 4020 601 60hz 12A4020G08 50hz The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water level above the impeller housing The pump is equipped with a mechanical seal that is self adjusting and requires no lubrication However the pump should not be operated unless circulating water The pump manufacturer recommends that a mechanical seal be kept as a spare When ordering a seal specify pump size type serial number and manufacturer s name as indicated on the nameplate Pump Discharge 1 1 2 FPT Pump Suction 2 FPT Seal Kit Part 12A4080S 12 a Pump Part 1244020601 60hz 12A4020G08 50hz FIGURE 9 12 Circulating Water Pump Cutter Gear Reducer Part No 12A4030R12 The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use M
66. EF VALVE DISCHARGES VALVE MUST BE REPLACED BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES PHONE 502 635 3000 4 15 14 10TA Service Manual 7 9 MAINTENANCE For The Manager Who Depends Upon This Machine For Efficient Operation Preventive Maintenance simply means that you or a delegated employee makes a daily visual check of your Tube Ice machine Here is what to look for and why Daily checklist 1 2 6 7 Is the machine running or is the bin full Bin doors kept closed Thermostat bulb in bracket Ice quality clarity and uniformity Does all ice discharge during harvest Cleanliness Unusual noises Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes in the operation of the machine which may require maintenance long before a service situation arises An ounce of prevention is worth a pound of cure 7 10 10TA Service Manual MAINTENANCE Note To Manager or Owner This page is a complete Preventive Maintenance Schedule that should be performed each 90 days The Preventive Maintenance page may be copied and given to your service person It should be signed dated and returned to you for permanent record Preventive Maintenance P
67. ENT SCREW CLOCKWISE RAISES PRESSURE Turn top screw to adjust the pressure setting also referred to as the Range Clockwise increase pressure setting thinner ice Counterclockwise decrease pressure setting thicker ice yo PANEL CABINET BACKING PLATE FIGURE 9 3 Freezer Pressure Switch The following procedure is recommended for initially setting a freezer pressure switch that has not been previously adjusted See FIGURE 9 2 1 Turn the bottom screw differential approximately 1 2 turn to the Left counter clockwise The pointer arrow which is at the top middle of the switch will be at the setting 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will be between 40 psi and 50 psi 3 After the machine is running the range adjustment top screw will have to be fine tuned to get the proper ice thickness Clockwise Thinner Ice Counter Clockwise Thicker Ice The freezing time can be such that a small percentage of the ice is frozen solid If so some ice from the top and bottom of the freezer should have a small hole in the center to insure that the freezing time has not been extended to where a loss in capacity would result It is preferable that the freezing cycle be such that a small diameter hole remains in the center of the ice cylinder 1 16 diameter for 7 8 d
68. ET AT 40 PSIG R 22 SET AT 52 PSIG R 404A CW RAISES SETTING DIFFERENTIAL ADJUSTING SCREW SET AT 20 PSIG CW RAISES SETTING RESET BUTTON Vogt Part 12A2117D02 LOW PRESSURE TEST CONNECTION HIGH PRESSURE 1 TEST CONNECTION HIGH PRESSURE ADJUSTMENT SET AT 300 PSIG 22 SET AT 350 PSIG R 404A CW RAISES SETTING DIFFERENTIAL FACTORY SET CE Approved machine Vogt Part 12A2117D01CE FIGURE 9 4 High Low Pressure Switch If it becomes necessary to install a new high low pressure switch the following procedure is recommended for its adjustment Turn the adjusting screws clockwise to raise the pressure setting Turn counter clockwise to lower the setting Adjust the switch to the indicated pressure settings and test with an accurate gage to be sure the switch functions properly before installation 7 1 14 10TA Service Manual 9 5 SERVICE OPERATIONS Head Pressure The head pressure should be maintained at 190 210 psig for R 22 and 230 250 psig for R 404a during the freeze cycle This pressure can be checked at the test connection in the high pressure line near the high low pressure switch Water Cooled Units A water regulating valve FIGURE 9 5A located in the condenser water inlet line is used to control the water flow through the condenser This valve should be adjusted to maintain a head pressure of 200 psig for R 22 and 235 psig for R 404a Increasing the water flow lowers the
69. G GAS STOP VALVE 90 CONTROL PANEL COMPRESSOR 3 LIQUID OUTLET STOP VALVE KING VALVE 58 WATER TANK 7 FIGURE 1 4 Assembly Water Cooled Front View A 1 7 INTRODUCTION HEAT EXCHANGER 13 LOW PRESSURE GAGE Es PG HIGH PRESSURE GAGE 2PG _ OIL PRESSURE P d SWITCH 94 HIGH LOW N N N N PRESSURE SWITCH 4PS HIGH PRESSURE TEST CONNECTION LOW PRESSURE TEST CONNECTION CIRCULATING WATER PUMP 6 1 8 INTRODUCTION SAFETY RELIEF VALVE 51 LIQUID RETURN STOP VALVE 91 OIL RETURN STOP VALVE
70. IAINIIA D 5 Ka a as UU Ju J 1 1 mip 0 1 SNOLLOHNNOO Ne 2 49 Wir OI XL E eo SSHOOV ANV NOLLV TIVLSNI Le 1 v WAWINI 21 NALA 401 E N E SS 4 SCI 8 1 1 X 4 SQVHWHL 1 1 SAI 8 X 4 84 ZI t 1 LOSOV96ETVTI 81 4 lt 1090V96 ZVZ1 LAVd SOIOHNNOO CATAL YOLOANNOO ATAI 320 TV LOS 101009 21 LUVd 01009 amp Luvd NO LIL 3OOT V LON N NOLL 320T V LOW XS x 2 gt T d SNISAL WASNAGNOD gt WIV LNAINHOVILV Q TAIA FIGURE 3 2 Connections and Space Diagram Air Cooled Machine 4 14 14 10TA Service Manual 3 4 INSTALLING YOUR TUBE ICE MACHINE 48 6 1 14471 8 1 T 2 SSHOOV 1IOSSH IdWOO HONV3IVS IO WAWININ NOLLOANNOD SSHOOV ANY NOLLV TIV LSNI HONV3IVST IO WOWINIW CT HOVdS LNdIOI4401S SdIAO ld 22 E 5 N SSHOOV ANVL IH LV A
71. Ice selector switch in the Ice position and machine operating in a freeze cycle PF Stops the machine when there is a power failure or interruption Also stops the machine when the high low pressure switch oil pressure safety control pump overload cutter overload compressor overload or the control circuit breaker is tripped If the Stop button was pushed any of the safeties tripped or there was a power outage the machine must be manually restarted by pushing the Start button SS Used to select operating mode of machine When in clean position only the water pump will run This allows cleaner to be circulated through the freezer without making ice In the off position the machine will shut down after the completion of a freeze and harvest period In the ice position machine will cycle on and off based on a control signal i e bin thermostat or timer or run continuously until manually stopped by setting the switch to the Off position T Controls the time of the thawing period TB amp TB1 Main terminal block numbered for multiple wire connections and ease of troubleshooting 2 Customer connections for auxiliary contacts on cutter pump and compressor contactors CE amp AUS approval TABLE 6 2 Description of Control Panel Component Function 4 14 14 4 4 14 10TA Service Manual 2 8 ELECTRON PROTECTION MODA COPULAND 40 60 COMPRESSORS
72. Ice button CAUTION 1 Set the Clean Off Ice switch to the Off position Do not use the machine disconnect to stop the machine If the disconnect is used the crankcase heater will be de energized and liquid refrigerant will migrate to the compressor 2 If ina freeze mode the machine will continue to run 3 At the completion of the freeze cycle the machine will harvest and stop The completion of a cycle ensures that all ice is removed from the freezer to prevent refreeze when the machine is restarted 4 If ina harvest the machine will complete the harvest and stop Operating Tips e If the operation of your machine is not controlled by a timer bin level control or some other mechanism to automatically start and stop ice production you should use ONLY the Clean Off Ice toggle switch to start and stop machine e By turning the Clean Off Ice selector switch to the machine will stop after the next harvest cycle Do not use the Stop push button or the machine disconnect for normal shutdown of the machine e Throw the Disconnect only in an emergency or for safety when performing certain service or repairs to the machine The compressor crankcase heater is de energized when the disconnect is thrown e The Start push button can be used to initiate a harvest cycle When it is pushed during a freeze cycle it will immediately initiate a harvest cycle 4 14 14 10TA Ser
73. NTING PLATE BOLTED TO CUTTER HOUSING 12A2250A108 ASSEMBLY 197450051805 CUT WASHER 5 16 S S ean 1 12A2215G1108 CAP SCREW 5 16 X 3 4 HEX HEAD 5 5 12 2160 0101 HUB SPLIT FOR CUTTER DRIVE GEAR 19T2615D01 DRIVE GEAR WITH TAPERED HOLE 12A2215F1112 CAP SCREW 1 4 X 1 1 4 HEX HEAD S S L 77 12422508107 LOCK WASHER 1 4 5 5 FIGURE 9 16 Cutter Drive Parts 4 28 14 9 22 10TA Service Manual SERVICE OPERATIONS Crushed Ice Production Your 10TA Tube Ice machine is capable of producing crushed ice with no loss of capacity However there are certain changes to be made in order to convert to crushed ice production Add Cutter Assembly 126413 2 Cutter Motor 3 4 HP 60hz 12A2900M0601 208 230V 460V 3 2 1 6A b 50hz 12 2900 0603 190 380V 4 2 2 1A 3 Gear Reducer 5 1 12A4030R 14 4 Motor Starter a 60hz 208 230V machine 12A7530E55UL 2 5 4 0A 460V machine 12A7530E54UL 1 6 2 5A b 50hz 200V machine 12A7530E56UL 4 0 6 3A 400V machine 12A7530E54UL 1 6 2 5A Change 1 Raise the freezer pressure switch setting to make ice 3 16 thick average 2 Reverse cutter direction 3 Reverse deflector Two people should normally accomplish this conversion process in 6 8 hours or less There must be ample room around the machine for the water tank removal It is recommended that you have good quality water when attemp
74. ODUCTION 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 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 4 14 14 1 4 10TA Service Manual INTRODUCTION THAWING GAS STOP VALVE Y 90 HEAT EXCHANGER s 13 CONTROL PANEL 0 Ao LOW PRESSURE GAGE 1PG HIGH PRESSURE GAGE 2PG OIL PRESSURE SWITCH 94 FAN CONTROL HIGH LOW SWITCH PRESSURE SWITCH 41A 4PS HIGH PRESSURE Socks TEST CONNECTION LOW PRESSURE TEST CONNECTION LIQUID OUTLET STOP VALVE KING VALVE 58 _ CIRCULATING WATER PUMP WATER TANK 6 7 FIGURE 1 1 Assembly Air Cooled Front View 4 14 14
75. RS THAT DO NOT HAVE CORESENSE PROTECTION CC a l FIGURE 6 4 6 9 ELECTRICAL CONTROLS COMPRESSOR WITH CORESENSE PROTECTION 45 amp 6D COMPRESSOR TERMINAL BOARD COMMON BLACK WIRE INTERNAL TEMPERATURE SENSORS ORANGE WIRES TO CORESENSE PROTECTION MODULE WIRE HARNESS CURRENT LOOP CT BLACK amp RED WIRE 51 52 53 COMPRESSOR JUNCTION BOX NOTE CURRENT LOOP USED ON ALL DISCUS COMPRESSORS TO DETECT WHEN IS RUNNING AND TO START MONITORING OIL PRESSURE NOTE ON 4D amp 6D COPELAND DISCUS COMPRESSOR INTERNAL TEMPERATURE SENSORS SEND SIGNAL TO CORESENSE PROTECTION MODULE TO PROVIDE OVER CURRENT PROTECTION NOTE ON 2D amp 3D COPELAND DISCUS COMPRESSORS HAVE INTERNAL LINE BREAK OVERCURRENT PROTECTION Compressor Schematic Detail All Voltages 50 60 Hz 6 10 10TA Service Manual ELECTRICAL CONTROLS BLANK 4 14 14 4 15 14 10TA Service Manual 7 1 MAINTENANCE 7 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 by setting the Clean Off Ice selector switch to Clean and starting and stopping the pump by the Start Manual Harvest and Stop switch For co
76. a MARCH 2011 E EE START PUSHBUTTON ESCHER I 1 1 I 12 I I I I I I I I I I I I I 1 I L we ss NORMALLY CUTTER STARTER AUX CONTACT we C NORMALLY OPEN PUMP SIARCEX Ai CONTACT NOTE CORESENSE ON ALL COMPRESSORS AFTER MARCH 201 neque e FIGURE 6 3 Control Circuit Electrical Schematic All Voltages 50 60 Hz ORCUTT BREAKER AH MENTARY For 020 480 57S MACHINES THIS CONNECTION NOT WAGNER OR COPELAND MONITORS AR COOLED Or Oh ELECTRICAL CONTROLS 6 7 10TA Service Manual 6 8 ELECTRICAL CONTROLS AIR COOLED MACHINES ONLY mes eer Bee 05 DISCONNECT CE AND AUSTRALI APPROVED MACHINE FIGURE 6 3A 3 Phase Power Electrical Schematic All Voltages 50 60 Hz 414 14 4 14 14 10TA Service Manual COMPRESSOR WITH ELECTRONIC MOTOR PROTECTION pe edi Eege r CM OL 22 COMPRESOR II TERMINAL BOARD SENSORS BROWN BLACK Electronic Motor Protector Module T2 2 1 COMPRESSOR JUNCTION BOX NOTE ELECTRONIC OVERLOAD PROTECTOR MODULE USED ON 4D amp 6D COPELAND DISCUS COMPRESSO
77. a full charge of refrigerant stored in the receiver Visually check all lines for mechanical damage If a leak is suspected check all joints with a Halogen Leak Detector All leaks should be reported to the Vogt Ice LLC to obtain authorization for repair CAUTION The approximate weight of the machine is 4900 pounds Always use equipment with adequate load carrying capacity CAUTION The machine frame has lifting lugs at each corner in the top for eyebolts and hooks to be used for lifting purposes if desired Lifting lugs should be used whenever possible CAUTION The Tube Ice machine is top heavy Secure to avoid tipping CAUTION If a forklift is used make sure its capacity is sufficient The forks must be wide enough apart to prevent tipping sideways and must extend beyond the extremities of the frame base structure The machine needs to be bound in place to prevent tipping Safety Valves Two safety pressure relief valves are an integral part of the packaged Tube Ice machine One is located in the low side of the system on the freezer and one is in the 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 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 from other sources sunlig
78. ain valve 15 open or leaking Controls for regulating freezing and thawing cycles not adjusted properly Excessively high head pressure Warm make up water for ice making Drain valve 12 open 8 7 TROUBLESHOOTING POSSIBLE REMEDY Check for and repair leaks and add refrigerant Check for a partially closed valve or an obstruction at the drier strainer solenoid valve or expansion valve The liquid line will normally have frost on the downstream side of a restriction especially as the suction pressure decreases Make sure the float switch is opening and closing Make sure the 1 valve is getting power Check the manual opening stem to make sure it is in the automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Remove freezer cover and clean the distributors See Water Distributors Section 7 Check water pressure 30 PSIG minimum recommended Check for a water restriction in the supply line or at the make up water float valve Repair replace or adjust float valve or close repair or replace water tank drain valve For highest capacity cylinder ice should have a small hole and crushed ice should be about 3 16 thick Check the freezer pressure switch and thaw timer for proper adjustment Section 9 Check water regulating valve or fan c
79. al start up Product Registration Form is located in the Owners Packet or can be found online at www vogtice com registration htm Piping and Drain Connections Figure 3 2A Air Cooled and 3 2B Water Cooled show locations and sizes for all connections CAUTION External shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 30 psig The maximum allowable pressure is 100 psig CAUTION Make up Water Tank Condenser Condenser Water In Drain Water In Water Out 1 2 MPT 1 FPT 2 FPT 2 1 2 TABLE 3 1 Water Supply and Drain Sizes condenser water outlet and water tank drain connections must be extended to an open drain or sump arranged for visible discharge Do not trap the water tank drain line as this will interfere with the operation of the automatic blowdown system CAUTION These lines must NOT be connected into a pressure tight common header due to the possibility that warm condenser water may back up into the water tank The condenser water outlet MUST be piped separately to the drain CAUTION Note Due to variations in water quality by geographic location water filtering or treatment may be required to reduce maintenance and inhibit hardness buildup on machine components tubes valves 4 14 14 3 2 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 14 14 Water
80. allows time for the motor to cool and the control circuit to reset WARNING Before checking the TI31AA model for its attached wiring sensor be aware that the sensor terminal has the same voltage as terminal 1 1 WARNING 2 Disconnect control circuit power to deenergize the module Connect a jumper wire across the control circuit M1 M2 terminals on the module control circuit terminal board This will bypass the control contact of the module 3 Reconnect control circuit power If the compressor will not operate with the jumper wire installed then the problem is external to the solid state protection system If the compressor operates with the module bypassed but will not operate when the jumper wire is removed then the control circuit relay or triac in the module is open 4 If after allowing time for motor cooling the protector still remains open the motor sensors may be checked as follows a Disconnect control circuit power to deenergize the module Remove the jumper of Step 2 Remove wiring connections from the sensor and common terminals on the module control circuit terminal board b CAUTION Use Ohmmeter with a maximum of 9 VAC for checking The sensors are sensitive easily damaged and no attempt should be made to check continuity through them with other than an ohmmeter Any external voltage or current applied to the sensors may cause damage requiring compressor replacement c Measure the r
81. aporator and is in contact with the outside of the ice making tubes in which water is being circulated The heat contained in this water passes through the wall of the tubes lowering the temperature of the water causing it to freeze and form a long tube of ice that adheres to the inside of each of the freezer tubes The flowing water keeps the accumulated ice clear by washing separated solids down into the sump area of the water tank The wet suction gas leaves the freezer and any remaining liquid droplets are removed by the accumulator and suction line heat exchanger The dry gas enters the compressor and is compressed then discharged to the condenser completing the cycle As the ice is formed in the freezer the suction pressure steadily reduces until it causes the freezer pressure switch to close initiating the harvest period During the harvest period the thawing gas solenoid valve the D valve is open allowing the warm high pressure gas to enter the freezer This heat melts a thin film from the outside of the ice reducing the diameter and letting it fall free from the freezer tubes This period lasts approximately 2 1 2 minutes Refrigerant Charge Included with the machine is the required charge approximately 500 165 of Refrigerant R 22 or R 404a depending on the model which has been isolated in the receiver 15 Before shipment of the machine the compressor service valves 34 35 and the stop valves in the various li
82. as solenoid valve 18 leaking Check the manual opening stem to make sure it through during the freeze cycle is in the automatic position stem screwed Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Float switch stuck or failed in the closed Check to make sure the float switch is opening position and closing Liquid feed A1 valve stuck open Check to make sure the 1 Valve is not in the manual open position Disassemble valve and inspect for debris which could hold the valve open 4 23 14 4 23 14 10TA Service Manual 8 5 TROUBLESHOOTING SYMPTOM Freeze up due to ice failing to discharge POSSIBLE CAUSE Insufficient heat for thawing because of low condensing pressure non condensables usually air in system low refrigerant charge or thaw gas pressure switch adjusted too low Thawing time too short Cutter or cutter disc does not turn Ice backs up into cutter or discharge opening jamming cutter Extended freeze period Compressor not unloading POSSIBLE REMEDY The head pressure should be maintained at approximately 210 PSIG for R 22 or 250 PSIG for R404a which relates to 105F 37 8C This is done by a water regulating valve water cooled units FIGURE 9 5A Section 9 or a Fan cycling switch air cooled units FIGURE 9 5B Section 9
83. by starting the machine in the clean mode and allowing it to run for several minutes To change direction of rotation for both cutter and pump disconnect power and reverse L1 and L3 incoming power wires at the compressor motor contactor Voltage Unbalance Voltage unbalance can cause motors to overheat and fail The maximum voltage unbalance between any two legs should be no greater than 2 Example Supply Voltage 230 3 60 Voltage Readings AB 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 Voltage Unbalance 100 x 4 224 1 78 Acceptable AC 227 224 3 Volts 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 two legs Current follows the path of least resistance therefore if terminal connection 1 1 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 L1 96 Amps 12 91 Amps Average 96 91 98 3
84. charge line by forcing some oil through the line before tightening the charging connection Cutter Gear Reducer The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil once a year Gear Reducer 10 1 Part 12A4030R12 Replacement food grade oil Part 19T3020C01 Vent Plug Vent Plug Texaco Cygnus 220 Oil Capacity 8 ounces Drain Plug Oil Level Plug Note Ventless gear reducer used after August 2010 FIGURE 7 2 Gear Reducer 7 8 MAINTENANCE 4 15 14 10TA Service Manual Preventive Maintenance A careful inspection of the Tube Ice machines refrigeration system for leaks and correct operational functions at time of installation will start its long satisfactory life of service In order to insure this degree of dependability a systematic maintenance program is recommended Therefore the following schedule is suggested as a minimum A Daily l 2 3 4 5 6 7 We 1 Check operating pressures suction discharge oil Check ice quality Check 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 oil trap Check make up water float valve adjustment ekly in addition to daily checks Check f
85. coming power to be connected to Power Distribution Block PDB AIR COOLED CONDENSER CONNTECTIONS Power for Fan Motors B7 B8 amp B9 AIR COOLED CONDENSER CONNTECTIONS Power for Condenser control circuit 11 amp 22 o 28245 AUX CONNECTIONS Cutter Motor Pump Motor amp Compressor Interlocks iit dE DEEN FIGURE 3 3 Control Panel Power Connections Standard Voltages Water Cooled Air Cooled F L A Min Ampacity Max Fuse F L A Min Ampacity Max Fuse 208 230 3ph 60 Hz 245 140 3 166 6 275 460 3ph 60 Hz 125 70 2 83 3 140 220 3ph 50 Hz 295 162 1 193 4 320 400 3ph 50 Hz 150 81 3 96 9 160 TABLE 3 2 Electrical Specifications 4 4 14 3 6 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 14 14 Phase Check CAUTION DO NOT attempt to start machine without priming pump and insuring proper rotation of both cutter and pump Refer to FIGURE 3 1 amp 3 2 space diagram for connection locations CAUTION Cutter and pump motor rotation are factory synchronized but must be checked at installation For ice production the cutter disc as viewed at the ice discharge opening should turn from left to right crushed rotation should be from right to left The pump rotation should match the marking on the pump housing The pump will need to be primed
86. d Remove the cover plate on the side of the frame to expose the condenser end plate e Remove the nuts water plates and gaskets from both ends of the condenser If the gasket does not lift off with the end plate do not try to pry it off The seal surface may be damaged which would cause a water leak To free a sticking gasket replace the water plate and tap it on the outside face with a mallet or a block of wood After a few taps the gasket will spring free and will then slip off with the water end plate f Gaskets need only be rinsed in running water rust scale or dirt will not stick to gasket material A rag or soft brush is all that is required to remove any foreign matter Part II The inside of the water end plates and the outer tube sheet surfaces should be cleaned only with clear water and a rag or a soft bristle brush A worn paint brush is excellent These surfaces have been coated with a special material which will give years of protection against corrosion unless damaged Never use a wire brush or a strong caustic on these surfaces 7 6 10TA Service Manual MAINTENANCE Flush condenser tubes clear with air water or a piece of rag on a stick or wire In many cases this is all that is required If the inside surfaces are smooth even though discolored further cleaning is not necessary It is useless to try and get a bright copper surface on the inside of the tubes They will discolor almost immediately in service and the co
87. d install the terminal cover 10 Check motor rotation to make sure the cutter turns in the proper direction Reverse two wires at the motor if necessary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 16 1 Turn power off and lockout disconnect 2 Remove motor from reducer 3 Loosen slightly the four bolts and nuts holding the gear reducer in place 4 Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove the reducer and mounting plate from the tank Measure the distance between the top of drive gear and the mounting plate for future reference D Remove the three cap screws from the gear and hub and install two 1 4 20 x 2 long all thread set or cap screws in the threaded holes of the drive gear These two screws can be used as jacking bolts to remove the gear from the tapered split hub The split hub can be removed by driving a screwdriver in the split and sliding the hub off the shaft The new gear reducer can then be installed by reversing the removal procedure oo Be sure the gear and hub is properly positioned on the shaft so it will have a full vertical mesh with the cutter ring gear 10 Final gear meshing should be adjusted so there is only a slight amount of play between the ring gear and drive 11 Make sure all bolts are tightened securely and there is no excessive gear noise when the cutter motor is r
88. designed piece of equipment If you have additional questions please call your distributor Also feel free to phone the factory direct at 502 635 3000 or 1 800 853 8648 1 2 10TA Service Manual INTRODUCTION Important Safety Notice This information is intended for use by individuals possessing adequate backgrounds of electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in personal injury and 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 Special Precautions To Be Observed When Charging Refrigeration Systems Only technically qualified persons experienced and knowledgeable in the handling of refrigerant and 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 refrigerants 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 R 22 R404A 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
89. e View 1 6 10TA Service Manual INTRODUCTION EN m SAFETY RELIEF _ VALVE 50 Ser COLD WEATHER J SOLENOID VALVE P X VALVE 7 53 27 4 Rik J 1 i RECEIVER 15R 2 EN RECEIVER Ch SIGHT GLASS sx gt 30 M OIL THAWING GAS _ ao SOLENOID VALVE D VALVE 18 RECEIVER DRAIN CUTTER MOTOR VALVE 44 5M p GEAR REDUCER Si 58 no 21211 1 2 MPT 22 MAKE UP WATER CONNECTION MAKE UP WATER FLOAT VALVE 12 FIGURE 1 3 Assembly Air Cooled Left Side View 4 14 14 4 14 14 10TA Service Manual CONDENSER 15 THAWIN
90. e compressor or system power may be applied disconnected and reapplied in less than two minutes In such case the time delay feature will prevent operation until the time delay has expired and this may be misinterpreted by service personnel as a module malfunction The time delay would be energized in the event of a discharge pressure or short circuit protector trip low voltage or a break in the power supply to the module The time delay is not energized on opening of the high or low pressure switches There are two major components in the protection system 1 The protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resistance 2 The control module is a sealed enclosure containing a relay or triac transformer and several electronic components Leads from the internal motor sensors are connected to the module as shown on the wiring diagrams While the exact internal circuitry is quite complicated basically the module senses the change in resistance of the sensors As the motor temperature rises or falls the resistance also rises or falls triggering the action of the control circuit at predetermined opening and closing settings Protector modules have two terminals on the module marked T1 T2 or L1 L2 These are to be connected to a power source of the proper voltage normally the line terminals on the compressor
91. e connections that mechanical pressure switches require to measure differential oil pressure These require careful handling and are known to be a source of leaks in refrigeration systems A second advantage of Sentronic is in the use of a precise electronic clock for the two minute time out circuit Traditional mechanical controls use resistance heaters to provide the time to trip in the event of low oil pressure 208 volt systems low ambient temperatures or brown out type conditions cause the heater output to be reduced thus increasing the time out period from two minutes to three or four minutes when low oil pressure conditions exist With the electronic clock the time out will always be the same As a result of the elimination of the capillary tube measuring system and a more precise timing circuit Sentronic will improve the overall reliability of the refrigeration system As in the past all new and replacement Copelametic compressors equipped with oil pumps require the use of a Copeland approved oil pressure safety switch Failure to use an approved oil pressure safety switch will be considered as misuse of the compressor and can adversely affect warranty replacement of the compressor should a lubrication connected failure occur Sentronic Oil Safety Control Entire Unit Part 12A2117A05 Sentronic Oil Safety Sensor Only Part 12A2117A0501 FIGURE 9 7A Sentronic Oil Pressure Safety Control Sentronic Sensor 2D 3D
92. e is no liquid refrigerant in the compressor crankcase prior to re starting the machine High Low safety pressure switch tripped If the machine stops by low pressure cut out the switch will reset automatically when the pressure raises to the cut in setting If it stops by high pressure cut out the switch will have to be manually reset after the pressure drops below the cut in setting Check switch settings and push the Start push button to start the machine in a thawing cycle Check the head pressure during the next freeze cycle See FIGURE 9 4 Section 9 High Low Pressure Switch 4 23 14 10TA Service Manual 8 3 TROUBLESHOOTING SYMPTOM Machine won t run CONT POSSIBLE CAUSE POSSIBLE REMEDY Low oil pressure switch tripped If the machine stops by low oil pressure cut out the switch will have to be manually reset Check the crankcase oil level Restart the machine by pushing the Start push button Check the oil level and net oil pressure net oil pressure pressure reading at the oil pump end bearing housing minus suction pressure The oil level should be 1 4 3 4 level in the glass If above 3 4 drain some oil out See page 9 9 Section9 Oil Pressure Sensor Cutter motor overload tripped Check and clear the cutter area and discharge path of all ice Check voltage and overload range adjustment against motor rating Reset the switch and restart the machine by the START push button Check the cut
93. e power run and error status of the PLC When power is on to the PLC and the run stop switch is in the run position the power and run indicators will be illuminated A solid or flashing error light indicates a processor or program error The LED indicators on the upper right hand side of the PLC indicates the input status and LED indicators on the lower right hand side of the PLC indicate the output status If the input X indicator is illuminated then the PLC is receiving the input If the output Y indicator is illuminated then the PLC is sending the output Use of these LED s will be helpful in troubleshooting the machine 10 6 OPTIONS AND ACCESSORIES 10TA Service Manual MITSUBISHI OV Y6 Y10 YO Yi YZ YS COM 2 v4 CO 4 Y7 Y 11 2 2 2 2 2 2 2 B o o 2 1019 9 9 x S Ox n S N a o S 2 lt lt N N lt N Mitsubishi ix 24MR PLC and FX s SER ES UL FIGURE 10 3 Mitsubishi PLC Inputs Description Outputs Description 0 Not used 0 Not used 1 Not used 1 High Side Control Interlock 2 Start Manual Harvest Button 2 Conveyor Control Contact 3 Selector Switch Clean position 3 ET
94. e should be kept to a minimum Long vertical rises should have traps every 20 feet Typical details are shown in FIGURE 3 6 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest The discharge and liquid lines must be insulated with 1 2 thick Armaflex insulation or equal Use only ACR grade copper pipe Type L Recommended line sizes are shown in TABLE 3 3 For field attachment instructions see FIGURE 3 4 Distance between ice machine and condenser must not exceed 150 equivalent feet Refer to Condenser Equivalent Line Size worksheet see TABLE 3 5 Condensers must be provided with a cold weather valve kit per FIGURE 3 5 These valves allow one half of the condenser to be disabled in cold weather Running the ice machine with one half of the condenser in cold weather makes it easier to maintain minimum necessary condensing pressure particularly in windy conditions Condensers with multiple fans must be provided with a thermostat to turn off unneeded fans in cold weather Turning off unneeded fans reduces on off cycling of the fan s and allows for a steadier condensing pressure and more consistent warm gas for ice harvesting 3 8 4 14 14 INSTALLING YOUR TUBE ICE MACHINE 14 When extreme cold conditions are expected or encountered temperatures below and wind greater than 15 MPH it may be nec
95. e valve located on the bottom of the oil separator If necessary the oil return float mechanism may accessed for cleaning or replacement by removing the bottom flange Note Make sure oil is drained and the pressure removed from oil separator before disassembling Discharge line from compressor Oil Separator Vogt Part 12A3025S08 Add 25 ounces of oil when installing new Oil return shutoff valve Note Valve may be located at compressor Oil return line to compressor FIGURE 9 8 Oil Separator Compressor Crankcase Heater 100Watt Part No 12A7509E12 When electrical power is supplied to terminals L1 L2 amp L3 of the control panel the crankcase heater is energized when the machine is not operating It is de energized when the compressor contactor is energized Control Circuit Protection Part No 12A7504E1 The electrical control circuit of the machine is protected by a 2 Pole 3A circuit breaker If the breaker should open the machine will immediately stop Before resetting the breaker open the disconnect switch to machine and set the Clean Off Ice selector switch to the off position If the machine was off for an extended time the crankcase heater must be energized for a minimum of two hours before restarting the machine When ready to restart the machine set the Clean Off Ice selector switch to Ice and depress the Start button The machine will start in a harvest and begin a new freeze cycle upo
96. ecommended that the tubes be blown out individually with air Alternatively a minimum of 25 ethylene glycol in the system will also prevent a freeze which can rupture the tubes 7 1 14 4 23 14 10TA Service Manual 7 5 MAINTENANCE Chemical Cleaning Vogt Ice LLC makes no recommendation for any particular chemical reparation The same chemical may not be effective for all situations CAUTION The following directions and precautions should be observed when cleaning is undertaken The warranty on condensers is void if they are damaged by improper cleaning tools or methods If harsh chemicals are used be sure to follow the manufacturer s recommendations regarding safety in handling those solutions CAUTION a Use only preparations from an established reliable source b Follow directions exactly particularly regarding amounts to use and flushing or neutralizing procedure after cleaning c Close the water supply stop valve Remove the condenser water regulating valve 41 d Circulate the solution through the condenser until it is considered clean e Flush the condenser according to directions f Install the water regulating valve and connecting piping Open the water supply stop valve and check for leaks Mechanical cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser
97. erating Maximum flooded R 404a Condenser Dimensions inches See Fig 3 7 A Width B Length C Height D Leg centerline E Leg centerline F Clearance below Recommended Line Sizes OD Liquid All lengths and orientations Discharge Gas Vertical Up all lengths Horiz or Down lt 75 ft Horiz or Down gt 75 ft Connections Condenser Liquid ODF Discharge Gas ODF Connections Ice Machine Liquid ODF Discharge Gas ODF TABLE 3 4 3 9 INSTALLING YOUR TUBE ICE MACHINE 04A029 427 500 393 300 45 46 233 16 49 15 38 106 15 3 20 5 1 3 8 1 5 8 1 5 8 2 1 8 1 3 8 2 1 8 1 1 8 1 3 8 Air Cooled Condenser Data 3 10 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE ELECTRICAL CONNECTION BOX THIS END ___ DIA MOUNTING HOLES E MOUNTING HOLE CENTERS MOUNTING HOLE CENTERS FIGURE 3 4 Condenser Dimensions Machine Bohn Part Vogt Part Coil Split 18 BNHS04A029 12 2115 11 50 50 Note Condensers listed above 200 208 230V 50 60hz 400 460V 50 60hz available 4 14 14 10TA Service Manual SOLENOID VALVE 3 11 INSTALLING YOUR TUBE ICE MACHINE AIR DISCHARGE INLET HOT GAS DROP 12 MIN OUTLET 4 LIQUID RETURN VALV NOID 501 oT plow M vALVE ga LET LINE CHECK VALVE
98. esistance from each sensor terminal to the common terminal The resistance should be in the following range 500 ohms cold to 20 000 ohms hot compressor tripped Resistance readings in this range indicate the sensors are good A resistance approaching zero indicates a short a resistance approaching infinity indicates an open connection Proper operation of the control system is dependent on a continuous parallel circuit through all three sensors with no individual resistance reading higher than 10 000 ohms On initial start up and after any module trip due to high temperatures the resistance of the sensors must be below the module reset point before the module circuit will close Reset values are 2700 4500 ohms 5 If the sensors have the proper resistance and are below 2700 ohms resistance the compressor will run with the control circuit bypassed but will not run when connected properly the solid state module is defective and must be replaced The replacement module must be the same voltage and be compatible with the original module on the compressor 4 28 14 4 28 14 10TA Service Manual 9 9 SERVICE OPERATIONS Sentronic Oil Pressure Safety Control 4D amp 6D compressors before March 2011 The Sentronic utilizes a pressure sensor and an electronic control module to precisely measure oil pump differential pressure The main advantage of Sentronic is the elimination of the traditional capillary tubes bellows and pressur
99. essary to install a protective enclosure around the condenser Apparatuses such as louvers may also be used for varying conditions Contact the factory for suggestions 15 After installation the field installed lines are to be evacuated to a vacuum of 500 microns or less and held for at least one hour After the vacuum pump is removed vacuum should hold at 500 microns or less for at least 5 minutes 16 The machine is shipped with a full operating charge of refrigerant sufficient to fill the condenser and connecting lines If the condenser piping is longer than 50 feet one way additional R 22 or R 404A may need to be added to retain enough refrigerant in the receiver for thawing purposes see table Refer to the operating level mark on the receiver and charge accordingly Each 1 of liquid level in the receiver equals approximately 5 5 pounds of R 22 or R 404a Liquid Line Size 75 ft 125 ft 150 ft 1 2 none None 2 5 8 none 4 6 7 8 none 8 12 1 1 8 none 12 18 TABLE 3 3 Pounds of R 22 R404A to Add vs Liquid Line Length 17 All piping must be done in accordance with applicable local and national codes Such codes may include Safety Code For Mechanical Refrigeration ANSI B9 1 and Code For Refrigerant Piping ANSI B31 5 18 The following installation guidelines are strongly suggested While they do not affect the machine warranty they may be required for safe operation and to com
100. head pressure and decreasing the water flow raises the head pressure The valve is adjusted during the factory test The valve stem should not be opened as far as it will go or the valve will not close fully when the head pressure drops below its setting Air Cooled Units The condenser fan switch mounted to the frame lower right side FIGURE 9 5B CPS is used to regulate the head pressure This is an adjustable pressure switch located on the right hand front of machine It controls the operation of the condenser fan motor s through a contactor FC FIGURE 6 2 located in the control panel The switch is set to cycle the fan motor s On at 210 psig and at 190 psig for R 22 On at 250 psig and at 230 psig for R 404a Higher settings may be necessary for and below ambient conditions to assure there is enough warm gas for ice harvesting CUT IN ADJUSTING SCREW SET AT 210 PSIG 22 SET AT 250 PSIG R 404A ADJUSTING STEM SET AT 200 PSI R 22 SET AT 235 PSI R 404A CW LOWERS SETTING CW LOWERS SETTING CUT OUT ADJUSTING SCREW SET AT 190 PSIG 22 SET AT 230 PSIG R 404A CW RAISES SETTING Vogt Part 12 2117 05 CONNECTED TO 2 CONNECTED CONDENSER COMPRESSOR DISCHARGE CE Approved machine Vogt Part 12A4200E1401 Vogt Part 12 2117 05 FIGURE 9 5A FIGURE 9 5B Water Regulating Valve Condenser Fan Switch Condenser Cleaning See Water Cooled
101. hen the expansion valve 17 and capillary At the expansion valve 17 and capillary feed the refrigerant is taken from a saturated liquid state of relatively high pressure and expanded to a very low pressure low temperature liquid The A2 21 solenoid and capillary feeds liquid to the freezer 2 during the entire freeze cycle The float switch 22 is wired to the 1 solenoid valve 20 The float switch energizes and de energizes the 1 solenoid in response to the level of refrigerant in the freezer The cold liquid refrigerant enters the freezer where it absorbs heat from the circulating water This cool gas is pulled out of the freezer at the suction outlet thereby completing the circuit The freezing period is completed by action of the freezer pressure switch in the control panel The water pump 6 is stopped and solenoid valves 1 amp 2 20 amp 21 are closed The thawing period then begins Solenoid valve D 18 is opened the cutter motor 5M is started and the harvest thaw timer is activated Warm gas from the receiver is discharged into the freezer through valve 18 thereby slightly thawing the outer edge of the ice which drops on the rotating cutter for sizing See Freezer Period and Harvest Period for more detailed description of operation 4 2 10TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 7 1 2014 Air cooled machines have a solenoid valve 53 sometimes referred to as
102. ht 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 NEMA 1 Therefore the machine should not be located in a hazardous area or sprayed with water The machine should be installed on a drainable condensate drip pan or in an area where water will not stand but will readily drain away from the machine See Space Diagram for clearances and utility connections FIGURES 3 2A and 3 2B 2 2 10 Service Manual RECEIPT OF YOUR TUBE ICE MACHINE Storage prior to installation or start up The machine must not be stored or installed in an area that may reach temperatures 115 F 46 1 C or above CAUTION This equipment contains HCFC 22 or HFC 404a refrigerant under pressure Do not store in an area exposed to temperatures above 115 F 46 C or in direct sun at temperatures above 105 F 40 C CAUTION The machine nameplate is located on the front of the control panel The model number and machine description are located in the top left hand corner The following figure can be used to verify that the correct model has been received Nominal Capacity XXXX XXXX XXXX XXX 02K 2000 Ibs day K 1000 s Ibs day tons day 03K 3000 Ibs day 04K 4000165 day Consult Specifications for Actual Capacity 3 tons day OST 5 tons day 107 10 t
103. iameter ice 1 8 diameter for 1 1 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 9 4 10TA Service Manual SERVICE OPERATIONS 4 28 14 Capillary Bypass The capillary bypass is located directly following the 2 solenoid The 2 solenoid should be energized Open during the entire freeze cycle The function of the capillary bypass is to meter a set minimum amount of refrigerant to the freezer during the freeze cycle thereby reducing cycling of the float switch High Low Pressure Switch The high low pressure switch HPS FIGURE 9 4 is a two pole dual function switch Located in the machine mounted to the frame near 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 and the cutout set at 20 psig for R 22 The LOW pressure cut in should be set at 52 psig and the cutout set at 28 psig for R 404a NOTE After tripping at the cutout setting the switch will reset automatically when the pressure rises to the cut in setting The HIGH pressure cutout should be set at 300 psig for R 22 and 350 psig for R 404a After tripping reset the switch manually RANGE ADJUSTING SCREW S
104. ice Manual Parameter Minimum Maximum Default Recommended Settings Unit Line Side Voltage Nominal Voltage 90 650 208 Supply voltage Volts Over Voltage tolerance 6 18 12 10 96 Under Voltage tolerance 6 18 12 10 96 Phase Unbalance 2 25 6 96 Lockout Time Delay on Break 0 1 25 0 5 Seconds Delay Time Delay on Make 0 30 0 Seconds Response Time Delay on Fault 0 1 20 2 Seconds Control Mode Off Auto On Auto N A Contactor Test OFF 5 OFF Volt Diff TABLE 10 1 Power Monitor Parameters Parameters adjustment in order of display Active display of Line Voltage this is the default normal display Active display of Load Side Voltage if connected Voltage Set Point VAC Flashes The value may be adjusted by pressing the up and down arrows This may be set to the normal operating voltage of the device being protected in one volt increments Under over Voltage Tolerance in UNDERVOLTAGE OVERVOLTAGE flashes The value may be adjusted by pressing the up and down arrows Imbalance Voltage Tolerance in IMBALANCE flashes The value may be adjusted by pressing the up and down arrows Lockout Time in seconds SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the delay on break timer value Delay time in seconds and tenths of seconds RESP SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the
105. ice Manual 9 15 SERVICE OPERATIONS Solenoid Valves All solenoid valves are pilot operated with floating type diaphragms For satisfactory operation be sure that the manual opening stem is in the closed or automatic position This means the stem is backed all the way out Correct direction of stem rotation should be labeled on the stem seal nut Hansen 1 1 4 Solenoid Valve Part No 12A4200A1001 208 230V coil Part No 126229 h DUR _ STAINLESS STEEL PISTON S aiino CLOSING SPRING PISTON Hansen Rebuild Kit HS7 Part No 12A4199V52 MANUAL OPENING STEM FIGURE 9 10A Thawing Gas Solenoid Valve D Valve WATERTIGHT MOLDED COIL lt STAINLESS STEEL CLOSING SPRING STAINLESS STEEL PISTON TEFLON DISC TAPERED SEAT MANUAL OPENING STEM Hansen Rebuild kit HS8 Part No 12A4199V51 Liquid Feed Solenoid Valve 1 amp 2 Valve FIGURE 9 10B 4 28 14 9 16 10TA Service Manual SERVICE OPERATIONS Capacity Control Valve Internal Construction A schematic illustration of the internal valve operation is shown in FIGURE 9 11 Part No 12A2110P0907 In the normal full capacity operating position with the solenoid valve de energized the needle valve is seated on the lower port and the unloading plunger chamber is exposed to suction pressure through the suction port Since the face of the plunger is open to the suction chamber
106. icient amount of oil remains in the crankcase While it is important to observe the oil splash during operation the true level can be obtained only when the compressor is stopped With the compressor idle the oil level should be at a height of 1 4 to 1 2 of the sight glass but never out of sight above it The machine is properly charged with oil for the test operation but it may be necessary to add some oil when or if new refrigerant is added to the system Generally air cooled machines will require additional refrigerant and oil to compensate for long piping runs to the condenser Refrigerant Recommended Lubricants Type of Lubricant 22 R 22 Suniso 3GS Texaco WF32 Calumet 15 Witco Mineral Oil R 404A Mobil EAL ARCTIC 22 CC ICI Virginia KMP Emkarate Polyol Ester Oil RL 32S TABLE 7 3 Recommended Lubricants Compressor HP Oil Charge 0z 6DYN amp 6DY3 21 140 6DNN amp 6DN3 2 140 7 4 Compressor Oil Capacity 4 15 14 10TA Service Manual 7 7 4 15 14 MAINTENANCE An oil pump should be used to force any oil that may be required into the system Oil may be added to the compressor through the oil separator oil return line fitting on the compressor or the compressor suction service valve The compressor suction service valve should be back seated to shut off pressure to the gauge port when connecting the oil pump Air should be purged from the oil pump dis
107. l Controls 6 1 Enclosure 6 1 Energy Saving 1 1 Equivalent Feet Due To Friction 3 11 Fan Contactor FC 6 2 6 4 6 5 6 6 Filter Drier 4 1 Float 9 2 Float Valve Make Up Water 9 1 Freeze Period Freeze Up Due To Extended Freezing Period 8 4 Freeze Up Due To Ice Failing To Discharge 8 5 2 4 1 Freezer Pressure Switch 9 3 G Gear Reducer 9 17 H Hand Expansion Valve 9 3 Harvest Period 4 2 Head Pressure 9 5 Heat Exchanger 4 1 Heater Crankcase 9 11 12 2 INDEX H Cont High Head Pressure Air Cooled 8 10 High Head Pressure Water Coo
108. l automatically Pumpdown before cycling off The PL C Interface provides programmable e Cutter delay amount of time at start of harvest before cutter comes e Conveyor control contacts delay at start of harvest before conveyor comes on and run time e Automatic Restart after a Power Failure enable disable e Auto restart time delay time before restarting recommended 2 hours for package machines The PLC provides Machine Fault indication with an alarm relay The PLC will log when the fault occurred time and date and were in the cycle the machine was when the fault occurred Machine Faults Compressor high discharge pressure e Compressor low suction pressure e Compressor oil pressure Compressor motor fault e Cutter motor overload e Water pump motor overload e Long cycle a freeze cycle lasting more than 60 minutes e Short cycle 3 consecutive freeze cycles 5 minutes or less in duration e Power failure Power return Pumpdown Cycle Package Machines When machine is turned off or the bin control tells the machine to cycle off the machine will complete the harvest cycle then go to the Pumpdown Mode During the Pumpdown cycle the compressor and water pump will be on When the FPS freezer pressure switch makes the machine will go through a 60 sec Pumpdown harvest Note Pumpdown harvest can be turned off using the Main Setup screen After completing this short harvest the machine will con
109. late voltage Low voltage requires the motor windings to carry more current at the same compressor load When this current gets too high or is applied for an extended period the motor windings overheat resulting in a failure or burnout 2 Loss of refrigerant The hermetic compressor motor is maintained at proper operating temperature by passing cool suction gas over the motor windings A loss of refrigerant can cause the winding to overheat resulting in a failure or burnout 3 High head pressure The system is designed to operate at 200 psig Excessive head pressure adds refrigerating load on the compressor that can cause the windings to overheat and result in a failure or burnout 4 Moisture Moisture in contact with refrigerant oil and the presence of heat will form hydrochloric or hydrofluoric acid The acid will destroy the insulation on the motor winding causing a short circuit which can increase motor temperature in excess of 3000 F This extreme temperature will also create a sludge or black residue in the system 5 Mechanical failure Mechanical failure has been determined as a major cause of motor burnout Bearing wear or wipe out may allow rotor to drag overheating the windings and burnout Whenever there is a compressor failure due to a motor burnout it is important that the system be thoroughly cleaned before replacing the damaged compressor or otherwise the new compressor may also be damaged 4 28 14 10TA Serv
110. led 8 9 High Low Pressure Switch History Tube lce 1 1 HMI Interface 10 5 Hub Cutter Drive Gear 9 21 1 Ice Bin Thermostat Location 3 13 Ice Capacity 11 3 Important Safety Notice 1 2 Inspection First Arrival 2 1 1 3 1 Installation Review A Checklist 3 14 Introduction 1 1 J L Low Compressor Oil Level 8 8 Low Ice Capacity 8 7 Low Pressure Switch Lubrication Lubrication Compressor 7 6 Lubrication Cutter Gear Reducer 7 7 M Machine Ratings 50 Hz 24 HP 11 2 Machine Ratings 60 Hz 21 HP 11 1 Machine Room 2 1 Machine Won t Run
111. ling tower needing maintenance Non condensables usually air in system Fouled dirty condenser POSSIBLE REMEDY Adjust or replace the valve Never adjust the valve stem as far open as it will turn because it will not close when the head pressure drops Check size of water line and pump output at the condenser Refer to the specification sheet for water requirements Check cooling tower sump level and make up water supply Check cooling tower fan belt and tighten or replace as needed Check spray nozzles and sump screen and clean as needed Check refrigerant tables for pressure temperature relation If non condensables are present Perform total pumpdown let stand for at least 6 hours allowing non condensables to gather in the upper part of the receiver Evacuate the freezer and attach a recovery unit to the top receiver purge valve 59 Open the valve and recover the vapor for about five minutes When the freezer is evacuated open the thaw gas solenoid valve manually for about 15 seconds letting the top vapor in the receiver blow into the freezer Close the solenoid valve and evacuate the freezer again Evacuate to 500 microns and restart the machine Follow the diagnostic procedure outlined in Section 7 and clean the condenser instructions under Condenser Cleaning 8 10 10TA Service Manual TROUBLESHOOTING SYMPTOM High head pressure Air cooled machine POSSIBLE CAUSE POSSIBLE REMEDY Condenser fan s
112. ltage 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 The Vogt Part number for a power monitor retrofit kit is 12 7700 1 MT MODEL DTP 3 D WAGNER VOLTAGE MONITOR T1 me Gren SC Te SELECT ADJUST CONTROL RELAY T3 18 277 VAC CONTACTS COM NC FIGURE 10 1 Power Monitor Voltage Monitor The Display The display normally shows the AB BC CA line voltages If the unit is waiting on a timer that timer will be displayed The timer display may be switched off by pressing SELECT The LCD will then display the normal AB BC CA line voltage pairs Pressing the SELECT button once shows the contactor load side voltages if the load side option is connected The display automatically returns to the display of line side voltage after a few seconds Press the Select button to step through the parameters As you step through the parameters the selected parameter will flash Use the up and down arrow keys to adjust to the desired operating value 10 2 OPTIONS AND ACCESSORIES Parameter limits 10TA Serv
113. motor Provides short circuit and over current protection Stops cutter motor and ice machine in the event of a mechanical or electrical malfunction that results in excessive motor amperes DS Disconnect switch CE and Australian Approved machines only ET Indicates hours of machine operation Energized when compressor is operating Cutter Motor Starter Manual motor starter and contactor Cycles the fan motor s of air cooled condenser on and off Activated by the condenser pressure switch Air cooled Machines ONLY Provides short circuit and over current protection Stops fan motors in the event of a mechanical or electrical malfunction that results in excessive motor amperes FPS Regulates the ice thickness by reading freezer pressure and initiating the thaw period at the set point FU1 amp 2 Overload and short circuit protection for control circuit and crankcase heater FU10 60 Short circuit protection for optional Power Monitor Pump Motor Starter Manual motor starter and contactor Starts and stops pump motor Provides short circuit and over current protection Stops water pump motor in the event of a mechanical or electrical malfunction that results in excessive motor amperes PB Used to stop machine immediately Should be used for emergency stopping only PB2 Used for starting machine or manually harvesting Will initiate a harvest cycle whenever pushed with the Clean Off
114. move cover plate Open drain valve 28 Clean tank thoroughly by flushing out with a hose and scrubbing with a stiff brush It may be necessary to completely remove the water tank in order clean all surfaces After cleaning close drain reinstall tank if necessary and fill the water tank with fresh water When restarting the machine be sure that the water pump is circulating water It is possible that air may have collected in the pump impeller housing and the pump may have to be stopped and started several times to expel the air Freezer Cover A clear polycarbonate freezer cover is provided for visual inspection of the water box and water distributors located at the top of the freezer The cover should be removed and cleaned if it becomes coated with deposits Generally if the freezer cover is coated with solids this is a prime indicator that the other areas i e water tank and distributors also require cleaning 7 4 10TA Service Manual MAINTENANCE Water Cooled Condensers Checking Operation How often condensers need cleaning depends on so many variables that it is impossible to recommend a schedule Some will seldom need cleaning others perhaps need cleaning once a year In rare cases cleaning is required several times a year Proper operation of cooling towers will increase the interval between cleaning considerably The tower overflow rate should be checked frequently If a tower is operated with insufficient overflow nominal 1 1 2
115. mplete instructions refer to the Cleaning Procedure attached to the equipment and duplicated here NOTE Before cleaning or sanitizing any Tube Ice machine pump the machine down and make sure the crankcase heater is working properly This will eliminate the possibility of refrigerant migrating to the compressor while circulating warm water through the evaporator Cleaning Procedure 1 10 11 12 13 14 Before cleaning any Tube Ice machine make sure the crankcase heater is working properly When the crankcase heater is not working there is a possibility for refrigerant evaporated by warm circulating water to migrate to the compressor during the cleaning operation Set Clean Off Ice selector switch SS to the Off position If the machine is running it will shut down on completion of the next ice harvest period Remove ice from storage area or cover opening into it Shut off water supply and drain water tank 7 by opening drain valve 39 Remove any loose sediment from tank Close drain valve 39 and fill water tank approximately 15 gallons with warm water Close the petcock on the water pump during the cleaning period Add 40 ounces 8 ounces per 3 gallons of Nu Calgon ice machine cleaner or equivalent food grade liquid phosphoric acid to water tank during the refill period Note Tank capacity 14 5 gallons Inspect the water distributors by looking through clean freeze cover If required remo
116. n 11 4 w Water Conditioning 3 1 Water Cooled Condenser 3 2 3 4 7 4 Water Cooled Condenser Cleaning 7 5 Water cooled Machine Installation 3 4 Water Cooled Piping Schematic 4 3 Water Cooled Units 9 5 Water Distributors 7 3 Water Pump Motor 9 17 Water Quality 3 1 Water Regulating Valve 9 5 Water Supply and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 4 Water Tank Water Tank Removal 9 19 Water Usage Condenser 11 4 Water Usage Make up 11 4 Wiring and Electrical Connection 3 5 Wiring Schematic Air Cooled Condenser Wiring Schematic All Voltages 50 60 Hz 6 7 X X Valve 4 2 Y Z 5 30 14 12 3 INDEX 12 4 10TA Service Manual INDEX 5 30 1
117. n completion Line to condenser Angle valve with gt 1 4 access fitting 9 12 10TA Service Manual SERVICE OPERATIONS Syrelec Timer Orange Crouzet Timer White Crouzet 10n 6 60s 6 2 S 1 10 1 10 01 1 10 100h Range Set pa to 1 10 g 9 min Light indicates timer has Light Time Base DA2RI indi Set to min _ indicates Scale Set to Light flashing when timing timer is timing Light Solid when timed out Allen Bradley Timer White lt 7 Power Light green lt lt Light blinks while timing Light solid when timed out Up Light red Light off while timing Light solid when timed Units Set to min 3 12 Y r Unit adjustment Time Range amp min adjustment 0 1 2 Range Set to O to 12 hrs 10h 0 3 0 12 FIGURE 9 9A 0 30 Thawing Timer Thawing Timer Part No 12A7503E22 The thawing timer governs the ice thawing period It is located inside the control panel FIGURE 6 2 It is started by action of the freezer pressure switch FPS which energizes the CR relay Set the thawing period for at least 30 seconds longer than the time required to harvest the entire discharge of ice If it sho
118. ndenser has been designed with an adequate reserve for moderate fouling on these surfaces If however a rough coating remains inside the tubes after flushing and wiping further cleaning is desirable The color of this coating varies with water conditions but roughness indicates cleaning tools should be used Any type tool to be considered should be tried first on a piece of copper tubing held in a vise or flare block Nylon brass or copper brushes are recommended If any flakes of copper appear or if score marks are made inside the tube the tool should not be used Never use anything with sharp or rigid edges which could cut into the copper tubing Lubrication Compressor When starting and charging the unit the oil sight glass 33 in the crankcase of the compressor should be watched carefully for the first hour to make certain the proper lubrication is being maintained The oil may become low in the crankcase on an initial start up if electrical current has been interrupted to the machine thus de energizing the compressor crankcase heater Before starting the machine again the heater should be energized for a time period of at least two hours to evaporate refrigerant that may have condensed in the crankcase during the shutdown period If the level is low after start up it should begin to return after a short period of operation The oil level should be checked frequently particularly during the start up operation to see that a suff
119. neral the same effect on the appearance of raw water ice and therefore in this rough tabulation can be grouped together Generally the sodium carbonates can be considered 1 1 4 times as objectionable as the sulfates and the chlorides about 3 4 as objectionable as the sulfates Therefore total the sulfates and chlorides separately and apply the factors Calcium Sulfate Calcium Chloride Magnesium Sulfate Magnesium Chloride Sodium Sulfate Sodium Chloride Sodium Carbonate Total Sulfates x 1 0 Total Chlorides x 0 75 Sodium Carbonate x 1 25 Sum Total Dissolved solids below 171 ppm 10 grains per gallon produces first quality ice 256 ppm 15 g p g good quality ice and 342 ppm 20 g p g an ice that is still marketable If dissolved solids are between 342 ppm and 684 ppm 40 g p g acceptable ice quality ice is questionable over 684 ppm marketable ice cannot be expected When cloudy or opaque is produced because of the water quality it is suggested that the water be analyzed by a reputable laboratory and their advice be followed Vogt Ice L L C Louisville KY 4 28 14 10TA Service Manual 10 1 OPTIONS AND ACCESSORIES 10 Options and Accessories Power Monitor Wagner Model DTP 3 All 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 vo
120. nes to the condenser and receiver have been closed These valves are tagged with instructions that the valves are to be opened prior to start up of the machine Before opening these valves it is advisable to check all joints for leaks that may have developed during shipment If no leaks are present a positive pressure should show on the suction and discharge pressure gages They should indicate a pressure approximately equal to the ambient temperature This pressure can be found using the pressure temperature chart for the applicable refrigerant TABLE 11 7 If it should ever become necessary to add refrigerant to the system charging valve 28 is provided for this purpose Through this valve refrigerant can be added in liquid form See Adding Refrigerant The compressor crankcase heater must be energized for a minimum of two hours prior to starting and running the compressor 5 2 10TA Service Manual START UP AND OPERATION 4 14 14 Start up Checklist Be sure to complete and return the Warranty Registration Start Up Report located at the front of the manual 1 See that water inlet and outlet connections are attached properly The water inlet shutoff valves for the water tank and condenser should be open The water level in the water pan should be at a height where the make up water float valve will be closed when the machine is idle See that the cutter motor gear reducer is lubricated see Section 7 Lubrication Cut
121. ng overloads 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 which may have developed during shipment NOTE the machine was shipped with a positive pressure of 20 25 PSIG verify on the freezer pressure gage CHECK All refrigerant piping 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 8126 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 CAUTION The compressor crankcase heater should be energized for a minimum of Two 2 hours before attempting to start the compressor CAUTION 4 14 14 3 18 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE BLANK PAGE 4 14
122. not running Defective motor fan control switch fan contactor or tripped fan motor overload Replace defective part Check condenser fan disconnect for thrown switch or blown fuse Replace fuse and reset switch If the condenser is split check the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted air flow Visually inspect condenser and clean as necessary Non condensables usually in Follow same procedure as specified for system removing non condensables from Water Cooled machine except evacuate the air cooled condenser also 4 23 14 4 28 14 10TA Service Manual 9 1 SERVICE OPERATIONS 9 Service Operations Adjustable Blowdown for clearer ice A petcock is installed on the overflow of the water pump to provide means for obtaining blowdown from the water tank during the freezing period The petcock was set at the factory to discharge enough water during the freeze cycle to produce clear ice After installation it should be adjusted to the minimum rate required to maintain clear ice and checked after a few days of ice making Adjustable Blowdown petcock valve
123. nstallation 3 7 Air Cooled Piping Schematic 4 4 Air Cooled Units 9 5 Assembly Drawing Air Cooled 1 4 1 5 1 6 Assembly Drawing Water Cooled 1 7 1 8 1 9 Automatic blowdown 9 1 B Basic Product Warranty inside back cover Bearing Cutter 9 19 Bill of Lading 2 1 Bin Thermostat Installation 3 13 Bin Thermostat Setup 3 14 Blowdown 9 1 Burnout Compressor 9 14 Capacity Ratings Capillary By paSS 9 4 Charging Refrigeration Systems 1 2 Check Valve 4 2 Checklist Installation Review 3 15 Chemical Cleaning 7 5 Circuit Breaker Control 6 2 6 4 6 5 6 6 Circulating Water Pump Motor 9 17 Clean Off Ice Switch
124. obile 600W cylinder oil or equal Change oil once a year The motor bearings are prelubricated and require no further lubrication For additional information refer to manufacturer s instructions Vent Plug Gear Reducer 10 1 Vent Plug Part 12A4030R12 Replacement food grade oil Part 19T3020C01 Texaco Cygnus 220 Oil Capacity 8 ounces Drain Plug Oil Level Plug Note Ventless gear reducer used after August 2010 FIGURE 9 13 Gear Reducer 9 18 10TA Service Manual 4 28 14 SERVICE OPERATIONS Component Removal and Replacement Operations Cutter Motor The cutter motor s bearings are prelubricated and sealed and require no further lubrication If the motor needs replacing proceed as follows 1 Turn power off and lockout disconnect 2 Check terminals with voltmeter to confirm power 18 off 3 Remove motor terminal cover and disconnect wires Mark wires for ease of replacement 4 Remove four cap screws around the motor flange and separate the motor from the reducer Watch for shaft key that must be reinstalled later m Check the motor electrically to confirm it is defective EN Apply Anti Seize lubricant to the shaft of the replacement motor 7 Position the shaft key in the motor keyway align it with the reducer keyway and install the motor Make sure the key stays in position as shaft is inserted 8 Install the four cap screws to hold the motor in place on the reducer Connect the wires an
125. ons day 2o To c Za tons day Model Variation PUL 50 tons day A number assigned to indicate major SOT 80 tons day variations within any one family series Basic Configuration Package Refrigerant L Low side F R 22 H High side Type of Ice A Ammonia B Cylinder H na K Crushed D Dual Ice Cru amp Cyl L 1 1 2 Long Cylinder Tube Size in 1 4 s of an inch X 2 Long Cylinder 4 Pe 1 sn d 1 1 6 _ 1 1 2 8 2 Electrical Codes 26 208 230 3 60 Condenser Type 46 460 3 60 Cooled 56 575 3 60 WC Water Cooled 25 200 3 50 HP High Pressure Water Cooled A5 400 3 50 SW Sea Water 21 230 1 60 NC No Condenser Product Variation Codes An alphanumeric designator assigned to specific variations 000 or Blank Standard Product If unsure of the product code shown on your machine please consult the factory Figure 2 1 Vogt Model Nomenclature 4 14 14 10TA Service Manual 3 1 INSTALLING YOUR TUBE ICE MACHINE 3 Installing Your Machine Only service personnel experienced and certified in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on this Tube Ice machine WARNING Important Notice To activate the machine warranty the Product Registration Form MUST be completed and returned to the factory promptly after the offici
126. ontrol adjustment Check to make sure the WC or AC condenser is clean Check refrigerant tables for pressure temperature relation Capacity of the machine is proportional to ice making water temperature Warmer water will reduce the ice making capacity See Section 11 Capacity Table Close drain valve 12 8 8 10TA Service Manual TROUBLESHOOTING SYMPTOM Low compressor oil level POSSIBLE CAUSE POSSIBLE REMEDY Oil separator not returning oil Check oil separator float and oil return stop valve 70 and line for a restriction The oil return line should be above ambient temperature most of the time as it returns oil It may be cooler at the start of a freeze cycle Repair or replace defective parts Repeated short cycling refrigerant carrying Usually caused by freeze up low refrigerant oil out of compressor charge low head pressure faulty timer faulty pressure switch or expansion valve clogged Use process of elimination Worn piston rings This condition is hard to detect without dismantling the compressor and checking piston ring tolerances Normally there will be a little puddle of oil laying on top of the piston when the head and valve plate are removed It is best to replace the compressor 4 23 14 4 23 14 10TA Service Manual 8 9 TROUBLESHOOTING SYMPTOM High head pressure Water cooled machine POSSIBLE CAUSE Misadjusted or defective water regulating valve Insufficient water supply Coo
127. op Valve 24 Condenser Water Outlet W C Machines 91 Receiver Liquid Return Stop Valve 25 Water Tank Drain Connection 1 94 Compressor Oil Pressure Safety Control 28 Refrigerant Charging Valve 101 Check Valve TABLE 4 1 Piping Nomenclature 4 3 HOSS3HdWOO Yo em Mut SLYM E EE NYALIY 25 EIE IZ CB z Pe 0 fe um 04 22 25 a9 Ls EN NI H3LVA H il ee She _ A 1 oh E 39HvH2SIQ 5 HOW YOUR TUBE ICE MACHINE WORKS HOSIC 1 3NIT ee ONILV In 10 vv P d ai See f Sv9 q 88 v Nyay ainon 8 M3
128. oper chemicals to use 3 3 INSTALLING YOUR TUBE ICE MACHINE 10TA Service Manual AVAA AqAIS LAHTI 91 1 OT 91 6 6 1 91 1 6 1 mE V Cm e 48 TI i i I HOVdS ben 5 I ACIAONd co NOLLOANNOO 1 I 91 59 ALYA LAN 211 TI il 7 SSHOOV XNV L N HONVWVHTONWnNININ At INIT 1 d iH TN z E NS LO 164 ADUYVHOSIG AI B NANLTA I qInorI IET N HGIS LHOTA NO T SSHOOV NOSSH3dINOO 3104 01 alle IND
129. or leaks after 400 hours or four weeks of operation C Monthly in addition to weekly checks 1 2 3 4 D Check calibration and operation of all controls high amp low press switches oil press 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 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 PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE BEFORE REPLACING RELIEF VALVE REVIEW REQUIREMENTS PER CURRENT LOCAL AND NATIONAL CODE NOTE IF RELI
130. ote Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm Note Tank capacity 14 5 gallons 5 Close drain valve 39 and fill water tank with sanitizing solution Close the petcock adjustable blow down on the water pump 6 Torun the pump only set the selector switch SS to the Clean position and press Start button to circulate the sanitizing solution 7 Mix an additional 5 gallons of warm water 90 F 115 F 32 46 and 8 ounces of Nu Calgon IMS II Sanitizing Concentrate or equivalent in the clean container Note Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm 8 Submerge a clean sponge in the sanitizing solution and wipe all inside surfaces of water box and water box cover including the makeup water float valve 9 With the water pump running add the additional 5 gallons of sanitizing solution to the water tank Install water box cover on water tank and allow sanitizing solution to circulate for at least 20 minutes 10 While circulating sanitizing solution open petcock valve adjustable blow down and allow solution to flow down the drain With petcock valve open allow water to circulate for a minimum of 3 minutes 11 Press Stop button to stop pump then drain and flush water tank with fresh water Open water supply to machine
131. per cycle Capacity check ice weight per cycle X 1440 Ibs 24 hr capacity total cycle time min Remarks 4 15 14 5 29 14 10TA Service Manual 8 1 TROUBLESHOOTING 8 Troubleshooting NOTE With the exception of bin control anytime the machine stops it must be manually re started by pushing the Start push button If it stopped while in a freeze cycle it will then start in a thawing cycle Always check the machine thoroughly after remedying the problem to prevent the same cause from reoccurring Symptom Machine Won t Run Freeze up Due To Extended Freeze Period Freeze up Due To Ice Failing To Discharge Poor Ice Quality Low Ice Capacity Low Compressor Oil Level High Head Pressure Water Cooled Machines High Head Pressure Air Cooled Machines Page 8 2 amp 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 8 2 10TA Service Manual TROUBLESHOOTING SYMPTOM Machine won t run POSSIBLE CAUSE POSSIBLE REMEDY Power failure Intermittent power Check electrical fused disconnect or circuit interruption breaker supplying power to the machine If power has been off make sure the compressor crankcase heater is energized the crankcase is warm and there is no liquid refrigerant in the crankcase prior to running the machine Push the Start button which will initiate startup in a thawing cycle Compressor motor overload CMS OL trips Check for a loose connection on all motor Note Used on 4D
132. perate until the low pressure switch stops the machine 20 PSIG If a lower pressure is desired it can be accomplished by jumping the low pressure switch and starting and stopping the machine by the Start and Stop push buttons Continually observe the oil level to make sure the oil is not carried from the compressor while operating at a low pressure T Close the thawing gas stop valve 90 the receiver liquid return stop valve 91 the compressor suction valve 34 the compressor discharge valve and the oil return stop valve 70 Removal Of Refrigerant From The Machine To transfer the refrigerant charge from the machine into a separate container proceed as instructed above under Pumpdown This will isolate most of the refrigerant in the receiver and the recovery unit can be connected to the access port 44 of the hand stop valve 58 at the bottom of the receiver Open the valve access port by turning the valve stem in front seat and operate the recovery unit until the system is considered empty WARNING Approved recovery equipment hoses gages and refrigerant containers must be used to comply with all local and federal EPA regulations WARNING WARNING Follow these instructions carefully Severe personal injury can result from improper discharge of refrigerant WARNING 4 28 14 9 14 10TA Service Manual SERVICE OPERATIONS WARNING It is not recommended that refrigerant be transfer
133. ply with all applicable electrical and mechanical codes a Local electrical code must be checked for wiring method b The installer must provide a disconnect switch s adjacent to the condenser c Electrical connections between the condenser and the Tube Ice machine require minimum 10 ga wire for 200 230V motors 14 ga wire for 400 460V motors For control wiring a minimum of 14 ga wire should be used d All electrical fittings and components exposed to the weather must be suitable for outdoor installation The design total heat rejection for each Tube Ice machine the recommended air cooled condenser and condenser physical and electrical data are shown on the next page Specified energy efficiency ratings of the ice machines are based on use of the recommended condenser and approved piping practices Recommended condensers provide the indicated total heat rejection at 90 F ambient 100 F condensing Vogt Ice LLC is not responsible for head pressure problems if other than the recommended condensers are used For continuous operation at ambient temperature above 105 F consult the factory about using a larger condenser 10TA Service Manual 10TA Service Manual 4 14 14 Ice Machine Model Electrical Frequency Hz Recommended Condenser Fans Number HP Each Total CFM Full Load Amps FLA 3 ph 208 230V 60 hz 3 ph 460V 60 hz 3 ph 200V 50 hz 3 ph 380V 50 hz Weight lbs Net Shipping Op
134. procedure as well as water tank usually indicated by a build up of removing the freezer cover and cleaning the mineral deposit on the sides and bottom of water distributors Adjust continuous the tank blowdown Insufficient water supply indicated by a low Check water pressure 30 PSIG is recommended level in the tank minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain valve is closed Water pump rotation wrong direction Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Low refrigerant charge Check refrigerant level mark on the receiver and on the painted portion of the gage glass guard Perform a pumpdown if necessary Be sure to keep the gage glass cocks closed when finished checking the level Insufficient blowdown during harvest Check for proper operation of the siphon vacuum break valve and restrictions or traps in the water tank drain assembly 4 23 14 4 23 14 10TA Service Manual SYMPTOM Low ice capacity POSSIBLE CAUSE Low refrigerant charge Restriction in liquid line Float switch stuck or failed in open position Thawing gas solenoid valve 18 leaking through during the freeze cycle Water distributors at top of freezer may be stopped up Inadequate water for ice making Make up water float valve 12 stuck open adjusted too high or water tank dr
135. r and cutter disc Install the tank and other parts reversing the procedure of removal 9 20 10TA Service Manual SERVICE OPERATIONS er CUTTER BEARING 47 BEARING GASKET SUPPORT BRACKET 1 F 3 8 BOLTS FASTEN BEARING DEFLECTOR DRIVE PIN SUPPORT TO CUTTER HOUSING FOR BEARING PLATE e CUTTER DISC CUTTER HOUSING DRIVE PIN FOR CUTTER DISC FIGURE 9 14 Cutter Assembly ADAPTOR PLATE FOR CAST CUTTER PART NO 19T2010A12 CUTTER ASSEMBLY FOR CYLINDER ICE PART NO 19T2160C0202 UHMW CUTTER BEARING PART NO 19T2160C0202 PIN FOR CUTTER BEARING PART NO 12A3040S02 CUTTER SUPPORT PART NO 12A2025B0102 SPIRAL PIN HOLDS DISC ASSEMBLY TO CUTTER SHAFT PART NO 12A3040S01 N __ CUTTER DISC ASSEMBLY PART NO 19T2163D0202 DEFLECTOR PLATE 19 40015023 PART NO 12 2600 05 ___ GEAR REDUCER PART NO 12A4030R12 19T4500S01805 CUTTER HOUSING ASSEMBLY lt CUTTER MOTOR 208 230 460V 3Ph 50 60Hz PART NO 12A2900M0508 FIGURE 9 15 Cutter Parts cylinder ice 4 28 14 9 21 SERVICE OPERATIONS 10TA Service Manual 12A2240A1108 HEX NUT 5 16 5 5 E aN 12422508 108 s e T 12A4030R12 LOCK WASHER 5 16 S S GEAR REDUCER GEAR REDUCER MOU
136. red from a refrigeration system 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 WARNING Refrigerant Leaks In addition to testing the machine for leaks as instructed under Refrigerant Charge it is advisable to again make a leak test after the unit has been in operation approximately one week Any noticeable change in operating conditions other than shown on the Certificate of Test may indicate a loss of refrigerant due to a leak Always remove the refrigerant pressure from the vessel or tubing before repairs are attempted Non condensable Gases 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 Compressor Motor Burnout There are several causes of compressor motor burnout Some of these are described below 1 Low line voltage A compressor motor is designed to operate within the range of plus or minus 1096 of its namep
137. rence is more than 10 F cleaning is indicated because this difference indicates a good heat exchange is not being made If this difference is less than 8 F something other than a fouled condenser may be causing the high head pressure In normal operation this difference will stay between 5 F and 10 F regardless of water inlet temperature when the water flow is regulated by a pressure operated water valve If this difference is less than 5 F restricted water flow or a low supply pressure is indicated A restriction can occur with foreign matter in the condenser but it is likely to be somewhere else in the system Draining Draining of water cooled condensers is recommended in preparation for the winter cold where units may be left exposed to ambient temperatures below 32 F Despite the fact that a condenser may have a vent and drain fittings the opening of these fittings is not sufficient for a natural gravity flow Water will be retained in a tube due to 1 surface tension and 2 the normal curvature between tube supports Experience has shown that as much as 20 of the water in the condenser can be retained To break the surface tension on the tubes and to drain all tubes completely it is necessary to actually tilt the condenser a minimum of 5 degrees Whether water left in the tubes will cause damage during a freeze up will be dependent upon how quickly the freeze occurs and the location of the water inside the condenser In the field it is r
138. rogram This form can be removed and duplicated for keeping accurate records Model Serial Date Customer Address Mgr Name Service Tech Name The following service performed and checked Last maintenance performed approx date Scale condition of water tank amp tubes good fair poor All drains freely draining water tank drip pan ice bin Water distributors cleaned Ice machine cleaner circulated through system Condenser clean if applicable Voltage at machine actual reading Compressor amps halfway through the freeze cycle Cutter motor amps cutting ice Water pump amps AC condenser motor amps if applicable Crankcase heater heating Refrigerant leak okay high low Leak checked system leaks found amp repaired Compressor oil level i e 1 4 1 2 3 4 low high Gear reducer oil okay low PSIG low pressure switch set PSIG high pressure switch set Bin stat s installed and operating properly Make up water float valve adjusted okay Adjustable blowdown adjusted for clear ice CYL Suction PSIG at end of freeze CYL Suction PSIG during harvest high low CYL CRU Discharge PSIG at end of freeze F C at machine F C outside ambient at condenser if applicable F C make up water temperature Freeze cycle time minutes Harvest cycle time minutes First ice out seconds All ice out seconds Pounds of ice
139. s This ensures vessel internal pressure does not exceed maximum allowable pressures PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE BEFORE REPLACING RELIEF VALVE REVIEW REQUIREMENTS PER CURRENT LOCAL AND NATIONAL CODE VALVE REPLACEMENT SHOULD BE MADE BY PROPERLY TRAINED PERSONNEL ONLY NOTE IF REFIEF VALVE DISCHARGES VALVE MUST BE REPLACED BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES PHONE 502 635 3000 9 24 10TA Service Manual SERVICE OPERATIONS Technical Service Bulletin No 88 5 All Models Subject Water Conditioning For Ice Cube Machines The quality of the ice produced by a commercial ice cube machine can only be as high as the quality of the water which is used Water which contains turbidity or sediment or which has a high concentration of dissolved minerals or gases will produce cloudy or opaque ice Ion exchange zeolite softening is used to advantage in many cases as the softener removes iron and most forms of turbidity and also prevents scale formation in the ice machines However softening the water by ion exchange does not reduce the concentration of minerals In addition most machines require a considerable blowdown to waste to prevent the buildup of the total dissolved solids and thus a considerable amount of softened water will be wasted All the sulfates chlorides and the sodium carbonate listed below have in ge
140. s little as one half to one third the energy required by competitors icemakers 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 All the skill in engineering and fabrication that we have learned in over a century of experience is reflected in the 10 model Tube Ice machines 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 operations have been proven over and over again in a network of varied types of installations throughout the world Furnished with your machine 18 the Certificate of report of operating data that is a record of the unit s satisfactory operation on our factory test floor It is evidence of our desire to deliver to you the 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 when you install it maintain it and service it properly Please read your manual carefully before attempting installation operation or servicing of this professionally
141. ter operation and motor amp draw If tripping repeats but ice is not jammed check the cutter bearing for wear the gear reducer for resistance and the motor for defect or single phasing Pump motor overload tripped Check voltage and overload range adjustment against motor rating Reset the switch set the Ice Clean switch to the Clean position and restart the machine by the Start push button Check the pump operation and motor amps If tripping repeats check for a defective overload defective motor or single phasing Bin thermostat or bin level control stops Adjust or replace the bin stat or level control machine Make sure bin stat bulb or level control is located properly in the bin See FIGURE 3 9 Section 3 Bin Thermostat Defective control panel component such as See FIGURE 6 3 Section 6 Wiring PF BC CMS CB T Etc Schematic Check for open circuit Refer to FIGURE 6 2 Section 6 Control Panel to identify parts Replace defective part restart machine and check power supply and current draw 4 23 14 8 4 10TA Service Manual TROUBLESHOOTING SYMPTOM Freeze up due to extended freeze period POSSIBLE CAUSE POSSIBLE REMEDY Freezer pressure switch setting too low Adjust freezer pressure switch or replace if defective See FIGURE 9 3 Section 9 Water tank drain valve 39 open or leaking or Close valve repair or replace as necessary make up water float valve 12 stuck open Thawing g
142. ter gear reducer 5R for instructions See that compressor crankcase oil level is at proper height of 1 4 to 1 2 of the sight glass NOTE All valves are tagged with instructions NOTE Open compressor service valves 34 and 35 the hand stop valve 90 in the thawing gas line the receiver liquid return stop valve 91 in the condenser return line hand stop valve 58 in the liquid line hand stop valve 69 to the freezer pressure switch top and bottom float switch hand stop valves 22A and stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage glass valves 31 on the receiver can be opened for liquid level observation but should remain closed for unattended operation IMPORTANT CHECK TO SEE that all stop valves in the various refrigerant lines are open except charging valves 28 amp 44 according to the attached tags Immediately after opening all valves entire machine should be checked for refrigerant leaks with electronic leak detector See that Ice Off Clean Switch SS is in the Ice position Close exterior disconnect switch to energize crankcase heater and check for compliance to nameplate 10TA Service Manual 5 3 START UP AND OPERATION Start Up CAUTION The crankcase heater should be energized for a MINIMUM of 2 hours and the crankcase must be free of liquid before attempting to operate the compressor
143. the X valve in the compressor discharge line and a check valve 101 in the liquid return line to the receiver These valves prevent the migration of refrigerant when the machine is not operating The X valve is open any time the compressor is running Freeze Period The Tube Ice is frozen inside the stainless steel tubes in the freezer 2 by the direct application of refrigerant to the shell side outside of the tubes The ice is produced from constantly recirculating water during the freeze period As the ice thickness increases the freezer suction pressure decreases At a set pressure the freezer pressure switch initiates the harvest period Harvest Period When the freezer pressure switch 56 FPS contact closes a control relay CR is energized The CR relay stops the water pump and starts the cutter motor The Al amp A2 liquid line solenoid valves close D thaw gas solenoid valve opens and the thaw timer T 18 energized The defrost pressure switch dps will open and close the D valve to maintain the proper pressure to get the ice to release but not add unnecessary heat As the ice releases and drops through the rotating cutter and onto the cutter disc it is discharged through the side opening of the water tank The harvest timer T is to be set for the time required to discharge all the ice plus 30 seconds longer usually 2 1 2 minutes CAUTION Make sure all the ice clears the freezer
144. the control circuit power supply and used to control a circuit with a different voltage See Figure 6 3 The Sentronic has a timing circuit that actually compares the amount of time with good oil pressure to that with insufficient oil pressure The module memory will shut the compressor down after a period of more than two minutes if the compressor has a history of oil pressure fluctuations with more unacceptable than acceptable pressures Sentronic also has a memory that retains the compressor oil pressure history for up to one minute in the event of a power loss Sentronic uses a permanent magnet integral with the reset button to reset its output control relay in the event of a trip When the reset button is depressed it magnetically pulls the Sentronic relay s armature to its original reset position Sentronic needs no voltage present to reset Coresense Protection Discus compressors manufactured after March 2011 will be supplied with CoreSense Protection CoreSense replaces the Sentronic Oil Pressure Safety Module on all Discus compressors and the Electronic Motor Protector Module on 4D amp 6D compressors Note 2D amp 3D compressors will continue to have Internal Line Break overload protection The oil pressure monitoring portion of the CoreSense will act very similar to the Sentronic Oil Pressure Safety switch A current transformer CT in the compressor junction box determines when the compressor is running and starts monitoring oil
145. time that a fault is allowed before shutdown occurs Control mode ON OFF AUTO flashes The value may be adjusted to OFF load will not turn on ON load will turn on whenever there are not faults and timers are finished and AUTO Load will turn on when there is a control input Contactor fault monitor mode CONTACTOR FAULT flashes This option allows you to monitor the contactor and lock it out if the line voltage and load side varies by more than 5 volts Pressing the up and down arrows selects off default or on The load side of the contactor must be connected to the load terminals of the DTP 3 to use this option Display of fault memories MEM flashes Pressing up or down displays the last fault conditions that took the unit off line The first 25 faults are recorded The top number displayed represents the fault memory The middle number represents the total number of faults that have occurred since the fault memory was cleared To clear the memory press and hold the up and down keys until the display is cleared 10TA Service Manual 10 3 OPTIONS AND ACCESSORIES Notes If you press SELECT and do not change a parameter by pressing the up or down arrow keys the DTP 3 automatically returns to displaying the line voltage in a few seconds The new settings are saved in permanent memory when the display returns to displaying the line voltage The new settings may be verified by pressing the select button to sequence through the
146. ting to produce crushed ice If the ice is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Also you should not attempt to produce crushed ice when the make up water temperature is below 50 F 10 C Colder water can cause a build up of ice fines in the tank and eventually result in short cycling Crushed Ice Cutter Part 126413B Gear Reducer 5 1 Part 12A4030R14 Crushed Ice Cutter Motor 3 4 HP 1140 1000 RPM Part 12 2900 0601 60hz Part 12 2900 0603 5082 Cutter Housing ________ FIGURE 9 17 Cutter Parts crushed ice option 4 28 14 4 28 14 10TA Service Manual 9 23 SERVICE OPERATIONS Defrost Pressure Switch DPS R404A Machines only The DPS is used to regulate the pressure in the freezer during the harvest cycle This pressure switch is wired in series with the D valve thaw gas valve which opens and closes during the harvest cycle to maintain 90 to 95 psig in the evaporator CUT IN CLOSE ADJUSTING SCREW SET AT 90 PSIG CW LOWERS SETTING CUT OUT OPEN ADJUSTING SCREW SET AT 95 PSIG CW RAISES SETTING Vogt Part 12A2117B03 CE Approved machine Vogt Part 12A2117B03CE Defrost Pressure Switch DPS FIGURE 9 19 Pressure Relief Valves Pressure relief valves are installed on the freezer receiver and the water cooled condenser These valves are designed to vent in emergency condition
147. tinue to pump down until it shuts off on low pressure 10TA Service Manual 10 5 OPTIONS AND ACCESSORIES Fault History log 5 faults will be created and can be viewed through the E150 Interface The PLC also logs time and date when a power failure occurs and when power is returned Cycle History log 10 cycles will also be created and viewed with the interface The PLC I O Status screen can be used to view PLC Inputs and Outputs without opening the control panel door A Total cycle counter and hour meter can also be view with the VOGT TUBE ICE LI a a a MONITOR START PLC VO 1 setup STORY Harvest STATUS 2 v Mitsubishi E1012 Operator Interface FIGURE 10 2 Mitsubishi HMI MITSUBISHI PLC The Mitsubishi Programmable controller contains 14 inputs and 10 outputs on the base unit with an additional 4 input and 4 outputs on an expansion module The power supply for the unit can be 100 240VAC 50 60 Hz and is internally fused for 3A The inputs are 24VDC internally fused for 5 7mA and supplied by the PLC All 24VDC control wiring is blue in color and is distinguished from the red 240VAC or 120VAC control wiring The outputs are externally fused for 2A Outputs 1 and 2 are dry contacts used for high side control interlock and conveyor control Outputs 0 3 11 amp 20 23 are relay type with 120V or 200 240 V connections The LED indicators on the right hand side of the Mitsubishi PLC indicate th
148. trate the piping diagram of the refrigerant and water circuits of the Tube Ice machines with numbers for easy reference Throughout this manual the numbers you see in parentheses refer to the numbers in this piping schematic The freezer 2 is a shell and tube type vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 Solenoid valve 20 sometimes referred to as the A valve is open and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 the 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 and into the condenser 15 In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid goes through the accumulator boil out coil 88 and suction line heat exchanger 13 where it is gives up heat to the suction gas for compressor protection In addition this liquid is subcooled and carried to the receiver 15R Condensed liquid refrigerant from the receiver flows through the thawing chamber 16 of the freezer the filter drier 46 the 1 and A2 liquid feed valves 20 amp 21 and t
149. ulated from the make up water The frequency of this cleaning operation will depend on the characteristics of the water supply The cleaning operation is needed when the inside diameter of a large proportion of the ice becomes irregular due to channeling of water or if some of the ice is opaque or if there is a noticeable decrease in ice capacity Vogt Part Size Ice Number of Tubes Water Distributor Freezer Cover Freezer Cover Gasket 1 156 12B2185N11 1BA2145C03 12A2600G15 1 1 4 102 12B2185N21 1 1 2 72 12B2185N31 TABLE 7 1 Number of Water Distributors Per Tube Size To clean distributors stop the unit and remove the freezer cover on top of the freezer The water distributors one in each tube may then be removed with pliers for cleaning Use pliers on the distributor s top part with a twisting upward motion Use care when removing distributors to avoid distorting orifice holes or the body of the distributor The distributors can be soaked in ice machine cleaner to remove mineral buildup Rinse distributors thoroughly before reinstalling and tap lightly with a rubber mallet to seat them in the freezer tubes Tube Size 1 1 1 4 1 1 2 Hole Size 1 16 1 8 Avg 1 8 3 16 Avg 1 4 3 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 Re
150. uld be necessary to change the setting of the timer turn the adjustment screw clockwise to increase the time or counter clockwise to decrease the time Verify time after each adjustment Je Js Ja Jz FIGURE 9 9B Thawing Timer Wiring 4 28 14 10TA Service Manual 9 13 SERVICE OPERATIONS Pumpdown The function of the pumpdown is to transfer all the liquid refrigerant from the freezer evaporator into the receiver Pumpdown should only be performed when the freezer is clear of ice Its main purposes are To check the total refrigerant charge To perform service or repair work on the machine To winterize the machine To prepare the machine for disconnecting and moving Before cleaning pO eu pace To perform a pumpdown follow this procedure 1 Push manual harvest button to clear the freezer of all ice and stop operation Close the liquid stop valve king valve 58 at the receiver 3 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 pumpdown 4 Start the machine and allow it to operate and complete one harvest During the thaw cycle close the 1 4 valve 69 at the top of the freezer to isolate the freezer pressure switch and prevent another thaw cycle 6 Allow the machine to o
151. unning 4 28 14 10TA Service Manual 9 19 SERVICE OPERATIONS Water Tank Removal oR Oe gee DOLES Turn off and lock out power to the machine Turn off water supply and disconnect lines from the tank Drain the tank and disconnect pump suction tube and drain line tubing and water lines Disconnect the ice discharge chute Loosen bolts holding the tank to the cutter assembly until the tank rests on the bars Loosen bolts holding the tank supports The tank can then be removed to the side of the machine Make sure the rubber gasket is in place and aligned properly when the tank is installed and bolted to the freezer Cutter and Bearing Removal Installation Refer to FIGURES 9 14 amp 9 15 for parts identification and location 1 2 3 4 Turn off and lock out power to the machine Remove the cutter motor from the reducer Remove the water tank assembly and then the cutter assembly With a 1 4 or slightly smaller punch reach in through the ice discharge opening drive the spiral pin out of the disc hub and cutter shaft and push or drive the disc off the shaft Lift the cutter assembly out of the bearing surface of the cutter The surface should be smooth and free from nicks or burrs Inspect the bearing for wear There should be no side movement between the shaft and bearing and the bearing thrust flange should be no thinner than 3 16 it is 1 4 thickness new 7 Before removing the bearing reference mark the
152. ve the cover Clean and remove any solid particles from the distributor orifices two orifices in each distributor Clean the rubber cover gasket and reinstall the cover To run the pump only set the selector switch SS to the Clean position and press Start Circulate cleaning solution until deposits are dissolved or solution is neutralized Repeat cleaning if necessary Press Stop button to stop pump then drain and flush water tank with fresh water Open water supply to machine Drain and flush tank and then refill with fresh water Clean inside of ice storage area and remove any solution that entered during the cleaning process Remove cover if one was installed over opening into storage area Start ice making cycle by setting the Clean Off Ice selector switch SS to Ice Check for water leaks around the freezer cover and tighten nuts if needed Adjust setting of pump petcock per instructions under Adjustable Blowdown in Section 9 7 2 10TA Service Manual MAINTENANCE Sanitizing Procedure 1 After pumping machine down set Clean Off Ice selector switch SS to the position 2 Remove ice from storage area 3 Shut off water supply and drain water tank 7 by opening drain valve 39 Remove any loose sediment from tank 4 Inaclean container mix 15 gallons of warm water 90 F 115 F 32 C 46 C 24 ounces of Nu Calgon IMS II Sanitizing Concentrate or equivalent N
153. vice Manual 5 5 START UP AND OPERATION Adding Refrigerant CAUTION If it should become necessary to add refrigerant to the system charging valve 28 is provided for this purpose Be sure to follow all local and federal regulations regarding the handling of refrigerants and their illegal emission into the atmosphere CAUTION Check the refrigerant level after the machine has operated for a few cycles It should be slightly above the minimum operating level as indicated on the receiver a few minutes prior to start of a thawing period If this level is low at this time sufficient refrigerant should be added to the system to raise the level above this point Add only a small quantity 10 165 or less at a time and operate the machine several cycles to check the level before adding additional refrigerant Refrigerant may be added as a liquid through the charging valve 28 only while the machine is operating It is important that no air or other non condensable gas enter the system when charging refrigerant into the unit It is also possible to check the refrigerant level by pumping machine down See 9 12 When the machine is pumped down a liquid level should be observed in the gage glass on the receiver Refrigerant Charging Procedure 1 Make connection between charging valve and refrigerant cylinder using hose or pipe suitable for R 22 or R 404a service See instruction card attached to refrigerant cylinder 2 Open
154. with at least 30 seconds to spare before the next freeze period begins This is to prevent refreezing CAUTION 1 Control Panel 30 Receiver Sight Glass 1PG Suction Pressure Gauge 31 Gage Glass Stop Valve 2PG Discharge Pressure Gauge 32 A C Condenser Service Connection 2 Freezer 34 Compressor Suction Service Valve 3 Compressor 35 Compressor Discharge Service Valve 4PS Dual High Low Pressure Switch 37 Oil Charging Drain Valve 5M Cutter Motor 39 Water Tank Drain Valve 5R Gear Reducer 40 Automatic Water Tank Blowdown 6 Water Pump 41 Condenser Water Regulator W C Machines 7 Water Tank includes cutter assembly 41A Condenser Pressure Control A C Machines 8 Water Distributing Chamber 43 Strainer 12 Make Up Water Float Valve 44 Receiver Drain Valve 13 Heat Exchanger 46 Filter Drier 14 Oil Separator 48 Muffler 15 Condenser 50 Receiver Safety Valve 15R Receiver 51 Freezer Safety Valve 16 Thawing Chamber 53 Cold Weather Solenoid Valve A C Machines 17 Expansion Valve 55 Discharge Line Stop Valve For A C Machines 18 Thawing Gas Solenoid Valve D 56 Freezer Pressure Switch 18S Thawing Gas Pressure Switch 58 Liquid Outlet Valve King Valve 20 Liquid Feed Solenoid Valve A1 59 Receiver Purge Valve 21 Liquid Feed Solenoid Valve A2 69 Freezer Pressure Stop Valve 22 Float Switch 70 Oil Return Stop Valve 23 Condenser Water Inlet W C Machines 88 Accumulator Heat Exchanger 23A Make Up Water Inlet 3 4 90 Thawing Gas St
155. x Contact 10 Amp 1 N C Side Mount 400 460V 12A7518E31 Aux Contact 10 Amp 2 N O Side Mount 12A7518E32 Aux Contact 5 Amp 2 N O Top Mount 12A7516E48 Compressor Motor Contactor 140 Amp 3 Pole Pus Ge 2 12 7518 43 Aux Outside Contact 2 Amp 2 N O Side Mount 12A7518E44 Aux Inside Contact 2 Amp 2 N O Side Mount CR 12A7517E27 Control Relay 10 Amp 2 N O 2 N C 208 240V Coil 12A7516E23 Contactor 9Amp 3 Pole with 1 N O Aux 208 240V Coil CU 12A7530E52UL Cutter Manual Motor Starter 0 63 1 0A 460V 60hz 12A7530E53UL Cutter Manual Motor Starter 1 0 1 6A 400V 50hz 12A7530E54UL Cutter Manual Motor Starter 1 6 2 5A 200 208 230V 50 60hz ET 12B7503E17 Timer Elapsed Panel Mount 220V 50Hz 12B7503E18 Timer Elapsed Panel Mount 220V 60Hz Condenser Fan Contactor 30 Amp 3 Pole 1 N O Aux Contact FC Coil Air Cooled Only 12A7530E58UL Fan Manual Motor Starter 10 0 16 0A 400 460V 50 60hz 12A7530E63UL Fan Manual Motor Starter 23 0 32 0 200 208 230 50 60hz FPS 12A2117E04 Freezer Pressure Switch FU1 amp FU2 12A7504E18 Fuses 5A 600V Class CC Time Delay FU10 FU60 12A7504E29 Fuses 1A 600V Class CC Fast Acting For use w optional Power Monitor 12A7516E23 Contactor 9Amp 3 Pole with 1 N O Aux 208 240V Coil 12A7530ES55UL Pump Manual Motor Starter 2 5 4 0A 400V 460V 50 60hz 12A7530E56UL Pump Manual Motor Starter 4 0 6

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