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P24A and P34A Service Manual

1. MOTOR STARTER 5 p TN COMPRESSOR COOLING OUTLET COMPRESSOR COOLING INLET CONTROL PANEL d o o 5 B 63 FLUSH WATER SOLENOID VALVE 62 MAKE UP WATER STOP VALVE 3 4 MAKE UP WATER INLET FOR ICE MAKING c 5 8 e2 1 8 7 Y WATER TANK OVERFLOW DO NOT REDUCE PIPE TO OPEN DRAIN 374 FLUSH WATER INLET FOR ICE MAKING 2 WATER TANK DRAIN 4 PIPE TO OPEN DRAIN 39 WATER TANK DRAIN VALVE FIGURE 1 1 P24A Front Side Control Panel 8 7 07 8 7 07 P24A amp P34A Service Manual 1 5 INTRODUCTION WATER DISTRIBUTION CHAMBER ku cd COMPRESSOR SUCTION VALVE 34 3 COMPRESSO
2. TB E TIME 30 G0HZ OR 2 21 TB 200 VOLTS 50HZ 11 10 TB 20 TH 460 VOLTS 60HZ OR 400 VOLTS 50HZ TF FIGURE 3 11 Power Supply Connections Voltage Unbalance Voltage unbalance can cause motors to overheat and fail Voltage imbalance between any two legs should be no greater than 2 Example Supply voltage 230 3 60 Voltage Readings 220 Volts BC 225 Volts Average 220 225 227 3 224 Volts AC 227 Volts AB 224 220 4 Volts Highest Deviation 225 224 1 Volts AC 227 224 3 Volts Voltage Unbalance 100 x 4 224 1 78 Acceptable 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 8 7 07 3 18 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE two legs Current follows the path of least resista
3. 9 1 C Capacity Ratings P24A 11 4 Charging From Tank Truck 5 3 Charging From Cylinders 5 3 Charging Refrigeration System Precautions 1 3 5 2 Charging Valve Freezer 28 2 4 1 4 Check Valve 101 1 11 Circulating Water Pump Motor 9 22 Cleaning Procedure Ice Making Section 7 3 Cleaning Ice Making Section 9 1 COmpreSsSor 7 6 Compressor Cooling Solenoid Valve 64 1 12 9 24 Compressor Cooling Water In And Out 3 10 Compressor Cooling Water Inlet Valve 45 1 12 Compressor Crankcase Heater 9 4 Compressor Diagram P24A 1 12 Compressor Discharge Purge Valve 78 1 12 Compressor Discharge Valve 35 1 6 1 9 Compressor Inspection Compressor Maintenance 7 7 Compressor Loosing Oil Excessively 8 10 Compressor Oil Changing 9 24 Compressor Oil Pressure Low 8 10 Compressor Running Unloaded During Freeze 8 9 Compr
4. 1 INDOOR COOLING TOWER SUMP TANK COOLING TOWER INLET OPENING AIR FLOW MAKE UP WATER gt INLET FIGURE 3 7 Cooling Tower Piping Diagram 8 7 07 8 7 07 P24A 4 P34A Service Manual 3 15 INSTALLING YOUR TUBE ICE MACHINE ao zZz ZS ZS COOLING TOWER A WATER gt Seq gt COOLED CONDENSER CHECK VALVE T INDOOR SUMP FIGURE 3 8 1 PUMP 2 WAY VALVE Poor Freeze Protection Because low flow rate high freeze chance MD cum COOLING TOWER c WATER gt m gt COOLED F4 CONDENSER Same flow rate to cooling tower Only enough water to maintain head a CHECK VALVE INDOOR SUMP 1 PUMP 3 WAY VALVE Better Freeze Protection 3 16 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE a cM AZA COOLING TOWER WATER gt COOLED CONDENSER lt uM CHECK VALVE INDOOR SU Outdoor pump is off until indoor sump needs cooling FIGURE 3 10 2 PUMP 2 WAY VALVE Best Freeze Protection Wiring and Electrical Connections WARNING Only service personnel experienced in refrigeration and qualified to work w
5. 9 14 P24A and P34A Cutter and Water Tank Part No TABLE 9 2 9 15 9 16 Cutter Ring Gear Replacement 9 16 Cutter Blade Replacement io re tee e e b e eR e 9 16 Cutter Blade and Adapter Plate Adjustment FIGURE 9 6 9 17 Cutter Adapter Plate Installation RE ED E ERE ge ete ee 9 17 PUMP UO WA eit sven neto tm RE ERE be deu Re ER 9 18 Removal of Ammonia Refrigerant from the 9 18 5 31 11 P24AL amp P34AL Service Manual TABLE OF CONTENTS Page No Retriger nt Ecak8 eter don ee d Mik Glaus bes dtt al 9 19 Non Condens ble GaseS eee ie innert eo Un Obere E eee i b om Receta eee e tee 9 19 Purgins Non Condensables eret eR RN ER ERO REDIERE eae 9 19 Draining the OIL IM 9 20 Removing Excess Water from Ammonia 9 2 Circulating Water Pump Motor xe scan Aten ee dn Melden A en ote bes 9 22 Gas Solenoid Valve ele roe re i bee oen ie ede 9 22 Thaw Gas Solenoid Valve FIGURE 9 7 00 2 41 22 2 2 222 0110000000000000000000000000000000000000 9 23 The Liquid Solenoid V lve reete ete ta ne bie debe at de Rag 9 23 The Liquid Feed Solenoid Valve FIGURE 9 8 9
6. 1 8 1 9 1 10 1 11 2 RECEIPT OF YOUR TUBE ICE MACHINE ER OON Saas ain il dnte ei ite t BR 2 1 Desctription ofMaclifie ree oe e tbe ee 2 1 Safety Tags and pe eU necem er ead bre epe euet ned eget 2 1 Model designation for P Series Ice Machine Figure 2 1 2 2 Storage prior to installation and 2 2 3 INSTALLING YOUR TUBE ICE MACHINE thoro einen ein dd teta 3 1 Space Requirements eden ec te N manes 3 1 Liting EE ened Sass runs 3 1 P24A Space Diagram FIGURE eti rr ede et nere tete a ete ea dede 3 2 3 3 P24A Foundation Layout FIGURE 3 2 3 4 P34A Space Diagram FIGURE 3 3 3 5 3 6 P34A Foundation Layout FIGURE 3 4 3 7 Lifting Procedure for P24A FIGURE 3 5 3 8 Lifting Procedure for P34A FIGURE 3 6 3 9 Piping andiDram Connections T ble3 1 eee ERR ED LR D ERR RE ee Ie hts 3 10 Make Up WaterTn icri eret ERREUR EH ERE ANREDE 3 10 Flushing EEG RI RE ARUM nes 3 10 Compressor Cooling Water Ii nd Out on pueden ean te eaaet be i Oei e bes 3 10 Wa ter Tank tot Eia ut eee 3 11 Water Tank 3 11 Condenser water mand Qf ipd endete e i dee nt et bea eben nes 3 11 5 31 11 P24AL amp P34
7. ie e SE 8 9 Compressor Running Unloaded During Freeze 8 9 Compressor Pressure EOW iR UH RO UR ERR RE AD UU RR UE RE e RE e 8 10 Cor pressor Loosing Oil Excessively niet RERUM A REI 8 10 Machine Short Cycles ERR ee etae e Re 8 11 Shut Down By Oil Pressure S witeli zi e d eni e ea p bee 8 11 High Compressor Discharge 4 8 11 Suction Line Frosting To Cormipress E 8 11 5 31 11 P24AL amp P34AL Service Manual TABLE OF CONTENTS Page No 9 SERVICE OPERATIONS Automatic Blowdown Harvest teeth et een tre ber et eee P eee aes ve 9 1 Cleaning tlie Ice Making Section iue ee ERR HII e e dE 9 1 Float Valve Water eet tiet oom edi ei ipe i o re ie e o rre HERE 9 1 Fl Gates witch ette AM rte Een AE n eis 9 1 Hand Expansion Valye i iu rc er eee oe net tite eee er 9 2 9 2 Freezer Press re Switch FIGURE 9 12 codage 9 2 High LEow Pressure Switch RO CREER OUI REED ERE RO IRE RES 9 3 High Low Pressure Switch FIGURE 9520 6 eerie erre eee ern 9 3 Control Cooling eiue tide re Ae eset ern
8. 2 1 39MVHOSIO FIGURE 4 1 for P24A Schemat iping P 8 7 07 P24A amp P34A Service Manual 4 4 HOW YOUR TUBE ICE MACHINE WORKS 86 Ca el 9 S31VM QI lt INIT GINOIT 1 18 08 1 137 4323345 1371100 JAWA 331738 1 84 TA 44 INIT NOILINS t LF UNO INIT SNIZITnO3 710 1 ge 3NIT 2610 3NIT 398VH2SIO INIT 7134 GInOI c 40114935 710 1 amp 3SN30NO2 S1 INIT SV9 06 131100 FATWA 330138 1 131100 FATWA 331134 e3WO1Sn2 48 1 1 1 S3SN3ONO2 9 77100 YFLVM 9 FIGURE 4 2 for P34A 1 Schemat iping P 8 7 07 P24A amp P34A Service Manual 5 1 START UP amp OPERATION 5 Start Up amp Operation Refrigeration System Review The refrigeration system uses anhydrous ammonia R 717 refrigerant Following the piping schematic Figure 4 1 or 4 2 you will see that during the machine s freeze
9. 9 17 adjustment 9 17 Cutter Assembly P244 9 13 parts list 9 15 Cutter Assembly Removal and Installation 9 10 Cutter Blade Replacement 9 16 adjustment 9 17 Cutter Disc Removal 9 10 Cutter Gear Reducer 7 7 9 6 drive gear replacement 9 6 gear reducer replacement 9 7 Cutter Height Adjustment 9 12 Cutter Motor Starters Cutter Ring Gear Replacement 9 16 Cutter Parts Weights 9 9 Cutter Shaft amp Bearing Removal Installation 9 11 D Description Of Machine 2 1 Discharge Stop Valve 55 1 5 Discharge Line Stop Valve 55 1 9 Draining Oil Trap 9 20 Drive Gear Replacement 9 6 E Electrical Schematic All Voltages 50 60 Hz 6 4 Electrical Controls 6 1 Equalizing Line Stop Valve 92 1 10 F Fan Control cooling to
10. 8 11 High Discharge Pressure 8 8 High Low Pressure Switch 1PS 9 3 High Suction Pressure 8 9 How Your Tube Ice Machine Works 4 1 Ice Lb Kg Harvest 2 3 Ice Making Section Cleaning Procedure 7 3 Ice Quality 8 7 Important Safety Notice 1 2 Initial Torque Adjustment Soft Starter 10 13 Inspection First Arrival 2 1 Installation 3 1 Installation Review A Checklist 3 20 J L Length of Ice 10 2 Lifting Procedures 3 1 lifting diagram for P24A 3 8 lifting diagram for P34A 3 9 Liquid Feed Solenoid Valve 20 1 7 1 8 9 23 9 24 Liquid Line Stop Valve 29 58 1 4 1 6 1 7 1 8 Liquid Return Stop Valve 91 Liquid Outlet Stop Valve 58 1 11 Low Discharge Pressure 8 9 Low Ice Capacity 8 6 8 7 Low Pressure Gage Stop Valve 69
11. 1 12 Low Pressure Switch 9 3 M Machine Room 3 1 Machine Short Cycles 8 11 Machine Stopped 8 2 8 3 Maintenance Checklist 7 1 Maintenance Program form 7 2 Make Up Water Float Valve 12 Make Up Water Flow Rate 2 3 Make Up Water In 3 10 8 7 07 P24A 4 P34A Service Manual Make Up Water Temperature 2 3 Make Up Water Stop Valve 62 1 4 Make Up Water Usage P24A and P344 11 6 Manual Harvest Push Button 3PB 5 5 6 3 Marley Cooling Tower Recommendations 3 12 Metric Conversion 11 10 Mitsubishi PLC 10 3 Model Designation Chart 2 2 Model P24A drawings front side view 1 4 right side view 1 5 back side view left side view 1 7 Model P34A drawings front side v
12. MAJS 3dId 2 1 1108 8 9 SNOII1V 1934 53002 VHSO 7743035 7 207 2 04022 NI NOILVONNOS 3HL OTING Ol 3 401502 FHL 20 ALITISISNOdS34 JHL SI II 5033 SIH 113 4538 01 YINOLSND AS 5 SNIOIAeSS 403 LI FONVAVITI NOILVONNOJ JHL 20 IZIS JHI ANVdWOI J3NIHOVW 190 FHL 9 031539905 3215 WNWINIW JHL SI NO NMOHS NOILVONNOJ 3HL JO 3215 FHL ILON 015 2 M3IA 3015 06 6 9 01 JJI ANNA 8 2 61 5 aiino 140 FIGURE 3 2 P24A Foundation Layout 8 7 07 P24A amp P34A Service Manual 3 5 INSTALLING YOUR TUBE ICE MACHINE 40 NOTE E 2 NOTH E FREEZER 36 NOTA D 16 o 1 174 amp 172 TUBES 147 6 TUBES SHE NOTE o ICH DISCHARGE 13 1 4 24 3 4 1 4 AS REQ D PER FOUNDATION DRG 40004 NOTE C 5 4 0 NOTE A FRONT VIEW NOTES REQUIRED TO SBRVICB CUTTER ASSEMBLY C REQUIRED MINIMUM FOR SERVICING D REQUIRED TO CLEAN OR CONDENSER TUBES HITHER END 56 S
13. cd t P 24A amp P 34A TUBE ICE MACHINE Service Manual 5 31 11 5 31 11 NOTICE This manual is the property of the owner of this particular Tube Ice machine Model 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 or 502 634 0479 IMPORTANT The Warranty Registration Start Up Report found in the front of this manual is to be completed and returned to the factory promptly after the official start up Please return to Tube Ice LLC 1000 W Ormsby Suite 19 Louisville KY 40210 Att Tube Ice Service Department Vogt Tube Ice Machine MID amp LARGE MACHINE WARRANTY REGISTRATION START UP REPORT MUST COMPLETE AND RETURN TO INITIATE WARRANTY Machine Model No Serial No Installed a
14. 710 NOSS3SdWOO LAINI M31VM NOSS3HdWO2 v ONT1009 055354 09 wt MO FIGURE 1 9 P24A Compressor Diagram 8 7 07 P24A amp P34A Service Manual 2 1 RECEIPT OF YOUR TUBE ICE MACHINE 2 Receipt Of Your Tube Ice Machine Only service personnel experienced in ammonia refrigeration and qualified to work on high amperage electrical equipment should be allowed to install or service this Tube Ice machine Eye protection should be worn by all personnel working on or around the Tube Ice machine It is very important that you are familiar with and adhere to all local state and federal etc ordinances and laws regarding the handling storing and use of anhydrous ammonia An approved ammonia mask should be readily available for use in an emergency and all personnel should be aware of its location and proper use CAUTION Inspection soon as you receive your machine inspect it for any damage If damage is suspected note it on the shipper s papers 1 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 Tube Ice L L C can void the machine s warranty You should also no
15. ELECTRICAL CONTROLS ICR 2CR 2M 3M DT 2 5 TB FIGURE 6 1 Control Panel Door Opened 1M Not shown Compressor Motor Provides power to the compressor motor Continuously energized Starter during freezing and thawing with auxiliary hold contact and auxiliary contact to de energize the compressor crankcase heater when the motor is running 2M Pump Motor Starter Provides power to the circulating water pump during the freezer period or when the Hand Auto switch is in the Hand position to circulate water or ice machine cleaner etc 7 Provides power to the cutter during the harvest period Control Relay With For making and breaking various circuits during freezing and Pneumatic Timer thawing period with pneumatic timer to delay the actual thawing process Energized during thawing Control Relay For making and breaking circuits during freezing and thawing Energized during freezing thawing and hand Momentarily de ized at the end of the harvest Energized during the harvest period DT Delay Timer Allows the compressor to start unloaded by delaying the energizing of the UR SOL unloader solenoid valve This gives lower in rush amps and helps prevent belt slippage at start up Controls the desired ice thickness hole size by sensing the freezer suction pressure and initiating the harvest period Elapsed T
16. 4 1 Production Check 7 2 Pumpdown 9 18 Purging Non Condensables 9 19 Q R R 717 Refrigerant 5 1 Rated Capacity 2 3 Receipt of Machine 2 1 inspection 2 1 description 2 1 safety tags and labels 2 2 Receiver Ammonia Drain Valve 44 1 11 Receiver Purge Valve 59 1 10 Refrigerant Adding 5 6 Refrigerant Leaks 9 19 Refrigerant Charge 5 2 Refrigerant Removal 9 18 Refrigeration System Review 5 1 Removing Excess Water from Ammonia 9 21 Rotation Check 3 18 S Safety Notice 1 2 Safety Switches 6 1 Safety Symbols and What They Mean 1 2 Safety Tags And Labels 2 2 Sa
17. 4 Readjust the freezer pressure switch to produce ice 3 16 1 4 thick for crushed ice To remove and install cutter parts it will be necessary to first remove the water tank assembly for unrestricted access The result is that the ice is approximately 1 2 long and frozen only 3 16 1 4 thick A modification of this type is not one you would want to make every time a temporary change to crushed ice was wanted Contact your distributor for more information and complete details Length of Ice Ice length can be changed by increasing or decreasing the length of the spacer under the adapter plates The water tank assembly must be removed for making this modification When installing the adapter plates make sure the horizontal dimension from the cutter blade edge to the edge of the adapter plate is as follows 7 8 space for 1 tubes 11 8 space for 1 1 4 tubes 1 3 8 space for 1 1 2 tubes See Figure 9 6 for illustration of this critical adjustment CAUTION Always witness several ice making cycles after making conversions or modifications to make sure all ice clearing during the set thawing time and adjust timer accordingly CAUTION 8 7 07 P24A amp P34A Service Manual 10 3 Options and Accessories PLC Programmable Logic Controller This section of the service manual applies only to Tube Ice models equipped with a Mitsubishi programmable controller and 10DUE operator interface The PLC version of th
18. REMOVE JUMPER 12 13 WHEN WIRING CONVEYOR m 22 MOTOR OR SAFETY CONTROLS 2 r m a 7MOL 19 CRANKCASE HEATER CH oe ttre fo MOTOR ee IS COMP STARTER EOD DEA ACROSS LINE START AEART MIND START cue as 2M OL N REMOVE JUMPER 9 8 WHEN USING BIN CONTROLS OM 15 CUSTOMER 2CR bil 11 3 IPS sc 7 Low LI S MES ie STOP 9 8 START OIL PRESSURE SWITCH OPS 27 ELAPSED TIME INDICATOR SOLENOID VALVE COMP WATER HAND AUTO PILOT LIGHT WHITE AMMONIA FEED FLOAT SWITCH AFS SOLENOID VALVE AMMONIA FEED ICR 25 17 PILOT LIGHT AMBER FREEZING STARTER COIL FREEZER WATER PUMP 2CR RELAY FREEZER 23 TREE PRESS SW 19 2TR TIMER THAWING GAS 2PS Ki SOLENIOD VALVE D THAWING GAS 24 ICR 41 SOLENOID VALVE WATER FLUSH DT 2E SOLENOID VALVE UR COMP UNLOADER 3PB MAN CAL HARVEST STARTER COIL CUTTER MOTOR ICR X Um PILOT LIGHT RED THAWING TIME DELAYED STARTER COIL CONVEYOR MOTOR T FAN CONTROL 18 to STARTER COIL TOWER FAN i a E e pu STARTER COIL CONDENSER PUMP 2TR 17 i RELAY 43 FIGURE 6 3 BY CUSTOMER REMOVE JUMPER 12 13 WHEN INSTALLING Electrical Schematic for P24A P34A all Voltages 50 60 Hz 8 19 04 P24A amp P34A Service Manual 7 1 8 7 2007 MAINTENANCE
19. 11 Check and adjust cutter height and meshing of the gear teeth 12 Install the water tank assembly Cutter Blade Replacement The cutter blades are designed to give many years of satisfactory service and rarely need to be replaced If they become damaged they can be replaced by the following procedure l Disconnect and lock out all power and remove the water tank assembly so the cutter assembly is accessible See water tank removal 2 Remove the 3 8 cap screws holding the blades to the cutter plate and remove the blades P24A amp P34A Service Manual 9 17 SERVICING OPERATIONS 3 Set the new blades in place and install the cap screws and washers but do not tighten 4 Refer to FIGURE 9 6 adjust each blade to dimension and lock the blade in position by tightening the 3 8 cap screws Note Use a 90 square as illustrated to obtain the proper blade clearance required for satisfactory ice discharge Dimension is critical and should be measured at both ends of the blade Note 3 8 x 1 cap screw must be flush with cutter blade 5 Make sure all bolts and nuts are tightened securely then reinstall the tank assembly CHECK DIMENSION A T BOTH ENDS OF BLADE 7 CUTTER BLADE her A ay EZA PROJECT UP 90 FROM EDGE OF THE ADAPTER PLATE ADAPTER PLATE SPACER CUTTER PLATE 4 CUTTER 174 172 1 3 8 3 8 Figure 9 6 Cu
20. After all of the ice clears the cutter and auger turn the Hand Auto switch to Hand and back to Auto This will interrupt the harvest cycle and start another freeze cycle See Freeze Cycle As the machine continues its freezing cycle the liquid ammonia will feed into the freezer until the level float switch 10 is satisfied The float switch will open and close the liquid line solenoid valve 20 to maintain that level of ammonia in the freezer during the freeze cycle When the suction pressure pulls down to the setting of the freezer pressure switch 2 5 the switch will close initiate the harvest cycle See Harvest Period 8 7 07 5 6 8 7 07 P24A amp P34A Service Manual START UP amp OPERATION Be sure to observe several complete cycles of ice production to confirm the satisfactory operation of the machine IMPORTANT Complete the remaining part of the Warranty Registration Start Up Report and return it to Vogt Tube Ice L L C IMPORTANT Check the refrigerant level at the receiver liquid gage glass to make sure it is near the operating level mark Adding Refrigerant Add refrigerant while the machine is running by the following procedure 1 With a cylinder of anhydrous ammonia laying on its side cylinder valve outlet pointing up and bottom end raised two inches higher than the valve end connect an approved for ammonia charging hose between the freezer charging valve 28 and t
21. OTHER EQUIPMENT Emergency eye wash stations and deluge safety showers must be available in the work area Post a list of emergency response contacts and telephone numbers SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES Boiling Point 28 1 F Vapor Pressure 4802 9 mm Hg 60 F Vapor Density 0 60 32 F Air 1 Solubility In Water High Percent Volatile By Volume 10095 pH Approx 11 6 for 1 N Soln in water Melting Point 107 9 F Specific Gravity 0 62 60 F water 1 Appearance Colorless pungent gas SECTION 10 STABILITY AND REACTIVITY STABILITY Material generally considered stable However heating above ambient temperatures causes the vapor pressure of ammonia to increase rapidly INCOMPATIBILITY Materials to Avoid Ammonia can react violently with strong acids Under certain conditions ammonia reacts with bromine chlorine fluorine or iodine to form compounds which explode spontaneously Reactions of ammonia with gold silver or mercury to form explosive fulminate like compounds have been reported HAZARDOUS DECOMPOSITION PRODUCTS Hydrogen on heating to over 850 F The decomposition temperature may be lowered to 575 F by contact with certain metals such as nickel HAZARDOUS POLYMERIZATION Will not occur CONDITIONS TO AVOID Not applicable SECTION 11 TOXICOLOGICAL INFORMATION Ammonia 15 a strong alkali and readily damages all body tissues Ammonia is not a cumulative metabolic poison SECTION 12 ECOLOGICAL INFORMATION Aq
22. 8 7 07 P24A amp P34A Service Manual 11 5 TABLES amp CHARTS Condensing Entering Leaving Pressur Average Total Heat Water Water e Drop of Rejection s BTU HR Table 11 4 P24A Condenser Water Usage Condensing Entering Leaving Water Flow Pressure Average Total Water Water Heat Temp F of 2 1 e 1 852 500 Table 11 5 P34A Condenser Water Usage 8 7 07 11 6 P24A amp P34A Service Manual TABLES amp CHARTS Cylinder Ice Crushed Ice Make Up Water Tube Size Temp F 1127 47 46 588 427 48 46 534 560 549 3 5594 1 Includes 25 blowdown per cycle Table 11 6 P24A Make Up Water Usage gpm Cylinder Ice Crushed Ice Make Up Water Tube Size Temp F 1127 20 6417 00 5 110 40 212746 845 769 957 1056 732 913 1005 Includes 25 blowdown per cycle Table 11 7 P34A Make Up Water Usage gpm 8 7 07 P24A amp P34A Service Manual 11 7 TABLES amp CHARTS Suction Pressure Discharge Pressure Harvest Times Ice per Freeze Time psig psig secs cycle minutes Endof Endof Endof Endof First AllIce Total Average Water Temperature deg F Freeze Thaw Freeze Out Harvest ee 25 25 56 Table 11 8 P24A Normal Operating Vitals Suction Pressure Discharge Pressure Harvest Times Ice per Freeze Time psig psig secs cycle minutes Endof Endof E
23. CW RAISES PRESSURE SETTING SET FOR DESIRED ICE THICKNESS CW RAISES PRESSURE SHTTING TO MAKE ICE THINNER ADJUSTABLE DEADBAND SWITCH PART NO 12 2117 03000000 TRANSDUCER UNIT PART NO 2 2117T0300000C NOTE WHEN INSTALLING NBW CONTROL BH SURE TO REMOVE PROTECTIVE PAPER FROM TRANSDUCER SURFACH SO THERE WILL BE NOTHING BETWEEN THE SWITCH AND TRANSDUCER FIGURE 9 1 ASCO Freezer Pressure Switch 2PS It is preferable that the freezing cycle be such that a small diameter hole remain in the center of the ice cylinder 1 16 diameter for 7 8 diameter ice 1 8 diameter for 1 1 8 diameter ice 1 4 diameter for 1 3 8 diameter ice This insures that the freezing cycle is not extended unnecessarily and eliminates a possible opaque core in the center of the ice as well as a loss of production High Low Pressure Switch The high low pressure switch 1PS Figure 9 2 is a two pole dual function switch mounted to the frame near the compressor It protects the machine from possible damage due to abnormal pressure during operation 8 7 07 P24A amp P34A Service Manual 9 3 SERVICING OPERATIONS 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 35 psig and the cut out set at 15 psig After tripping at the cut out setting the switch will reset automatically when the pres
24. P34A Back Side 8 7 07 P24A amp P34A Service Manual 1 11 INTRODUCTION 23 4 Em 3 4 3 8 FREEZER PURGE ACCUMULATOR 20 13 16 CONDENSER SAFETY VALVE 60 LIFTING LUG LIFTING LUG 27 15 16 LIFTING LUG LIQUID RETURN STOP VALVE 91 101 CHECK VALVE SUCTION VALVE 34 OIL SEPARATOR FLOAT 14A GAGE GLASS STOP VALVE 43 LIQUID LINE STRAINER GAGE GLASS 50 LIFTING 106 CONTROL PANE 2PG DISCHARGE PRESSURE GAGE GAGE GLASS STOP VALVE OIL TRAP IPG SUCTION PRESSURE GAGE E DISCHARGE CEIVER RECEIVER AMMONIA DRAIN VALVE 44 FREEZER OIL AMMONIA DRAIN VALVE LIQUID OUTLET STOP VALVE 101 5 4 FIGURE 1 8 P34A Left Side Control Panel 8 7 07 P24A 4 P34A Service Manual 1 12 INTRODUCTION 3SVOXNVHO YJLIWOWYJHL ED 1 1002 QV3H HOSS3HdWOO H3l3WOWH3Hl AN WA NOILINS HOSS3HdWO2 4 JAVA L3 NI N31VM 05 NOSS34dWO2 M31VM 9NI1009 710 NH313AOWH3SHL 0 JAVA 4018 0138 IO 62 NIV3O 710 SNOSS3HdWO9 9 431009 110 HOSS3HdWOO0 S S 89 JAYA 4016 39V9 33055344 HOLIMS 35055359 110 9 1 3SVOMNVS23 GD OION3 OS M31VM NOSS334dWOO 09 HILIMS 34nSS3ud MOVHOIH 6 JAVA 398VHOSIO HOSS3HdAOS D 831 YOSSJYdAWOI 69 5 110 H31VM
25. Poor Ice Quality 8 7 Power Supply Connection 3 17 Power Monitor 10 14 Contactor test 10 15 contrast adjustment 10 16 control mode 10 15 delay on 10 14 delay on fault 10 15 delay on make 10 15 fault mode 10 16 locking out setup menu 10 16 nominal voltage 10 14 parameters 10 14 phase unbalance 10 15 read mode 10 16 reset mode 10 15 troubleshooting 10 18 voltage range 10 14 wiring 10 17 Pressure Temperature Chart 11 9 Preventive Maintenance 7 1 Preventive Maintenance Form 7 2 1 1 Principle of Operation
26. 3 Makeup water is maximum value and includes 2596 blowdown each cycle 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 5 Tower sized for 75 F wet bulb temperature Vogt reserves the right to change designs and specifications without notice Table 11 1 8 7 07 P24A amp P34A Service Manual 11 3 TABLES amp CHARTS P34A SPECIFICATIONS 400 460 Volt 3 Phase 50 60Hz Tube Size inches cm 112 Nominal Capacity M Tons day 38 6 35 0 427 38 7 38 8 35 2 Overall Dimensions LxWxH Feet meters 8 5 9 14 5 8 5 9 16 2 5 2 7 4 8 8 5 9 16 2 5 2 7 4 8 2 5 2 7 4 4 Water Requirements oo o S S E Connection Sizes S G E condenser waterinet FT ww condenerwaterouet TowerPump 0 0 14 flow 180 81 6 180 81 6 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F ambient and 25 blowdown 2 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower 3 Makeup water is maximum value and includes 2596 blowdown 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 5 Tower sized for 75 F wet bulb temperature Vogt reserves the right to change designs and specifications without notice Table 11 2 P24A Capacity Ratings 8 7 07 11 4 P24A amp P34A Service M
27. 7 Maintenance Preventative Maintenance A careful inspection of the Tube Ice machine for leaks and correct operational functions at the time of installation and start up will begin its long satisfactory life of service In order to insure this degree of dependability a systematic maintenance program is necessary Therefore the following schedule is suggested as a minimum A Daily 1 Check operating pressures suction discharge oil 2 Check ice quality 3 Check out time maintain 30 seconds of continued harvest after last ice is out 4 Check compressor oil level 5 Check refrigerant operation level 6 Check frost pattern on freezer shell and oil trap 7 Check make up water float valve adjustment 8 Rotate the Mycom Cuno oil filter tee handle two complete turns B Weekly in addition to daily checks 1 2 Check all belts for proper tension Do not use belt dressings Check for leaks after 400 hours or four weeks of operation C Monthly in addition to weekly checks 1 2 3 4 5 6 7 Check calibration and operation of all controls high and low pressure switches oil pressure switch etc Check cooling tower spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures Check water distributors in freezer for scale accumulation Check water tank for solids to be removed Check all motor drive units compressor cutter and pu
28. 7 07 2 2 P24A amp P34A Service Manual RECEIPT OF YOUR TUBE ICE MACHINE The machine is available in three different tube sizes for producing ice 7 8 OD x 1 long 1 1 8 OD x 1 long or 1 3 8 OD x 1 long The ice is cut to length by a rotating breaker type cutter Ice be produced up to 1 1 2 long by modifying the spacers under the adapter plates see Chapter 10 Ice Length for modifying instructions Crushed ice is also available by modifying the cutter and making minor adjustments to the machine see Chapter 10 Crushed 02 4 26 RC Nominal Capacity 02K 2000 Ibs day K 1000 s Ibs day T tons day 03K 3000 Ibs day 04K 4000Ibs day 3 tons day OST 5 tons day 10T 10 tons day 25T 25 tons day 50T 50 tons day Model Variation 80T 80 tons day A number assigned to indicate major variations within any one family series Consult Specifications for Actual Capacity Basic Configuration P Package Refrigerant L Low side E R 22 H High side Type of Ice A Ammonia B Cylinder H R 404a K Crushed D Dual Ice Cru amp Cyl Tube Size in 1 4 s of an inch 1 1 2 Long Cylinder 4 5 1 1 4 6 1 1 2 Electrical Codes 26 208 230 3 60 Condenser Type 46 460 3 60 AC Air Cooled 25 200 3 50 WC Water Cooled 45 400 3 50 HP High Pr
29. F Tube Ice Density 32 35 Ibs fC Water Sensible Heat 1 BTU Ib F Ice Melting Effect IME 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 Ibs ft 8 33 lbs gal 12013 Ib day Weight of air 0 0749 Ibs ft 0 0100 Ibs gal TABLE 11 12 8 7 07 Appendix Material Safety Data Sheet 4001 LAROCHE INDUSTRIES INC 2 15 96 SECTION 1 CHEMICAL PRODUCT amp COMPANY IDENTIFICATION CHEMICAL NAME Anhydrous Ammonia TRADE NAMES SYNONYMS Ammonia PRODUCT CODE 5B81 83 MANUFACTURER AND OR DISTRIBUTOR EMERGENCY TELEPHONE NUMBERS LaRoche Industries Inc Transportation CHEMTREC 800 424 9300 1100 Johnson Ferry Rd NE Environmental Health Safety 800 528 4963 Atlanta Ga 30342 Customer Service 800 491 7987 SECTION 2 COMPOSITION INFORMATION ON INGREDIENTS CHEMICAL FORMULA BY WEIGHT CAS OSHA PEL NIOSH REL ACGIH TLV IDLH C grade P grade Ammonia 99 5 99 995 7664 41 7 50ppm TWA 25ppm TWA 35ppm STEL 300 Water 0 4 33ppm 7732 18 5 None None None Oil c 0 1 2ppm None None None SECTION 3 HAZARDS INDENTIFICATION EMERGENCY OVERVIEW 1 Colorless gas or compressed liquid with extremely pungent odor 2 Liquid ammonia reacts violently with water Vapor cloud is produced 3 Avoid contact with liquid and vapor 4 Stay upwind and use water spray to absorb vapor 5 Not flammable under conditions likely to be encountered outdoors 6 Stop discharge if possible POTENTIAL HE
30. F 109 or higher room temperature A 5 or larger vacuum pump is best 9 During evacuation add new oil to the compressor Also purge the receiver for non condensables 10 After evacuation break the vacuum by manually opening the liquid line solenoid valve and gradually opening the liquid line stop valve 29 and 58 letting liquid ammonia enter the freezer and raise the pressure 11 When the freezer suction pressure is up to at least 60 PSI manually close the liquid line solenoid valve connect wire 17 to the freezer pressure switch and restore power to the machine 12 Open the compressor discharge valve oil return valve and all other valves that should be opened for normal operation 9 22 P24A amp P34A Service Manual SERVICING OPERATIONS 13 Turn the HAND AUTO switch to HAND When the receiver liquid level is near its normal operating level or the pressures are near equal and the compressor crankcase has warmed the compressor can be started and ice production resumed 14 After several cycles check the system for symptoms of excessive water and if necessary repeat the pumpdown and evacuation procedure Note Whenever excessive water is present in the system the source should be identified and corrections made prior to further operation Circulating Water Pump Motor The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water le
31. Lb Per Ice Lb Per Harvest Day Water FreezeTime Harvest Time First Ice Out AllIceOut Avg Hole Temp Min Sec Min Sec Min Sec Min Sec Size Note Ice lb per day can be found by ice Ib per harvest x 1440 freeze time harvest time The machine operated satisfactorily for continuous hours Date Comments Installer signature End user signature Please return to Tube Ice LLC 1000 W Ormsby Suite 19 Louisville KY 40210 5 31 11 VOGT TUBE ICE MACHINES P24AL amp P34AL Model H71L14 Tube Ice LLC 1000 W Ormsby Avenue Suite 19 Louisville Kentucky 40210 800 853 8648 e 502 635 3000 Fax 502 634 0479 5 3111 i P24AL amp P34AL Service Manual TABLE OF CONTENTS TABLE OF CONTENTS Vogt TUBE ICE MACHINES Model P24A amp P34A Page No 1 INTRODUCTION A Brief History Of Our Company uino ee er PR Me Sct 1 1 Vogt Machines issii AR A E e E R Ea ER 1 1 Preview date bug et ave 1 1 Importants afety ete eee nt ttd 1 2 Safety Symbols and What They 1 2 Special Precautions Be Observed When Charging Refrigeration Systems see 1 3 Assembly Drawing Model P24A Machine eret tette tette tette tette 1 4 1 5 1 6 1 7 Assembly Drawing Model P34A Machine eerte tette tette
32. P34A the condenser and the receiver are separated The P34A receiver contains the heating coil 8 7 07 5 2 P24A amp P34A Service Manual START UP amp OPERATION Start up Checklist Be sure to complete and return the Warranty Registration Start up Report located in the front of the manual 1 See that the water inlet connections are attached properly The water inlet shutoff valve 62 for the water tank should be open The water level in the water tank should be at a height where the make up float valve will be closed when the machine is idle and water is not running out of the overflow 9 2 See that the condenser cooling water is connected properly and the valves are opened for circulation 3 Fill the cooling tower sump and check the tower manufacturer s installation and operation instructions to make sure it is ready to run 4 Check condenser cooling water pump rotation 5 Check rotation of augers or ice handling equipment to make sure they are rotating the proper direction 6 Check all tagged valves and make sure they are in their correct operational position opened closed or automatic 7 See that the electrical disconnect is closed and the proper power is supplied to the machine 8 See that the compressor oil temperature is 100 110 F and there is no liquid ammonia in the crankcase The oil level should be 1 2 3 4 of the sight glass 9 Check the elapsed time indicator ET and make sure wire 22 and 27 are
33. The wet suction gas leaves the freezer and passes through the suction accumulator 88 where liquid droplets are removed allowing dry gas to enter the suction side of the compressor The suction gas is then compressed and discharged once again completing the cycle As ice continues to form in the freezer tubes the suction pressure steadily decreases until the freezer pressure switch is satisfied and the contact closes initiating the thaw harvest cycle Note Freezing time will vary depending on make up water temperature and thickness of ice produced During the harvest period the D thawing gas valve 18 opens and the compressor unloads allowing the warm high pressure gas from the receiver to enter the freezer As the tubes warm up to slightly above freezing the inside the tubes releases and falls down onto the rotating cutter for sizing and discharging Harvesting requires about three minutes but can vary depending on ice thickness suction pressure and discharge pressure thawing gas temperature IMPORTANT It is a good idea and will be profitable for you to observe and become familiar with the proper operating characteristics of your Tube Ice machine It will help you to recognize and correct minor irregularities as they occur in order to help prevent major problems ounce of prevention is worth a pound of cure IMPORTANT Note in the P24A the condenser and receiver are combined In the
34. Tons day Temp 2000 165 24 hours 2000 Ibs 24 hrs 2000 Ibs 24 hours 85 F 29 C 75 F 23 C 20 5 4 27 4 60 21 0 65 F 18 C Ice Ib harvest 750 165 340 Kg 600 165 272 Kg 450 165 204 Kg Shipping weight 12 200 1bs 5533 Kg 12200 16 5533 Kg 11 800 165 5352 Kg Model P34A 1 5 Model P34A 1 25 Model P34A 1 Makeup Water Capacity Tons day Water Capacity Tons day Water Capacity Tons day Water Temp 2000 Ibs 24 hours GPM 2000 Ibs 24 hrs GPM 2000 Ibs 24 hours GPM TEN 80 F 24 C 15 23 65 F 18 C SSHL 42 879 44 966 417 870 Ice Ib harvest 1350 1bs 612 Kg 1300 165 589 Kg 850 1bs 385 Kg Shipping weight 21500 1bs 9750 Kg 21500 1bs 9750 Kg 20900 15 9480 Kg Operating weight 23000 Ibs 10500 Kg 23000 Ibs 10500 Kg 22400 Ibs 10200 Kg Notes 1 Makeup water is average flow and includes 25 blowdown Peak flow rate is 15 GPM at 40 PSI minimum When water quality is good machine can be operated with 596 to 1096 blowdown 2 Ratings are at 90 F ambient for ice machine 3 Capacity ratings are based on 85 F water entering condenser For entering water temperatures above 85 F deduct 4 in capacity for each 5 F 4 Capacity shown is the average for model Individual machines may vary up to 596 above or below depending on field conditions TABLE 2 1 P24A and P34A Specifications Storage prior to installation or start up The machine must not be stored or installed in an
35. aid INGESTION Do not induce vomiting Have the victim drink large quantities of water if conscious Immediately seek medical aid Never give anything by mouth to an unconscious person SECTION 5 FIRE FIGHTING MEASURES FLASH POINT method used Not Applicable FLAMMABLE LIMITS 16 25 in air EXTINGUISHING MEDIA With a source of ignition ammonia will burn in the range of 16 2596 in air Stop flow of gas or liquid SPECIAL FIRE FIGHTING PROCEDURES Move containers from fire zone if possible if not use water to cool fire exposed containers Use water spray to control vapors Do not put water directly on liquid ammonia Personnel must be equipped with appropriate protective clothing and respiratory protection NFPA HAZARD CLASSIFICATION Health 3 Flammability 1 Reactivity 0 least 0 lt gt 4 highest SECTION 6 ACCIDENTAL RELEASE MEASURES Release of 100 Ibs or more of ammonia within 24 hours must be immediately within minutes reported to the National Response Center at 1 800 424 8802 as well as appropriate local and state agencies Suggested Local Action Stop leak if feasible Avoid breathing ammonia Evacuate personnel not equipped with protective clothing and equipment Use copious amounts of water spray or fog to absorb ammonia vapor DO NOT put water on liquid ammonia Contain run off to prevent ammonia from entering a stream lake sewer or ditch Any release of this material during the course of loading transporting unloading or temporary
36. ammonia contaminated atmosphere breathing should be held to a minimum and eyes opened only as necessary Because ammonia vapor is lighter than air a trapped person should remain close to the floor to take advantage of lower vapor concentrations while seeking an escape route unless liquid ammonia has been spilled If respiratory equipment is not available some temporary protection may be afforded by holding a wet cloth over the nose and mouth Should a leak occur which is extensive such as might be involved with a spill of liquid ammonia all persons in the path of the vapor should be warned If necessary local emergency authorities should be contacted to control evacuation The evacuation area should be adjusted according to wind changes and observed effects on population Suggested evacuation distances are given in Table 3 starting with the circle as shown in the accompanying diagram With good ventilation or rapidly moving air currents ammonia vapor being lighter than air can be expected to dissipate readily to the upper atmosphere Further action may not be required other than to stop the leak If necessary the concentration of ammonia vapor in the air can be reduced effectively by the use of an adequate volume of water applied through a spray or fog nozzle Under some conditions ammonia in a container may be colder than the available water supply At such times water must not be applied to the container walls since heat would
37. ammonia not covered in this booklet are urged to consult with LaRoche Industries or with the Compressed Gas Association Inc Arlington VA or The Fertilizer Institute Washington DC for assistance PLEASE NOTE The information and suggestions compiled in this booklet are derived from sources believed to be reputable and reliable HOWEVER LAROCHE INDUSTRIES SUPPLIES THIS BOOKLET MERELY AS A GRATUITOUS SERVICE AND MAKES NO WARRANTY OR GUARANTEE OF RESULTS EXPRESSED OR IMPLIED AND ASSUMES NO LIABILITY IN CONNECTION WITH THE INFORMATION AND SUGGESTIONS HEREIN No assumption shall be made as to the absolute correctness or sufficiency of any representation in the booklet or that certain circumstances may not warrant or require modified or additional precautions or actions This booklet should not be confused with federal state or municipal regulations insurance requirements or national safety codes although some statements may be similar or identical CONTENTS Page FOREWORD eer ree epe Bele Seah CE ene Dale aet bade i GENERAL vei ge RR Ed Chers mr Fa ume Pete 1 PRIMARY HAZARDS 2 OTHER HAZARDS ee RN 2 rrr Rp Pe DRM RUNI dea ORAE DH IE 2 THERMAL EXPANSION 2 HUMAN PHYSIOLOGICAL EFFECTS 2 EXPOSURE LIMITS ou be
38. attached 10 Reconfirm Rotation Check for compressor cutter and water pump See Section 3 Refrigerant Charge Prior to charging the machine with anhydrous ammonia R 717 make sure the system is leak tight and free of non condensibles or other contaminants The machine will require a full charge of pure anhydrous ammonia Make sure it is from a reputable supplier who can and will furnish quality ammonia of Refrigeration or Federal Technical grade ee Grade Ammonia Content Water Content Oil Content ea Federal Technical 99 98 200 PPM 5 PPM Metallurgical 99 99 33 PPM 2 PPM 10 ml g 99 999 5 PPM 1 PPM 7 PPM TABLE 5 1 Ammonia Specification By Grade Reference Ammonia Data Book Chapter 1 General Information NOTE Do not use Fertilizer grade ammonia Total ammonia R717 charge required is approximately P24A 800 lbs P34A 1600 lbs Special precautions to be observed when charging refrigeration systems Only technically qualified persons experienced and knowledgeable in the handling of anhydrous ammonia refrigerant and operation of refrigeration systems should perform the operations described in this manual local federal and EPA regulations must be strictly adhered to when handling ammonia R717 refrigerants See Material Safety Data Sheet MSDS Code5B81 83 located in the Appendix A 8 7 07 8 7 07 P24A amp P34A Service Manual 5 3 START UP amp OPERATION
39. be removed if necessary 5 If further cleaning is needed follow Cleaning Procedure 6 If further cleaning is not needed close the drain valve and refill the tank with fresh water 7 Make sure the float valve is adjusted properly and install the water box cover 8 Start and stop the pump again to make sure it is circulating water and is not air bound Water Cooled Condenser Cleaning As water evaporates from a cooling tower the solid impurities remain and must be flushed from the system to prevent a scale build up in the condenser and cooling tower This can be accomplished by a continuous bleed off valve located in the pump discharge line The valve should be adjusted to bleed off an equal amount of water which is evaporated If water hardness is very high a higher bleed off rate or chemical treatment may be required Consult your local water treatment company for recommendations If after a period of time scale has formed inside the tubes mechanical cleaning may be necessary See Servicing Section Condenser Cooling Tower Evap Condenser See Figure 3 7 for parts location 1 Bleed off valve The bleed off valve should be checked monthly to assure that is not blocked and that water is flowing as required If the unit is controlled by a water treatment system the bleed off valve may not be required 2 Strainer The pan or sump strainer is located in the bottom of the sump at the suction connection to the pump The strainer sh
40. be transferred to the ammonia thus causing increased pressure within the container resulting in aggravation of any leakage or relief valve discharge Water should not be applied to a liquid spill unless at least 100 parts of water to one part of ammonia are available Runoff of a liquid spill should be diverted if the direction of flow will create an additional problem UNDER NO CIRCUMSTANCES SHOULD AN BE MADE TO NEUTRALIZE AN AMMONIA SPILL WITH AN ACID It is recommended that an up to date telephone listing of various emergency rescue medical and regulatory agencies be maintained for use by designated personnel should it become necessary to call for sources of outside help to cope with a situation which is beyond the self sufficiency of local plant employees Included in the listing should be numbers for fire and police departments ambulance rescue or paramedical services doctors hospitals governmental authorities material and equipment suppliers Also listed should be the names and numbers for selected company supervisory and management personnel such as foreman superintendent safety and public relations directors etc who are to be notified of an emergency situation Where appropriate both day and night or alternate numbers should be shown If company or security personnel are not present at a facility during off hours the name s and telephone number s of a responsible individual s should be posted at
41. bearing bracket assembly removed from the tank press the shaft out of the housing from the bottom up Note The two top bearings may come out with the shaft along with the upper seal and excluder Turn the bracket over and press the bottom bearing out the bottom along with the lower seal There are three spacers on the shaft which should be removed and labeled as to their location Remove them as they are made accessible Clean and inspect all parts for wear or damage Discard all parts showing any indication of damage Cutter Shaft and Bearing Installation l 10 11 12 Clean the inside of the bearing housing of grease or foreign matter Further clean the top bearing housing with pro lock cleaner and primer or a suitable substitute and remove the pipe plugs from the side of the housing Apply a thin coat of Loctite RC 609 retainer or a suitable substitute to the inner surface and bearing shoulder of the top of the bearing bracket Insert a bearing in the top housing and set it in place Clean the cutter shaft and press the top bearing onto the shaft Slide the upper bearing spacer on the shaft and begin driving the shaft down through the middle bearing of the housing Do not start the top shaft bearing in the housing Partially fill the housing with grease MPG 2 or a USDA approved grease Use enough to fill the area between the two upper bearings forcing some out the pipe plug hole when the shaft and top bearin
42. contaminating the ice Be sure to size the filter large enough to meet the water demands of 15 GPM peak flow allowing for a restriction through the filter as it traps these particles The inlet water pressure should be a minimum of 40 psi Refer to TABLE 3 1 for line size and TABLE 2 1 for average flow rate at various water temperatures Flushing Water In Flushing water blowdown is necessary to melt ice fines and flush dissolved solids from the water tank during the thawing harvest cycle This function is important and helps to maintain good ice quality If water quality is superior this blowdown can be reduced by installing a smaller orifice in the flushing outlet elbow Make sure there is enough flushing water to prevent the accumulation of excessive ice fines in the tank If make up and flushing water are from the same source they can be connected by a common line to the machine Compressor Cooling Water In and Out This water supply should be a maximum temperature of 85 F 29 C It is used for cooling the oil and compressor heads A thermometer and water regulating valve are installed at the cooling water outlet The regulating valve should be adjusted to maintain a water outlet temperature of 100 F 37 8 C when the compressor is running A solenoid valve is installed at the cooling water supply inlet to prevent water flow through the oil cooler and heads when the compressor is not operating This is to avoid condensation of refrige
43. harvest cycle the machine will begin the freeze cycle harvest cycle The interface will display the current freeze time and the previous cycle freeze time during the FREEZE PREV FREEZ B RESET CYCLE freeze cycle Upon completion of the freeze cycle the machine will begin the harvest cycle If the on off switch is moved to the OFF position or the ice level sensor opens the machine will complete the current ice making cycle then stop The interface will indicate that the machine is standing by This message will be displayed anytime the machine is turned off If the machine is off because of a fault safety or power interruption a different message will be displayed A PUMPDOWN Pressing on the operator interface at this point will cause the machine to begin pumpdown sequence 8 7 07 8 7 07 P24A amp P34A Service Manual 10 7 Options and Accessories PLC Programmable Logic Controller When the machine is pumping down the operator interface will indicate PUMPING DOWN During the pumpdown sequence the compressor is running and the liquid feed valve A Valve is closed The machine will complete one harvest cycle then the compressor will continue to run until the freezer pressure reaches the low pressure safety switch setting The pumpdown sequence will move most of the refrigerant from the freezer to the receiver for servicing operations It is recommended that th
44. has two water connections The lower connection is the inlet and the upper connection is the outlet See TABLE 3 2 for water requirements and machine total heat rejection The condenser water outlet must be extended to an open drain or sump for visible discharge CAUTION The condenser water outlet must not be connected onto a pressure tight common header with the water tank due to the possibility that contaminated condenser water may back up into the water tank The condenser water outlet must be piped separate from the drain or sump CAUTION Cooling Tower When selecting a cooling tower careful attention must be given to operating wet bulb conditions It is advisable to check with your local cooling tower distributor for their recommendations based on actual operating conditions in your area An average wet bulb of 78 F is typical in the U S but many localities have designed wet bulbs as low as 72 F or as high as 82 F The cooling tower water pump must be capable of delivering the required volume of water through the condenser Due to cooling tower location and pressure drop through water lines and regulating valves the water pump must be sized for each installation Refer to TABLE 3 2 for condenser water requirements The water piping for the cooling tower and the installation of the pump must be in accordance with the manufacturer s instructions Caution must be used to prevent the condenser water pump from losing it s prime d
45. i 9 3 Fan Switch FIGURE 9 3 eee ede Eee doce te 9 3 Compressor Cra kcase Heater Re RU Pee EORR E o REO ER ree 9 4 Oil Pressure S witch incer ctr eoe ne RERO RING TIR e IE e aes 9 4 Oil Press r Switch FIGURE O eter cR 9 4 Control Circuit Protection eae hate a veel dee dde E ace Ce ROS 9 4 SN WANS feces aa cad c e e eS ML S MEI I E SE 9 5 Thawn Timer FIGURE UNO iU Tet 9 5 Condenser bem e mtd nee e OR eret ded be e 9 5 M M 9 6 Drive Gear Replacement Ra 9 6 Gear Reducer Replacement sev e dE 9 7 Water Tank and Cutter Parts Weights TABLE 9 1 9 9 WaterTank is lets AREA AMPLE 9 9 Cutter Assembly Removal and Installation 0 etn Rer ae ertet e Rees 9 10 Bearing Bracket and Cutter Disc 9 10 Cutter Shattiand Bearing oet et eme rn Itc dl e 9 11 Cutter Shaft and Bearing Installation eerte entente SEERE AEE ERE EE SEATER 9 11 Cutter Height Adjustment ieee eerte eb Pe be eR du 9 12 Water Tank Installatioiiz e eee Eee 9 13 P24A Cutter Assembly FIGURE 0 54 tete entren rtr 9 13 P24A Water Tank Assembly FIGURE 9 5
46. installed at of the terminal block 8 7 07 P24A amp P34A Service Manual Symptom Machine Stopped con t Possible Cause 8 3 TROUBLESHOOTING Possible Remedy High Low pressure safety switch 1PS tripped Low oil pressure tripped OPS Defective control panel component such as 1PB 1SS 1M contact 2CR contact Circuit breaker CB2 or CB3 for pump or cutter motor tripped 8 7 07 If the machine stops by low pressure cutout the switch will reset automatically when the pressure raises to the cut in setting Check thaw gas valve 18 to make sure it opens during harvest time If the machine stops by high pressure cutout the switch will have to be manually reset after the pressure drops below the cut in setting Check the head pressure during the next freeze cycle See FIGURE 9 2 Section 9 High Low Pressure Switch Manually reset the switch after the switch heater cools Check the crankcase oil level 1 4 3 4 full Add oil if below 1 4 glass before attempting to restart the machine Restart the machine and check net oil pressure net oil pressure oil pump line pressure minus crankcase suction pressure See FIGURE 9 4 Section 9 Oil Pressure Switch See Low Compressor Oil Pressure Net oil pressure range Mycom 17 28 psig Vilter 35 50 psig See FIGURE 6 3 Wiring Schematic and check for open circuit Refer to FIGURES 6 1 and 6 2 Control Panel to identify parts C
47. l 2 3 Always use matched sets banded belts for multiple belt applications Too much tension shortens belt life and motor bearing life Never use a petroleum base belt dressing 9 26 P24A amp P34A Service Manual SERVICING OPERATIONS 4 The proper tension is just enough to prevent slipping Reasons for premature wear 1 Pulley misalignment 2 Belts not matched 3 Dirt or foreign material present 4 Excessive slipping loose tension 8 7 07 Belt Replacement Belts which are worn cracked frayed or over stretched should be replaced 1 2 b Remove the belt guard and loosen motor hold down bolts Move the motor and sheave closer to the compressor until there is enough slack to remove the old belts Remove the old belts and clean the sheave grove is necessary with non flammable non toxic degreasing agent or commercial detergent Install new belts by rotating the belt and sheaves to obtain seating in the grooves Note on drives having more belt grooves in the sheaves than needed use the grooves closest to the motor and compressor Make sure that the belts are all slack on the same side of the drive preferably the bottom prior to tightening Move the sheaves apart until the belts are snug Check the motor and compressor shafts to make sure they are parallel and check the flywheel and motor sheave with a straight edge string or wire to make sure they are parallel and in the same plain
48. later adjustment Clean the split hub and drive gear insert the hub into the gear making sure the tapers of the two match and slide the hub and gear onto the shaft Position the hub on the shaft note measurements previously taken so the full width of the gear teeth will engage when assembled and tightened Tighten the cap screws three or four progressively and uniformly around the hub checking the measurements and adjusting as necessary 9 8 P24A amp P34A Service Manual SERVICING OPERATIONS 14 Install the reducer and mounting plate assembly on the water tank bracket and fasten in place with the side and top cap screws 15 Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount of backlash between the gear teeth 16 If the gear tooth tip clearance needs adjusting loosen the four hex nuts around the reducer base and move the reducer as required for proper tooth clearance Tighten the hex nuts securely and recheck for backlash 17 Reconnect the electrical wires and conduit to the motor 18 Check cutter rotation and correct as necessary NOTE When the cutter runs under a no load condition it should have a smooth uniform sound The weights listed in TABLE 9 1 will give you an idea of manpower or equipment needed when servicing and handling the various parts of the water tank and cutter Be sure to use safe lifting and handling practices to prevent bodily injury and or damage
49. maintain a desirable head pressure discharge pressure of 175 to 200 psi during operation See Fan Control Switch 6 1 6 2 P24A amp P34A Service Manual ELECTRICAL CONTROLS ICR 2CR 2M 3M DT 2 5 TB FIGURE 6 1 Control Panel Door Opened 1M Not shown Compressor Motor Provides power to the compressor motor Continuously energized Starter during freezing and thawing with auxiliary hold contact and auxiliary contact to de energize the compressor crankcase heater when the motor is running 2M Pump Motor Starter Provides power to the circulating water pump during the freezer period or when the Hand Auto switch is in the Hand position to circulate water or ice machine cleaner etc 7 Provides power to the cutter during the harvest period Control Relay With For making and breaking various circuits during freezing and Pneumatic Timer thawing period with pneumatic timer to delay the actual thawing process Energized during thawing Control Relay For making and breaking circuits during freezing and thawing Energized dur
50. not running It is deenergized when the compressor is operating Adjust the heater to maintain a temperature of 8 7 07 9 4 P24A amp P34A Service Manual SERVICING OPERATIONS 8 7 07 the oil in the crankcase at 100 110 F 38 43 C when the compressor is not running This will prevent the migration of refrigerant to the compressor during off periods Oil Pressure Switch The compressor is protected by a manual reset type low oil pressure safety switch which is set at 15 psig The oil pressure switch has a built in 60 second time delay If the net oil pressure pump pressure minus suction pressure equals net oil pressure falls below the switch setting for a time period of 60 seconds and the pressure does not increase at least 5 psi above the setting during that 60 seconds the switch contact will open and stop the machine After a period of time as the delay heater cools the switch can be manually reset and the machine restarted The compressor should not be operated under low oil pressure or low oil level conditions If oil is added to the compressor crankcase to resume operation after a loss of oil be sure to observe several cycles to make sure the oil level remains stable See Troubleshooting Low Oil Pressure Switch Tripped If it is necessary to install a new oil pressure switch see FIGURE 9 4 for adjusting CAUTION When this switch causes the machine to stop the cause should be identified and corrected b
51. oil drain valve located at the base of the compressor and purge the compressor until all pressure is relieved Remove the compressor side cover handhole cover being careful to protect the gasket and surface from damage Inspect the crankcase inside for foreign material such as sludge metal flakes burrs or anything which may look unusual indicating excessive wear or damage Remove all remaining oil and wipe out the compressor with a lint free cloth The extent of internal inspection should be dependent on the degree of evidence of wear Inspect and clean the oil strainer Cleaning can be accomplished with light oil diesel fuel or mineral spirits Make sure excess cleaning agents are removed prior to closing the crankcase Clean the oil sight glass and install the side cover plate using a new gasket if necessary and torqueing bolts tot he correct specification Evacuate the compressor and add new oil to the crankcase 10 Restore power to the crankcase heater allowing time to warm the oil 11 Open the suction valve discharge valve oil return valve and any other valves which may have been closed for servicing and check for leaks 12 Check and confirm sufficient oil pressure as you witness at least one complete cycle when operation is resumed Belt Tension New belts should be checked after the first day running after the first week for tension then at regular intervals for tension alignment and wear
52. peer 4 4 5 START UP AND OPERATION Retriger tion System Revie Wa o en ena doa eh ne SER 5 1 Startup Checklist oun tro todo i D bins 5 2 Refrigerant Charge ist nits nete nA ense iiA Mi ELS 5 2 Ammonia Specification By Grade TABLE 5 2 Special Precautions to be Observed when Charging Refrigeration Systems eee 5 2 Charging Front Tank Truck 4 e RR Re pupa p ep pce pue ene re pos 5 3 Charsing From Cylinders e eae e rd dei iter e E te Hr bee 5 3 MAM E ME Rr ERE EE IDE 5 5 Adding Refrigerator tee e Ee I er ie MO 5 6 Operating Tips 2 3 02 virt a et ect biet me b ee Pe eet t ea eb ve mde ae 5 6 6 ELECTRICAL CONTROLS amp THEIR FUNCTIONS Bin Level Control 6 1 Safety Switches 6 1 Control Panel Door Opened FIGURE 6 1 6 2 Description of Control Panel Parts Inside TABLE 6 6 2 Control Panel Door Closed EIGURE 6 2 5 ierit en eR EVE 6 3 Description of Control Panel Parts Outer Door TABLE 6 2 6 3 Electrical Schematic All Voltages 50 60 Hz Across Line Start FIGURE 6 3 sse 6 4 5 31 11 lll P24AL amp P34AL Service Manual TABLE OF CONTENTS Page No 7 MAINTENANCE Preventive Rae E E E 7 1 Preventativ Maintenance POEt eoe eee terri rte leere e ette 7 2 Ice Making Section iore te ee een e ore eR He e ber an a eee dina
53. product contains ammonia which if released to the environment in quantities of 100 165 or more requires notification to the National Response Center in Washington DC at 1 800 424 8802 WHMIS One Percent 1 CALIFORNIA PROPOSITION 65 Reproductive No Carcinogen No OSHA PROCESS SAFETY MANAGEMENT 29 CFR 1910 119 This product is subject to the Process Safety Management requirements of 29 CFR 1910 119 if maintained on site in quantities of 10 000 lbs or greater EPA CHEMICAL ACCIDENT RELEASE PREVENTION 40 CFR PART 68 This product is subject to the Risk Management Plan requirements of 40 CFR Part 68 if maintained on site in quantities of 10 000 165 or greater DRINKING WATER Maximum use dosage in potable water is 5 mg l This information is taken from sources or based upon data believed to be reliable however LaRoche Industries Inc makes no warranty as to the absolute correctness or sufficiency of any of the foregoing or that additional or other measures may not be required under particular conditions Industrial Products Group Anhydrous Ammonia Safety La ROCHE INDUSTRIES INC UE ery Copyright 1989 by LaRoche Industries Inc rights reserved Quotation or production in whole or part without written permission is expressly prohibited FOREWORD Ammonia frequently called anhydrous ammonia is one of the most valuable and versatile chemical compounds in today s modern world For example it finds wide application i
54. refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant brought on by an increase in temperature CAUTION Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 120 F 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 a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements CAUTION 1 4 INTRODUCTION P24A amp P34A Service Manual SUCTION ACCUMULATOR 1 2 CHARGING VALVE FREEZER 28 LIQUID LINE STOP VALVE 29 HAND EXPANSION VALVE 17
55. restaurants sports arenas packing plants and wholesale operations around the globe at great savings In addition Tube Ice machines are renowned for their long life giving many customers more than 35 years of dependable service Ask someone who owns one Preview the skill in engineering and fabrication that we ve learned in over a century of experience is reflected in every Tube Ice machine Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s economic and reliable operation has been proven over and over again in a network of varied types of installations throughout the world Furnished with your machine is the Certificate Of Test the report of operating data that is a record of the unit s satisfactory operation at 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 provided you install maintain and service it properly Please read your manual carefully before attempting installation operation or servicing of this professionally designed piece of equipment Also make sure the Warranty Registration Start up Report is completed and returned If you have additional questions please call your di
56. rotate the adjustment toward 0 counterclockwise 2 Start the motor and determine if the soft start is acceptable If not continue to rotate the start time adjustment until an acceptable start is obtained Note The soft starter should be adjusted to bring the cutter up to full speed in 10 to 15 seconds Any longer than this will not obtain a further reduction in starting current Wiring The soft starter should be wired in series between the cutter motor contactor and the compressor 10 14 P24A amp P34A Service Manual Options and Accessories Power Monitor Several Vogt Tube Ice machine models are available from the factory with a three phase line voltage power monitor with LCD display The units are also available for after market or retrofit installation These units monitor line voltage inputs from 190 to 610 volts and provide protection against line voltage variances which can damage or destroy the compressor motor Features include automatic system shutdown and restart based on current line conditions a voltmeter and a non volatile system memory so settings are retained even if power is lost If machine is ordered with this option the power monitor can be factory set to customer specifications Operation Parameters Press Setup Key to enter Setup Mode Holding the Setup key down for 2 seconds will place all settings at their defaults To change settings press the Setup Key repeatedly to step through each menu item chan
57. storage must be reported to U S D O T as required by CFR 171 15 and 171 16 SECTION 7 HANDLING AND STORAGE Refer to the ANSI K61 1 standard for storage and handling information Protect containers from physical damage and temperatures exceeding 120ooF Use only approved storage systems Zinc copper silver cadmium and their alloys must not be used in ammonia systems since they can be rapidly corroded by it Avoid hydrostatic pressure which can cause equipment rupture by adhering to proper filling procedures and the use of hydrostatic pressure relief valves where appropriate SECTION 8 EXPOSURE CONTROLS PERSONAL PROTECTION RESPIRATORY PROTECTION Respiratory protection approved by NIOSH MSHA for ammonia must be used when exposure limits are exceeded Whether a chemical cartridge respirator or a self contained breathing apparatus 1s sufficient for effective respiratory protection depends on the type and magnitude of exposure EYE PROTECTION Chemical splash goggles approved for use with ammonia must be worn to prevent eye contact with liquid or vapor A face shield should be used for increased protection from contact with liquid VENTILATION Local positive pressure and or exhaust ventilation should be used to reduce vapor concentrations in confined spaces Ammonia vapor being lighter than air can be expected to dissipate to the upper atmosphere Ammonia concentrations may also be reduced by the use of an appropriate absorbent or reactant material
58. sure all the ice clears the freezer with at least 30 seconds to spare before the next freezer period begins This is to prevent refreezing and to allow the ice moving augers etc to clear CAUTION 1PG 2PG 4PS 15R 16 17 18 20 23 24 25 28 29 29A 30 31 34 35 Control Panel Suction Pressure Gauge Discharge Pressure Gauge Freezer Compressor Dual High Low Pressure Switch Cutter Motor Gear Reducer Water Pump Water Tank includes cutter assembly Water Distributing Chamber Water Tank Overflow 3 FPT Refrigerant Float Switch Make Up Water Float Valve Heat Exchanger Oil Separator Condenser Receiver Thawing Chamber Hand Expansion Valve Thawing Gas Solenoid Valve Liquid Feed Solenoid Valve A1 Condenser Water Inlet W C Machines Condenser Water Outlet W C Machines Water Tank Drain Connection 1 Refrigerant Charging Valve Liquid Line Stop Valve Float Switch Stop Valve Sight Glass Gage Glass Stop Valve Compressor Suction Service Valve Compressor Discharge Service Valve 36 37 39 41 41A 43 44 45 50 51 52 54 55 56 58 59 61 62 63 64 69 70 75 76 77 78 82 88 90 92 94 101 Oil Trap Oil Charging Drain Valve Water Tank Drain Valve Condenser Water Regulator Condenser Pressure Control Strainer Receiver Drain Valve Compressor Cooling Water Inlet Valve Receiver Safety Valve Freezer Safety Valve 3 Way Valve Compressor Water Regu
59. the cycle count and pounds of ice produced to zero This will not reset the total cycles displayed on the main set up screen Pressing from this screen will call the second monitor screen The second monitor screen displays the previous total cycle time lbs of ice produced per cycle and lbs of ice produced per day based on the last cycle time The screen is shown below PREV CYCLE ICE CYCLE LBS ICE DAY LBS The user can set the pounds of per cycle from this screen The capacities and ice production totals calculated on these two screens are based on the user input number for pounds of ice per cycle This depends on how thick the ice is and how the machine is set up For best results the number used here should be the average actual measured weight from two or more consecutive cycles 10 8 7 07 12 Options and Accessories LI P24A amp P34A Service Manual FAN FUSED DISCONNECT CONTACTOR SWITCH BY CUSTOMER CONDENSER AIR COOLED ONLY FAN MOTORS T JUMPER MUST BE IN PLA CE MACHINE WILL STOP IMMEDIATELY WHEN REMOVED TRANSFORMER GE MODEL 9761870 1 0 50 HZ 12 75 9E02000000 400 3 50 MACHINES ONLY TRANSFORMER GE MODEL 9T5IBOOIO KVA 60 HZ 12 7519 03000000 460 3 60 MACHINES ONLY o X XH FOR 208 230 3 60 amp 200 3 50 M
60. to stop the leak the valve should be closed If the valve should fail to close completely it should be plugged PRESSURE RELIEF DEVICE A leak or discharge through a pressure relief device such as a pressure relief valve or hydrostatic relief valve may occur if the pressure within the equipment piping tank or container exceeds the rated pressure setting of the device or if the device is faulty Reducing the pressure within the system by removing ammonia as a vapor to process or cooling the container with a water spray may permit the device to reseat If reseating does not take place it most often will be necessary to replace the device with one approved for ammonia service and of the proper pressure rating and capacity No attempt should be made to plug cap or otherwise tamper with a pressure relief device under any circumstances However a pressure relief valve may sometimes be provided with a shut off valve in an arrangement whereby the leaking device can be isolated for removal purposes while another pressure relief valve s provides not less than the full rate of discharge capacity required for safety Unless returned to the manufacturer a pressure relief device should not be repaired or adjusted in any manner Pressure relief valves should be replaced at regular intervals as suggested by the manufacturer Failure to Observe these precautions could result in a serious weakening or catastrophic rupture of the equipment piping ta
61. to parts If additional information is needed you should contact your distributor or the factory To inspect the cutter assembly and make repairs or replace parts it will be necessary to lower and remove the water tank from its mounting to the bottom of the freezer The water tank has metal casters allowing it to be rolled out from under the freezer for inspection and servicing 8 7 07 8 7 07 P24A amp P34A Service Manual 9 9 SERVICING OPERATIONS Weight Ibs Description P34 Water tank bare 428 Bearing bracket assembly and cutter disc 150 Cutter assembly and ring gear 164 528 742 57 97 14 56 96 85 85 TABLE 9 1 Water Tank and Cutter Parts Weights Water Tank Removal l 2 Disconnect and lock out all power to the machine There should be ample space to roll the water tank from under the machine It may be necessary to provide a flat level surface such as a sheet of plywood sufficiently supported to hold the weight of the tank and cutter assembly See TABLE 9 1 Turn off water supply drain water and disconnect water and drain lines from the tank Remove the overflow tubing from the water tank and remove the circulating water tubing from the pump P34A only the water pump is mounted to the structural frame of the machine and will have to be disconnected from the tank at the pump inlet bolted flange before moving the water tank Disconnect the ice discharge chute or hopper from the ice disch
62. to spew out immediately close the valve 6 Remove the hose and install a plug in the valve DO NOT attempt to reuse any oil taken from the system unless it is properly reclaimed and meets the proper specifications Removing Excess Water from Ammonia If excessive water is in the ammonia it will cause frost on the suction line to the compressor and dilution of the oil This condition should not go uncorrected and the water needs to be removed 1 Perform a total pumpdown of the freezer See PUMPDOWN 2 Atotal pumpdown is accomplished when there is no frost or ice on the freezer or oil trap and the freezer pressure is below that pressure relative to the surrounding temperature Refer to the Temperature Pressure chart for ammonia 3 With the freezer pressure below 25 PSIG attach a hose to the oil trap drain valve 461 and extend the other end into a container 5 gallon bucket etc 4 Open the drain valve a little and drain out the oil and water that is present 5 Continue to drain oil water and purge the freezer and compressor to 0 PSIG 6 Close the compressor discharge stop valve and the oil return valve Make sure the power is disconnected and locked out 7 Drain the compressor oil remove the compressor side cover and clean the inside of all oil and foreign matter and reinstall the side cover 8 Connect a vacuum pump or pumps to the freezer and compressor and evacuate them to 2000 microns or below while maintaining 60
63. 0 valve to purge air from that section of the line 6 When purging is complete tighten the compression nut manually close the solenoid valve stem in until it protrudes about 1 8 out from the housing 7 Reopen stop valves 490 and check for leaks 8 Adjust the regulating valve to approximately 65 70 psig to the freezer pressure during harvest 8 7 07 8 7 07 P24A amp P34A Service Manual 9 23 SERVICING OPERATIONS ruo COIL PILOT LINE THAW GAS SOLENOI PART NO Ld 12A 4200A14030000 THAW GAS STRAINER PARTNO 12 4140803000000 FLOW E X MANUAL OPENING STEM FIGURE 9 7 Thaw Gas Solenoid Valve The Liquid Feed Solenoid Valve 20 Figure 9 8 is opened and closed during the freezer cycle by the float switch 10 in order to maintain the proper freezer refrigerant level It is closed when the machine is off to prevent liquid flow from the receiver to the freezer Repair or replace as follows l With the receiver pressure higher than the freezer pressure close the hand stop valve 58 29 upstream and downstream in the liquid line between the receiver and liquid feed solenoid valve Manually open screw stem in until only 1 8 protrudes and allow the liquid to flow to the freezer and clear this part of the line of liquid leaving only vapor Close the othe
64. 00150415 197400180411 Splash Curtain 12A 4078C03000000 12A 4078C02000000 Cutter Ring Gear Replacement l 2 Remove the water tank assembly see water tank removal Remove the cutter assembly from the cutter shaft Remove the 3 16 drive pins 1 4 on P34A which hold the ring gear to the cutter bank P2426 pins 34 8 pins The ring gear is a shrink fit onto the cutter band and therefore will have to be driven off It should be driven off progressively and uniformly around its circumference to avoid binding Inspect and clean the cutter bank removing any burrs scale or dirt Attempt to put the new gear onto the cutter and check for fit If it will not fit it will have to be expanded by heat Move the ring gear away from the cutter and heat the gear uniformly to 300 400 F 150 205 C This can be done by passing a hand held oxy acetylene torch uniformly over the entire ring gear DO NOT HEAT THE CUTTER Align the valley of the ring gear teeth with the existing drive pin holes and carefully set the ring gear onto the cutter Make sure it is fully seated all the way against the machined shoulder of the cutter bank After the gear has cooled drill 3 16 holes 1 4 on P34A in the valley between the teeth of the ring gear and install the drive pins Make sure the drive pins do not protrude and interfere with the engagement of the drive gear 10 Install the cutter assembly onto the shaft
65. 03 979 0900 Agricultural Ammonia Safety Booklet P15 The Fertilizer Institute 1015 18th Street NW Washington DC 20036 202 861 4900 Safe Handling of Anhydrous Ammonia Rural Accident Protection Bulletin National Safety Council Farm Department 444 North Michigan Avenue Chicago 6061155D 312 527 4800 For the Rest of Your Life 16mm color sound film National Society for the Prevention of Blindness Inc 79 Madison Avenue New York New York 10016 212 684 3222 8 7 07 P24A amp P34A Service Manual A A Brief History Of Vogt Tube Ice L L C Adding Refrigerant 5 6 Ammonia Specification by Grade 5 2 Ammonia amount required 5 2 Ammonia Removal 9 18 Assembly Drawing 24 1 4 1 5 1 6 107 Assembly Drawing P34A 1 8 1 9 1 10 1 11 Automatic blowdown Harvest Cycle 9 1 Auxiliary Controls or Equipment 3 19 B Basic Product Warranty inside back cover Bearing Bracket and Cutter Disc Removal 9 10 Belt Tension 9 25 Belt Replacement 9 26 Bin Level Control 6 1 Blowdown
66. 1108 3A33S 3dId 2 1 1709 8 9 INIGTING 53002 VHSO 7743435 7207 TIV HLIM 2 04020 NI NOILVONNOF FHL OTING 01 YIWOLSND FHL JO ALITIGISNOdS3Y JHL SI 11 5433 SIH 114 1539 01 3 401502 FHL GINIWYFLIG 38 GIOHS 9NIOIAeSS 4034 LI ONnOSMV FINVEVITI NOILIVONDOJ JHL 20 321 JHL 02 JNIHOVW 190A FHL 031539905 321 0381103 WOWINIW SI SIHL NO NMOHS NOILVGONDOJ FHL 3O 3215 JHL JLON 1 8340152 A8 9 YOASANOD TN L 22 NN id 7110 L T 1 T 49 87 73 aA E YN YY gt 84 510 Y 323354 lt rra RUK lt lt 7 NN 4 us 1 01140 321 455 831109 gt FIGURE 3 4 P34A Foundation Layout 8 7 07 P24A 4 P34A Service Manual 3 8 INSTALLING YOUR TUBE ICE MACHINE 140 WOllO8 NO LOAId TIIM ANIHOVW NOLISOd 9 1 40 OL ANIHOVW SNINOIIISOd UINDnONO 54 312 3NIHOVW NAHM SNIMS 3ZIWINIW OL A FI338V29 NOILISOd WNv3g8 LYOddNS
67. 201 8 222 3 124 7 228 5 5 213 8 234 9 132 4 241 3 136 4 247 9 140 5 254 6 144 7 261 5 162 2 290 1 275 5 297 6 305 2 353 9 408 4 53 2 66 7 71 4 103 1 192 9 106 5 198 6 217 5 380 4 223 1 389 5 228 8 398 9 DegF R 12 R 22 R 502 R 134a R 404A R 717 MP 39 234 6 KE 84 2 161 2 jM M x EINE Sm lt 9s Eo 33 3 4 1 Lupus ni Gur pir pues ae 0 3 DegF R 12 R 22 R 502 R 134a R 404A R 717 MP 39 N T 1 1 T eo 1 69 Ut N 99 lt N i T Es Ta 26 1 5 69 115 3 8 132 08 TABLE 11 10 pressures are in Ibs in gage psig 8 7 07 11 10 P24A amp P34A Service Manual TABLES amp CHARTS REFERENCE INFORMATION CONVERSION FACTORS English to Metric Multiply by Area fe m 9 2903e 2 in 6 416 4 Energy Joule J 1054 48 hp BTU Hr 2546 2 kW hp 1 34 Length ft m 0 3048 in m 0 0254 Pressure Ibf fc Paschals 47 88 Ibf in psi Paschals 6894 76 in Hg psi 0 491 in psi 0 03612 Temperature 5 9 32 9 5 32 ft 2 8317 2 gal U S 3 7854 3 ft gal U S 7 48 TABLE 11 11 CONSTANTS Specific heat of Water 1 BTU dbm F Specific heat of Air 4 19 kJ kg C 0 24 BTU Ibm
68. 24 Water Valve vo eae Rede e 9 24 Compressor Cooling Solenoid Valve dedicated high side only eene 9 24 Compressor Orl Chanti edre deer e e Po er d deese ette s 9 24 Compressor Inspection ee Eher t ee DU re ER bee OR RU EE Recibe d eee ee de Rit 9 25 Belt Pension E 9 25 Compressor Servicing 9 26 10 OPTIONS AND ACCESSORIES Cr shed Ice Production dac der bio bv at em ded desc epe i 10 2 Length of I6e nu ER RR REED 10 2 PLC Programmable Losic Controller 10 3 R duced Voltage Cutter Motor Starte 10 13 Power Monitor A stint o Re ee be Mte tie Se 10 14 11 TABLES AND CHARTS 24 Specifications TABLE 11 T ERREUR 11 2 P34A Specifications TABLE 1 2 unto e e a e e D P RS 11 3 P24A Capacity Ra ngs TABLE 113 ui ect i e derit aee ET bes 11 4 P24A Condenser Water Usage TABLE 11 4 11 5 P34A Condenser Water Usage TABLE 11 5 5 teinte 11 5 P24A Make up Water Usage TABLE 11 6 21004004 0 0 nennen treten E EEA EE teens 11 6 4 Make up Water Usage etr ime eee aan o te eer Ree Pe EXER EK 11 6 P24A Normal Operating Vitals TABLE 11 8 11 7 P34A Normal Operating Vitals TABLE 11 9 11 7 Recommended Spare Parts 14
69. 29 9 14 26 30 Figure 9 5 P24A Water Tank Assembly 8 7 07 8 7 07 P24A amp P34A Service Manual 9 15 SERVICING OPERATIONS Item 5 8 11 NC x 3 Long S S Stud NC x 2 Long S S Stud 1 1 1 5 3 4 x PVC 90 12 2450 07000000 12 2450 07000000 1 1 1 1 1 1 1 1 1 1 8 S S Lock Washer 8 12A 2250B11300000 2A 2250B11300000 1 1 1 7 10 11 12 13 14 16 17 18 19 20 21 22 1 1 WC 90 7 8 ODC 23 3 4 Brass Service Valve 1 for P34A 24 3 4 MPT x 1 2 PVC Bushing 25 26 3 4 MPT x 7 8 ODC Adapter 27 28 29 30 WC 3 4 FPT x 7 8 ODC Adapt 31 32 33 E H S 5 L L L 1 Sq 4i 4 4 4 4 4 4 4 4 1 ock washer 5 16 S S 2 2250810800000 12A 2250B10800000 ock washer 3 8 S S 2A 2250B10900000 12A 2250B10900000 ock washer 5 8 S S 2 2250B11300000 12A 2250B11300000 1 1 1 1 1 1 1 1 1 1 34 35 36 37 38 39 0 2 3 4 5 6 7 8 9 50 52 53 Key 3 8 x 5 167 3 4 S S 54 Gear Motor 55 Cotter Pin 3 16 x 1 1 2 5 5 56 57 5 5 8 9 60 61 62 63 64 65 9 16 SERVICING OPERATIONS 8 7 07 P24A amp P34A Service Manual 12B 2615D03000000 12C 2615D05000000 68 Splash Curtain Holder 197400150162 197400150163 69 Splash Curtain Bottom Plate 19 4
70. 4011048 NO LOAId 3NIHOVW 1 016 3NIHOVW 72 1 1 Sv 9 1 9NILJI 8323384 OL 193NNOO 71 3NIHOVW SNILJI 311IS S9NILIV H3dO 01 3AOMW ANIHOVW 1311 Q31valsn rir Sv S NI 9NILJI 4343344 OL L193NNOO MINAL 3NIHOVW S9NILJI FIGURE 3 5 Lifting Procedure for P24A 8 7 07 P24A amp P34A Service Manual 15 8 POSITION A 3 9 INSTALLING YOUR TUBE ICE MACHINE 49 LIFTING MACHINE FROM TRUCK USING THREE 3 POINT HOOKUP CONNECT CRANE TO MACHINE AS ILLUSTRATED POSITION D 7 YL p te 3 f Vy LIFTING MACHINE UPRIGHT POSITION A USING TWO 2 POINT HOOKUP CONNECT FROM CRANE TO MACHINE AS ILLUSTRATED POSITION B RAISE MACHINE SLOWLY UNTIL BACK EDGE OF MACHINE CLEARS GROUND 1 RS 24 vt SITTIN i LIFTING MACHINE UPRIGHT POSITION C USING TWO 2 POINT HOOKUP CONNECT FROM CRANE 2 TO MACHINE AS ILLUSTRATED POSITION D RAISE MACHINE TO LEVEL UPRIGHT POSITION THEN LOWER MACHINE TO POSTTIONING USING FOUR 4 FROM C
71. 66 22 01 2 0000000 00000000000000000000000000000000000000 0 tentent rettet trennen ens 11 8 Temperature Pressure Chart for Common Refrigerants TABLE 11 10 esee 11 9 Conversion Factors English to Metric TABLE 11 11 40 11 1 000010000000000000505 055555 5 11 10 Constants TABELE innen ect E EROR Cree 11 10 12 APPENDIX 5 31 11 5 31 11 P24AL amp P34AL Service Manual TABLE OF CONTENTS P24A amp P34A Service Manual 1 1 INTRODUCTION 1 Introduction Vogt Tube Ice L L C A Brief History Of Our Company Vogt Tube Ice L L C formerly Henry Vogt Machine Co was founded as a small machine shop in Louisville Kentucky in 1880 Today it is one of the world s leading producers of ice making equipment In 1938 Vogt built the first Tube Ice machine and revolutionized the ice making industry Our first sized ice machine quickly replaced the old can ice plants which required hard labor and large amounts of floor space for freezing cutting and crushing ice by hand Vogt Energy Saving Tube Ice Machines Are Cost Effective Today Vogt Tube Ice machines enjoy a well earned reputation as the most energy efficient dependable ice making equipment in the world Using as little as one half to one third the energy required by competitors ice makers Tube Ice machines produce the same amount of ice in
72. ACHINES USE JUMPERS FROM TO L4 AND FROM B3 TO L5 L4 L5 FU 1 Fu 2 CUTTER MOTOR MARATHON V56TI7F5308 T 1 260 2 2 FAST ACTING 208 230 460 3 50 60 FUSES 2 1 2 2 1 FLA 12A 2900 050 10000 2 cc 3 fL ee a Q L HEATER 0 0 o 9 Ln m 4 OIL PRESSURE CONTROL OPC 1 LOCATED ON COMPRESSOR E i X soL L ATR COOLED ONLY r 10 5 o Fc 9 AIR COOLED ONLY AIR COOLED ONLY SENE STOP 6 Tm 2 lo L N PLC 7 24V ov INPUT OUTPUT 4 Y Ys CUTTER OL Y4 COMP OL FPS coms OFF ON s 2 Iwe CONVEYOR CONTROL CONTACT oe o 17 FU YI an o 18 HARVEST Er id o 19 SEQUENCING INPUT FU Yo Yo 20 SEQUENCING INPUT SEQUENCING OUTPUT 21 Figure 10 3 Wiring Schematic PUMP MOTOR WATER PUMP MOTOR GOULD NPE 3ST 208 230 460 3 50 60 4 5 4 8 2 4 FLA 12A 40260 10000000 8 7 07 P24A amp P34A Service Manual 10 13 Options and Accessories Reduced Voltage Soft Start Cutter Motor Starters Several Vogt Tube Ice ma
73. AL Service Manual TABLE OF CONTENTS Page No Cooling TOWeE nen erdt Ee oio ee RR ea E RUN e cei 3 11 Condenser Water Requirements TABLE 3 2 3 12 Marley Cooling Tower Recommendations 3 12 Satety Valves 3 13 Cooling Tower Piping Diagram FIGURE 3 7 sse 3 14 Freeze Protection FIGURES 3 8 3 9 3 10 4 0 2 000000000000000000000000000000 3 15 3 16 Wiring and Electrical Connections ane EET 3 16 Power Supply Connections FIGURE 3 11 2 00008400 N te tnst etn S 3 17 Voltase Urnbalatce eR Und he n 3 17 Current Unbalarce 4 2t bec eee e nti eee dedit bett 3 17 Rotation 3 18 Auxiliary Controls or Equipiierit e e er 3 19 Installation Review A Checklist 3 20 HOW YOUR TUBE ICE MACHINE WORKS Operating ECatules eom DRE ERE EE EDT ORE BOE 4 1 Principle of Operation Freeze Period 4 1 Harvest PENOU soa e den et ea do teni be i en det d 4 2 Piping Nomenclature oe ed eti e eR 4 2 Piping Schematic for P24A 4 1 4 3 Piping Schematic for P344 FIGURE 4 2
74. ALTH EFFECTS ROUTES OF ENTRY Inhalation Skin Contact Eye Contact Ingestion TARGET ORGANS Eyes skin and respiratory system EYE CONTACT Exposure to liquid or high concentrations of vapor can cause painful instant and possibly irreversible damage to tissue such as the conjunctiva cornea and lens SKIN CONTACT Prolonged contact with high concentrations can cause painful tissue damage frostbite and serious chemical burns INHALATION Depending on exposure concentration and duration s effects can vary from none or only mild irritation to obstruction of breathing from laryngeal and bronchial spasm to edema and severe damage of the mucous membranes of the respiratory tract with possible fatal results Latent edema and residual reduction in pulmonary function may occur INGESTION Tissue damage chemical burns nausea and vomiting can occur Ammonia is a gas under normal atmospheric conditions and ingestion is unlikely CARCINOGENICITY NTP No IARC No OSHA No SECTION 4 FIRST AID MEASURES EYE CONTACT Flush with large amount of water for at least 15 minutes then immediately seek medical aid SKIN CONTACT Immediately flush with large quantities of water for at least 15 minutes while removing clothing Clothing frozen to the skin should be thawed with water before removal Seek immediate medical aid INHALATION Remove from exposure If breathing has stopped or is difficult administer artificial respiration or oxygen as needed Seek immediate medical
75. AW GAS CHECK VALVE 101 LIQUID LINE SOLENOID VALVE 20 W STRAINER AND CHECK VALVE 1 4 PURGE VALVE OIL TRAP LIQUID LINE STOP VALVE 58 ICE 1 4 DISCHARGE 1 4 7 FIGURE 1 4 P24A Left Side 1 8 P24A amp P34A Service Manual INTRODUCTION 109 2 LIQUID LINE STOP VALVE FREEZER CONDENSER WATER OUTLET CONDENSER THAW GAS OUTLET STOP VALVE e CONDENSER WATER INLETH LIQUID LINE SOLENOID VALVE HAND EXPANSION VALVE OVERFLOW FREEZER CHARGING VALVE PPS eh NN ICE DISCHARGE MAKE UP WATER 25 il CUTTER TANK ASSEMBL Y 20 ti N pe EN 66 WATER PUMP 92 1 2 FIGURE 1 5 P34A Front Side 8 7 07 P24A amp P34A Service Manual FREEZER SAFETY VALVE FLOAT SWITCH STOP VALVE LIFTING LUG DISCHARGE VALVE 55 THAW GAS SOLENOID VALVE 18 THAW GAS STOP VALVE 90 STRAINER 43 LIFTING LUG CUTTER GEAR REDUCER 5R 3 4 1 9 INTRODUCTION 55 DISCHARGE LINE STOP VALVE 10
76. Charging From Tank Truck The machine may be charged by bulk from a tank truck and be pumped directly into the receiver through the drain valve 44 Follow these instructions with caution 1 Using a ammonia approved charging hose connect one end to the charging valve 44 in the bottom of the receiver 2 Connect the other end of the charging hose to the tank truck It is best to have a gage in this line to indicate pressure 3 Open the charging valve 44 and the fill valve from the tank truck 4 Fill the receiver to the indicated mark on the sight glass 30 CAUTION Do NOT attempt to bulk charge the machine through the freezer charging valve 28 The freezer will not hold the full charge without exposing the compressor to serious damage CAUTION Charging From Cylinders The machine may also be charged from refrigerant cylinders To charge from cylinders the compressor will have to operate to transfer the ammonia from the freezer to the receiver Again make sure all the necessary valves are opened for operation and the compressor crankcase heater has been energized for a minimum for four hours Follow these instructions with caution 1 Using a approved for ammonia charging hose connect one end to the charging valve 28 in the liquid line near the freezer 2 Lay a full cylinder of anhydrous ammonia horizontally with the cylinder valve outlet pointing up to withdraw liquid and the bottom end raised about 2 hig
77. Ey pha ee Re n 3 PERSONAL PROTECTIVE 3 EMERGENCY PROTECTIVE AND SAFETY EQUIPMENT 3 SAFETY SHOWER eter ar I Wesen ne mee DR RC CA te 3 RESPIRATORY DEVICES 3 PROTECTIVE CLOTHING 4 RESCUE 65 4 WATER SYSTEM 2 45 epp deed eo 4 STRETCHER AND BLANKETS 4 FIRST AID PROCEDURES 4 INHALATION i tos aici eat rn ce eed ask a eee T rae VER 5 BYES sche ie cc ha vu tet SR A ho ein ran 5 SKIN AND MUCOSA 5 INTERNAL i oue eee ede rr e E eoe RR aed Ree eden 5 EMERGENCY 5 6 6 LEAK DETECTION cid erre dx REPRE CERE CRI REA 7 LEAK CONTROL eden ne Rode 8 EQUIPMENT OR PIPING 8 VALVE eet et Ne Hate RT ey 8 PRESSURE RELIEF DEVICE 8 STORAGE TANK 1 p ree t eek abe a Re de Pb a 8 SHIPPING CONTAINER 9 FIRE EXPOSURE e X ROS E Gada 9 EMPLOYEE SAFETY TRAINING 10 TABLES TABLE 1 VAP
78. LLING YOUR TUBE ICE MACHINE 26 SQ NOTE E gt ICE DISCHARGE O 9 10 1 4 15 174 25 1 4 gt SIDE VIEW SE heus NOTE B NOTE A NOTES A REQUIRED TO SERVICE ELECTRICAL CONTROLS AND CUTTER ASSEMBLY REQUIRED TO REMOVE COMPRESSOR CRANKSHAFT E REQUIRED ABOVE FREEZER TO SERVICE FREEZER TUBES CUSTOMER NOTE THIS DRAWING IS INTENDED TO BE USED AS A GUIDE ONLY 8 7 07 FOR MINIMUM SPACE REQUIREMENT FOR SERVICING AND OPERATING P24A VOGT TUBE ICE MACHINE SPACE REQUIREMENTS FOR OTHER EQUIPMENT SUCH AS CONVEYORS AUGERS BAGGERS ETC MUST BE CONSIDERED FIGURE 3 1B P24A Space Diagram Side View P24A amp P34A Service Manual 3 4 INSTALLING YOUR TUBE ICE MACHINE M3IA 1 0205 NOILVONNOS nee SV 15 9 AQ HOASANOO AVWNOT1dO NOILVONNOS SV LH9IZH 34vS 38 OL 321 435 5 0 301
79. Make adjustment as required Adjust tension following these guidelines Best tension is the lowest tension at which the belts will not slip under the highest load condition Check tension after the first two to four hours and again after 24 to 48 hours of operation then periodically thereafter If a belt slips tighten it Retighten motor hold down bolts after each adjustment Compressor Servicing Refer to your compressor manual for specific instructions regarding repair and servicing of internal parts It is important to be familiar with the operation and function of your equipment so you can provide the best possible service P24A amp P34A Service Manual 10 1 Options and Accessories 10 Options and Accessories Option Accessory Page No Crushed Ice 10 2 Length of Ice 10 2 PLC Controls 10 3 Soft Start 10 13 Power Monitor 10 14 8 7 07 10 2 P24A amp P34A Service Manual Options and Accessories Crushed Ice Production Your P24 or P34 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 The following modifications are required 1 Remove the existing cutter adapter plate and install new adapter plates for crushed ice 2 Remove the existing tines disc assembly and install new crushed ice disc assembly 3 Remove the existing ice shield and scraper and install new shield and scraper
80. OMPETENT MEDICAL ADVISOR As a guide in case of injury caused by ammonia the following first aid procedures are suggested INHALATION Any conscious person who has incurred irritation due to inhalation of ammonia vapor should proceed at once to a location free of ammonia and breathe fresh air If exposure has been minimal usually no other treatment will be necessary person overcome by ammonia must be carried to a location free of ammonia and the services of a physician obtained promptly Successful resuscitation requires SPEED and EFFICIENCY DELAY AND INEXPERIENCE MAY RESULT IN A FATALITY If there is an obstruction to the patient s breathing the airway must be cleared by appropriate methods which may include proper positioning of the patient s head pulling the tongue forward and clearing any blockage from the mouth such as dentures or vomitus If spontaneous breathing does not resume after the airway has been cleared artificial respiration should be started immediately by mouth to mouth resuscitation expired air ventilation rescue breathing preferably by an individual trained in the procedure Oxygen therapy may be indicated once the patient s breathing has been restored or if it continues to belabored Such therapy should not replace immediate mouth to mouth resuscitation and should only be applied during a sustained resuscitation period or if the patient is to be moved CAUTION It may not be advisable to administer oxyge
81. OR PRESSURE AND VOLUME OF LIQUID AMMONIA AT VARIOUS TEMPERATURES 1 TABLE PHYSIOLOGICAL EFFECTS OF AMMONIA VAPOR 3 TABLE 3 TABLE OF DISTANCES TO 7 ANHYDROUS AMMONIA SAFETY GENERAL The term anhydrous ammonia appearing in the title of this booklet refers to the compound having the formula NHs formed by the chemical combination of nitrogen and hydrogen Whenever the term ammonia appears in this booklet it should be understood as meaning anhydrous ammonia and not aqua ammonia aqueous ammonia or ammonium hydroxide which are solutions of ammonia in water Ammonium hydroxide solutions generally range in concentrations of ammonia from about 3096 down to the 2 to 496 found in the well known household ammonia These solutions are all commonly known as ammonia but should never be confused with liquid anhydrous ammonia which has a much greater hazard potential Anhydrous means free from water At room temperature and atmospheric pressure ammonia is a pungent colorless gas approximately 4096 lighter than air Compressed and cooled ammonia gas condenses to a colorless liquid about 6896 as heavy as water At atmospheric pressure the liquid boils at 28F In a container ammonia in the liquid form normally coexists with vapor Temperature affects both the vapor pressure and volume of liquid ammonia As the temperature of the liquid rises the vapor abo
82. P34A Service Manual E O O CONTROL PANEL MMMM us 2 26 2 NOTE E 174 amp 1 2 TUBES 6 I TUBES NOTE F SQ HATCH NOTE D 15 2 FRONT VIEW e 18 NOTE NOTES C 8 0 18 c D E E REQUIRED TO REMOVE CONDENSER HEADS AND SERVICE TUBES REQUIRED TO CLEAN OR REPLACE CONDENSER TUBES EITHER END 26 SQUARE OPENING NOT REQUIRED IF THERE IS AT LEAST 7 2 CLEARANCE BETWEEN END OF CONDENSER AND WALL EITHER END REQUIRED ABOVE FREEZER TO SERVICE FREEZER TUBES MACHINE SHOWN WITH STANDARD SUPPORTS INCREASE AS REQUIRED TO ACCOMODATE EXTENDED BASE IF USED CUSTOMER 8 7 07 NOTE THIS DRAWING IS INTENDED TO BE USED AS A GUIDE ONLY FOR MINIMUM SPACE REQUIREMENT FOR SERVICING AND OPERATING A P24A VOGT TUBE ICE MACHINE SPACE REQUIREMENTS FOR OTHER EQUIPMENT SUCH AS CONVEYORS AUGERS BAGGERS ETC MUST BE CONSIDERED FIGURE 3 1A P24A Space Diagram Front View P24A amp P34A Service Manual 3 3 INSTA
83. Push Button 1 5 5 6 3 Suction Line Frosting to Compressor 8 12 T Temperature Pressure Chart 11 9 Thaw Gas Check Valve 101 1 7 Thaw Gas Solenoid Valve 18 1 5 1 9 9 22 9 23 Thaw Gas Stop Valve 90 1 5 1 9 Thawing Timer 2 9 5 Three Way Valve 52 1 6 1 10 Troubleshooting 8 1 U V Valves 9 22 Valves location see figures 1 1 through 1 12 V Belt Maintenance 7 8 Voltage Unbalance 3 17 Warranty Basic Product inside back cover Water Cooled Condenser Cleaning 9 5 Water Distributors Chart 7 3 cleaning procedure 7 4 Water Flush Solenoid Valve 63 1 4 1 9 9 24 Water 7 4 Water Tank Drain Valve 39 1 4 1 9 Water Tank and Cutter Parts Weights 9 9 12 3 INDEX 12 8 7 07 4 INDEX Water Tank Assembl
84. QUARE OPENING NOT REQUIRED IF THERE IS AT LEAST 8 O CLEARANCE BETWEEN END OF CONDENSER AND WALL BITHBER END E REQUIRED ABOVE FREEZER TO SERVICE FREBHZER TUBES F MACHINE SHOWN WITH STANDARD SUPPORTS INCRBASE AS REQUIRED TO ACCOMODATE HXTENDED BASE IF USED CUSTOMER NOTE THIS DRAWING IS INTENDED TO BE USED AS A GUIDE ONLY FOR NIMUM SPACE REQUIREMENT FOR SERVICING AND OPERATING P34A VOGT TUBE ICE MACHINE SPACE REQUIREMENTS FOR OTHAR EQUIPMENT SUCH AS CONVEYORS AUGERS BAGGHRS ETC UST BE CONSIDERED FIGURE 3 3A P34A Space Diagram Front View 8 7 07 3 6 INSTALLING YOUR TUBE IC NOTES E MACHINE 40 NOTA E ICH DISCHARGE 9 NOTE B RIGHT SIDE VIEW B REQUIRED TO REMOVE COMPRESSOR CRANKSHAFT E REQUIRED ABOVE FREEZER TO SHRVICH FREEZER TUBES REQUIRED FOR ICE HANDLING EQUIPMENT THIS DRAWING IS INTENDED TO USED AS A GUIDE ONLY CUSTOMER NOTH FOR MINIMUM SPACE REQUIREMENT FOR SERVICING AND OPERATING 8 7 07 P34A VOGT MACHINE SPACE REQUIREMENTS FOR OTHER EQUIPMENT SUCH AS CONVEYORS AUGERS ETC MUST BE CONSIDERED FIGURE 3 3B P34A Space Diagram Side View P24A 4 P34A Service Manual 3 7 INSTALLING YOUR TUBE ICE MACHINE P24A amp P34A Service Manual A IHN3SSV 1 9311 9 AT EG 16 71 130
85. R 399939975 gt 999999359 STRAINER THAW GAS SOLENOID VALVE 18 THAW GAS STOP VALVE THAW GAS STOP VALVE 90 DISCHARGE STOP VALVE WATER TANK MAKE UP WATER FLOAT 12 5 CONDENSER WATER OUTLET WATER PUMP 6 69 172 15 3 4 3 CONDENSER WATER INLET 20 1 4 FIGURE 1 2 P24A Right Side 1 6 P24A amp P34A Service Manual INTRODUCTION THREE WAY VALVE FREEZER SAFETY VALVES ACCUMULATOR 10 REFRIGERANT FLOAT SWITCH iP GAGE GLASS STOP VALVE sg COMPRESSOR DISCHARGE VALVE 35 CONDENSER SAFETY VALVES 50 6 FREEZER DRAIN VALVE OIL SEPARATOR 14 41A CONDENSER FAN 1 CONTROL SWITCH 15 CONDENSER RECEIVER CONDENSER PURGE VALVE 59 8 5 CONDENSER AMMONIA DRAIN CHARGING VALVE 58 LIQUID LINE STOP VALVE FIGURE 1 3 P24A Back Side 8 7 07 8 7 07 P24A amp P34A Service Manual 1 7 INTRODUCTION LIFTING LUG FREEZER PURGE VALVE 76 COMPRESSOR MOTOR TH
86. RANE TO RAISE MACHINE LOWER MACHINE MACHINE POINT HOOKUP CONNECT MACHINE AS ILLUSTRATED AND MOVE IT TO OPERATING SITE TO FINAL POSITION GROUND FIGURE 3 6 Lifting Procedure for P34A 8 7 07 3 10 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE Piping and Drain Connections See Figure 1 1 to 1 8 for connection locations CAUTION Exterior shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 40 psig The maximum allowable pressure is 100 psig CAUTION Compressor Compressor Condenser Water Water Make up Flushing Cooling Cooling Water Tank Tank Model Water In Water In Water In Water Out In and Out Drain Overflow P24A 3 4 FPT 3 4 FPT 3 4 FPT 1 3 FPT 2 FPT 3 FPT 72 gal 3 min P34A 1 FPT 3 4 FPT 3 4 FPT 1 FPT 5 FPT 2 FPT 3 FPT 104 gal 3 min TABLE 3 1 Water Supply and Drain Connections See FIGURE 1 1 through 1 8 for locations Make Up Water In The water required for ice making must be potable water safe for human consumption and should be of the highest quality available The best way to determine water quality is to have a complete water quality analysis by a qualified laboratory It is advisable to install a particle filter in the make up and flushing water lines to trap dirt sand rust or other solid particles prior to entering the water tank and
87. REFRIGERANT FLOAT SWITCH LIFTING LUG me 77 TEES T CUTTER MOTOR FLUSH WATER SOLENOID VALVE 63 MAKE UP WATER FLOAT VALVE 12 8 7 07 2 WATER TANK DRAIN FIGURE 1 6 P34A Right Side 59 WATER TANK DRAIN VALVE P24A 4 P34A Service Manual 1 10 INTRODUCTION THREE WAY VALVE 76 FREEZER PURGE 3 4 24 1 2 di CONDENSER PURGE Ce AMMONIA DUMP CONNECTION 25 85 4 ACCUMULATOR y a 5 88 CONDENSER 14 1 4 OIL SEPARATOR COMPRESSOR COMPRESSOR RECEIVER SAFETY VALVE io BY RECEIVER PURGE VALVE EQUALIZING LINE STOP VALVE 1 7
88. Remedy Oil diluted with refrigerant Oil will be very foamy Check liquid feed control for overfeed problem Oil pressure regulating valve out of adjustment Adjust valve to increase oil pressure Turn stem in to increase out to decrease Compressor rotation incorrect Check rotation direction by arrow indication Reverse rotation if necessary Restriction strainer oil filter pick up tube or Clean strainer or restriction in passage or oil replace filter Compressor thrust bearing installed upside The Mycom compressor thrust bearing on the down shaft seal end has an oil passage hole which has to be in the proper position when installing the thrust bearing Hole up for WA and WB series Mycom compressor Refer to your compressor manual Symptom Compressor loosing oil excessively Possible Cause Possible Remedy Non effective oil separator or float The oil separator will normally return a good portion of oil leaving the compressor if it is working properly Check the oil float and return line to see it is not restricted Liquid refrigerant in crankcase Check liquid feed to make sure it is not overfeeding and that the solenoid valve 20 is not leaking through when the machine is stopped seized or broken replace defective parts A few drops per minute is okay If ammonia is leaking replace the seal 8 7 07 8 7 07 P24A amp P34A Service Manual Symptom Machine short cycles Possible Cause Possible Re
89. SURE SWITCH OPS 27 ELAPSED TIME INDICATOR SOLENOID VALVE COMP WATER HAND AUTO PILOT LIGHT WHITE AMMONIA FEED FLOAT SWITCH AFS SOLENOID VALVE AMMONIA FEED ICR 25 17 PILOT LIGHT AMBER FREEZING STARTER COIL FREEZER WATER PUMP 2CR RELAY FREEZER 23 TREE PRESS SW 19 2TR TIMER THAWING GAS 2PS Ki SOLENIOD VALVE D THAWING GAS 24 ICR 41 SOLENOID VALVE WATER FLUSH DT 2E SOLENOID VALVE UR COMP UNLOADER 3PB MAN CAL HARVEST STARTER COIL CUTTER MOTOR ICR X Um PILOT LIGHT RED THAWING TIME DELAYED STARTER COIL CONVEYOR MOTOR T FAN CONTROL 18 to STARTER COIL TOWER FAN i a E e pu STARTER COIL CONDENSER PUMP 2TR 17 i RELAY 43 FIGURE 6 3 BY CUSTOMER REMOVE JUMPER 12 13 WHEN INSTALLING Electrical Schematic for P24A P34A all Voltages 50 60 Hz 8 7 07 8 19 04 P24A amp P34A Service Manual ELECTRICAL CONTROLS 6 Electrical Controls Your packaged Tube Ice machine is equipped with a compressor motor starter 1M as required for your particular voltage and a transformer if required for the control circuit power The motor starter and transformer are mounted on the machine front side see Figures 1 1 or 1 8 The control panel wiring schematic FIGURE 6 3 illustrates these components as well as provisions for auxiliary equipment which may be incorporated by th
90. Section 9 Purging Non Condensables The refrigerant level in the receiver should be near the operating mark at the end of a freezing cycle to provide enough volume of warm gas for harvesting DO NOT OVERFILL RECEIVER Check cutter gear reducer and drive gear for proper operation and alignment Check for broken gear teeth or sheared shaft key Replace defective parts Check compressor motor Amp draw During the thaw cycle the compressor motor Amp draw should be 60 70 of normal amp draw during the freeze cycle Check compressor unloader solenoid coil UR to make sure it is energized and the valve opening during the thaw cycle 8 6 P24A amp P34A Service Manual TROUBLESHOOTING Symptom Low ice capacity Suspicions of low ice capacity should be confirmed by accurate calculations of actual ice product Much weight can be lost by melting and off fall through augers and other ice handling equipment 1 Time the total freeze and thaw cycle for the cycle which is to be caught and weighed 2 Catch all the ice at the ice discharge opening of the machine 3 Weight the total amount of ice caught Lbs ice per cycle Cycle time minutes X 1440 Ibs production per 24 hours More than one cycle should be caught and weighed to get an accurate average Possible Cause Possible Remedy Inadequate water for ice making Water pressure of 40 psig minimum is required to assure proper water supply Check water pressure Check for a restri
91. The PLC equipped machines have an alarm output relay that can be used to initiate external alarms such as a siren light telephone dialer or modem Conveyor Control Contacts Control contacts are provided for starting and stopping conveyors in sequence with the ice machine Normally the contacts are closed during the entire harvest cycle and open during the freeze cycle In many cases it is necessary to run the conveyors for a period of time 8 7 07 8 7 07 P24A amp P34A Service Manual 10 5 Options and Accessories longer than the harvest cycle to allow the conveyor to finish delivering the ice The PLC allows the user to set the duration of the conveyor run cycle independently of the harvest cycle The user can also set a delay between the start of the harvest cycle and the conveyor start Estimated Ice Production The PLC allows the user to enter the weight per cycle of ice being produced This weight will depend on how the machine has been set up to run and the size of the hole in the ice however the weight per cycle should remain relatively constant from cycle to cycle The PLC uses this information coupled with the freeze and harvest times to report the capacity based on the last cycle in lbs of ice per day The PLC will also track total accumulated ice production in Ibs over a period of time This value can be reset to zero by the user The operator interface shown in Figure 10 1 provides two 16 character lines of text which a
92. The freezer pressure switch will automatically compensate for variations in water temperature and operating conditions to provide consistent ice thickness The PLC allows the length of the freeze cycle to be a fixed time The freeze time will have to be adjusted as water temperature and operating conditions change however this method of control can prove helpful when sequencing two or more machines to avoid simultaneous harvest cycles Blowdown Adjustment Normal operation is for blowdown to occur during the entire harvest cycle The PLC allows the user to adjust the amount of blowdown by setting the length of time that blowdown will occur The time can be set from zero no blow down to five minutes Diagnostic Indicators The PLC provides text messages in the event of a malfunction or fault The PLC will alert the user in the event of the following conditions high or low pressure short cycling three consecutive freeze cycles five minutes or less in duration e long cycle a freeze cycle lasting more than 60 minutes water pump overload e cutter motor overload e 1055 of oil pressure power failure Cutter Delay PLC equipped machines delay start of the cutter motor for eight seconds after the water pump has stopped This allows water to drain from the freezer and cutter assembly before the cutter assembly starts turning thereby reducing the amount of water that can be splashed out the ice discharge opening Alarm Relay
93. a gate or entrance for purposes of notification by local authorities should an emergency arise LEAK DETECTION An ammonia leak is readily detectable by its characteristically pungent odor TABLE 3 Table of Initial Isolation and Protective Action Distances Small Spill A Downwind Distance 0 2mi B Crosswind Distance 0 2mi C Isolation Zone Diameter 150 ft WIND 10 MPH lt Initial Protective Action Zone No Fire 1 Large Spill A Downwind Distance 1 mi B Crosswind Distance 1 mi C Isolation Zone Diameter 300 ft gt Derived from Guidebook for First Reponse to Hazardous Materials Incidents 1990 U S Depart ment of Transportation P5800 5 The location of a small leak may often be determined by holding a moist strip of phenolphthalein or red litmus paper near the suspected leak source The rapidity and intensity of the color change in the paper will give some indication of leak proximity or size In the presence of ammonia phenolphthalein paper will turn from white to pink or deep red whereas the red litmus will become blue Sulfur dioxide vapor reacts with ammonia to form a dense white cloud and may be used for leak detection Care must be exercised to avoid breathing sulfur dioxide vapor as it is also highly irritating It should be noted that a gas mask canister which is specific for ammonia will not offer protection against sulfur dioxide If there is a
94. alarms fire fighting equipment safety showers or other water Sources first aid supplies and shut down equipment such as valves and switches Training should also stress the avoidance of body contact with liquid ammonia or inhalation of gas and the reporting of equipment failures to appropriate supervisory authority This material has been reviewed by experienced safety medical and other technical personnel competent to evaluate its accuracy and practicability Additional copies of this booklet are available by forwarding a request to LaRoche Industries at any of the office locations shown below Material Safety Data Sheets are also available by similar request REGIONAL OFFICES Eastern Southern 20 Meta Lane 1990 Lakeside Parkway Suite 130 Lodi NJ 07644 Tucker GA 30084 201 472 8008 404 691 0596 Western 1900 Spring Road 15116 Canary Avenue OakBrook IL 60521 LaMirada CA 90638 708 571 4950 213 691 0596 Industrial Products Group LaRocue INDUSTRIES INC 1100 JOHNSON FERRY ROAD ATLANTA GEORGIA 30342 404 851 0300 10 SELECTED AMMONIA SAFETY REFERENCES 1 AND TRAINING AIDS Safety Requirements for the Storage and Handling of Anhydrous Ammonia ANSI K61 1 American National Standards Institute Inc ANSI 1430 Broadway New York New York 10018 212 354 3300 Anhydrous Ammonia Pamphlet G 2 Compressed Gas Association Inc CGA 1235 Jefferson Davis Hwy Arlington VA 22202 7
95. anual TABLES amp CHARTS Makeup Rated Capacity Ibs day Water 60Hz 50Hz Temp Cylinder Crushed Cylinder Crushed g si Z ie 1 d p ERI 59 37 800 48 800 41 200 39 300 50 700 42 800 37 800 48 800 41 200 39 300 50 700 42 800 60 37 500 48 500 41 000 39 000 50 400 42 600 37 500 48 500 41 000 39 000 50 400 42 600 7768 35 100 46 100 39 400 36 500 47 900 40 300 35 100 46 100 39 400 36 500 47 900 40 900 69 _ 34 800 45 800 39 200 36 100 47 600 40 700 34 800 45 800 39 200 36 100 47 600 40 700 75 33 000 44 000 38 000 34 300 45 700 39 500 33 000 44 000 38 000 34 300 45 700 39 500 80 32 000 42 500 37 000 33 200 44 200 38 400 32 000 42 500 37 000 33 200 44 200 38 400 7786 80 800 40 700 35 800 32 000 42 800 37 200 30 800 40 700 35 800 32 000 42 00 37 200 89 30 200 39 800 35 200 31 400 41 300 36 600 30 200 39 800 35 200 31 400 41 300 36 600 90 30 000 39 500 35 000 31 200 41 000 36 400 30 000 39 500 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 596 above or below Capacity rating is for clear ice production with makeup water containing no more than 200ppm total dissolved solids Table 11 3
96. aper bushing 7 Using two of the same cap screws in the threaded holes of the bushing jack the gear off the bushing and remove both from the gear reducer shaft 8 Clean the split bushing and tapered hole of the new drive gear and insert the bushing into the drive gear making sure the tapers match 9 Slide the split hub and gear onto the keyed shaft with the key in place positioning the hub by measurement previously recorded so the full width of the gear teeth will engage when assembled and tightened 10 Tighten the cap screws three or four progressively and uniformly around the hub and recheck the location measurement If it is not correct loosen the cap screws hub and gear assembly and make correction Then retighten the cap screws 11 Install the reducer and mounting plate assembly on the water tank bracket and fasten in place with the side and top cap screws 8 7 07 P24A amp P34A Service Manual 9 7 SERVICING OPERATIONS 12 Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount 13 of backlash between the gear teeth NOTE There should be only a slight amount of backlash more specifically tooth tip clearance Too much clearance will cause premature wear and possible tooth damage When the cutter runs under a no load condition it should have a smooth uniform sound For lubrication see Section 7 Maintenance If the tooth tip clearance needs adjusting loosen t
97. area that is subject to reach temperatures at or above 110 F 43 3 C 2 4 P24A amp P34A Service Manual RECEIPT OF YOUR TUBE ICE MACHINE 8 7 07 8 7 07 P24A amp P34A Service Manual 3 1 INSTALLING YOUR TUBE ICE MACHINE 3 Installing Your Tube Ice Machine Your machine will be shipped to you as one package You will need to arrange for the handling of the package as soon as it arrives see the machine specifications Table 2 1 for shipping and operating weight Before you remove the unit from the truck be certain that any sign of damage however slight is noted on the carrier s papers Note See Lifting Procedure drawing furnished with this manual Fig 3 5 and 3 6 Machine Room The machine must be located inside a suitable building and must not be subjected to ambient temperatures below 50 F 10 C or above 110 F 43 3 C Heat radiation from other sources sunlight furnaces condenser etc and unusual air current may affect the operation of the machine and should be avoided The electrical components of the Tube Ice machine are rated NEMA 1 Therefore the machine should not be located in a hazardous area or sprayed with water The machine should be installed in an area where water will not stand but will readily drain away from the machine Space Requirements Refer to the space diagrams Figures 3 1 and 3 3 for recommended minimum clearance around the machine for ease of servicing and observation Pay particular attent
98. arge opening of the water tank making sure the tank is free to be moved Remove the mounting bolts from around the flange of the tank allowing the tank to be lowered to rest on its casters P344 only the channel support at the right side base of the machine opposite from the pump side will have to be removed for the tank to be rolled out from under the freezer Roll the water tank from under the freezer turning it as you go to clear the gear reducer and motor It is now accessible for inspecting and or repair of the cutter assembly 9 10 SERVICING OPERATIONS 8 7 07 P24A amp P34A Service Manual Cutter Assembly Removal and Installation 1 2 7 Follow water tank removal instructions Steps 1 9 See Figure 9 5B Remove the socket head cap screw from the center of the cutter shaft and lift out the retainer and gasket Lift the cutter straight up and off the shaft taking care to catch the shaft key as it is removed To install the cutter lower it down onto the shaft allowing the ring gear to mesh with the drive gear Rotate the cutter aligning the shaft and hub key way and inserting the key to its full depth Install the gasket the retainer and the socket head cap screw and tighten to approximately 15 ft Ib torque Check and adjust the cutter height per Cutter Height Adjustment instructions Bearing Bracket and Cutter Disc Removal l 2 7 8 Remove the cutter assembly per instructi
99. as described above to adjust the display to a visible condition LCD contrast adjustments are stored in the permanent memory and will remain constant once set Locking Out Setup Menu In some field installations it may be desirable to lock out unwanted changes from being made to the programmed parameters This can be achieved by using the lock feature The setup menu can be viewed but not changed when the lock is on TO LOCK out operator adjustments Hold the FAULT key down until FAULTS CLEARED appears on the Display While holding the FAULT key down press the ARROW UP key once This will turn the Setup Lock on TO UNLOCK the panel and allow operator adjustments Hold the FAULT key down until FAULTS CLEARED appears on the Display While holding the FAULT key down press the ARROW DOWN key once This will turn the Setup Lock off 8 7 07 P24A amp P34A Service Manual 10 17 Options and Accessories When the operator adjustments are locked out the ability to load default parameters is also locked To use the press and hold the setup key to load default values function you must first unlock the setup menu as explained above Wiring The power monitor should be wired to the line and load side of the compressor contactor with 1 amp fused connections The connections labeled control should be wired to a 230 volt power source and Run connections should be wired in series with the syst
100. ber gasket on the top of the tank flange It can be held in place with narrow strips of tape through the bolt holes 2 Push the water tank in and under the freezer aligning the bolt holes and installing the mounting bolts around the flange and tightening the nuts securely 3 Reconnect the discharge chute or hopper to the ice discharge opening 4 Mount the water pump P34 only and attach the circulating water tubing and overflow tubing 5 Reconnect all water piping such as drain overflow and make up water lines Turn water on and check for leaks 6 Fill the water tank with water and make sure the drain valve is closed When ready turn the power to the machine but don t operate the compressor until the oil is warm and there is no liquid refrigerant in the crankcase 43X46 49 a Vie be 4 pu 47 55165 51 37 SECTIONAL DETAIL BEARING BRACKET ITEM 34 SHOWN ROTATED FOR CLARITY Figure 9 5A P24A Cutter Assembly 8 7 07 9 14 P24A amp P34A Service Manual SERVICING OPERATIONS 16 15 24 25 27 28
101. caused by a restriction in the liquid line inadequate make up or circulating FAULT SHORT CYC 3 IN A ROW A FOR RESTART B SILENCE ALARM water or a defective freezer pressure switch FAULT LONG CYC A FOR RESTART B SILENCE ALARM It will be necessary to press A on the operator interface to restart the machine CAUTION When the operator interface indicates a fault something has gone wrong Every effort should be made to discover the reason for the fault Do not simply reset the fault and resume operation The underlying cause will likely reoccur interrupt ice supply and potentially damage equipment CAUTION 10 10 P24A amp P34A Service Manual Options and Accessories PLC Programmable Logic Controller CHANGING THE SETUP VALUES Several operating parameters of the machine can be modified The set up screen must be accessed to make any modifications set up screen can be accessed by pressing the button on the operator interface When in the setup screen the interface will display the information shown below The arrow buttons can be used to scroll through the lines of the screen TUBE ICE SET UP SCREEN CNVYR RUNZHHISEC A MORE SETUP B MONITOR SCRN TCYCLES RUN TIME 0 To change the value of a variable scroll to that variable on the screen press the SET button on the interface enter the new value using the numeric key pa
102. chine models are available from the factory with a reduced voltage soft cutter motor starters These units reduce inrush current to approximately 20096 of rated full load amps as compared to 60046 for across the line start The units are also available for after market or retrofit installation soft starters include a NEMA 12 water tight enclosure and should be mounted near the control panel Initial Torque Adjustment The initial Torque adjustment is factory preset for maximum torque maximum starting voltage 1 Rotate the START TIME adjustment fully clockwise to 100 so that the longest starting time is obtained 2 Rotate the INITIAL TORQUE adjustment to midrange on the dial 50 to lower the starting torque 3 Start the motor If more or less torque is required to break the load free turn off the power rotate the INITIAL TORQUE adjustment in the appropriate direction until the load just begins to move when power is first applied Start Time Adjustment The START TIME adjustment range is 1 2 to 30 seconds for a motor voltage from 10 to 100 of line voltage The higher the value of the INITIAL TORQUE the shorter the duration of the overall time period In most applications it is desirable to start the motor as quickly as possible without causing unnecessarily high inrush currents 1 During the INITIAL TORQUE adjustment process the START TIME was adjusted for the longest start possible If a shorter time is desired
103. control set to EXTERNAL the unit will respond to the signal connected to the CONTROL input With the control mode set to ON the unit will turn on its output relay if line parameters are within setup parameters Setting the control mode to OFF causes the unit to ignore the control input and keep it s output relay off Default is external Operation continued 10 16 P24A amp P34A Service Manual Options and Accessories Read Mode For reading individual phase to phase voltages Pressing the read key will enter read mode Press the read key to step through the voltages Read voltages in the following order Voltage A to B Voltage A to C Voltage B to C Pressing the read key again will exit read mode Fault Mode Recalls faults from most recent to the oldest in order Press the FAULT key to enter fault mode FAULT 1 is the most recent fault Press the fault key again to step to the next fault Pressing the fault key at the last fault will exit fault mode Press and hold fault key down for two seconds to clear fault from memory and reset the unit Contrast Adjustment When the SETUP READ and FAULT LED s are all off the unit is in the monitor mode While in the monitor mode the UP and DOWN arrow keys will control the display contrast NOTE LCD display contrast will vary with changes in ambient temperature and under extreme temperature conditions the LCD display may be dark or clear If this occurs simply use the arrow keys
104. ction in the incoming line or at the make up water float valve Freezer pressure switch or thaw timer out of Check hole size in Tube Ice See TABLE 7 2 adjustment Crushed ice should be 3 16 1 4 thick Check and adjust thawing time Thawing should be 30 seconds longer than it takes for all the ice to clear the freezer Excessive ice chips in the water tank causing Check incoming water temperature 45 F short cycling minimum Check flushing valve to make sure ice chips are being melted and flowing out the tank overflow during the harvest cycle Compressor running unloaded or not pumping Check compressor motor amp draw Check for full volume belt slippage and tighten as needed Check for leaking compressor suction or discharge valves Refer to your compressor manual See other related symptoms Restriction in the refrigerant liquid line or float Check for partially closed valve or an switch not operating properly obstruction at the strainer solenoid valve or hand expansion valve The liquid line will normally have frost on the downstream side of a restriction especially as the suction pressure decreases Low refrigerant charge causing re freeze Check the receiver gage glass mark for the proper level Check for and repair leaks Add refrigerant Warm make up water for ice making Capacity of the machine is proportional to ice making water temperature Warmer water will reduce the ice making capacity Refer to Section 10 Ca
105. cycle the compressor discharge gas goes through the oil separator 14 to remove any oil present in the discharge gas and return the oil to the compressor crankcase From the oil separator the discharge gas continues through a heat coil in the lower part of the condenser receiver 15 It is then discharged into the condenser and condensed into a liquid by the removal of heat by water passing through the condenser tubes A reservoir of liquid R 717 approximate 375 Ibs for and 625 lbs for P34A is accumulated in the receiver and is required for thawing purposes Liquid from the receiver flows through the strainer to the A solenoid valve 20 which opens and closes by action of the low side float switch 10 The liquid is then expanded through the hand expansion valve 17 and into the evaporator 2 freezer The cold wet R 717 refrigerant floods the evaporator and is in contact with the outside of the ice making tubes which water is being circulated through The heat contained in the water passes through the wall of the tubes lowering the temperature of the water causing it to freeze and form a long tube of ice that adheres to the inside of freezer tubes Since the purest water freezes first the circulating water continues to wash the dissolved solids down into the sump area of the water tank The flushing valve helps to rid the water tank of increased dissolved solids by flushing them out the overflow during the harvest thawing period
106. d and press ENTER The only variables that can be changed from this screen are the harvest time blowdown time conveyor run time and conveyor delay time last two lines of the display report total cycles and run time of the machine Pressing on the operator interface while in the set up screen will allow you to access a second set up screen where the autostart and the timed freeze cycle features can be turned on or off The A TIMEDFRZ OFF FRZ TIME B AUTOSTART OFF display will be as shown below Pressing from this screen will toggle the timed freeze feature from off to on If the display reads A TIMEDFRZ the timed freeze feature is active Pressing from this screen will toggle the auto restart feature from off to on If the display reads B AUTOSTRT ON the automatic restart feature is activated The freeze time can also be set by the user from this screen 8 7 07 8 7 07 P24A amp P34A Service Manual 10 11 Options and Accessories PLC Programmable Logic Controller MONITORING FUNCTIONS From the set up screen two additional screens can be displayed by pressing on the operator interface These two screens are refereed to as monitor screens The first screen displays the cycles and lbs of ice produced since the operator has reset the counter The screen is shown below THHHHE CYCLES THHHHHHE LBS ICE Pressing from this screen will reset
107. d line and you will hear liquid refrigerant flowing through to the liquid solenoid valve 20 Turn main power disconnect to the on position and the machine is read for start up and ice production P24A amp P34A Service Manual 5 5 START UP amp OPERATION PUMP CUTTER RESET RESET ILT 217 SLT FREEZING LIQUID FEED THAWING START HAND AUTO SWITCH SWITCH STOP MANUAL SWITCH HARVEST FIGURE 5 1 Control Panel Start Up Starting the machine can be accomplished as follows 1 Make sure the crankcase oil temperature is approximately 100 F and there is no liquid ammonia in the compressor crankcase 2 Turn the Hand Auto switch 1SS to the Hand position and allow the water tank to refill MAKE SURE THE DRAIN VALVE IS CLOSED 3 Push the green Start push button to start the compressor and immediately observe the oil pressure the oil level the discharge pressure and listen for any unusual sounds The compressor starts unloaded and will load automatically after several seconds by action of the delay timer DT 4 Turn the Hand Auto switch to the Auto position 5 When the discharge pressure increases to about 170 psi push the Manual Harvest button to initiate the harvest cycle See Harvest Period 6 When the suction pressure raises to 50 55 psig any ice made should release and discharge
108. der pressure The cylinder may be considered empty of liquid R 717 5 4 8 7 07 P24A amp P34A Service Manual START UP amp OPERATION 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 hose from the cylinder Loosen the union in the refrigerant charging line carefully to avoid liquid ammonia release 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 Transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended As the machine is being charged continually observe the following operating characteristics a Discharge pressure 175 psi to 200 psi maximum b Compressor oil pressure Mycom 18 27 psi above suction Vilter 35 50 psi above suction c Liquid level in receiver marked on gage glass guard d Compressor cooling water 100 F outlet temperature e Compressor oil level approximatel
109. ding 40 psig Net Oil Pressure 25 psig The compressor oil should be changed at close intervals during initial break in operation and up to the first 1000 hours see Table 7 4 below Your machine was test operated at the factory and compressor oil was drained crankcase cleaned suction strainer sock cleaned new oil filter installed if applicable and clean oil added prior to shipping 8 7 2007 P24A amp P34A Service Manual 8 7 2007 MAINTENANCE Note It is the owner s responsibility to make sure normal maintenance is initiated to insure that the compressor is not subjected to premature wear or failure due to neglect or lack of sufficient maintenance and care Frequency 2nd 4th Change oil 200 hr 500 hr 1500 hr 4000 hr every 4000 hrs Clean suction strainer cloth 200 hr 500 hr Remove if clogging is minimal TABLE 7 4 Compressor Maintenance The above maintenance is only a guide The compressor should be inspected anytime there is unusual noise damage is suspected or the oil becomes discolored The oil should be changed any time the compressor is opened For specific recommendations and instructions refer to the particular compressor manufacturer s manual See Compressor Oil Changing and Inspection Although the ice machine is equipped with an oil separator which has an automatic return some oil will pass through the separator and eventually settle in the oil trap 36 which is offset fr
110. e Tube Ice enhances the operation of the standard version by providing Selectable automatic restart after a power failure choice of timed or pressure switch controlled freeze cycles programmable blowdown adjustment diagnostic indicators power failure indication alarm relay built in cutter delay programmable conveyor control contacts estimated ice production display and a total cycle counter MITSUBISHI PLC The Mitsubishi Programmable controller contains 14inputs and 10 outputs 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 24VDC control wiring is blue in color and is distinguished from the red 240V AC control wiring Figure 10 3 The outputs are externally fused for 2A Outputs 0 1 and 2 are dry contacts used for sequencing and conveyor control Outputs 3 11 are relay type with 200 240 V connections Figure 10 1 shows the Mitsubishi PLC installed in the Tube Ice machine The LED indicators on the right hand side of the Mitsubishi PLC indicate the 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 If an error is indicated contact the factory immediately The LED indicators on the left hand side of the Mitsubishi PLC indicate the input and output status of the PLC If the input X indicator is illuminated then the PLC is receivin
111. e customer such as FU1 Main power disconnect SM Conveyor motor starter and overload SMOL 6M Tower fan starter and overload 6MOL 7M Condenser pump starter and overload 7MOL When adding motor starters for auxiliary equipment be sure to incorporate the overload protection as indicated between terminals 12 13 and remove the jumper wire This will assure that the machine will shutdown when any auxiliary equipment fails Bin Level Control Included in the wiring schematic is provision for a bin level control BLC The NC contract of your control should be wired between terminals 8 9 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown However the machine will still need to be manually started to resume production Safety Switches The machine is also equipped with the following safeties and control switches which are mounted to the frame near the compressor Refer to the wiring schematic FIGURE 6 3 for their circuitry e High Low dual pressure switch 1PS to stop the machine if the compressor suction pressure goes too low 15 20 psi or the compressor discharge pressure goes too high 225 250 psi See High Low Pressure Switch e Oil failure pressure switch OPS to stop the machine if the compressor oil pressure drops to 15 psi net suction pressure minus oil pressure gage reading See Oil Pressure Switch Fan control switch to
112. e king valve be closed during servicing of the ice machine PUMPING DOWN B RESET CYCLE Upon completion of the pumpdown sequence the interface will display the message shown below It will be necessary to press the start button to resume operation This screen will also appear upon completion of a clean cycle or after a fault has been detected and reset The words PUMPED DOWN YES will appear if the machine is pumped down PRESS START PUMPED DOWN YES When the switches are in the ON and CLEAN positions the machine will begin a clean cycle after completing the current ice making cycle The interface will display the time that the machine has been in a clean cycle During the clean cycle the water pump will run To stop the water pump clean cycle move the on off switch to the OFF position To restart the water pump clean cycle return the switch to the ON position and press the start button TIME The machine will automatically exit the clean cycle after 2 hour period At the completion of the clean cycle the interface will always return to the start up display requiring that the start button be depressed PRESS START PUMPED DOWN NO B RESET CYCLE 10 8 P24A amp P34A Service Manual Options and Accessories PLC Programmable Logic Controller MACHINE FAULTS Hi Low Pressure The interface will display the message shown below if the combination high low pressure safety switch ope
113. e producing plant If installed and maintained properly it will give many years of operation with a minimum amount of repairs Refer to piping schematics FIGURE 4 1 and 4 2 to identify component parts while following the information and instructions in this manual The machine is manually started and stopped by the START and STOP push buttons The machine will automatically stop by safeties such as compressor cutter and pump overloads as well as other auxiliary motor overloads It will also stop automatically by high head pressure low suction pressure or low compressor oil pressure The circulating water pump can be operated independently for chemically cleaning the freezer tubes and water tank by use of the HAND AUTO selector switch The machine can be manually forced into a harvest cycle with the manual harvest push button Principle of Operation The freezer 2 is a shell and tube type vessel During the freezing period cycle water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 The float switch 10 opens and closes the liquid feed A solenoid valve 20 and maintains the desired refrigerant level in the freezer 2 evaporator Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 and to the compressor 3 Here the cool gas is compressed to a high temperature high pressure gas wh
114. e purged from the system by following instructions in Section 9 Purging Non Condensables Cooling tower or evap condenser in need of Check fan motor and fan belts for proper maintenance operation and tension Check spray nozzles tubes sump and sump screen for accumulation of mineral deposit and clean as required Check tower blowdown and chemical treatment if applicable Dirty condenser tubes Visually inspect the condenser tubes to see if there is any build up of mineral deposit which would reduce the cooling effect of the tubes and water Clean chemically or mechanically as applicable Too much liquid in condenser receiver Remove refrigerant so all tubes will be above covering tubes causing inefficiency liquid refrigerant level 8 7 07 P24A amp P34A Service Manual 8 9 TROUBLESHOOTING Symptom Low discharge pressure check gage accuracy Possible Cause Possible Remedy Fan cycling switch out of adjustment or Check adjustment Refer to FIGURE 9 3 Fan defective Control Replace if defective Compressor running unloaded or not pumping Check compressor motor amp If the efficiently compressor is running unloaded the amperage will only be approximately 60 of normal amp draw FLA Refer to the compressor manual blowing through tower excessive cooling Install an indoor sump Too much cold water circulating through Install a water regulating valve in the water condenser line form the condenser and control
115. e seriousness of the injury A stretcher provides the most acceptable method of hand transportation and it may be used as a temporary cot at the first aid station or during transit in a vehicle FIRST AID PROCEDURES Ammonia is one of the most water soluble of all gases Accordingly the best means of providing first aid for an injury caused by ammonia contact with the eyes or skin is to flush immediately the injury area with large quantities of clean water Promptness in initiating treatment using adequate quantities of water and continuing its application for at least fifteen minutes or longer if necessary are all essential in successful first aid management of an eye or skin injury resulting from contact with ammonia Cool coffee tea and even fruit flavored beverage are all reported as having been used with good effect in starting first aid treatment when water was not immediately available A physician must be called promptly for any person who has been burned severely or overcome by ammonia The physician should be given a complete account of the cause of injury Speedy removal of the patient from the contaminated location is important to avoid aggravation of the injury PRIOR TO MEDICAL AID BY THE PHYSICIAN FIRST AID PROCEDURES SHOULD BE EMPLOYED THOSE PRESENTED HEREIN ARE BASED UPON WHAT IS BELIEVED TO BE COMMON PRACTICE IN INDUSTRY THEIR ADOPTION IN ANY SPECIFIC CASE SHOULD OF COURSE BE SUBJECT TO PRIOR ENDORSEMENT BY A C
116. eck normal line voltage using high line voltage flashes due READ feature Re adjust voltage to fault range as required Control Mode setting is OFF Press setup to get to Control Mode then use arrow keys to set mode to EXTERNAL Unit makes whistling or Normal Normal Some sound coming from the unit sizzling sound is normal and may vary with input voltage 8 7 07 P24A amp P34A Service Manual 11 1 TABLES amp CHARTS 11 Tables amp Charts 8 7 07 11 2 P24A amp P34A Service Manual TABLES amp CHARTS P24A SPECIFICATIONS 400 460 Volt 3 Phase 50 60Hz Tube Size inches cm 114 3 17 112 3 18 Nominal Capacity Tons day M Tons day 21 0 210 90 0 22 6 19 9 20 0 18 1 Overall Dimensions LxWxH Feet meters 7 5 8 14 5 7 5 8 16 2 3 2 4 4 8 7 5 8 16 2 3 2 4 4 8 2 3 2 4 4 4 Shipping Weight o Weight bs Kp Refrigerant Charge R 717 800 362 8 800 362 8 800 362 8 Total FLA Water Cooled 86 1 86 1 86 1 MaximumFuse 48 1 12 k WaterRequirements o o Connection Sizes Water Pump HP KW FLA Tower Pump o o ooo e y y 195 442 195 442 195 442 100 45 3 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F ambient and 25 blowdown 2 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower
117. ed in the eyes unless ordered BY A PHYSICIAN If prescribed BY PHYSICIAN 2 to 3 drops of topical anesthetic such as 1 296 tetracaine hydrochloride Pontocaine may be instilled to relieve pain and to permit more thorough flushing of the eyes with water SKIN AND MUCOSA If contacted by liquid ammonia the body area affected should be immediately flooded with water If no safety shower is available utilize any available water source Water will have the effect of thawing out clothing which may be frozen to the skin Such clothing should be removed and flooding of the skin with water continued for at least 15 minutes Do not apply salves or ointments to skin or mucous membrane burns during the 24 hour period following injury Subsequent medical treatment is otherwise the same as for thermal burns INTERNAL Swallowing of liquid ammonia is very unlikely However if ammonia has been taken internally and if the patient is CONSCIOUS and able have him drink large quantities of water immediately NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON Should the patient vomit place his face down with head lower than hips to prevent vomitus from entering lungs Transport patient to a physician promptly and apply other first aid treatment as he may prescribe EMERGENCY MEASURES Every plant warehouse office or other facility is susceptible to emergency situations which can result in property damage and or bodily harm to employees visit
118. ed when the circulating water pump is running and solenoid valve 20 is opened the float switch 10 is closed Indicates that the liquid line GLT Red Pilot Light Thawing Illuminated when the machine is in a harvest period PB Green Push Button Start For starting the compressor motor and ice production NO 1PB Red Push Button Stop For stopping the compressor motor and ice production NC 3PB White Push Button Manual For manually initiating a harvest cycle NO Harvest 155 Selector Switch Hand Auto Hand position for running the circulating water pump independently at start up or for cleaning the freezer tubes and water tank Auto position for provision of automatic system shutdown if there is a control circuit power interruption TABLE 6 2 Description of Control Panel Parts Outer Door 6 3 6 4 ELECTRICAL CONTROLS P24A amp P34A Service Manual 1047 WIRING BY CUSTOMER CONNECT TO TERMINALS INSIDE THE 17 8 CONTROL PANEL AS INDICATED 13 ACROSS THE LINE START TO TOWER FAN TO CONI IDENSER PUMP COMPRESSOR MOTOR STARTER 231 32 33 pe E 2 21 1 KVA TRANSFORMER TRANSFORMER USED ALTERNATE 8 6 ON 400 460V ONLY PART WIND START gt gt PUMP MOTOR CUTTER MOTOR COMS TARTER 0708 STARTER STARTER
119. eflector plate in the ice discharge opening 20 Install the cutter assembly using the 1 4 X 1 4 X 3 3 16 Ig stainless steel key to align the key ways and lock the cutter and shaft together 2 Install the red rubber gasket retainer and 3 8 stainless steel socket head cap screw Tighten to approximately 15 ft Ibs 22 Check and adjust the cutter height per Cutter Height Adjustment instructions Cutter Height Adjustment The height of the cutter can be adjusted by the four bolts holding the bearing bracket assembly in place These bolts are threaded into holes in the end of each arm through holes in the water tank The current design has these washers welded in place after the cutter height is properly adjusted This helps to insure proper adjustment during servicing Using a true straight edge long enough to reach across the top flange of the water tank 30 for P24 and 40 for P34 the top of the cutter rim and blade should be 1 8 1 16 below the top of the water tank flange Keep one end of the straight edge at the same point and swing the other end across the tank at various points to check the clearance Also rotate the cutter to check all points If adjustment is necessary loosen the four side bolts and raise or lower each arm as needed Tighten the bolts securely to approximately 90 ft Ib 8 7 07 P24A amp P34A Service Manual 9 13 SERVICING OPERATIONS Water Tank Installation 1 Place the 3 16 thick gum rub
120. efore resuming operation CAUTION CRANKCASE PRESSURE ADJUSTING WHEEL SET AT 5 PSIG CW TO RAISE SETTING PART 12 2117 02000000 CALIBRATION POINTER MANUAL RESET BUTTON OIL PRESSURE 174 FPT FIGURE 9 4 Oil Pressure Switch Control Circuit Protection The electrical control circuit of the machine is protected by a 6 amp circuit breaker CB4 If this breaker should open the machine will immediately stop Before resetting the circuit breaker open the disconnect switch and lock out all power to the control panel Reset CB4 and restore power Check circuitry with a volt meter If the machine was off for an extended time the crankcase heater must be energized for a minimum of four 4 hours and no liquid refrigerant in the crankcase before restarting the machine When ready to restart the machine depress the Start button As usual initiate a harvest cycle if there is ice remaining in the freezer Check Amp draw through the breaker for excessive load or unbalance Thawing Timer The thawing timer 2TR Figure 9 5 governs the ice thawing period It is located inside the control panel FIGURE 6 1 It is started by action of the freezer pressure switch 2 5 which energized the relay This timer is set prior to shipment for approximately a 8 7 07 P24A amp P34A Service Manual 9 5 SERVICING OPERATIONS three minute period To replace the timer simply pull the timer from its base and plug
121. elief valve leaking Check gage accuracy and High discharge pressure Feel the compressor heads for hot spots or one head running hot Replace worn or leaking valves Check all hand and check valves to make sure they are fully opened and not stuck Repair or replace as needed Check the compressor manual to see if your compressor is so equipped Replace accordingly 8 12 P24A amp P34A Service Manual TROUBLESHOOTING Symptom Suction line frosting to compressor Possible Cause Possible Remedy Liquid refrigerant overfeed Check float switch to make sure it is functioning properly Replace if defective Check solenoid valve 20 to make sure it is not leaking through Repair or replace if defective Refrigerant contaminated with water Test refrigerant or oil for water contamination Completely pump the freezer out pumpdown and blow excess water out through the oil trap drain valve 61 Refer to Service Section 9 Removing Excess Water 8 7 07 8 7 07 P24A amp P34A Service Manual SERVICING OPERATIONS 9 Servicing Operations Automatic Blowdown harvest cycle A feature of this machine is a solenoid activated flushing valve 63 which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water tank This flushing during the harvest cycle helps to remove salts or solids accumulated in the water as a result of the freezing action It also helps melt ice chips which fall
122. em control circuit Note that specified connections are for P18XT models only Consult factory for other models POWER MONITOR WATSCO EAC 8000 5 0 LINE TO 3 PHASE SUPPLY 5 GH H gt COMPRESSOR MOTOR 3 FUSES 3 AMP FUSES CONNECT AT 3 ON COMPRESSOR CONTACTOR CONNECT AT 3B ON TERMINAL BLOCK CONNECT AT 22 ON CUTTER CONTACTOR CONNECT AT ON TERMINAL BLOCK NOTE FOR FIELD INSTALLATION JUMPER BETWEEN 3B AND SC MUST BE REMOVED FIGURE 10 6 Phase Protector wiring schematic 8 7 07 10 18 P24A amp P34A Service Manual Options and Accessories Troubleshooting for Power Monitor SYMPTOM DISPLAY SOLUTION Load will not energize LOAD LED Check control input not lit Parameters will not change Indicates Normal Parameters are locked out See when arrows pressed parameters Locking Out Setup Menu when SETUP is pressed LEDS blink periodically but Occasional Blinking Line voltage too low and or phase unit never comes up Flash missing Control LED does not go out CONTROL Control input is very sensitive when control is off LED always Insure control voltage 2 volts for on off condition Output relay never turns on System trips out on low or FAULT LED Ch
123. equire attention 9 To perform a total pumpdown it may be necessary to apply heat directly to the oil trap in order to boil off the liquid ammonia and oil mixture Removal of Ammonia Refrigerant from the Machine Liquid ammonia can be removed from the machine through the receiver drain valve 44 Refer to Sections 1 2 and Appendix A for special warnings and instructions regarding the handling of ammonia Make sure you are familiar with and technically qualified to handle anhydrous ammonia refrigerant P24A amp P34A Service Manual 8 7 07 P24A amp P34A Service Manual 9 19 SERVICING OPERATIONS WARNING It is not recommended that refrigerant to be transferred from a refrigeration system directly into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer of any applicable code requirements WARNING If ammonia vapor is released from the machine it may be purged into water which will absorb it Follow the purging instructions See Purging Non Condensables Note Observe all local codes when handling and discharging anhydrous ammonia refrigerant Refrigerant Leaks Anhydrous ammonia leaks can be detected by odor sulfur stick soap solution or test paper The odor is normally noticed first and the location of
124. essor Servicing 9 26 Compressor Suction Valve 34 1 5 1 11 Compressor Suction Purge Valve 77 1 12 Compressor Water Regulating Valve 54 1 12 Condenser Ammonia Drain Valve 44 1 6 1 11 Condenser Ammonia Charging Valve 44 1 6 Condenser Cleaning 9 5 Condenser Purge Valve 59 1 6 1 10 Condenser Safety Valves 50 E 1 6 12 Index 1 1 1 10 Condenser Taw Gas Outlet Stop Valve 89 1 8 Condenser Water In And Out 3 11 Condenser Water Requirements 3 12 Condenser Water Usage P24A and P344 11 5 Control Circuit Protection 9 4 Control Panel 5 5 6 2 6 3 Control Panel Parts 6 2 6 3 Cooling Tower Cooling Tower Evap Condenser 7 5 Cooling Tower Maintenance Schedule 7 6 Cooling Tower Piping Diagram 3 14 Crushed Ice Production 10 2 Current Unbalance 3 17 Cutter Adapter Plate Installation
125. essure Water Cooled 21 230 1 60 SW Sea Water NC No Condenser Product Variation Codes A number or letter designator assigned to specific variations within a family 000 or Blank Standard Product 001 Pillsbury Job 002 Liquid Overfeed Less Control Panels 003 Liquid Overfeed Panel shipped separate No Wiring RCP Remote Control Panel PWS Part Wind Starter LOF Liquid Overfeed 120 120 Volt Controls FPS Freezer Pressure Switch Instead of timer HKA Insulated Casings amp Part Wind Start Hong Kong Airport LCP Less Control Panel 45T Transformer added for 400 3 50 0 K Models SSC Stainless Steel Casing VTC Von s Type Cutter ISC Insulated Stainless Steel Casings SCT Stainless Steel Casings and Bin Thermostat FIGURE 2 1 Model Designation for P Series Ice Machines 8 7 07 8 7 07 P24A amp P34A Service Manual 2 3 RECEIPT OF YOUR TUBE ICE MACHINE Rated Capacity The Tube Ice machine is rated to produce a given amount of ice when operating under the proper conditions as specified in this manual You should be prepared to handle the ice produced as it is discharged from the machine and move it to your storage or bagging area promptly The following specifications are given to help you do just that Model P24A 1 5 Model P24A 1 25 Model P24A 1 Makeup Water Capacity Tons day Capacity Tons day Capacity
126. estricted Check water pressure 40 psig is recommended minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain is closed Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Check refrigerant level mark on the receiver and on the painted portion of the gage glass guard Be sure to keep the gage glass cocks closed when finished checking the level Check for closed valve defective solenoid valve 20 float switch defective or strainer restricted The liquid line will normally have frost on the down stream side of a restriction especially as the suction pressure decreases 8 8 P24A amp P34A Service Manual TROUBLESHOOTING Symptom High discharge pressure check gage accuracy Possible Cause Possible Remedy Insufficient water flow through the cooling Check the condenser water pump to make sure tower or condenser it is pumping enough water as specified in TABLE 3 2 Check sump strainer screen and clean Check condenser pump direction of rotation Fan control out of adjustment Check adjustment Refer to FIGURE 9 3 Fan Control Replace if defective Non condensable in system If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant will be cooler although the pressure will be high Air can b
127. eze cycle to a minimum of 30 F 9 1 9 2 P24A amp P34A Service Manual SERVICING OPERATIONS Hand Expansion Valve The hand expansion valve is located directly after the 1 solenoid valve This valve should be set at a point where the float switch is open for a length of time approximately equal to the time it is closed Freezer Pressure Switch freezing time period for producing ice of a desired thickness is controlled by the freezer pressure switch 2PS Figure 9 1 located inside the control panel The original switch was set at the factory to produce ice of recommended thickness Look at the Certificate of Test which was provided with the machine for a sample set of pressure readings with corresponding time periods and water temperatures Also see TABLE 11 8 11 9 Operating Vitals for typical settings When making adjustments allow two ice discharging cycles between adjustments Switch adjustment is as follows See Figure 9 1 1 Turn the low signal adjustment nut CCW until low signal setting indicator is fully down Turn the high signal adjustment nut until high signal setting indicator is slightly beyond the actuation setting of 55 psig 2 Starting with the pressure above the actuation pressure reduce the pressure to desired actuation pressure of 55 psig contact opens 3 Advance the low signal adjusting nut until the switch actuates and contact closes SET AT APPROXIMATELY 55PSIG cq CONTACTS OPEN
128. fer to the space diagrams to Section 2 to make sure ample room is provided for removing the condenser heads and using the mechanical cleaning equipment 2 Order replacement cover gaskets for use at the time of reassembly Disconnect and lock out power to the ice machine and auxiliary equipment 4 Disconnect water piping and drain the condenser Additional water can be drained by loosening the cover heads hex nuts and separating the covers from the condenser end Remove the heads stud bolts and gasket completely 6 Inspect the tubes for excessive corrosion and possible ammonia leaks to determine whether or not further cleaning is feasible 7 Clean the inside of each tube as well as possible being careful not to damage the tube Follow the instructions for the particular tool being used 8 Flush each tube with water to remove all loose material to prevent contamination of the cooling tower and sump 9 Clean the ends of the tube sheets so the new gasket will seal properly 10 the stud bolts to the proper depth and install the replacement gasket Make sure the gasket does not cover the extended tube ends Oo 9 6 8 7 07 P24A amp P34A Service Manual SERVICING OPERATIONS 11 Install the end covers heads and fasten securely in place with the hex nuts 12 Reconnect the water piping turn on the power Check for leaks by turning the Hand Auto switch to Hand allowing the condenser pump to run 13 Tur
129. fety Valves 3 13 see figures 1 6 through 1 11 for location Servicing Operations 9 1 Shipping weight 2 3 Shut Down by Pressure Switch 8 11 Soft Start Cutter Motor Starters 10 13 initial torque adjustment 10 13 start time adjustment 10 13 Wiring 10 13 Solenoid ValveS 9 22 see figures 1 1 through 1 9 for location Space Requirements 3 1 Space Diagram P244 3 2 3 3 Space Diagram P34A 3 5 3 6 Spare Parts List P24A and P34A 11 8 Specifications for P24A 2 3 11 2 Specifications for P34A 2 3 11 3 Start Push Button 2PB 5 5 6 3 Start Time Adjustment Soft Starter 10 13 Start Up 5 5 Start Up amp Operation 5 1 Start Up Checklist 5 2 Storage prior to installation and start up 2 3 Stop
130. flow by receiver pressure Thaw gas valve 18 leaking through Make sure manual opening stem is in the automatic screwed in position Repair or replace defective parts Symptom High suction pressure check gage accuracy Possible Cause Possible Remedy Compressor running unloaded or not pumping Check compressor motor amp If the efficiently compressor is running unloaded the amperage will only be approximately 60 of normal amp draw Refer to the compressor manual Thaw gas valve 18 leaking through Make sure manual opening stem is in the automatic screwed in position Repair or replace defective parts Defective gage Check pressure with accurate gage and replace as necessary Symptom Compressor running unloaded during freeze Possible Cause Possible Remedy Low oil pressure Check compressor net oil pressure Net oil pressure oil pressure gage reading less suction pressure Mycom 17 28 psig Vilter 35 50 psig Refer to the compressor manual for Oil Pressure Adjustment Unloader solenoid valve open Check solenoid coil to make sure it is not energized If valve is stuck open replace valve Unloader mechanism not working properly Refer to compressor manual Mycom compressor can be loaded manually 8 7 07 8 10 P24A amp P34A Service Manual TROUBLESHOOTING Symptom Compressor oil pressure low check gages See Section 7 for compressor oil pressure requirements Possible Cause Possible
131. g are seated Finish driving the shaft and bearing into the housing until it is firmly seated Turn the bracket and shaft upside down and fill the housing around the shaft with MPG 2 or suitable substitute grease Slide the lower bearing spacer over the shaft and into the housing With the top end of the shaft supported install the lower bearing on the shaft driving it down into the housing firmly against the housing shoulder Slide the seal spacer ridged end in flat end out and seal open face out onto the shaft together Uniformly tap the seal into the housing against its shoulder NOTE The purpose of the seals and excluders are to prevent moisture from entering the 9 12 P24A amp P34A Service Manual SERVICING OPERATIONS housing area not to hold the grease in 13 Wipe off excess grease and install the two pipe plugs 14 Install the largest excluder on the bracket as illustrated by the assembly drawing 15 Install the tines disc the 1 4 x 1 4 key spacer spring washer castle nut and cotter pin 16 Turn the assembly right side up and install it in the water tank locating the support arms as they were match marked when removed and secure in place using the 5 8 stainless steel cap screw and lock washer maximum torque should be 90 ft Ibs 17 Install the top seal open side facing out tapping it uniformly into the housing until it seats 18 Install the top water excluder 19 Install the splash shield and ice d
132. g 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 SENE ___ eeee _ L I e xc xis xis 518 s OU Oe tps On MITSUBISHI Re POWER te RUN Ort j 24MR ES TN ON E ziv e COND COMB Teo 0000 200 8 ooo 4 69 2 mE ejeeeeoemgeeeoeme i 10 12 bs PA Sete Figure 10 1 Mitsubishi Programmable Logic Controller KEY FEATURES 8 7 07 10 4 P24A amp P34A Service Manual Options and Accessories Automatic Restart TUBE ICE machines are equipped with a power failure relay This relay prevents the machine from automatically restarting in the event of a power failure The machine should have power on the crank case heater for a minimum of two hours before it is restarted with the start switch The PLC allows the user to select between having to restart the machine manually or restarting automatically two hours after power is restored Timed Freeze Cycle The normal mode of operation for the length of the freeze cycle is determined by the freezer pressure switch setting
133. ging settings where required As you step through the Setup Menu the unit will remain on line monitoring your system and logging any faults in memory for you to review after you leave the setup mode The Setup LED will stay on during setup operations When you have passed the last parameter in the setup menu the setup LED will extinguish and you will be returned to the SYSTEM ON LINE display NOTE The power monitor has no on and off switch so the unit will power up a few seconds after power is applied Nominal Voltage Set this value at the Incoming Line Voltage Use the arrow keys to change voltage 190 610 Voltage Adjustment Default voltage is 208 Voltage Range Use the arrow keys to set the under over percentage 2 to 2596 of incoming voltage This will turn off equipment for a specified time 1f incoming voltage exceeds set percentage The recommended voltage range is 10 Default is 10 Delay On Break Ranges from Off to 10 minutes in 1 minute increments Use the arrow keys for adjustment Delay On Break is energized when the Load Relay is deactivated and the load will remain off until the specified time has elapsed Default is 5 minute 8 7 07 8 7 07 P24A amp P34A Service Manual 10 15 Options and Accessories Delay On Make Ranges from Off to 10 minutes in 1 minute increments Use the arrow keys for adjustment Delay On Make is energized when the control voltage is reactivated and the load will remai
134. he cylinder valve 2 Purge all air from the charging hose and open the cylinder valve gradually to check for possible leaks around the packing nut or hose fittings Then open the cylinder valve fully 3 While the ammonia feed light is not illuminated open the charging valve 28 and ammonia will flow from the cylinder to the freezer 4 Close the cylinder valve immediately when the ammonia feed light comes on and reopen it when the light goes out Repeat until properly charged CAUTION Do not leave a refrigerant cylinder attached to the machine unattended Disconnect it immediately when the machine is charged or the cylinder is empty CAUTION Operating Tips Make sure the machine is left running in the Auto position This will assure a complete shutdown if a safety or overload is tripped To initiate a harvest cycle simply push the Manual Harvest push button 3PB e To interrupt the harvest cycle and revert to a freeze cycle turn the Hand Auto switch to Hand and back to Auto e Too much ammonia in the condenser receiver can contribute to high discharge pressure Do not go above 13 1 2 for the P24A or 25 for the P34A from the center of the lower gage glass cock while in normal operation A higher level can begin to cover the condenser tubes and reduce condenser efficiency e The circulating water overflow tubing will show that water is being slightly lifted up the tubing near the end of
135. he four hex nuts holding the reducer to the mounting plate and move the reducer as required for proper tooth engagement Tighten the hex nuts securely and recheck backlash Gear Reducer Replacement 1 2 10 11 12 13 Disconnect and lock out all power to the machine Disconnect electrical wires and conduit from the motor Remove the top and side bolts holding the mounting plate to the support bracket and lift the plate and gear reducer assembly from the tank bracket Inspect the drive gear teeth for proper vertical alignment and wear pattern If the wear pattern indicates less than a full width of tooth engagement measure the distance so correction can be made at the time of reassembly Measure and record either the distance of the drive gear from the mounting plate or the split hub from the shaft end for future reference when reassembling Remove the three or four cap screws from the split taper bushing Use two of the cap screws in the threaded holes of the busing as jacking screws for pushing the drive gear from the hub Drive a wedge in the split of the hub bushing and slide both the hub and gear from the shaft Remove the four hex nuts and lock washers from the carriage bolts around the reducer base and mounting plate and separate the plate and reducer Install the replacement gear reducer and motor onto the mounting plate using the carriage bolts lock washers and hex nuts Tighten the nuts snug only for
136. he valve has been cleaned and reinstalled check to ascertain if the proper water level is being maintained After the machine is stopped and the water in the tank seeks its normal level there should be no water flow through the float valve or out the overflow It is advisable to install a large area strainer in the water supply line to protect the float valve from dirt or solids in the water which would necessitate frequent cleaning A strainer of 40 mesh screen is usually satisfactory Float Switch 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 1 solenoid 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 closes thereby energizing and opening the 1 feed solenoid until sufficient level has been reached to open the float switch The float switch has a fixed 1 2 differential The float switch 15 installed at the correct height at the factory and should not need to be adjusted The float switch is installed at the position which provides highest capacity The correct height will produce compressor superheat which climbs throughout the fre
137. heck for loose wires Replace defective part restart machine check power supply and current draw Check for loose connection on all terminals reset breaker and check amp draw against breaker rating Check voltage and current unbalance Section 3 Replace breaker if defective 8 4 P24A amp P34A Service Manual TROUBLESHOOTING Symptom due to extended freeze period Possible Cause Possible Remedy Freezer pressure switch 2PS set too low or Adjust switch or replace if defective See defective FIGURE 9 1 Water tank drain valve make up water float Close repair or replace valve as needed The valve or flushing valve stuck or opened float valve should be adjusted low enough that water should not run out the tank overflow during the freeze cycle Thaw gas solenoid valve 18 leaking through Check the manual opening stem to make sure it during freeze is in the automatic position stem screwed in Check for leakage by sound temperature difference and frost during the freeze cycle Leakage should stop by closing the hand stop valve downstream of thaw gas valve Isolate and repair or replace the valve as needed Compressor running unloaded If the compressor is running unloaded the motor amp draw will only be 60 70 of the normal amp draw of a loaded compressor Check the delay timer DT electrical circuit to make sure the UR SOL coil is not energized Refer to the compressor manual for normal
138. her than the top end 3 Connect the other end of the charging hose to the cylinder valve It is recommended that a gage be attached to this line to indicate cylinder pressure 4 Close the liquid line stop valve 29 or 58 5 Open charging valve 28 and carefully purge air from the charging hose 6 Open the cylinder valve slowly checking for leaks in the line and allow the suction pressure to build up to approximately 40 psig and check again for leaks in the system 7 With the power off open the control panel door and disconnect wire 24 from the freezer pressure switch 2PS then turn the power back on 8 Check compressor rotation by starting and stopping the compressor momentarily using the green Start push button 2PB and the red Stop push button 1PB Correct compressor rotation is indicated by an arrow on the outer rim of the oil pump assembly opposite the shaft end of the compressor 9 Set the Hand Auto switch 1SS to the Hand position allowing the circulating water pump to circulate water through the freezer 10 As the pressure continues to rise in the freezer start the compressor and pump the ammonia into the receiver Make sure water is circulating through the condenser and freezer tubes 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 cylin
139. hly Six Months 1 debris from unit Check fan and pump rotation X _ OE Clean spray nozzles x x Dminsumpandpiping TABLE 7 3 Cooling Tower Maintenance Schedule gt lt gt lt im gt Compressor In starting and charging the unit the oil sight glass should be continually checked to make sure an adequate oil level is maintained The oil level should be 1 4 3 4 of the sight glass If the oil level drops below 1 4 of the glass add two quarts of 300 SSU viscosity refrigeration oil as per the compressor manufacturer recommendations Never allow the oil level to be out of sight above or below the sight glass when the compressor is operating CAUTION The crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compressor CAUTION During operation the specified net oil pressure should be maintained for proper lubrication and operation of the cylinder unloader mechanism Mycom N amp W Series net oil pressure 17 28 psig Vilter 450 Series net oil pressure 35 50 psig Note Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pressure gage reading while the compressor is running Example Oil pressure gage reading 65 psig Suction pressure gage rea
140. hould be sized for each installation The ice machine is supplied with a fan control switch for cycling the cooling tower fan on and off thereby maintaining the proper operating head pressure If the condenser inlet water temperature is expected to be below 75 F 24 C a water regulating valve should be installed in the condenser water inlet line and adjusted to maintain a head pressure of not less than 175 psig See FIGURES 3 5 through 3 8 for possible cold climate installations with indoor sump P24A amp P34A Service Manual 3 13 8 7 07 INSTALLING YOUR TUBE ICE MACHINE Safety Valves Four safety pressure relief valves are an integral part of the packaged Tube Ice machine Two are located in the low side of the system on the freezer and two are 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 Refer to the International Institute of Ammonia Refrigeration standard for specific requirements and instructions 3 14 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE CDNDENSER CHECK VALVE BALL VALVE _ MOTOR TOWER DRAIN E
141. ich discharges through the oil separator 14 then through the heat coil of the condenser and then into the P24 condenser receiver 15 P34A condenser 15C receiver 15R In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid goes out the liquid line through a strainer 43 liquid A solenoid valve 20 check valve 101 and hand expansion valve 17 At the hand expansion valve 17 the refrigerant expands from a saturated high pressure liquid state to a low pressure low temperature liquid This cold liquid enters the freezer 2 where it absorbs heat from the circulating water in the freezer tubes Cool gas is again pulled out of the freezer through the suction outlet thereby completing the circuit The freezing period is completed by action of the freezer pressure switch 2PS in the control panel The water pump 6 stops and the solenoid valve 20 closes After a delay of 20 30 seconds the cutter motor starts the thawing gas D solenoid valve 18 opens and the harvest thawing timer 2TR is activated Warm gas from the receiver is discharged through the thawing chamber 16 check valve 101 and into the freezer There it warms the refrigerant and the outer surface of the freezer tubes allowing the ice to release on the inside of the tubes and drop down onto the rotating cutter for sizing After sizing the ice drops on the tines cutter disc and di
142. iew 1 8 right side view 1 9 back side view 1 10 left side view 1 11 N NEMA 1 3 1 Non Condensable Gases 9 19 Normal Operating Vitals P24A and P34A 11 7 Pressure Switch 9 4 Return Line Stop Valve 70 1 12 Operating Features 4 1 Operating 5 6 Operating Vitals 24 and P34A 11 7 Operating 2 3 24 capacity ratings 11 4 condenser water 11 5 make up water usage 11 6 normal operating vitals 11 7 specifications 11 2 condenser water usage make up water usage normal operating vitals specifications Pha
143. ime Indicator Indicates total hours of machine operation Is powered when the compressor is running control circuit CB2 Circuit Breaker Secondary protection for the circulating water pump motor CB3 Circuit Breaker Secondary short circuit protection for the cutter motor TB Terminal Block Numbered for multiple wire connections and ease of troubleshooting TABLE 6 1 Description of Control Panel Parts Inside 8 7 07 8 7 07 P24A P34A Service Manual ELECTRICAL CONTROLS PUMP RESET ILT CUTTER RESET 217 SLT FREEZING Lrourp THAWING START SWITCH HAND AUTO SWITCH STOP MANUAL SWITCH HARVEST FIGURE 6 2 Control Panel Hinged Door Amber Pilot Light Freezing Illuminated during the freeze period or whenever the circulating water pump is running QLT Clear Pilot Light Liquid Feed Illuminated when the circulating water pump is running and solenoid valve 20 is opened the float switch 10 is closed Indicates that the liquid line GLT Red Pilot Light Thawing Illuminated when the machine is in a harvest period PB Green Push Button Start For starting the compressor motor and ice production NO 1PB Red Push Button Stop For stopping the compressor motor and ice production NC 3PB White Push Button Manual For manually i
144. in another set to X1 and Min and set the thawing period for at least 30 seconds longer than the time required to harvest the entire discharge of ice If it should be necessary to change the setting of the timer turn the adjustment dial clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment Note Thicker ice may require a longer thaw period due to slower ice release time TIME RANGE ADJUSTMENT DIAL p INDICTES THAT TIMER IS TIMED OUT SCALE SELECTION SWITCH OR BASE SELECTION SWITCH HOURS MINUTES SECCONDS LIGHT INDICATES THAT TIMER IS TIMING FIGURE 9 5 Thawing Timer 2TR Condenser Cleaning There are 124 1 1 4 OD x 84 long steel tubes in the P24A condenser receiver These tubes are approximately 1 1 32 inside diameter contact the factory for P34A condenser tube sizing Any brush or cleaning tool should be sized accordingly so as not to damage the tubes during cleaning The cleaning tools should be rotated at the specified speed for the particular tool used The tubes should be kept wet during cleaning After cleaning the tubes should be flushed thoroughly and all foreign material removed Contact your distributor or Vogt s Service Department to obtain the proper cleaning tools The following is the condenser cleaning procedure 1 Re
145. ing freezing thawing and hand Momentarily de ized at the end of the harvest Energized during the harvest period DT Delay Timer Allows the compressor to start unloaded by delaying the energizing of the UR SOL unloader solenoid valve This gives lower in rush amps and helps prevent belt slippage at start up Controls the desired ice thickness hole size by sensing the freezer suction pressure and initiating the harvest period Elapsed Time Indicator Indicates total hours of machine operation Is powered when the compressor is running control circuit CB2 Circuit Breaker Secondary protection for the circulating water pump motor CB3 Circuit Breaker Secondary short circuit protection for the cutter motor TB Terminal Block Numbered for multiple wire connections and ease of troubleshooting TABLE 6 1 Description of Control Panel Parts Inside 8 19 04 P24A P34A Service Manual 8 19 04 ELECTRICAL CONTROLS PUMP RESET ILT CUTTER RESET 217 SLT FREEZING Lrourp THAWING START SWITCH HAND AUTO SWITCH STOP MANUAL SWITCH HARVEST FIGURE 6 2 Control Panel Hinged Door Amber Pilot Light Freezing Illuminated during the freeze period or whenever the circulating water pump is running QLT Clear Pilot Light Liquid Feed Illuminat
146. ing to prevent water from splashing out and contaminating any stored ice 6 Add sufficient ice machine cleaner to the water tank P24 tank 2 5 gallons water per inch of water height in tank 13 32 5 gallons P34 tank 4 7 gallons water per inch of water height in tank 13 60 6 gallons Mix cleaning solution according to manufacturer s recommendations 7 Remove top water box cover inspect distributors remove any hard particles from orifices and make sure all distributors are in place Replace cover 8 Turn Hand Auto switch to Hand position and circulate the cleaning solution until deposits are dissolved or the solution is neutralized After draining the pump may have to be stopped and restarted to dispel air 9 Turn switch to Auto position to stop the pump Drain and flush the water tank Repeat cleaning as necessary 10 After cleaning fill the tank with fresh water start the pump again and circulate for 15 minutes 11 Stop the pump drain and flush the tank and again refill with fresh water 12 Remove the cover from the ice discharge opening and clean any area that may have been splashed with solution during cleaning 13 Make sure the make up water float valve is adjusted properly and the drain valve is closed 14 Start and stop the pump again to make sure it is circulating water and it is not air bound E You are now ready to produce ice Water Distributors The water distributors are
147. ing upward 3 Lift the distributor out of the hole To install the distributors 1 Insert one in each tube hole and seat firmly by using a short piece of pipe or conduit 2 Slide the pipe or conduit down over the vent tube and gently tap the distributor in place 3 Do not allow the distributor to be recessed below the top of the tube sheet To replace the cover Replace water distributor box cover gasket Install the cover over the bolt studs Install the four 4 cover retaining rings sections and nuts Tighten the wing nuts firmly to prevent foreign materials from entering the water box Tu pes Note freezer cover and gasket are not intended to hold the pressure of the circulating water in the event of a freeze up Therefore every effort should be made to prevent the Tube Ice from freezing solid with no hole 11 2 1 1 4 1 47 3 8 Avg 1 8 3 16 Avg 1 16 1 8 Avg TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank contains a concentrated amount of solids or salts See Troubleshooting Poor Ice Quality To clean the water tank P24A amp P34A Service Manual 8 7 2007 MAINTENANCE 1 Stop the machine at the end of harvest 2 Shut off the make up water supply 3 Open the drain valve and drain the tank 4 Remove the water box cover and flush out any loose sediment from the tank The wire mesh screen can
148. into the water tank during harvest The flushing valve is opened energized during each thaw cycle when the water pump stops and the water in the freezer tubes returns to the water tank If water quality is superior this blowdown can be reduced by installing a smaller reducer bushing in the outlet elbow The flushing action carries accumulated salts solids and ice chips fines out through the water tank overflow pipe This overflow should be kept open at all times to allow the water to drain freely and keep the water level below the cutter disc and ice discharge opening If the flushing solenoid valve leaks through during the freeze cycle it can be disassembled and cleaned then reassembled Cleaning Ice Making Section Refer to Section 7 Maintenance for instructions for cleaning the circulating water tubes water distributors and water tank Float valve make up water The make up water float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank during the freezing period so that there will be a quantity of blowdown only during the thaw mode The water level during the freeze mode should always be below the overflow piping to prevent excessive waste of cold water resulting in loss of ice capacity If it should become necessary to clean the float valve close the stop valve in the make up water line to the machine and remove the float valve After t
149. ion emergency protective and safety equipment may include one or more of the following SAFETY SHOWER Parts of the body injured by contact with ammonia must be flooded immediately with large quantities of water An emergency safety shower eye wash fountain or other source of clean water can be used for this purpose Such a source should be protected from freezing in cold weather RESPIRATORY DEVICES 1 A full face GAS MASK with an ammonia green or a universal red industrial size canister approved by MSHA NIOSH formerly U S Bureau of Mines OSHA regulations require at least two gas masks to be maintained at a stationary ammonia storage installation It should be noted these canisters are limited to brief periods of use not exceeding 15 minutes and in concentrations of ammonia not exceeding 3 30 000 ppm in air by volume Spare canisters within usable date limitations as marked should be kept on hand Replacement of over age canisters even though not used is recommended A person wearing a mask must leave a contaminated area immediately on detecting an odor of ammonia or experiencing difficulty in breathing These are indications that the mask or canister is not functioning properly that the ammonia concentration is excessive or that adequate oxygen is not available 2 For protection where ammonia concentrations are unknown or may exceed 396 or in oxygen deficient atmospheres SELF CONTAINED AIR BREATHING APPARATUS
150. ion to the additional space required If it ever becomes necessary to mechanically clean the condenser tubes extra space will be required on one end preferably on the opposite end from the water inlet and outlet for the cleaning tools Foundation Refer to the space diagrams Figures 3 2 and 3 4 for recommended minimum foundation requirements The figures show anchor bolt details and machine anchor hole details Contact your local distributor for seismic anchoring requirements in your area WARNING Lifting or moving heavy equipment should only be attempted by competent rigging and hoisting contractors Never allow personnel near or under heavy equipment when it is being moved or lifted Failure to comply could result in personal injury or loss of life WARNING Lifting Procedures Your Tube Ice machine is provided with lifting lugs for the purpose of unloading and moving the machine to its operation location Refer to the enclosed drawings for instructions and illustrations of their use P24A Figure 3 5 Machine weight 13 000 158 P34A Figure 3 6 Machine weight 22 000 Ibs These figures are intended as a guide to unloading and lifting the P24A and P34A Tube Ice machine Vogt Tube Ice L L C is not responsible for product damage or personnel injury or loss of life during the loading or lifting procedure 3 2 INSTALLING YOUR TUBE ICE MACHINE 26 SQ NOTE E N S S P24A amp
151. is highly alkaline Contact of the skin or mucosa with liquid ammonia or a high concentration of vapor can result in a caustic burn Due to the great attraction of water to ammonia water may be absorbed simultaneously from the tissue resulting in dehydration of the affected area Liquid ammonia boils at 28F under atmospheric conditions acting as a refrigerant to remove heat from any warmer object it may be contacting Accordingly liquid ammonia in contact with the skin can cause frostbite Exposure levels of ammonia vapor which are tolerated by some persons may produce adverse reactions in others Persons having chronic respiratory disease or persons who have shown evidence of undue sensitivity to ammonia should not be exposed to ammonia Table 2 indicates human physiological response to various concentrations of ammonia in air upon inhalation TABLE 2 PHYSIOLOGICAL EFFECTS OF AMMONIA VAPOR PPM Ammonia in Effect Air by Volume Least perceptible odor MEM 5 ppm Readily detectable odor 20 50 ppm No discomfort or impairment of health for prolonged exposure 50 100 ppm General discom ort and eye tearing no lasting effect on short exposure 150 200 ppm Severe irritation of eyes ears nose and throat no lasting effect on short exposure 400 700 ppm Coughing bronchial spasms 1 700 ppm Dangerous less than 1 2 hour exposure may be fatal Serious edema strangulation asphyxia rapidly fata Immediately fatal F
152. ith high voltage electrical equipment should be allowed to install or work with the Tube Ice machine WARNING A fused disconnect must be provided near the Tube Ice machine The control panel and compressor motor starter are attached to the structurals on the front of the Tube Ice machine see FIGURE 3 11 Incoming 3 phase power will be connected at the compressor motor starter 1M Terminals L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of the compressor cutter motor and water pump is required see rotation check Also if one leg of 3 phase power is higher or lower wild then it should be connected to terminal L3 Connect the ground wire to the ground terminal provided Make sure wires 22 and 27 are connected to the elapse time ET indicator in the control panel 8 7 07 P24A amp P34A Service Manual 3 17 INSTALLING YOUR TUBE ICE MACHINE LIL2L3 LI HLT FUSIBLE CONTROL ITRANSFORMER zl IF USED x2 LIL2L3 FIG 2 ICR 2CR 29203 2M 3M e 2TR g 2 1 92 93 Li L3 2 3 Alla 4 2 6 T 3 2
153. l Included in the wiring schematic is provision for a bin level control BLC The NC contract of your control should be wired between terminals 8 9 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown However the machine will still need to be manually started to resume production Safety Switches The machine is also equipped with the following safeties and control switches which are mounted to the frame near the compressor Refer to the wiring schematic FIGURE 6 3 for their circuitry e High Low dual pressure switch 1PS to stop the machine if the compressor suction pressure goes too low 15 20 psi or the compressor discharge pressure goes too high 225 250 psi See High Low Pressure Switch e Oil failure pressure switch OPS to stop the machine if the compressor oil pressure drops to 15 psi net suction pressure minus oil pressure gage reading See Oil Pressure Switch Fan control switch to maintain a desirable head pressure discharge pressure of 175 to 200 psi during operation See Fan Control Switch 6 1 6 2 P24A amp P34A Service Manual
154. lating Valve Discharge Line Stop Valve Freezer Pressure Switch 2PS Liquid Outlet Valve King Valve Receiver Purge Valve Freezer Oil Ammonia Drain Valve Make up Water Inlet Valve Water Flush Solenoid Valve Compressor Cooling Water Solenoid Valve Low Suction Pressure Stop Valve Oil Return Stop Valve Strainer Purge Valve Freezer Purge Valve Compressor Suction Purge Valve Compressor Discharge Purge Valve Discharge Pressure Gage Stop Valve Accumulator Thawing Gas Stop Valve Receiver Liquid Return Stop Valve Compressor Oil Pressure Safety Control OPS Check Valve Piping Nomenclature 4 3 P24A amp P34A Service Manual HOW YOUR TUBE ICE MACHINE WORKS r c 4301515 JJLVM YISNFONOT 137100 N31vM 935 30 02 1 110 2 1 100 2 1 e GINOIT 18 4 1 7102 9NILV3H M3AISO3M 62 E 2 NIV SELVA 2 CAE HSN 6 CAUTRBAD LE WA 331 Be 1 3 INI d 39VW doxeh ern 18 8 SYI gt E x SZ E 62 oz 101 ZI ec Cuznuno FATWA 3 NOILOnS
155. ling weather conditions f Corrective measures being applied g Name of caller and location now and where telephone contact may be re established with caller or other responsible party at the emergency site Environmental protection and or other regulatory authorities should be notified of an ammonia spill as may be appropriate and required by statute FIRE EXPOSURE If possible an ammonia container should be disconnected and removed immediately from the fire zone If for any reason a container cannot be moved it should be kept cool with water spray until well after the fire is extinguished Firefighting personnel should be equipped properly with protective clothing and respiratory equipment EMPLOYEE SAFETY TRAINING Safety in working with ammonia depends on more than just the availability of personal or emergency protective equipment and clothing Employee training in safe operation procedures in first aid measures and in the use of suitable operating and protective equipment properly maintained must also be included as an essential element in any comprehensive safety program Such safety training is the responsibility of management and should be given to new and old employees at periodic intervals as needed to maintain high proficiency levels Included should be written and oral instructions followed by drills regarding the location purpose and use of personal and emergency protective clothing equipment emergency
156. located under the top freezer cover These distributors are similar in design to those used in mid size and small machines i e P18F P118 etc except they have a small vent tube It is important that this plastic vent tube remain in place in each distributor The distributors may require occasional or periodic cleaning to remove solids foreign particles or mineral deposit accumulated from the circulating make up ice making water The frequency of cleaning operation will depend on the characteristics of the water supply The distributors need inspection when the inside diameter of a large portion of the ice becomes irregular due to channeling of water if some of the is opaque or if there is a noticeable decrease in ice capacity and quality 7 3 7 4 P24A 6 P34A Service Manual MAINTENANCE 8 7 2007 Model Number of Distributors TABLE 7 1 Water Distributors You may look through the plastic freezer cover to inspect the water distributors if the view is clear For a closer inspection you should stop the unit remove the nuts and retaining ring sections and lift off the top cover Make sure the two orifices in the side of each distributor are open the vent tubes are in place and a distributor and vent tube assembly is installed firmly in each tube To remove the water distributors for cleaning 1 Grip the top of the distributor body not at the vent tube with adjustable pliers 2 Hold and twist the distributor while pull
157. medy Freezer pressure switch 2PS set too low or Adjust switch or replace if defective See defective FIGURE 9 1 See Freeze up due to extended freezer period and Freeze up due to ice failing to discharge Clogged water distributors Clean water distributors Lack of water for making ice Freeze up Lack of sufficient liquid refrigerant feed Water pump rotation incorrect or pump defective Symptom Shut down by oil pressure switch Possible Cause Possible Remedy Switch adjusted too high or defective Oil pressure low See Compressor oil pressure low Low oil level Add oil Defective thawing timer causing long harvest Replace defective timer cycle and oil dilution 8 11 TROUBLESHOOTING Check water tank for sufficient water level Check for restriction in water line defective float valve open drain valve excessive ice chips or low water pressure and correct Check float and float switch solenoid valve and coil 20 in liquid line strainer and refrigerant level in receiver Check pump motor rotation Check for leaking pump seal or defective motor and repair or replace as needed Check switch adjustment and cutout pressure activation against an accurate gage Replace switch if defective See Figure 9 4 Symptom High compressor discharge temperature Possible Cause Possible Remedy High head pressure Defective suction or discharge valves Restriction in the discharge gas line Internal r
158. mp motors cooling tower fan and pump etc for abnormal noise and or vibrations Check oil level in gear reducer Check one complete freeze thaw cycle record data and compare with production check of Registration Start up Report D Yearly in addition to weekly and monthly 1 2 3 4 5 6 7 8 9 Check entire system for leaks Drain water from condenser and cooling tower and check condenser tubes Check closely for damage by corrosion or scale Remove all rust from all equipment clean and paint Check all motors for shaft wear and end play Check operation and general condition of all electrical controls relays motor starters and solenoid valves Check freezing time ice release time and ice out time Change oil in gear reducer box once a year Lubricate compressor motor bearings Drain compressor oil open compressor inspect and clean inside crankcase Change oil filter and add new oil Inspect compressor suction strainer 7 2 P24A 6 P34A Service Manual MAINTENANCE PREVENTATIVE MAINTENANCE FORM This form can be removed and duplicated for record keeping Date Model Serial The following service performed and checked Hour meter reading Ambient temperature inside F Make Up water float valve adjusted properly Water distributors clean and in place All drains freely draining Cleaned and flushed water tank Compressor oil changed Cleaned and inspected inside compressor cra
159. n 9 Condenser Cleaning Purging Non Condensables Air and other non condensable gases in a refrigeration system are not desirable Purging air from your Tube Ice machine will greatly improve system performance and save money Non condensable gas effects are 1 Higher condensing pressure than desired 2 Greater electrical power consumption 3 Reduced refrigeration capacity 4 Longer than normal compressor running time 9 20 P24A amp P34A Service Manual SERVICING OPERATIONS Slow ice release and long thaw cycle Air collects mostly in high pressure condensers receivers and other high pressure components It collects mostly in the coolest lowest velocity area of these components Evaporative condensers usually have purge points at the top of the outlet header of each circuit Receivers usually have a purge point at the top away from the inlet where it is coolest and the gas velocity is the lowest The freezer can be purged through the valve at the top of the suction accumulator but should be done only during the thaw cycle or after the system has been idle at least two hours Follow this procedure when purging Connect a suitable hose to the purge valve and place the other end in water Open slightly the purge valve and allow air to escape Air will appear as bubbles in the water rising to the surface The larger the bubbles the more air is escaping DO NOT leave the purge hose unattended When air bubbles a
160. n appreciable quantity of ammonia in the air it may be difficult to pinpoint the leak source Various types of devices are available to detect and measure the concentration of ammonia vapor in air One such device employs a colorimetric detector tube through which air to be tested is drawn by a special hand or battery operated pump comparison of the length of the color stain produced in the tube is made with a calibrated chart which gives an indication of the concentration LEAK CONTROL EQUIPMENT OR PIPING If a leak occurs equipment or piping shut off the ammonia supply and carefully vent all ammonia from the system before attempting to dismantle any part or make repairs The appearance of frost on an external surface indicates the presence of liquid ammonia vaporizing in the system Accordingly the frost should be allowed to dissipate before breaking any connection If welding is required the system should be thoroughly purged until all ammonia and any oil residue has been removed Welding must conform with applicable codes VALVE Aleak at a valve stem can usually be stopped by tightening the packing gland nut A leak at a valve bonnet may be stopped by tightening the bonnet threads or the bolts holding the bonnet to the valve body All tightening should be performed slowly and without application of excessive force Packing gland nut and bonnet threads on some ammonia valves are left handed If tightening procedures fail
161. n food production and processing textile and chemical manufacturing refrigeration metal treating and pollution abatement An ever increasing use of ammonia has been accompanied by a corresponding growth in the need for the dissemination of knowledge regarding ammonia safety among persons working with ammonia under either normal or emergency conditions Recognizing this need LaRoche Industries has prepared this booklet which contains a selected collection of helpful information and suggestions for the ammonia user and for safety personnel The suggestions may be employed as an aid in the preparation of the ammonia user s own comprehensive safety program and should be altered or augmented in accordance with individual requirements Anyone working with ammonia either directly or indirectly whether at a supervisory or non supervisory level has a responsibility not only to be thoroughly familiar with basic ammonia safety principles but also to observe faithfully all necessary precautions and to react promptly and appropriately should an emergency arise Readers of this booklet will find answers to questions most often asked regarding general properties potential hazards exposure effects personal protective and safety equipment first aid procedures and methods of dealing with emergencies involving ammonia Information as to the manufacture transportation storage or application of ammonia is not detailed Persons requiring any information regarding
162. n off until the specified time has elapsed Default is 1 minute Phase Unbalance Use the arrow keys to set the Phase Unbalance percentage 2 to 20 of incoming 3 Phases This will turn off equipment for a specified time if incoming Phase Unbalance exceeds set percentage The recommended setting is 5 Default is 5 Delay On Fault Ranges from Off to 15 seconds in 1 second increments Use the arrow keys for adjustment Delay On Fault is energized when any line fault occurs The fault must be present set time in order to be registered or acted upon Default is 2 0 seconds Contactor Test Selectable number of Contactor Retries 1 to 10 or OFF on Contactor Fault Use the arrow keys to adjust the number of times the contactor will be operated in order to seal the contacts Setting retries to OFF means do not check load side Any input to the load inputs will be ignored Default is off Reset Mode Manual Automatic Choose whether to let the unit automatically reset or to wait for you to manually reset it The recommended setting is automatic because faults must be cleared in order to reset from the manual mode To reset from a fault condition in the manual mode press and hold the fault button for two seconds Default is manual reset Control Mode This setting allows you to select the control source Pressing the arrow keys in this setup mode takes you through ON OFF and EXTERNAL The normal setting would be EXTERNAL With the
163. n the switch back to Auto and wait for the crankcase heater to warm up compressor before starting the machine Cutter Gear Reducer The cutter motor and gear reducer 54 Figure 9 5B drive the ring gear of the cutter assembly It is important that the teeth of the drive gear and the ring gear mesh properly both vertically and horizontally drive gear and hub can be raised or lowered on the gear reducer shaft to obtain maximum vertical tooth engagement and the reducer assembly can be moved in or out horizontally to obtain the proper tooth depth for maximum gear life Note The motor and gear reducer are an integral unit Only qualified personnel should attempt to disassemble and repair this unit Drive Gear Replacement 1 Disconnect and lock out all power to the machine 2 Remove the top and side bolts holding the mounting plate to the support bracket Lift the plate and gear reducer from the bracket and rest the assembly on a stable work table sitting next to the tank Leave the electrical conduit connected to the gear reducer motor 3 Inspect the drive gear teeth for proper vertical alignment and wear pattern 4 Ifthe wear pattern indicates less than a full width of tooth engagement measure the difference and make a note to correct at the time of reassembly 5 Measure and record the dimension from the drive gear to the bottom side of the mounting plate 6 Remove the three or four cap screws holding the drive gear to the split t
164. n under positive pressure if the patient is in shock or there is impending or existing cardiovascular failure Oxygen therapy equipment should be used only by qualified and experienced personnel Treatment with oxygen may be discontinued if breathing becomes easy the color is good and there are no signs of lung congestion During treatment the patient should be placed in a reclining position or if he prefers in a sitting position He should be kept quiet at rest and comfortably warm but not hot The patient should be examined by a physician and not allowed to return to work until found free of injury EYES If contacted by ammonia the eyes must be flooded immediately with copious quantities of clean water Speed is essential If contact lenses are worn they must be removed otherwise ammonia may be trapped underneath causing a severe burn In isolated areas water in a squeeze bottle which can be carried in the pocket is heipful for emergency irrigation purposes eye fountain should be used but if not available clean water from any source may be poured over the eyes In any case the eyelids MUST BE HELD OPEN and irrigation continued for at least 15 minutes Repeat this procedures every ten minutes for an hour each time irrigating for a period of five minutes until medical attention can be obtained Such attention must be received promptly from a physician preferably an opthalmologist No oils or any medication should be plac
165. nce therefore if terminal connection L1 is loose or dirty L2 and or L3 will have higher current Higher current causes more heat to be generated in the motor windings The maximum acceptable current unbalance is 10 Example Current Readings L1 96 Amps L2 91 Amps Average 96 91 98 3 O5Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation L3 98 95 3 Amps Current Unbalance 100 x 4 95 4 2 Acceptable Rotation Check The compressor cutter and pump motor rotation are factory synchronized but must be checked at installation For cylinder ice production the cutter disc as viewed at the ice discharge opening should turn from left to right Check rotation by the following procedure 1 Turn the power to the machine on and check voltages 2 Make sure the water tank is full of clean water 3 Turn the Hand Auto switch ISS to HAND position The water pump will start and the freezing and the liquid feed 2LT pilot lights will illuminate Check pump rotation 4 Push the MANUAL HARVEST button The water pump will stop the Freezing and Liquid Feed lights will go out and after 20 30 seconds the cutter motor will start The thawing gas solenoid valve will open and the Thawing pilot light 3LT will illuminate 5 Check the cutter disc rotation It should be turning from left to right CCW looking from the top 6 Turn the HAND AUTO switch to AUTO to stop the cu
166. ndof Endof First AllIce Total Average Water Temperature deg F Freeze Thaw Freeze Thaw Ice Out Harvest Ibs 60 uia Re GNE EE Focal ee ee EU 1 25 53 180 66 60 180 260 850 134 125 11 7 11 4 13 5 215 Y 60 1 R 11 4 U 3 14 1 4 125 Table 11 9 P34A Normal Operating Vitals 8 7 07 11 8 P24A amp P34A Service Manual TABLES amp CHARTS 8 7 07 RECOMMENDED SPARE PARTS LIST Vogt Model P24A and P34A Tube Ice Machine 12A2590G12 12A2590G10 Suction pressure gage 30 150 Discharge pressure gage 307 3008 12A4200HP02 12A4200HP02 Float for Roberts 6 1 1 1 1 1 1 12A2600G08 27 OD 12A2600G1 37 OD 1 1 1 1 Coil for Hansen Solenoid 1 12A2117T03 12A2117T03 Transducer for above control Asco REIOA44 Fuse 10 amp 11 9 TABLES amp CHARTS TEMPERATURE PRESSURE CHART FOR COMMON REFRIGERANTS F psig P24A amp P34A Service Manual SIAL CO QN KO CO CO 1 T co YS O IRI e ESI ed N N N NAAN ped am EB OM 22265 9 NIN 838 SS 86 8 336 0 184 6 204 3 190 2 210 2 9
167. nitiating a harvest cycle NO Harvest 155 Selector Switch Hand Auto Hand position for running the circulating water pump independently at start up or for cleaning the freezer tubes and water tank Auto position for provision of automatic system shutdown if there is a control circuit power interruption TABLE 6 2 Description of Control Panel Parts Outer Door 6 3 6 4 ELECTRICAL CONTROLS P24A amp P34A Service Manual 1047 WIRING BY CUSTOMER CONNECT TO TERMINALS INSIDE THE 17 8 CONTROL PANEL AS INDICATED 13 ACROSS THE LINE START TO TOWER FAN TO CONI IDENSER PUMP COMPRESSOR MOTOR STARTER 231 32 33 pe E 2 21 1 KVA TRANSFORMER TRANSFORMER USED ALTERNATE 8 6 ON 400 460V ONLY PART WIND START gt gt PUMP MOTOR CUTTER MOTOR COMS TARTER 0708 STARTER STARTER REMOVE JUMPER 12 13 WHEN WIRING CONVEYOR m 22 MOTOR OR SAFETY CONTROLS 2 r m a 7MOL 19 CRANKCASE HEATER CH oe ttre fo MOTOR ee IS COMP STARTER EOD DEA ACROSS LINE START AEART MIND START cue as 2M OL N REMOVE JUMPER 9 8 WHEN USING BIN CONTROLS OM 15 CUSTOMER 2CR bil 11 3 IPS sc 7 Low LI S MES ie STOP 9 8 START OIL PRES
168. nk or container which was being protected by the device STORAGE TANK Aleak at a threaded or flanged storage tank opening may often be stopped by a careful tightening of threads or bolts Should such efforts fail it will be necessary to empty the tank of all ammonia before attempting further repair If the leak is small the tank can frequently be emptied by removing the ammonia as a vapor or liquid to process If necessary to remove the ammonia promptly or if the tank is equipped with a vaporizer your supplier should be contacted for advice and assistance Occasionally a storage tank will develop a leak in a plate weld or coupling No attempt to peen such a leak should be made Instead call your tank or ammonia supplier promptly Welding on an ammonia storage tank must be performed in accordance with ASME code procedures and on ly after complete purging SHIPPING CONTAINER Ammonia is shipped in special containers which are fabricated transported and maintained in accordance with U S Department of Transportation regulations Shipping containers include cylinders portable tanks tank trucks rail tank cars barges and tankers If an ammonia leak occurs in a shipping container while at the user s facility these actions should be taken to limit and control the escape of ammonia 1 If liquid is leaking from a cylinder position it if possible so that vapor instead of liquid escapes The quantity of ammonia released from a vap
169. nkcase Changed compressor oil filter Checked adjusted compressor belt tension Lubricate compressor motor bearings Check change cutter gear reducer oil Check adjust cutter drive gear meshing Leak check entire system Check liquid refrigerant level in receiver Drained oil from oil trap Compressor crankcase heater working Compressor net oil pressure gage reading less suction LAE JEJE EE E ETE TE TEE TEE JE JEJE Motor amps Compressor Cutter Pump Suction psig end of freeze Discharge psig end of freeze Suction psig end of thaw 2 Discharge psig end of thaw Compressor water Tower fan cycles Off Production Check Harvest First Time Ice Out Per Harvest Comments Name 8 7 2007 P24A amp P34A Service Manual 8 7 2007 MAINTENANCE Ice Making Section The ice making section of the Tube Ice machine should be cleaned at least twice a year more often if water conditions cause mineral build up Use an approved food grade ice machine cleaner The water pump is used to circulate the cleaner through the system For complete instructions follow the Cleaning Procedure below Cleaning Procedure Stop the machine at the end of harvest Shut off make up water supply Drain the water tank flushing out any loose sediment Close the drain valve and fill the tank with warm water Warm water promotes faster cleaning Cover the ice discharge open
170. ns The machine will stop immediately FAULT HI LOW RESET A FOR RESTART B SILENCE ALARM When the low pressure switch resets or the manual reset button for the high pressure safety is depressed and the pressure is in the acceptable range the interface will display PRES OK PRES OK B SILENCE ALARM After the safety switch is reset it will be necessary to press the button on the operator interface to return to the start up screen Pressing on the operator interface at this time will open the alarm contacts Button will always change the display to the set up screen when a fault screen is displayed Cutter or Pump Overload The interface will display the message shown below if the water pump overload protection trips open The machine will stop immediately and the overload reset button FAULT PUMP O L PUMP OL OK A FOR RESTART B SILENCE ALARM located on the motor starter must be depressed PUMP OL RESET When the overload has been reset the interface will display OL OK It will be necessary to press A on the operator interface to restart the machine The cutter overload fault display operates identically to the pump overload displays Low Oil Pressure The interface will display the message shown below if the compressor oil pressure safety switch opens The machine will stop immediately and the oil pressure switch must be reset manually by depressing the red but
171. of an approved pressure demand type should be used This apparatus which consists of a full face piece a pressure and flow control and a high pressure cylinder of air provides protection for a period of time which varies with the amount of air carried and the extent of exertion by the user Any respiratory device must be used and maintained in accordance with the manufacturer s instructions Because the device is normally used in an emergency where there is tension and excitement a person who uses it should have received thorough training and practice PROTECTIVE CLOTHING Emergency or rescue personnel required to work in high ammonia concentrations should wear protective gloves boots pants and jacket or slicker impervious to ammonia A hard hat should be worn as required by plant practice or dictated by special hazards RESCUE HARNESS A safety belt and lifeline should be worn by an individual using respiratory equipment and entering contaminated air in a confined location Another person also wearing respiratory equipment and protective clothing should be located outside the contaminated area to act in case of emergency WATER SYSTEM Atalarge installation a high capacity water system should be available not only for fire fighting but also for controlling ammonia leaks STRETCHER AND BLANKETS Inadequate facilities for transporting a seriously injured person from the scene of an accident to a first aid station can add to th
172. oil pressure needed to load the compressor cylinders and any further procedures to check the mechanical function of the unloader mechanism 8 7 07 P24A amp P34A Service Manual 8 5 TROUBLESHOOTING Symptom Freeze up due to ice failing to discharge Possible Cause Possible Remedy Extended freeze period Thaw time too short Insufficient heat for thawing due to low condensing pressure Insufficient heat due to non condensables usually air in the system Insufficient heat due to low refrigerant charge Cutter or cutter disc does not turn Compressor not running unloaded during thaw cycle Check freezer pressure switch 2 5 adjustment See FIGURE 9 1 for adjustment and TABLE 7 2 for average hole size Make sure all water distributors are in place one in each tube Adjust thaw timer 2TR to allow all ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Replace defective timer The head pressure should be maintained form 175 190 psi maximum 200 usually by a water regulating valve or fan cycling switch Check to make sure these controls are working properly Cold prevailing wind can also be a factor If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver and the refrigerant will be cooler although pressure will be high Air can be purged from the system by following the procedure in the
173. om the base of the freezer This oil trap will have evidence of frost on its surface during the freeze cycle and may be more pronounced at the end of a normal freeze cycle just before the harvest Where there is oil in the trap there will not be frost Where there is frost there will not be oil When the trap is 1 2 to 3 4 full of oil it should be drained The machine should be shutdown for at least 12 hours before attempting to drain oil from the trap Follow the procedure outlined in the service section Draining Oil Trap CAUTION Only qualified refrigeration service personnel familiar and experienced in the handling and use of anhydrous ammonia R717 should be authorized to perform the Draining Oil Trap procedure CAUTION Cutter Gear Reducer The oil level of the gear reducer should be checked monthly or when there is any evidence of leakage The correct level is indicated by the pipe plug in the side of the gear housing The oil should run out of the hole when the plug is taken out If low add oil through one of the top plugged holes A high grade lubricant such as Mobil 600W or SAE 140 gear oil should be used The oil should be changed annually Drain the oil and flush the gear case with mineral spirits Drain the mineral spirits completely and refill with the proper oil Note If a USDA high food grade lubricant is desired use Chevron FM Lubricating Oil 460X CAUTION Follow all lock out and tag out
174. ons Match mark the bearing bracket support arms with the water tank for reassembly reference Remove the splash shield and ice deflector plate from the ice discharge opening Support the bearing bracket to keep it from falling in the tank Loosen and remove the four cap screws and lock washers from the ends of the bearing bracket support arms Lift the bracket and cutter disc from the tank Be sure the support arms are match marked for reassembly You may have to gently drive the support arms up or down to release them from the tank walls With the bracket and disc assembly turned upside down remove the cotter pin from the shaft Loosen and remove the slotted hex nut spring washer and spacer Lift the cutter disc from the keyed shaft being careful not to loose the shaft key The cutter shaft and bearings are sealed in the bearing bracket assembly The cavity between the bearings has been filled with a food grade grease to prevent the presence of moisture and prolong the life of the unit If there is any vertical or side movement of the shaft or if the bearings feel rough or tight when turning the shaft the assembly should be dismantled and rebuilt Refer to the cutter tank assembly drawing Figure 9 5B for parts location and identification Cutter Shaft and Bearing Removal 8 7 07 P24A amp P34A Service Manual 9 11 SERVICING OPERATIONS Note Use only a soft mallet or other soft tool for fitting all parts into place With the
175. or leak is considerably less than from a liquid leak through an opening of the same size 2 If possible move the container to an area of reduced hazard 3 If no risk is entailed attempt to reduce the pressure in the container by removing the ammonia to process as a vapor 4 Reduce the quantity of vapor in the atmosphere with a water spray applied to the leak area 5 Aside from trying to stop a leak from a shipping container by tightening a valve packing nut closing a valve or possibly tightening a flange bolt no other repairs should be attempted or authorized by the user 6 It is a violation of federal regulations to transport an ammonia shipping container which is leaking or damaged If a shipping container is damaged or is leaking in a manner which cannot be handled by personnel at the site the nearest office of the producer or supplier should be called for assistance If the producer or supplier cannot be reached contact the Chemical Transportation Emergency Center by telephoning the toll free number 800 424 9300 add long distance access number if required for advice and help day or night When calling for assistance be prepared to provide the following information a Nature of emergency when where and extent b Type and condition of container c Name of shipper or supplier d Extent of injuries or property damage if any e Description of surrounding area and prevai
176. ors or even neighbors Management bears responsibility within its own organization for the development and implementation of comprehensive and effective plans designed to meet these situations in a manner as will protect the safety of human life physical assets and the environment to the greatest degree practicable within the constraints of governmental regulations and prudent business practice No one plan will serve the needs of all companies and each organization must assess the various potential emergency conditions that might occur and develop a program to suit its own requirements Where ammonia is stored and used the following procedures and actions are suggested for incorporation into an emergency response plan When an ammonia leak occurs personnel trained for and authorized to handle such situations should take immediate steps to locate and control the condition Respiratory equipment and protective clothing as may be necessary and suitable for ammonia must be worn All other persons must be kept away from the affected area until the leak has been stopped Keep on the windward side of the leak when possible If ammonia vapor is released the irritating effect of the vapor will generally force personnel to leave the area before they are overcome by harmful concentrations Sufficient well marked and readily accessible exits must be provided to facilitate rapid evacuation from a building Should an individual become trapped in an
177. otor starter overload 1MOL Check for a loose connection on all motor tripped starter and motor terminals which could cause excessive amp draw Reset overload and restart the machine check amperage power supply and head pressure Check TR in part wind starts only Water pump cutter motor tower fan tower Check for loose connection on all terminals pump conveyor motor overload tripped which could cause excessive amp draw Reset the overload and manually run that particular motor to check actual voltage and amperage against motor rating Freezer water pump motor overload 2MOL Check for loose terminal connections and or tripped defective breaker CB2 reset the overload and start the pump by turning the selector switch 155 to Check voltage and amperage against motor rating Confirm proper rotation Cutter motor overload 3MOL tripped Check for loose terminal connections and blown fuse reset the overload Clear all ice that may have jammed cutter Turn the selector switch 1SS to Hand and push the Manual Harvest button Check voltage and amps against motor rating If tripping repeats but ice is not jammed check the gear reducer for resistance cutter bearings for wear drive gear and ring gear for proper engagement and reducer motor for defect or single phasing Bin level control optional open Adjust or replace control as required If bin level control is not used make sure jumper wire 8 and 9is
178. ould be inspected monthly and kept clean Do not operate the unit without the strainer in place 3 Make up water float valve This valve should be checked monthly for proper operation and adjustment It should be adjusted to maintain a water level below the overflow and high enough to prevent the pump from cavitating when the system is in operation 4 Spray nozzles The spray nozzles should be checked monthly to make sure none are restricted and the spray pattern is complete and even 5 Pump motor and fan motor The motors should be checked and or lubricated every six months according to the motor manufacturer s recommendations 6 Fan bearings The fan bearings should be lubricated every six months Make sure the proper grade of grease is used normally conforms to NLCI Grade 2 and it is best to use a hand grease gun 7 Fan belts The fan belt tension should be checked weekly for the first two weeks of operation then monthly during continuous use The best tension for a V belt is the lowest tension at which the belt will not slip under its full load Never use dressing on V belts Keep belts and grooves clean and free of oil grease and foreign material Clean with non flammable non toxic degreasing agent or commercial detergent and water CAUTION Follow all lock out and tag out procedures before servicing any electrical equipment CAUTION 7 5 7 6 P24A amp P34A Service Manual MAINTENANCE Service Frequency SUP Mont
179. pacity Table Check float adjustment and water tank drain valve 8 7 07 8 7 07 P24A amp P34A Service Manual Symptom Low ice capacity cont Possible Cause 8 7 TROUBLESHOOTING Possible Remedy Excessively high head pressure Thawing gas solenoid valve 18 leaking through during freeze cycle Symptom Poor ice quality Possible Cause Possible Remedy Excessive concentration of solids in the water tank usually indicated by a build up of mineral deposit on the sides and bottom of the tank and Opaque ice production Also water distributors restricted Insufficient water supply indicated by a low level in the tank Water pump rotation wrong direction Low refrigerant charge causing an ice out problem and re freeze Restriction in liquid line causing short freeze cycle Check cooling tower or evap condenser to make sure sufficient water is provided for cooling and the equipment is operational to cool the water Also see Symptom High Head Pressure Check the manual opening stem to make sure it is in the automatic position stem screwed in Check for leak by sound temperature difference and frost during a freeze cycle Close the stop valve 90 to confirm suspicion of leakage Repair or replace the valve Perform a cleaning procedure as well as removing the freezer cover and cleaning the water distributors Make sure the flushing valve 63 is functioning and the tank overflow piping is not r
180. pdown follow this procedure 1 With the machine running close the liquid feed stop valve 58 nearest the receiver 2 Open the water tank drain valve partially to allow a continuous flow of warm make up water into the water tank and still maintain a good level in the tank An auxiliary supply of warm water not to exceed 100 F may be used if available Warmer water affords a more complete pumpdown 3 Allow the machine to operate and complete two freeze and harvest cycles 4 After the second harvest cycle stop the machine throw the electrical disconnect and lock out all power to the machine 5 Remove wire 17 from the freezer pressure switch 2PS and insulate the end to prevent a short circuit 6 Restore power to the machine and start the water pump only to circulate warm water through the freezer 7 When the suction pressure increases to 70 psig or higher start the compressor and allow the machine to stop automatically by the low pressure switch at approximately 15 psig Lower pressure can be obtained by jumping out the pressure switch Remove all power from the machine before opening the control panel cover With the pressure switch jumped out the machine can be manually started and stopped Do not operate the machine below 2 psig 8 When the desirable pumpdown is obtained close the thawing gas stop valve 90 and the discharge line stop valve 55 Other valves may also be closed to isolate a particular area which may r
181. per zinc and alloys containing these elements For this reason materials of construction used for ammonia containers fittings piping and equipment are limited to steel and iron or certain non ferrous alloys resistant to attack by ammonia Ammonia is a highly reactive chemical forming salts with many inorganic and organic acids usually with the release of heat Under certain conditions ammonia is known to react with bromine chlorine fluorine or iodine to form compounds which explode spontaneously Ammonia has been reported as reacting with gold silver or mercury to form fulminate like compounds which are explosive THERMAL EXPANSION Liquid ammonia exhibits a high coefficient of cubical expansion given quantity of liquid ammonia therefore expands considerably in volume with a rise in temperature See Table 1 For this reason appropriate measures must be taken to avoid hydrostatic rupture of containers piping or other equipment as could be caused by such expansion HUMAN PHYSIOLOGICAL EFFECTS Ammonia is NOT a cumulative metabolic poison ammonium ions are actually important constituents of living systems Depending upon concentration and time the effects of exposure to ammonia vapor vary from none or only mild irritation to obstruction of breathing from laryngeal and bronchial spasm to edema and severe damage of the mucous membranes of the respiratory tract with possible fatal results Ammonia in the presence of water
182. procedures before servicing any electrical equipment CAUTION 7 7 7 8 MAINTENANCE 8 7 2007 P24A amp P34A Service Manual V Belt Maintenance Belts should be kept clean free of oil and protected from sunlight as much as possible To clean belts they should be wiped with a dry cloth The safest way to remove dirt and grime is to wash the belt with soap and water and rinse well BELT DRESSING SHOULD NEVER BE USED ON A V BELT DRIVE The tension on 5 rib banded V belt can be checked as follows 1 Apply 50 75 pounds of deflection force uniformly across the belt midway between the pulley centers Lay a straight edge across the sheaves to measure the deflection The deflection should be 5 8 to 3 4 When installing a new belt move the sheaves together to allow the belt to slide across the sheaves Rotate the belt and sheaves to obtain proper seating Remove the slack from the belt and measure the outside circumference to the nearest 1 4 Multiply this reading by 0075 and 001 add these amounts to the circumference reading Elongate the belt to the new length Example 105 x 0075 7875 105 7875 105 7875 105 3 4 min 105 x 001 1 05 105 1 05 106 05 106 1 16 max Check compressor sheave and motor sheave with a straight edge to be sure they are parallel and in the same plane The tension should be checked after 24 to 48 hours of operation to compensate for initial stretch and wea
183. ps 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 which should be indicated on the suction and discharge gages CHECK water supply and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK All field installed equipment augers conveyors cooling towers bin level controls etc for proper installation CHECK The applicable portion of the warranty registration start up report for proper completion CHECK Cutter gear reducer oil level oil should run out of side pipe plug when removed CHECK _ The water distributors at top of freezer to make sure they are all in position one seated firmly in each tube with a vent tube in each distributor CAUTION The crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compressor CAUTION 8 7 07 8 7 07 P24A amp P34A Service Manual 4 1 HOW YOUR TUBE ICE MACHINE WORKS 4 How Your Tube Ice Machine Works Operating Features Your packaged Tube Ice machine is an efficient ic
184. quality 8 7 High discharge pressure 8 8 Low discharge pressure 8 9 High suction pressure 8 9 Compressor running unloaded during freeze 8 9 Compressor oil pressure low 8 10 Compressor loosing oil excessively 8 10 Machine short cycles 8 11 Shut down by oil pressure switch 8 11 High compressor discharge temperature 8 11 Suction line frosting to compressor 8 12 Notice Opening the compressor for observation or determination of failure does NOT void the warranty Contact your distributor first for technical service assistance about operation problems not covered in this manual Also feel free to contact the factory for additional service 502 635 3235 8 7 07 8 2 P24A amp P34A Service Manual TROUBLESHOOTING Symptom Machine Stopped Possible Cause Possible Remedy Power failure or interruption Check fused disconnect or circuit breaker supplying power to the machine If power has been off make sure the crankcase heater is energized and there is no liquid refrigerant in the compressor crankcase prior to restarting the compressor If ice is in the freezer initiate a manual harvest Circuit breaker CB4 for control circuit Check compressor crankcase heater coils of tripped relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and reset circuit breaker Make sure there is no liquid refrigerant in the compressor crankcase prior to restarting the machine Compressor m
185. r hand stop valve 29 downstream This will isolate the solenoid valve Purge the remaining ammonia from this line through the strainer purge valve 75 Repair or replace the valve as needed making sure all connections are tight Evacuate or purge air from this isolated part of the liquid line through the strainer purge valve After purging manually close screw stem out the solenoid valve and open stop valves 29 and 58 check for leaks 9 24 P24A amp P34A Service Manual SERVICING OPERATIONS SOLENOID VALVE A PART NO 12A 4200A06000000 CHECK VALVE um PART NO 2A 4200B06000000 FLOW 4 STRAINER PART NO 120505000909 MANUAL OPENING STEM FIGURE 9 8 Liquid Line Solenoid Valve Water Flush Solenoid Valve 63 is opened during the thaw harvest cycle to flush out some of the impurities form the water in the tank thereby improving the ice quality Repair or replace as follows 1 Turn off the water supply to this valve 2 Dismantle the valve and inspect for dirt etc and wear Reverse osmosis water can cause premature wear and erosion of the brass parts of this valve you may want to consider replacing the valve with a stainless steel valve 3 Repair or replace the valve as needed 4 Turn on the water supply and check for leaks Compressor Cooling Solenoid Valve 64 is opened all
186. r ie oO ches 7 3 Cleanin amp Procedure oie D Ue en Ue ree aus RR bee i er a a ade eee 7 3 Water Distrib tors LABLEE ICE ER RETO RR RRs 7 3 Average Hole Size in Tube Ice TABLE 7 2 7 4 b ito is AA E Ets 7 4 Water Cooled Condenser Cleaning 7 5 Cooling Tower Eyap Condenser ER Dee 7 5 Cooling Tower Maintenance Schedule TABLE 7 3 7 5 COMPrESS OT 7 6 Compressor Maintenance enne denen nd acid et et o n et bete 7 7 nd edente e 7 7 EE 7 8 8 TROUBLESHOOTING List OESymptoIBs uere etr e ene euer erae RM pd 8 1 Machine Stopped 25 50 92 65 dte tent teen aiu bloat ee Bol 8 2 8 3 Freeze Up Due To Extended Freezing Period 8 4 Freeze Up Due To Ice Failing To Discharge airsean na iea a enne eterne tentent nenne treten tnnt 8 5 LOW Capacity neo tte e a Pete ied eme db ee E nete tt eor debe n dead 8 6 8 7 Poor Ice Quality 8 7 High Discharge Pressure 8 8 Low Discharge Pressure 8 9 High Suction Pressures tos
187. r in Periodic checks should be made and tension restored as necessary General Rules 1 2 3 4 The best tension for V belt drive is the lowest tension at which the belt will not slip under the highest load Too much tension shortens belt and bearing life Check tension often during the first 48 hours of operation and periodically afterwards Keep belts and sheaves free of any foreign material which may cause slippage If a belt slips tighten it P24A amp P34A Service Manual 8 1 TROUBLESHOOTING 8 Troubleshooting Note Your machine s electrical system has several built in safety and overload protection features to stop operation when a single component fails or there is a problem from an outside source such a power supply Make sure all auxiliary equipment is connected to incorporate safety and overload circuits and protect all related equipment When the machine stops it must be manually restarted by pushing Start button If it stopped while in a freeze cycle it should be manually harvested to remove all ice from the freezer This is done by pushing the white Manual Harvest button Always check the machine operation thoroughly after remedying the problem Be sure to correct the source or cause of the problem to prevent the problem from occurring again Symptom Page Machine stopped 8 2 Freeze up due to extended freeze period 8 4 Freeze up due to ice failing to discharge 8 5 Low ice capacity 8 6 Poor ice
188. rant in the compressor during shut down periods The cooling water outlet should be extended to an open sump or drain in order to observe water flow and temperature and to make sure there is no water 8 7 07 8 7 07 P24A amp P34A Service Manual 3 11 INSTALLING YOUR TUBE ICE MACHINE flow through the heads during shutdown Do not connect this drain line into a common header with any drain line from the water tank Note The water regulating valve contains a 1 8 orifice through inter gate to permit some flow though the compressor if the solenoid is open Water Tank Drain This valve and connection is for the purpose of flushing and draining the water tank of impurities foreign material and cleaning chemicals used during servicing It should be piped to an open drain or sump for visible discharge It can be tied in with the overflow line but no others Water Tank Overflow A 3 FPT connection on the side of the water tank is provided to carry away overflow water during the thawing harvest cycle This water contains ice fines accumulated during harvesting and dissolved solids accumulated during the freezing cycle Do not reduce the size of this line Three inches is needed to provide sufficient area for ice fines to be flushed out especially if the incoming flushing water is 55 F 13 C or below This overflow line should not tie in with any other drain line except the water tank drain Condenser Water In and Out One end of the condenser
189. re reduced to a minute size smaller than 1 16 it can be considered that most of the air has escaped and purging can be ceased at this point Additional purging can be done at other purge points 8 When purging is completed close the valve disconnect the hose and install a plug in the purge valve O ul Draining the Oil Trap After many hours of operation the oil which escapes the oil separator will pass through the receiver and to the freezer where it will settle in the oil trap 36 Indication of oil in the trap will be evident by the frost line At the end of a freeze cycle frost or ice will form on that part of the oil trap where oil is not present When frost is seen only on the top 1 4 to 1 2 of the oil trap the oil trap should be drained Do not allow the oil trap to fill completely with oil or it will cause loss of ice production and possible refrigerant floodback to the compressor 1 Stop the machine and wait 12 hours or more 2 Attach a suitable hose to the oil trap drain valve 61 Make sure there are no kinks or restrictions in the hose 3 Open the valve slightly until oil begins to drain 4 Continually observe the oil flow being ready to close the valve quickly DANGER Do not leave the oil trap drain valve opened or unattended severe injury may result DANGER 8 7 07 8 7 07 P24A amp P34A Service Manual 9 21 SERVICING OPERATIONS 5 When a small amount of liquid ammonia begins
190. re used to report faults operating conditions and programming information to the user The key pad is used to enter or modify values in the PLC Operation of the interface is menu driven Basic directions for operation are displayed on the operator interface P24A TUBE ICE SET UP SCREEN o REG T D DD 0000k OOOO 0200900 ES Figure 10 2 Operator Interface for PLC Programmable Logic Controller 10 6 P24A amp P34A Service Manual Options and Accessories GETTING STARTED The operator interface displays two lines of text however the message or instructions may be longer than can be displayed on two lines The rest of the text can be accessed by pressing the up and down arrows scrolling Scrolling progresses down the screen one line at a time When power is first connected to the unit or restored after a power interruption the interface will PRESS START POWER FAILURE With the control switches in the ICE positions the machine will begin a harvest cycle display the message shown below when the start button is depressed The machine starts in the harvest cycle to clear any ice from the freezer if a power failure has occurred The interface will display the current harvest time and the previous cycle harvest time during the HARVEST PREV HRVST B RESET CYCLE Upon completion of the
191. rom Anhydrous Ammonia Pamphlet G 2 Seventh Edi tion Compressed Gas Association Inc 2 000 3 000 ppm 5 000 10 000 ppm over 10 000 ppm EXPOSURE LIMITS Occupational Safety and Health Administration OSHA regulations require that an employee s short term exposure limit STEL for ammonia not exceed a time weighted average of 35 ppm ammonia in air by volume in any 15 minute period The American Conference of Government and Industrial Hygienists ACGIH has established an exposure limit of 25 ppm ammonia in air by volume as an 8 hour time weighted average TWA PERSONAL PROTECTIVE EQUIPMENT Persons working with ammonia under routine circumstances of operation and maintenance should wear flexible fitting hooded ventilation goggles and rubber or plastic gauntlet gloves impervious to ammonia so as to protect critical body areas which are most vulnerable to contact with ammonia should a minor leak occur A full face shield may be worn over the goggles for additional protection but not as a substitute for the goggles EMERGENCY PROTECTIVE AND SAFETY EQUIPMENT Each location having an ammonia installation should have readily available and freely accessible emergency protective and safety equipment as may be required by federal state and local governmental regulations The location of such protective and safety equipment should be well identified by appropriate signs Depending upon the size and nature of the installat
192. scharged through the ice discharge opening See Freeze Period and Harvest Period for more detailed description of machine Freeze Period The Tube Ice is frozen inside the stainless steel tubes of the freezer 2 by the direct application of refrigerant to the outside shell side of the tubes Ice is produced from constantly recirculating water down each tube As the ice thickness increases the freezer suction pressure decreases At a set pressure the freezer pressure switch 2PS energizes the relay 1CR which stops the water pump closes the liquid feed solenoid valve 20 turns out the two pilot lights ammonia feed and freezing 4 2 HOW YOUR TUBE ICE MACHINE WORKS 8 7 07 P24A 4 P34A Service Manual Harvest Period About 20 30 seconds after the 1CR relay is energized the thaw gas valve 18 opens the H water flush solenoid valve 63 opens the compressor unloads the cutter motor starts the thaw timer 2TR is energized the red thawing gas light illuminates and auxiliary equipment such as conveyors etc start When the refrigerant in the freezer is warmed sufficiently to allow the ice in the tubes to release and be sized the ice is discharged into the customer s ice handling equipment See Ice Handling for more information on this subject The thaw timer 2TR is adjustable and should be set for the time required for all the ice to clear the freezer plus 30 seconds more CAUTION Make
193. se Protector wiring schematic Piping and Drain Connections 3 10 Piping Nomenclature 4 2 Piping Schematic for P24A 4 3 Piping Schematic for P34A 4 4 PLC Programmable Logic Controller 10 3 10 5 alarm relay 10 4 automatic restart 10 4 blowdown adjustment 10 4 changing the setup values 10 10 compressor overload conveyor control contacts cutter delay cutter or pump overload P24A amp P34AService Manual 8 7 07 PLC Programmable Logic Controller Continued diagnostic indicators 10 4 estimated ice production 10 5 getting started 10 6 hi lo pressure 10 8 long or short cycle safety 10 9 low oil preSSUre 10 8 machine faults 10 8 monitoring functions 10 11 timed freeze cycle 10 4 wiring schematic 10 12
194. severe personal injury WARNING CAUTION Means hazards or unsafe practices could result in personal injury or product or property damage CAUTION 8 7 07 8 7 07 P24A amp P34A Service Manual 1 3 INTRODUCTION Special Precautions To Be Observed When Charging Refrigeration Systems Only technically qualified persons experienced and knowledgeable in the handling of anhydrous ammonia 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 ammonia R 717 refrigerant See Material Safety Data Sheet MSDS Code No 5B81 83 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 717 refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary excessive or illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a
195. ssure pipelines at ambient temperatures and is shipped by barge or tanker as refrigerated liquid at 28F and atmospheric pressure When stored in large quantities such as at a terminal ammonia is generally refrigerated and kept in insulated tanks at 28F PRIMARY HAZARDS Ammonia acts as an irritant to human tissue in varying degrees depending upon concentration and exposure The pungent and distinctive odor of the vapor even at low concentrations provides adequate warning so that no person will voluntarily remain in concentrations which are hazardous See HUMAN PHYSIOLOGICAL EFFECTS At the time of this printing ammonia is classified by the U S Department of Transportation as a NONFLAMMABLE GAS Conditions favorable for ignition are seldom encountered in normal handling due to its narrow range of susceptibility to ignition In the presence of a flame or spark at about 1200F ammonia vapor will ignite but only within the limited range of 16 2596 of ammonia in air by volume The heat generated by combustion is insufficient to maintain a flame which therefore will extinguish upon ignition source removal OTHER HAZARDS CHEMICAL As a chemical compound ammonia is highly associated and stable at ordinary temperatures At about 840F ammonia begins to dissociate with the formation of nitrogen and highly flammable hydrogen Ammonia will not corrode most of the common metals but in the presence of water ammonia will attack cop
196. stributor Also feel free to phone the factory direct at 502 635 3000 8 7 07 1 2 P24A amp P34A Service Manual INTRODUCTION Important Safety Notice This information is intended for use by individuals possessing adequate backgrounds in electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in personal injury and or property damage The manufacturer or seller cannot be responsible for the interpretation of this information nor can it assume any liability in connection with its use It is important that personnel understand the properties of this refrigerant and that they be thoroughly trained in safe practices for its use and handling Refer to the enclosed Anhydrous Ammonia Safety in Appendix A Safety Symbols amp What They Mean Prior to installation or operation of the Tube Ice machine please read this manual Are you familiar with the installation start up and operation of a Tube Ice machine Before you operate adjust or service this machine you should read this manual understand the operation of this machine and be aware of possible dangers These safety symbols will alert you when special care is needed Please heed them DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates strong possibility of a hazard and that an unsafe practice could result in
197. sure rises to the cut in setting The HIGH pressure cut out should be set at 250 psig After tripping reset the switch manually Note Do not rely on the switch calibration for accuracy For accurate adjustment check settings with a test gage DIFFERENTIAL ADJUSTING SCREW ET AT 15 CW RAISES SETTING RANGE ADJUSTING SCREW SET AT 35 PSIG CW RAISES SETTING HIGH PRESSURE ADJUSTMENT SCREW SET AT 250 PSIG CW RAISES SETTING DIFFERENTIAL FACTORY T AT 55 PSIG MANUAL RESET PART NO 12A 2117D01000000 MANUAL RESET BUTTON LOW m scd CONNECTION HIGH PRESSURE CONNECTION FIGURE 9 2 High Low Pressure Switch 1PS Fan Control cooling tower The fan control switch is used to cycle the cooling tower fan on and off thereby maintaining the proper operating head pressure This switch is mounted on the frame of your machine and should be adjusted to maintain a head pressure between 175 190 psig max 200 psig The fan control supplies power to the starter coil for the tower fan motor s 6M not furnished by Vogt See FIGURE 9 3 for adjustment instructions CUT OUT ADJUSTING SCREW SET AT CUT IN ADJUSTING SCREW CW RAISES SETTING SET AT 190 PSIG CW LOWERS SETTING PART NO 12A 2117F07000000 FIGURE 9 3 Fan Control Switch Compressor Crankcase Heater When electrical power is supplied to terminals 12 and 22 of the control panel see Figure 6 3 the crankcase heater is energized when the compressor is
198. t Phone Address City State Zip Installed by Date Address City State Zip Describe any damage to machine repairs made Start up by Company Name Phone Date Address Name of person starting up machine PRE START UP CHECK Q HECK Service Manual on hand Machine room suitable 50 F minimum 110 F maximum Proper power supply actual voltage r machine not running Compressor crankcase heater on 12 hour minimum Necessary hand valves opened as required Solenoid valve stems in auto position System leak checked tight Auxiliary equipment overloads wired into control circuit Compressor oil level 1 4 glass min All water distributors in place visually inspected Water supply and drain lines installed and connected properly Compressor pump cutter and other motor direction of rotation correct Make up water float valve adjusted properly Hour meter in control panel connected aoaaa OPERATION CHECK Machine charged with refrigerant lbs Actual voltage machine running Ambient temp F Fan cycles On Off Tower water in F out F Comp motor RLA Actual Pump RLA A Actual Cutter motor RLA Actual 3 Suction pressure end of freezing end of harvest Discharge pressure end of freezing end of harvest Evaporator suction line frost Receiver liquid level operating Ice
199. the freezing cycle If this action ceases and water begins overflowing from the top water box it is an indication that the tubes are freezing solid and the machine should begin a harvest cycle It is best not to freeze the ice solid with no hole Tocease ice production manually allow the machine to complete the harvest period and start the freeze period When the liquid feed light comes on at the beginning of the freeze period push the Stop button to cease ice production 8 7 07 P24A amp P34A Service Manual ELECTRICAL CONTROLS 6 Electrical Controls Your packaged Tube Ice machine is equipped with a compressor motor starter 1M as required for your particular voltage and a transformer if required for the control circuit power The motor starter and transformer are mounted on the machine front side see Figures 1 1 or 1 8 The control panel wiring schematic FIGURE 6 3 illustrates these components as well as provisions for auxiliary equipment which may be incorporated by the customer such as FU1 Main power disconnect SM Conveyor motor starter and overload SMOL 6M Tower fan starter and overload 6MOL 7M Condenser pump starter and overload 7MOL When adding motor starters for auxiliary equipment be sure to incorporate the overload protection as indicated between terminals 12 13 and remove the jumper wire This will assure that the machine will shutdown when any auxiliary equipment fails Bin Level Contro
200. the leak is found with soap or sulfur stick Soap solution can be purchased from your refrigeration supply house or it can be made by mixing four parts water one part liquid soap and a few drops of Glycerin for better capillary attraction e Apply soap solutions with a narrow brush or spray bottle to all joints welds or areas of suspicion The solution will form bubbles if there is a leak Sulfur sticks and test paper can be obtained from your ammonia supplier e Light the end of the sulfur stick and pass it around suspected points of leakage A white cloud will form where a leak is even if it is very small Moisten a strip of test paper and pass it around the suspected area If the paper comes in contact with ammonia it will turn red Coils submerged in water or condenser cooling water may be tested by dipping a strip directly in the water If ammonia is present the paper will turn red Always remove refrigerant pressure from the vessel tubing or component part before repairs are attempted Non condensable Gasses Satisfactory operation of the machine is not possible if non condensable gases usually air are present in the system Excessive condensing pressure is an indication of such gases Excessive condensing pressure in water cooled condensers may also be due to the accumulation of scale in the cooling coil or due to insufficient cooling water or excessive water temperature See Water Cooled Condensers Section 7 and Sectio
201. the time the compressor is running It provides water for cooling the compressor oil and heads There should be no water flow through the compressor heads when the compressor is not running Water through the heads water jackets during off times could cause liquid ammonia condensing in the crankcase and dilute the oil or slug the compressor at start up Repair or replace this valve by following the same procedure outlined for the Water Flush Valve 63 Compressor Oil Changing See Table 7 4 for frequency recommendations 1 Turn off power to the machine and make sure the compressor crankcase heater is not energized 2 Drain the oil through the oil drain valve located at the base of the compressor 3 When all oil is drained new oil of the required specifications can be pumped into the crankcase to the proper level 8 7 07 8 7 07 P24A amp P34A Service Manual 9 25 4 5 SERVICING OPERATIONS Turn the power on and allow the crankcase heater to warm the oil prior to start up Be sure to confirm sufficient oil pressure at start up Restore power to the crankcase heater allowing time to warm the oil Be sure to confirm sufficient oil pressure at start up Compressor Inspection l 2 9 Close the compressor suction valve and allow the machine to stop by low pressure cut out Close the compressor discharge valve oil return stop valve Disconnect and lock out all power to the machine Drain the oil through the
202. tify your Vogt distributor or the factory Description Of Machine A Vogt package Tube Ice machine is a complete ice producing plant requiring only make up water supply condenser water supply electrical connection and the proper refrigerant charge The machine has been fully factory tested prior to shipment and should require minimum adjustment After factory testing of the machine the liquid ammonia is removed and only ammonia gas pressure is allowed to remain This prevents air or moisture from entering the system during transit There should be a positive pressure 20 25 psig indicated on the control panel gages when the machine is received The compressor oil is drained and the compressor suction strainer and cloth filter are cleaned and reinstalled The crankcase is inspected and cleaned by removing the side handhold cover swabbing out the remaining oil and wiping the interior sides and bottom with a clean dry cloth Do not use woolen fabrics or material which may leave loose fibers New oil is added and the compressor is evacuated then pressurized with ammonia vapor to 20 25 psig Refer to your compressor manual for additional operation service maintenance instructions and information Safety Tags and Labels Be sure to read and adhere to all special tags and labels attached to valves or applied to various areas of the machine They provide important information necessary for safe and efficient operation of your equipment 8
203. ton located on the front of the oil pressure safety switch Mouser OIL RESET OIL PRES OK A FOR RESTART A FOR RESTART B SILENCE ALARM B SILENCE ALARM When the oil pressure safety switch has been reset the interface will display OIL PRES OK It will be necessary to press A on the operator interface to restart the machine 8 7 07 8 7 07 P24A amp P34A Service Manual 10 9 Options and Accessories PLC Programmable Logic Controller Compressor Overload The interface will display the message shown below if the compressor motor safety overload switch opens The machine will stop immediately The compressor overload will reset automatically after the compressor has time to cool off WAIT COMP OK B SILENCE ALARM B SILENCE ALARM When the compressor overload resets the interface will display COMP OK It will be necessary to press on the operator interface to restart the machine Long or Short Cycle Safety The interface will display the messages shown below if there is a long or short cycle condition The machine will stop upon indication of either of these conditions A long cycle is defined as a freeze cycle that extends for a duration of one hour This could be caused by an open drain valve leaking hot gas valve or defective compressor The short cycle safety will stop the machine after three consecutive freeze cycles of less than five minutes duration Short cycling can be
204. tter To change rotation follow this procedure Disconnect power to the machine and lock it out to make sure it can t be turned back on Check for power at L1 L2 L3 with a volt meter to make sure it is off At the compressor motor starter 1M or at the power disconnect reverse wires L1 and L2 Make sure these terminals are tight and restore power to the machine Perform rotation check again to confirm that it is correct pad s CAUTION Do not attempt to start the compressor motor until first making sure all conditions listed in the Installation Review Checklist and all necessary valves have been opened for operation CAUTION 8 7 07 P24A amp P34A Service Manual 3 19 INSTALLING YOUR TUBE ICE MACHINE Auxiliary Controls or Equipment When connecting other equipment such as tower fan condenser pump conveyor motors bin level control etc refer to the control panel wiring drawing for the proper connecting terminals and instructions See Figure 6 3 8 7 07 3 20 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE IMPORTANT Be sure to follow the wiring schematic when incorporating overloads of conveyor fan or pump motor starters i e 5 MOL 6 MOL 7 MOL Also remove jumpers as instructed This is necessary to provide proper protection for the Tube Ice machine and its component parts IMPORTANT Installation Review A Checklist Make a visual check to be sure these ste
205. tter Blade and Adapter Plate Adjustment Cutter Adapter Plate Installation 1 Disconnect and lock out all power to the machine and remove the water tank assembly so the cutter is accessible see water tank removal 2 Locate the new adapter plate holding the correct dimension A from the edge of the plate to the edge of the blade See Figure 9 3 Using two C clamps to hold the adapter plate securely in place drill four 7 16 diameter holes through the adapter plate and through the cutter plate at the same time so they will adjoined properly 4 Countersink the holes in the adapter plate to make the bolt heads flush with the plate 5 Install bolts and spacers as illustrated and tighten securely Note the length of ice is determined by the spacer length Refer to Ice Length for details 6 Install the water tank assembly to the machine Note Length of cylinder ice can be changed See Section 10 8 7 07 9 18 8 7 07 SERVICING 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 remove excess water from the ammonia To prepare the machine for disconnection or moving 09 To perform pum
206. uatic Toxicity 2 0 2 5 ppm 1 4 days goldfish amp yellow perch LC 60 80 ppm 3 days crawfish LC oo 8 2 ppm 96hr fatheadminnow TLm Waterfowl Toxicity 120 ppm Biochemical Oxygen Demand Not pertinent Food Chain Concentration Potential None SECTION 13 DISPOSAL CONSIDERATIONS Recover ammonia if feasible Otherwise let ammonia evaporate 1f appropriate Only personnel experienced in ammonia spills should add water to liquid ammonia Dispose of diluted ammonia as a fertilizer or in an industrial process For Hazardous Waste Regulations call 1 800 424 9346 the RCRA Hotline SECTION 14 TRANSPORT INFORMATION Domestic Shipments International Shipments Proper shipping name Ammonia Anhydrous Liquefied Ammonia Anhydrous Liquefied DOT Hazard Class 2 2 nonflammable gas 2 3 poison gas Identification Number UN1005 UN1005 Packing Group None None SECTION 15 REGULATORY INFORMATION NOTICE This product is subject to the reporting requirements of SARA 1986 Section 313 of Title and 40 CFR Part 370 OSHA HAZARD COMMUNICATION RULE 29 CFR 1910 1200 Ammonia is considered a hazardous chemical OSHA HAZARD COMMUNICATION RULE 29 CFR 1910 1200 Ammonia is considered a hazardous chemical EMERGENCY PLANNING AND COMMUNITY RIGHT TO KNOW SARA TITLE Section 302 Extremely Hazardous Substance Yes Section 311 312 Hazardous Categories Immediate acute health hazards Section 313 Toxic Chemical Yes CERCLA SUPERFUND 40 117 302 This
207. uring off cycles Proper water treatment for the prevention of mineral and foreign matter accumulation in the condenser or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use The use of a 40 mesh strainer in the condenser water supply line is also recommended 3 12 P24A amp P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 8 7 07 Entering Flow Cond 14 Water GPM PSID 18 2 eR 70 F esr 66 Total Heat Rejection 981 300 BTUH 1 Total Heat Rejection 1 852 500 BTUH Condenser water flow is based on pulldown of 30 F SST and 105 F SDT Condenser water pressure drop does not include water regulating valve Consult factory for sizing if desired TABLE 3 2 Condenser Water Requirements The following table show the model of Marley cooling tower required for operating at various wet bulbs to cool 91 F 33 C entering water to 85 F 29 4 C exiting water Cond PD Model GPM PSIG 75 F 76 F 77 F 78 F 79 F 80 F TABLE 3 3 Marley Cooling Tower Recommendations Tower nozzles will be selected based on GPM required for condenser The condenser water pump should be sized on GPM required for condenser at 80 ft total discharge head for a typical installation However due to cooling tower location and pressure drop through water lines the water pump s
208. ve the liquid phase exerts increased pressure It should be noted that the pressure observed within a container is NOT a measure of the quantity of the liquid present With increasing temperature ammonia in the liquid phase expands For example in an ammonia cylinder at 65F loaded to its maximum allowable limit in accordance with Federal regulations the vapor phase occupies about 1296 of the total cylinder volume This vapor space would be completely filled with liquid ammonia if its temperature were permitted to reach 145F Upon further temperature rise the cylinder will bulge and could rupture due to the internal hydrostatic pressure caused by the expanding liquid Because of these characteristics ammonia containers should not be exposed to excessive heat See THERMAL EXPANSION and FIRE EXPOSURE Under equilibrium conditions the vapor pressure and volume of liquid ammonia vary with temperature as shown in Table 1 TABLE 1 VAPOR PRESSURE AND VOLUME OF LIQUID AMMONIA AT VARIOUS TEMPERATURES Vapor Temperature Pressure Volume Degrees F psig Gal CWT 28 0 0 1757 0 LO 18 10 30 45 0 18 72 60 92 9 19 43 90 165 9 20 25 115 25155 21 04 130 315 6 21 58 derived from U S Bureau of Standards Circular 1421 Ammonia is most frequently shipped by highway and rail and stored in pressure containers as a liquefied compressed gas at ambient temperatures Ammonia in very large quantities is transported in high pre
209. vel above the impeller housing The pump is equipped with a mechanical seal which 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 Solenoid Valves The P24 and P34 are equipped with several solenoid valves to perform various functions for proper operation and good ice production The Thaw Gas Solenoid Valve 18 Figure 9 7 is opened during the thaw cycle to allow warm gas to pass from the receiver to the freezer Repair or replace as follows 1 With the receiver pressure higher than the freezer pressure manually open the valve by turning the manual stem out until you hear gas passing through the valve 2 Close the two hand stop valves 490 tight on either side of solenoid valve when there is vapor only in that part of the line 3 Loosen the 1 4 tubing compression nut at the strainer slightly to purge that section of the thaw gas line and continue to purge until all pressure is relieved 4 Repair or replace the valve as needed making sure all connections are tight 5 With the valve manually opened stem out open slightly only one stop valve 90 and purge air from the line through the 1 4 tubing compression nut at the strainer Then close that valve 90 and open the other 49
210. wer 9 3 Fan Control Switch 9 3 Float Switch 9 1 Float Switch Stop Valve 10 1 9 Float Valve Make Up Water 9 1 Flushing Water In 3 10 Foundation 3 1 foundation layout for 24 3 4 foundation layout for P34A 3 7 12 1 INDEX 12 2 INDEX Freeze Period 4 1 Freeze Protection Diagram 3 15 3 16 Freeze Up Due To Extended Freeze Period 8 4 Freeze Up Due To Ice Failing To Discharge 8 5 Freezer Drain Valve 61 1 6 1 11 Freezer Pressure Switch 2PS 9 2 Freezer Purge Valve 76 1 7 1 10 Freezer Safety Valves 51 1 6 1 9 G Gage Glass Stop Valve 31 1 6 Gear Reducer Replacement 9 7 H Hand Expansion Valve 17 1 4 1 8 9 2 Harvest Period 4 2 Head Pressure 8 8 High Compressor Discharge Temperature
211. y 24 9 14 parts list 9 15 Water Tank Drain 3 11 Water Tank Installation 9 13 Water Tank Overflow 3 11 Water Tank Parts Weights 9 9 Water Tank Removal 9 9 Wiring and Electrical Connections 3 16 Wiring Soft Starter 10 13 Wiring Schematic All Voltages 50 60 Hz 6 4 X Y Z P24A 4 P34A Service Manual
212. y 1 2 glass While charging the machine the low pressure switch will stop operation at approximately 15 psi suction pressure The switch will automatically reset at 35 psi at which time you can restart the machine It is best to use warm water in the tank and open the tank drain valve somewhat to allow cold water to exit and warm water to enter continually The idea is to prevent ice from freezing in the tubes as much as possible while charging It may be necessary to initiate a short harvest cycle to dispel any ice made To initiate a harvest cycle close the charging valve and push the manual harvest push button 3PB while the compressor is running As soon as all the ice clears the cutter area turn the Hand Auto switch to Hand and then back to Auto This will stop the harvest and start another freeze to continue the charging procedure When the liquid level in the receiver is near the pumpdown level and the freezer is down to 15 psi suction with little of no frost on the shell you can stop the charging procedure and disconnect the cylinder Make sure the charging valve is closed and the cylinder valve is closed before attempting to disconnect the cylinder Loosen the union in the charging line gradually to relieve the ammonia pressure slowly When charging is complete stop the machine disconnect and lock out the power Open the control panel door and reconnect wire 24 to the freezer pressure switch Open valves 29 and 58 in the liqui

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