VOGT ICE TUBE-ICE P-24A Service Manual Download Page 65

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P24A & P34A Service Manual

ELECTRICAL CONTROLS

12/17/12

6-9

Soft Start Settings

Dip

Switch #

Setting

On/Off

Setting

Soft Start

Off

10 sec

Off

Normal

Off

Manual

Off

Enabled

Line

Phase Rotation

Line or Delta

Current Limit or Softstart

Off

65%

Off

Overload Reset (Man/Auto)

Overload Trip Class

Description

Aux #1 (Normal/Up to Speed)

Initial Torque (% of LRT)

Start Time t1 (sec)

Soft Stop Time t3 (sec)

Kick Start Time t2 (sec)

TABLE 6-6

Allen Bradley Soft Start Settings and Faults

Faults

LED description (Number of Flashes)

Overload

Overtemperature

Phase Reversal

Phase Loss/Open Load

Phase Imbalance

Shorted SCR

Test

Summary of Contents for TUBE-ICE P-24A

Page 1: ...12 20 12 P 24A P 34A TUBE ICE MACHINE Service Manual 5000 ...

Page 2: ...enses 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...

Page 3: ...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...

Page 4: ...12 20 12 ...

Page 5: ...2 VOGT TUBE ICE MACHINES P24A P34A Model Installation Service Manual and Parts Catalog 12A4171L13 Vogt Ice LLC 1000 W Ormsby Avenue Suite 19 Louisville Kentucky 40210 800 853 8648 502 635 3000 Fax 502 634 0479 ...

Page 6: ...12 20 12 ...

Page 7: ...pection 2 1 Description of Machine 2 1 Safety Tags and Labels 2 1 Model designation for P Series Ice Machine Figure 2 1 2 2 Rated Capacity 2 3 Storage prior to installation and start up 2 3 3 INSTALLING YOUR TUBE ICE MACHINE Machine Room 3 1 Space Requirements 3 1 Foundation 3 1 Lifting Procedures 3 1 P24A Space Diagram FIGURE 3 1A 3 1B 3 2 3 3 P24A Foundation Layout FIGURE 3 2 3 4 P34A Space Diag...

Page 8: ...4 1 Freeze Period 4 1 Harvest Period 4 2 Piping Nomenclature 4 2 Piping Schematic for P24A FIGURE 4 1 4 3 Piping Schematic for P34A FIGURE 4 2 4 4 5 START UP AND OPERATION Refrigeration System Review 5 1 Start up Checklist 5 2 Refrigerant Charge 5 2 Ammonia Specification By Grade TABLE 5 1 5 2 Special Precautions to be Observed when Charging Refrigeration Systems 5 2 Charging From Tank Truck 5 3 C...

Page 9: ...Preventive Maintenance 7 1 Preventative Maintenance Form 7 2 Ice Making Section 7 3 Cleaning Procedure 7 3 Water Distributors TABLE 7 1 7 4 Average Hole Size in Tube Ice TABLE 7 2 7 4 Water Tank 7 4 Water Cooled Condenser Cleaning 7 5 Cooling Tower Evap Condenser 7 5 Cooling Tower Maintenance Schedule TABLE 7 3 7 6 Compressor 7 6 Compressor Maintenance TABLE 7 4 7 7 Cutter Gear Reducer 7 7 V Belt ...

Page 10: ...9 5 9 5 Condenser Cleaning 9 6 Cutter Gear Reducer 9 6 Drive Gear Replacement 9 7 Gear Reducer Replacement 9 8 Water Tank and Cutter Parts Weights TABLE 9 1 9 9 Water Tank Removal 9 9 Cutter Assembly Removal and Installation 9 10 Bearing Bracket and Cutter Disc Removal 9 10 Cutter Shaft and Bearing Removal 9 10 Cutter Shaft and Bearing Installation 9 11 Cutter Height Adjustment 9 12 Water Tank Ins...

Page 11: ... Inspection 9 23 Belt Tension 9 24 Compressor Servicing 9 24 10 OPTIONS AND ACCESSORIES Crushed Ice Production 10 1 Length of Ice 10 1 Power Monitor 10 2 11 TABLES AND CHARTS P24A Specifications TABLE 11 1 11 2 P34A Specifications TABLE 11 2 11 3 P24A Capacity Ratings TABLE 11 3 11 4 P24A Condenser Water Usage TABLE 11 4 11 5 P34A Condenser Water Usage TABLE 11 5 11 5 P24A Make up Water Usage TABL...

Page 12: ...12 20 12 ...

Page 13: ...s of dependable service Ask someone who owns one Preview All 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 ...

Page 14: ...Anhydrous Ammonia Safety in Appendix A Safety Symbols 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...

Page 15: ...f refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it and...

Page 16: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 4 FIGURE 1 1 P24A Front Side Control Panel ...

Page 17: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 5 FIGURE 1 2 P24A Right Side ...

Page 18: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 6 FIGURE 1 3 P24A Back Side ...

Page 19: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 7 FIGURE 1 4 P24A Left Side ...

Page 20: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 8 FIGURE 1 5 P34A Front Side ...

Page 21: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 9 FIGURE 1 6 P34A Right Side ...

Page 22: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 10 FIGURE 1 7 P34A Back Side ...

Page 23: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 11 FIGURE 1 8 P34A Left Side Control Panel ...

Page 24: ...P24A P34A Service Manual INTRODUCTION 12 18 12 1 12 FIGURE 1 9 P24A Compressor Diagram ...

Page 25: ... 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 prev...

Page 26: ...3 50 21 230 1 60 Basic Configuration P Package L Low side H High side Refrigerant F R 22 A Ammonia H R 404a J R 507 Type of Ice B Cylinder K Crushed D Dual Ice Cru Cyl L 1 1 2 Long Cylinder Condenser Type AC Air Cooled WC Water Cooled HP High Pressure Water Cooled SW Sea Water NC No Condenser Tube Size 4 1 5 1 1 4 6 1 1 2 7 1 3 4 8 1 7 8 Product Variation Codes A number or letter designator assign...

Page 27: ... Model P34A 1 Makeup Water Temp Capacity Tons day 2000 lbs 24 hours Makeup Water GPM Capacity Tons day 2000 lbs 24 hrs Makeup Water GPM Capacity Tons day 2000 lbs 24 hours Makeup Water GPM 85 F 29 C 36 0 7 50 39 5 8 24 35 9 7 48 80 F 24 C 36 9 7 69 40 5 8 45 36 7 7 66 75 F 23 C 37 8 7 89 41 6 8 67 37 6 7 84 70 F 21 C 38 8 8 10 42 7 8 90 38 6 8 04 65 F 18 C 39 9 8 32 43 8 9 14 39 6 8 25 60 F 15 C 4...

Page 28: ...P24A P34A Service Manual RECEIPT OF YOUR TUBE ICE MACHINE 12 26 12 2 4 ...

Page 29: ...earance around the machine for ease of servicing and observation Pay particular attention to the additional space required If it ever becomes necessary to mechanically clean the condenser tubes extra space will be required on one end preferably on the opposite end from the water inlet and outlet for the cleaning tools Foundation Refer to the space diagrams Figures 3 2 and 3 4 for recommended minim...

Page 30: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 2 FIGURE 3 1A P24A Space Diagram Front View ...

Page 31: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 3 FIGURE 3 1B P24A Space Diagram Side View ...

Page 32: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 4 FIGURE 3 2 P24A Foundation Layout ...

Page 33: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 5 FIGURE 3 3A P34A Space Diagram Front View ...

Page 34: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 6 FIGURE 3 3B P34A Space Diagram Side View ...

Page 35: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 7 FIGURE 3 4 P34A Foundation Layout ...

Page 36: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 8 FIGURE 3 5 Lifting Procedure for P24A ...

Page 37: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 9 FIGURE 3 6 Lifting Procedure for P34A ...

Page 38: ...ugh 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 g...

Page 39: ...ction 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 s...

Page 40: ...gpm water flow 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 should be sized for each installation The ice machin...

Page 41: ...P24A P34A Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 20 12 3 13 FIGURE 3 7 Cooling Tower Piping Diagram ...

Page 42: ... INDOOR SUMP CHECK VALVE FIGURE 3 8 1 PUMP 2 WAY VALVE Poor Freeze Protection Because low flow rate high freeze chance COOLING TOWER WATER COOLED CONDENSER INDOOR SUMP CHECK VALVE Same flow rate to cooling tower Only enough water to maintain head pressure FIGURE 3 9 1 PUMP 3 WAY VALVE Better Freeze Protection ...

Page 43: ...onnect 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 r...

Page 44: ... 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 o...

Page 45: ...eed 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 to...

Page 46: ...essure of 20 25 PSIG which should be indicated on the suction and discharge gages CHECK _____ All water supply and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK _____ Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maxi...

Page 47: ...enser 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 lo...

Page 48: ...rain Valve 5R Gear Reducer 45 Compressor Cooling Water Inlet Valve 6 Water Pump 50 Receiver Safety Valve 7 Water Tank includes cutter assembly 51 Freezer Safety Valve 8 Water Distributing Chamber 52 3 Way Valve 9 Water Tank Overflow 3 FPT 54 Compressor Water Regulating Valve 10 Refrigerant Float Switch 55 Discharge Line Stop Valve 12 Make Up Water Float Valve 56 Freezer Pressure Switch 2PS 13 Heat...

Page 49: ...P24A P34A Service Manual HOW YOUR TUBE ICE MACHINE WORKS 8 25 05 4 3 FIGURE 4 1 Piping Schematic for P24A ...

Page 50: ...P24A P34A Service Manual HOW YOUR TUBE ICE MACHINE WORKS 8 25 05 4 4 FIGURE 4 2 Piping Schematic for P34A ...

Page 51: ... 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 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...

Page 52: ... indicator ET and make sure wire 22 and 27 are attached 10 Reconfirm Rotation Check for compressor cutter and water pump See Section 3 Refrigerant Charge Prior to 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 sup...

Page 53: ...ose 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 higher 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 ...

Page 54: ... d Compressor cooling water 100 F outlet temperature e Compressor oil level approximately 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 ...

Page 55: ... 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 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...

Page 56: ...ylinder 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 To interrupt the harvest cycle and revert to a fr...

Page 57: ...ipment 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 S...

Page 58: ...uring freezing and thawing Energized during freezing thawing and hand Momentarily de energized at the end of the harvest 2TR Thawing Timer Controls the time of the harvest thawing period 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 slip...

Page 59: ...ing Illuminated when the machine is in a harvest period 2PB 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 Harvest For manually initiating a harvest cycle NO 1SS Selector Switch Hand Auto Hand position for running the circulating water pump independently at...

Page 60: ...P24A P34A Service Manual ELECTRICAL CONTROLS 12 17 12 6 4 FIGURE 6 3 Electrical Schematic for P24A and P34A all Voltages 50 60 Hz ...

Page 61: ...ing means to lowside control panel Supplies power to lowside unit FB1 Fuse Block 1 Provides short circuit protection for one half of motor 3 fuses FB2 Fuse Block 2 Provides short circuit protection for one half of motor 3 fuses R1 Relay Relay used to energize 1M2 contactor Note R1 is a control relay used on machines where contactor 1M2 is too large for TR to energize TB1 Terminal Block 1 Main Powe...

Page 62: ...ide over current protection for compressor motor CB1 Circuit Breaker 3 pole Provides short circuit protection and a disconnecting means to lowside control panel Supplies power to lowside unit TB Terminal Block Used for connections to Lowside panel DS1 not shown CE panel Highside Disconnect Used to disconnect power from panel when panel door opened TABLE 6 4 Description of Control Panel Parts ...

Page 63: ...necting means to lowside control panel Supplies power to lowside unit F Fan Enclosure Fan FR Fault Relay Energizes when soft start fault occurs LT Fault Light ON when soft start fault occurs SS Soft Start Compressor Motor Soft Start TB Terminal Block Used for connections to Lowside panel DS1 not shown CE panel Highside Disconnect Used to disconnect power from panel when panel door opened TABLE 6 5...

Page 64: ...P24A P34A Service Manual ELECTRICAL CONTROLS 12 17 12 6 8 FIGURE 6 7 Allen Bradley Soft Start Motor Wiring ...

Page 65: ...On Line Phase Rotation Line or Delta Current Limit or Softstart Off 65 Off 20 Overload Reset Man Auto Overload Trip Class Description Aux 1 Normal Up to Speed Initial Torque of LRT Start Time t1 sec Soft Stop Time t3 sec Kick Start Time t2 sec TABLE 6 6 Allen Bradley Soft Start Settings and Faults Faults LED description Number of Flashes 1 Overload 2 Overtemperature 3 Phase Reversal 4 Phase Loss O...

Page 66: ...P24A P34A Service Manual ELECTRICAL CONTROLS 12 17 12 6 10 TABLE 6 7 Allen Bradley Soft Start Dip Switch Settings ...

Page 67: ...h and low pressure switches oil pressure switch etc 2 Check cooling tower spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulation 4 Check water tank for solids to be removed 5 Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc for abno...

Page 68: ...k 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 Motor amps Compressor ________ Cutter ________ Pump ________ Suction psig end of freeze __________ Discharge psig end of freeze _____________ Suction psig end of thaw __________ Discharge psig end of thaw _____________ Compre...

Page 69: ...er 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 op...

Page 70: ...nsert one in each tube hole and seat firmly by using a short piece of pipe or conduit 2 Slide the pipe or conduit down over the vent tube and gently tap the distributor in place 3 Do not allow the distributor to be recessed below the top of the tube sheet To replace the cover 1 Replace water distributor box cover gasket 2 Install the cover over the bolt studs 3 Install the four 4 cover retaining r...

Page 71: ...hly 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 should be inspected monthly and kept clean Do not operate the unit without the strainer in place 3 Make up wat...

Page 72: ...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 W Series n...

Page 73: ...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 C...

Page 74: ...ing 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 3 Check compressor sheave and motor sheave with a straight edge to be sure they are paral...

Page 75: ... the problem Be sure to correct the source or cause of the problem to prevent the problem from occurring again Symptom Page Machine stopped 8 2 Freeze up due to extended freeze period 8 4 Freeze up due to ice failing to discharge 8 5 Low ice capacity 8 6 Poor ice quality 8 7 High discharge pressure 8 8 Low discharge pressure 8 9 High suction pressure 8 9 Compressor running unloaded during freeze 8...

Page 76: ... TR in part wind starts only Water pump cutter motor tower fan tower pump conveyor motor overload tripped Check for loose connection on all terminals 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 tripped Check for loose terminal connections and or defect...

Page 77: ...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 Defective control panel component such a...

Page 78: ...freeze Check the manual opening stem to make sure it 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 wil...

Page 79: ... the system If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver and the refrigerant will be cooler although pressure will be high Air can be purged from the system by following the procedure in the Section 9 Purging Non Condensables Insufficient heat due to low refrigerant charge The refrigerant level in the receive...

Page 80: ...ck 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 short cycling Check incoming water temperature 45 F 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 full volume Check...

Page 81: ...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 restricted Insufficient water supply indicated by a low level in the tank Check water pressure 40 psig is recommended minimum Check for a water line restriction partially closed valve or defective make up water flo...

Page 82: ...at the receiver The refrigerant will be cooler although the pressure will be high Air can be purged from the system by following instructions in Section 9 Purging Non Condensables Cooling tower or evap condenser in need of maintenance Check fan motor and fan belts for proper operation and tension Check spray nozzles tubes sump and sump screen for accumulation of mineral deposit and clean as requir...

Page 83: ...ewed in position Repair or replace defective parts Symptom High suction pressure check gage accuracy Possible Cause Possible Remedy Compressor running unloaded or not pumping efficiently Check compressor motor amp If the 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 open...

Page 84: ...Mycom compressor thrust bearing on the 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 oi...

Page 85: ...k for leaking pump seal or defective motor and repair or replace as needed Symptom Shut down by oil pressure switch Possible Cause Possible Remedy Switch adjusted too high or defective Check switch adjustment and cutout pressure activation against an accurate gage Replace switch if defective See Figure 9 4 Oil pressure low See Compressor oil pressure low Low oil level Add oil Defective thawing tim...

Page 86: ...e 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 ...

Page 87: ...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 the valve has been cleaned and reinstalled check to ascertain if the proper water l...

Page 88: ... 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...

Page 89: ...r tripping reset the switch manually Note Do not rely on the switch calibration for accuracy For accurate adjustment check settings with a test gage 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 s...

Page 90: ...tarted 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...

Page 91: ...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 FIGURE 9 5 Thawing Timer 2TR Syrelec Timer Orange Light indicates timer is timing Light indicates timer has timed out Time Base Set to min Scale Set to X1 Crouzet...

Page 92: ...on 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 gaske...

Page 93: ...ive 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 ...

Page 94: ... and separate the plate and reducer 10 Install the replacement gear reducer and motor onto the mounting plate using the carriage bolts lock washers and hex nuts Tighten the nuts snug only for later adjustment 11 Clean the split hub and drive gear insert the hub into the gear making sure the tapers of the two match and slide the hub and gear onto the shaft 12 Position the hub on the shaft note meas...

Page 95: ...all power to the machine 2 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 3 Turn off water supply drain water and disconnect water and drain lines from the tank 4 Remove the overflow tubing from the water t...

Page 96: ...h marked for reassembly You may have to gently drive the support arms up or down to release them from the tank walls 6 With the bracket and disc assembly turned upside down remove the cotter pin from the shaft 7 Loosen and remove the slotted hex nut spring washer and spacer 8 Lift the cutter disc from the keyed shaft being careful not to loose the shaft key The cutter shaft and bearings are sealed...

Page 97: ...end of the shaft supported install the lower bearing on the shaft driving it down into the housing firmly against the housing shoulder 11 Slide the seal spacer ridged end in flat end out and seal open face out onto the shaft together 12 Uniformly tap the seal into the housing against its shoulder NOTE The purpose of the seals and excluders are to prevent moisture from entering the housing area not...

Page 98: ...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 lb Water Tank Installation 1 Place the 3 16 thick gum rubber gasket on the top of the tank flange It can be held in place with narrow strips of tape through the bolt holes 2 Push the water tank in and under the freezer aligning the bolt holes and ...

Page 99: ...P24A P34A Service Manual SERVICING OPERATIONS 12 18 12 9 13 Figure 9 5B P24A Water Tank Assembly ...

Page 100: ... x 3 3 16 S S 12A 2785S04 12A 2785S04 32 Cutter Adapter Plate 19T2010A11 19T2010A05 33 Bearing 12A 2020M02 12A 2020M02 34 Bearing Bracket 19T2025B0105 19T2025B0106 35 Cutter Blade 19T2035B0100 19T2035B0200 36 Breaker Cutter Assembly 19T2160C0401 19T2160C0501 37 Tines Disc Assembly 19T2163D0302 19T2163D0403 38 Top Excluder 12A 2210E01 12A 2210E01 39 Bottom Excluder 12A2210E04 12A2210E04 44 Carriage...

Page 101: ...e 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 11 Check and adjust cutter height and meshing of the gear teeth 12 Install the water tank assembly Cutter Blade Replacement The cutter bla...

Page 102: ...e 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...

Page 103: ...om 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 ju...

Page 104: ...d test paper can be obtained from your ammonia supplier 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 d...

Page 105: ...ther purge points 8 When purging is completed close the valve disconnect the hose and install a plug in the purge valve 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...

Page 106: ...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 F 10 c or higher room temperature A 5 CFM 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...

Page 107: ...lly open the valve by turning the manual stem out until you hear gas passing through the valve 2 Close the two hand stop valves 90 tight on either side of solenoid valve when there is vapor only in that part of the line 3 Loosen the 1 4 tubing compression nut at the strainer slightly to purge that section of the thaw gas line and continue to purge until all pressure is relieved 4 Repair or replace...

Page 108: ...rainer purge valve 75 5 Repair or replace the valve as needed making sure all connections are tight 6 Evacuate or purge air from this isolated part of the liquid line through the strainer purge valve 7 After purging manually close screw stem out the solenoid valve and open stop valves 29 and 58 check for leaks Machine Strainer Solenoid Check Valve P24A 12A4140S05P 12A4200A06P P34A 12A4140S07P 12A4...

Page 109: ... and allow the machine to stop by low pressure cut out 2 Close the compressor discharge valve oil return stop valve Disconnect and lock out all power to the machine 3 Drain the oil through the oil drain valve located at the base of the compressor and purge the compressor until all pressure is relieved 4 Remove the compressor side cover handhole cover being careful to protect the gasket and surface...

Page 110: ...w 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 5 Move the sheaves apart until the belts are snug 6 Check the motor and compressor shafts to mak...

Page 111: ...tank assembly for unrestricted access The result is ice that is approximately 1 2 long and frozen only 3 16 1 4 thick A modification of this type is not one you would want to make every time a temporary change to crushed ice is wanted Contact your distributor for more information and complete details Length of Ice Ice length can be adjusted by increasing or decreasing the length of the spacer unde...

Page 112: ...ower is lost If machine is ordered with this option the power monitor can be factory set to customer specifications The Vogt Part number for a power monitor retrofit kit is 12A7700K01 The Display The display normally shows the AB BC CA line voltages If the unit is waiting on a timer that timer will be displayed The timer display may be switched off by pressing SELECT The LCD will then display the ...

Page 113: ...E flashes The value may be adjusted by pressing the up and down arrows Imbalance Voltage Tolerance in IMBALANCE flashes The value may be adjusted by pressing the up and down arrows Lockout Time in seconds SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the delay on break timer value Delay time in seconds and tenths of seconds RESP SECONDS flashes The value may ...

Page 114: ...ally calculates cut in voltages for the return from undervoltage conditions The cut out voltage is always based on user voltage and tolerance settings while the cut in voltage is 3 closer to the nominal voltage setting This quality is sometimes referred to as hysteresis This is to help reduce oscillation that may occur on weak power distribution system When the load is switched off due to undervol...

Page 115: ...P24A P34A Service Manual TABLES CHARTS 12 18 12 11 1 11 Tables Charts ...

Page 116: ...KW FLA 60 44 7 77 60 44 7 77 60 44 7 77 Water Pump HP KW FLA 3 2 2 4 1 3 2 2 4 1 3 2 2 4 1 Cutter Motor HP KW FLA 1 0 75 2 0 1 0 75 2 0 1 0 75 2 0 THR Btu hr kW 981 300 287 8 981 300 287 8 981 300 287 8 Marley Cooling Tower 5 4832 4832 4832 dim LxWxH ft meters 4x5x6 5 1 2x1 5x2 4x5x6 5 1 2x1 5x2 4x5x6 5 1 2x1 5x2 shipping weight lbs Kg 755 342 4 755 342 4 755 342 4 operating weight lbs Kg 1360 616...

Page 117: ... 93 2 156 125 93 2 156 125 93 2 156 Water Pump HP KW FLA 10 7 4 12 0 3 2 2 4 1 3 2 2 4 1 Cutter Motor HP KW FLA 2 1 5 3 2 2 1 5 3 2 2 1 5 3 2 THR Btu hr kW 1 852 500 543 3 1 852 500 543 3 1 852 500 543 3 Marley Cooling Tower 5 4861 4861 4861 dim LxWxH ft meters 8x6 5x8 2 4x2 0x2 4 8x6 5x8 2 4x2 0x2 4 8x6 5x8 2 4x2 0x2 4 shipping weight lbs Kg 1 805 818 7 1 805 818 7 1 805 818 7 operating weight lb...

Page 118: ...00 36 800 48 200 41 100 35 400 46 400 39 600 36 800 48 200 41 100 68 35 100 46 100 39 400 36 500 47 900 40 900 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 70 34 500 45 500 39 000 35 800 47 300 40 500 34 500 45 500 39 000 35 800 47 300 40 500 71 34 200 45 200 38 800 35 500 47 000 40 300 34 200 45 200 38 800 35 500 ...

Page 119: ...981 300 100 75 95 93 3 981 300 100 80 95 125 6 981 300 100 85 95 187 14 981 300 Table 11 4 P24A Condenser Water Usage Condensing Temp F Entering Water Temp F Leaving Water Temp F Water Flow gpm Pressure Drop psig Average Total Heat of Rejection BTU HR 100 50 95 82 1 1 852 500 100 55 95 93 1 1 852 500 100 60 95 106 1 1 852 500 100 65 95 124 1 1 852 500 100 70 95 148 2 1 852 500 100 75 95 185 3 1 85...

Page 120: ... 5 34 5 60 5 20 90 4 08 4 27 3 97 5 10 5 34 4 96 Includes 25 blowdown per cycle Table 11 6 P24A Make Up Water Usage gpm Cylinder Ice Crushed Ice Make Up Water Tube Size Tube Size Temp F 1 1 1 4 1 1 2 1 1 1 4 1 1 2 40 9 47 10 57 9 62 11 83 13 21 12 02 50 8 94 9 95 9 05 11 17 12 43 11 31 60 8 47 9 39 8 55 10 58 11 73 10 68 70 8 04 8 90 8 10 10 05 11 12 10 13 80 7 66 8 45 7 69 9 57 10 56 9 61 90 7 31...

Page 121: ...4 375 9 3 8 31 7 5 6 8 6 1 U 1 1 2 26 53 180 66 14 226 250 433 12 9 12 0 11 2 10 4 9 4 Table 11 8 P24A Normal Operating Vitals Suction Pressure psig Discharge Pressure psig Harvest Times secs Ice per cycle Freeze Time minutes End of End of End of End of First All Ice Total Average Water Temperature deg F Freeze Thaw Freeze Thaw Ice Out Harvest lbs 90 80 70 60 50 C 1 25 53 180 66 60 180 260 850 13 ...

Page 122: ...2A4199V26 Gage glass O ring 1 12A7500E24 12A7500E24 Switch assembly for float switch 1 126229 126229 Coil for Hansen Solenoid 1 12A2117C03 12A2117C03 Freezer pressure switch Asco PA16A 1 12A2117T03 12A2117T03 Transducer for above control Asco RE10A44 2 12A7504E01 12A7504E01 Fuse 10 amp 3 12A7504E06 12A7504E06 Fuse 15 amp 3 12A7504E03 12A7504E03 Fuse 20 amp See Part No 12B2185V32 144 EA 12B2185V32 ...

Page 123: ...0 2 120 1 229 0 190 1 138 0 0 9 2 24 0 31 1 6 5 33 5 15 6 6 7 100 117 2 195 9 216 2 124 3 235 0 196 1 142 0 2 10 2 25 6 32 9 7 5 35 6 17 1 7 7 102 120 9 201 8 222 3 128 5 242 0 203 3 146 0 4 11 2 27 3 34 9 8 5 37 4 18 6 8 8 104 124 7 207 7 228 5 132 9 249 0 210 2 151 0 6 12 3 29 1 36 9 9 6 39 4 20 3 9 9 106 128 5 213 8 234 9 137 3 256 0 217 2 156 0 8 13 5 30 9 38 9 10 8 41 6 21 9 11 0 108 132 4 22...

Page 124: ...TC 5 9 TF 32 C F TF 9 5 TC 32 Volume ft3 m3 2 8317e 2 gal U S m3 3 7854e 3 ft3 gal U S 7 48 TABLE 11 11 CONSTANTS Specific heat of Water 1 BTU lbm F Specific heat of Air 4 19 kJ kg C 0 24 BTU lbm F Tube Ice Density 32 35 lbs ft3 Ice Latent Heat 144 BTU hr Water Sensible Heat 1 BTU lb F Ice Melting Effect IME 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 lbs ...

Page 125: ...Appendix A ...

Page 126: ...dical 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 aid INGESTION Do not induce vomi...

Page 127: ... SECTION 12 ECOLOGICAL INFORMATION Aquatic Toxicity 2 0 2 5 ppm 1 4 days goldfish yellow perch LC 60 80 ppm 3 days crawfish LC100 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 if appropriate Only personnel experie...

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Page 143: ...sor 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 6 Condenser Purge Valve 59 1 6 1 10 Condenser Safety Valves 50 P24A 1 6 P34A 1 10 Condenser Taw Gas Outlet Stop Valve 89 1 8 Condenser Water In And Out 3 11 Condenser Water Requirements ...

Page 144: ... 7 Low Pressure Gage Stop Valve 69 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 1 9 Make Up Water Flow Rate 2 3 Make Up Water In 3 10 Make Up Water Temperature 2 3 Make Up Water Stop Valve 62 1 4 Make Up Water Usage P24A and P34A 11 6 Manual Harvest Push Button 3...

Page 145: ... Valves 9 21 see figures 1 1 through 1 9 for location Space Requirements 3 1 Space Diagram P24A 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 Operation 5 1 Start Up Checklist 5 2 Storage prior to installation and sta...

Page 146: ...P24A P34A Service Manual INDEX 12 26 12 12 4 ...

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