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HEC-Series Service Manual

ELECTRICAL CONTROLS & THEIR FUNCTIONS

10/21/01

6-12

NOTE: Part #12A-7536M01000000. PLC must be pre-programmed for specific model.

FIGURE 6-4
PLC Display

Input

Description

Output

Description

Cylinder Ice Bin Stat / Selector Switch

Flush Valve (Special Order Only)

Crushed Ice Bin Stat / Selector Switch

A-valve

Freezer Pressure Switch / Manual Harvest

Compressor (X-valve / air cooled machine)

Start Switch

Reversing Relay

Clean Switch

Water Pump

Ice Switch

Cutter / D-valve

High / Low Pressure Safety Switch

Service Indicator Switch

TABLE 6-3

PLC Inputs & Outputs

Summary of Contents for HEC-10

Page 1: ...HEC SERVICE MANUAL ...

Page 2: ... OF YOUR TUBE ICE MACHINE Inspection 2 1 Safety Valves 2 1 Machine Room 2 1 Storage 2 1 3 INSTALLING YOUR TUBE ICE MACHINE Installation Without Bin 3 1 Bin Installation 3 1 Two Methods Of Lifting Setting Machine On a Level Ice Storage Bin 3 1 Forklift Blocks Method FIGURE 3 1 3 2 Forklift Rope Or Lifting Straps Method FIGURE 3 2 3 3 Wiring and Electrical Connection 3 4 Power Connection FIGURE 3 3 ...

Page 3: ...Storage Bin FIGURE 3 14 3 17 Wiring For Single Thermostat Operation FIGURE 3 15 3 18 Installation Review A Checklist 3 19 4 HOW YOUR TUBE ICE MACHINE WORKS Principle of Operation 4 1 Piping Diagram With Reference Numbers FIGURE 4 1 4 2 How Ice Is Stored Dual Ice 4 3 Single Ice 4 4 Ice Bin Capacity 4 4 Refrigeration System 4 5 5 INITIAL START UP AND OPERATION Start up Checklist 5 1 Solenoid Valve L...

Page 4: ...2 PLC Inputs Outputs TABLE 6 3 6 12 PLC Modes FIGURE 6 5 6 13 Machine Off Dual Ice FIGURE 6 6 6 14 Machine Off Single Ice FIGURE 6 6A 6 15 Freeze Cycle Dual Ice FIGURE 6 7 6 16 Freeze Cycle Single Ice FIGURE 6 7A 6 17 Harvest Cycle Dual Ice FIGURE 6 8 6 18 Harvest Cycle Single Ice FIGURE 6 8A 6 19 Clean Cycle Dual Ice FIGURE 6 9 6 20 Clean Cycle Single Ice FIGURE 6 9A 6 21 7 MAINTENANCE Ice making...

Page 5: ...IONS Adjustable Blowdown For Clearer Ice 9 1 Automatic Blowdown Harvest Cycle 9 1 Float Valve Make Up Water 9 1 Expansion Valve 9 1 Expansion Valve Adjustment Procedure Installation 9 2 Recommended Superheat Setting TABLE 9 1 9 2 Freezer Pressure Switches 9 3 Freezer Pressure Switch Allen Bradley FIGURE 9 1 9 3 Allen Bradley Switch 9 4 High Low Pressure Switch 9 4 High Low Pressure Switch FIGURE 9...

Page 6: ... 9 16 Pumping Down Freezer 9 17 Removal Of Refrigerant From Machine 9 17 Refrigerant Leaks 9 18 Non Condensable Gases 9 18 Compressor Motor Burnout 9 18 Solenoid Valve Liquid Line and Thawing Gas FIGURE 9 13 9 19 Solenoid Valves 9 19 Water Distributors 9 19 Water Tank 9 20 CPR Crank Pressure Regulator FIGURE 9 14 9 20 CPR Valve Settings TABLE 9 2 9 21 Cylinder Ice to Crushed Ice Conversion 9 21 Cy...

Page 7: ... 10 23 01 vi Page No 11 TABLES AND CHARTS Ice Capacity TABLE 11 1 11 1 Normal Operating Vitals TABLE 11 2 11 2 Temperature Pressure Chart TABLE 11 3 11 3 English Metric Conversion TABLE 11 4 11 4 12 TECHNICAL SERVICE BULLETINS 12 1 13 INDEX 13 1 ...

Page 8: ...ervice 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 the HEC model Tube Ice machines Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s economic and reliable operation have been proven ...

Page 9: ... disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary and illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe ...

Page 10: ...manual understand the operation of this machine and be aware of possible dangers These safety symbols will alert you when special care is needed Please heed DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates a strong possibility of a hazard and that an unsafe practice could result in severe personal inju...

Page 11: ... shown atop a typical ice storage bin with a condensate drain pan The bin and drain pan are optional equipment NOTICE The ice storage bin is shown for illustration purposes only Vogt Tube Ice LLC accepts no responsibility for the selection or use of any ice bin in conjunction with the Tube Ice machine ...

Page 12: ...HEC Series Service Manual INTRODUCTION 10 24 01 1 5 FIGURE 1 2A Assembly Model HEC 30 Air Cooled Front View ...

Page 13: ...HEC Series Service Manual INTRODUCTION 10 24 01 1 6 FIGURE 1 2B Assembly Model HEC 30 Air Cooled Rear View ...

Page 14: ...HEC Series Service Manual INTRODUCTION 10 24 01 1 7 FIGURE 1 2C Assembly Model HEC 30 Water Cooled Front View ...

Page 15: ...HEC Series Service Manual INTRODUCTION 10 24 01 1 8 FIGURE 1 3B Assembly Model HEC 30 Water Cooled Rear View ...

Page 16: ...tion 23A Make Up Water Inlet Connection 24 Condenser Water Out Connection 25 Water Tank Drain Connection 28 Refrigerant Charging Connection 30 Gage Glass 32 AC Condenser Service Connection 34 Compressor Suction Service Valve 35 Comp Discharge Service Valve 39 Water Tank Drain Valve 40 Automatic Blowdown Piping 41 Condenser Water Regulating Valve 43 Strainer 46 Filter Drier 48 Muffler 50 Receiver R...

Page 17: ...o to obtain authorization for repair Safety Valves Two safety pressure relief valves are an integral part of the packaged Tube Ice machine One is located in the low side of the system on the freezer and one is in the high side of the system on the receiver You must vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes Machine Room The...

Page 18: ...ur legs Screw these legs to the bottom of the bin You can make MINOR leveling adjustments by using these legs as leveling screws as outlined in the manufacturer s instructions Once the ice storage bin is level the Tube Ice machine can be elevated and placed inside the condensate drip pan on the top of the bin FIGURES 3 1 and 3 2 illustrate two methods of lifting setting Tube Ice machine on a level...

Page 19: ...f the ice storage bin Step 3 Lift and set Tube Ice machine on wood blocks Step 4 Remove forklift Step 5 Stack 3 ft long 2X4 s beside drip pan overlapping front and back of bin Step 6 Using a pry bar with fulcrum on 2X4 s raise side of machine enough to remove the TOP wood blocks CAUTION Do not remove top AND bottom blocks at the same time CAUTION Step 7 Repeat steps 5 and 6 on other side Step 8 Wi...

Page 20: ...ccess panels Step 2 Position fork truck so that forks are resting flat on top angles of Tube Ice machine Step 3 Use the rope or straps to securely bind forks to the top angles CAUTION Be sure the bin is level and is set in its proper location See the space diagrams FIGURE 3 4 and 3 5 CAUTION Step 4 Lift Tube Ice machine and set into drip pan of bin Step 5 Remove rope or straps and fork truck Step ...

Page 21: ...ect the Ground wire to the Ground terminal provided See Initial Start up and Operation Section 5 Scroll compressor rotation must be checked and confirmed to be correct Attach pressure gages to the suction discharge service valves to make sure there is an immediate decrease in the suction pressure and increase in discharge pressure upon start up If not reverse two 2 compressor wires L1 L2 L3 at the...

Page 22: ...FPT 1 FPT Condenser Water Out 3 4 FPT 3 4 FPT 3 4 FPT 1 FPT TABLE 3 1 Water Supply and Drains When the ice machine sits on a storage bin the bin must be provided with a drip pan for catching the condensate from the ice machine Separate drains for the condensate and for the bin are necessary See FIGURE 3 4 or 3 5 space diagram drawings for typical water and drain connections Condensate drain must n...

Page 23: ...HEC Series Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 6 FIGURE 3 4 Space Diagram Water Cooled Machine ...

Page 24: ...HEC Series Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 7 FIGURE 3 5 Space Diagram Air Cooled Machine ...

Page 25: ... must rise no more than 12 feet before dropping back down to the elevation of the ice machine When the condenser is located below the ice machine expect a 16 psig increase in head pressure and at least 3 reduction in capacity 4 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with relia...

Page 26: ... be added as follows Liquid Line Size 75 ft 100 ft 125 ft 150 ft 1 2 none none none 2 5 8 none 2 4 6 7 8 none 4 8 12 1 1 8 none 6 12 18 Table 3 2 Pounds R 22 to Add Vs Liquid Line Length 15 All piping must be done in accordance with applicable local and national codes Such codes may include The Safety Code for Mechanical Refrigeration ANSI B9 1 and The Code for Refrigerant Piping ANSI B31 5 The fo...

Page 27: ... 50 hz 3 ph 230V 50 hz 3 ph 400V 50 hz 2 5 N A N A 3 0 N A N A 2 5 N A N A 3 0 N A N A 5 0 N A N A 5 8 N A N A 5 0 N A N A 5 8 N A N A Locked Rotor Amps 1 ph 208 230V 60 hz 3 ph 208 230V 60 hz 3 ph 460V 60 hz 1 ph 230V 50 hz 3 ph 230V 50 hz 3 ph 400V 50 hz 7 N A N A 8 2 N A N A 7 N A N A 8 2 N A N A 15 N A N A 17 5 N A N A 15 N A N A 17 5 N A N A Weight lbs Net Shipping Operating maximum flooded 1...

Page 28: ...E 10 21 01 3 11 FIGURE 3 6 Condenser Dimensions Condenser pictured DD 101 or DD 131 Note Dash lines indicate customer supplied piping The Check Valve in the return line labeled Output To Machine is supplied with the condenser FIGURE 3 7 Condenser Field Piping ...

Page 29: ...g Type Number Used Factor Total Globe Valve open Angle Valve open 45 Elbow 90 Elbow Feet of Straight Copper Used Total Fitting Factor Total Equivalent Feet Fitting Factors Copper Tube O D Type L 1 2 5 8 7 8 1 1 8 Globe Valve open 14 16 22 28 Angle Valve open 7 9 12 15 45 Elbow 5 1 1 1 5 90 Elbow 1 2 2 3 TABLE 3 4 FIGURE 3 8 Minimum Traps for Discharge Lines ...

Page 30: ...HEC Series Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 13 FIGURE 3 9 Condenser Piping With Cold Weather Valve Kit ...

Page 31: ...ies Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 14 FIGURE 3 10 Wiring For DD 61 With Cold Weather Valve and Single Fan FIGURE 3 11 Wiring For DD 101 DD 131 With Cold Weather Valve And Dual Fans ...

Page 32: ...HEC Series Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 15 FIGURE 3 12 Air Cooled Condenser Enclosure ...

Page 33: ...HEC Series Service Manual INSTALLING YOUR TUBE ICE MACHINE 10 21 01 3 16 FIGURE 3 13 Field Attachment Air Cooled Condenser Refrigerant Tubing ...

Page 34: ... when the bin is full For a divided bin locate the control bulbs as illustrated in FIGURE 3 14 This allows space for the machine to make an additional discharge of ice AFTER the ice contacts the bulb WITHOUT the ice building up into the discharge opening of the chute Note As an option the PLC can be programmed for your machine to produce a specified amount of ice during a certain time each day Con...

Page 35: ...stat is necessary The wiring may be modified to use only one thermostat and bulb See With No Divider in Bin Section 4 and FIGURE 3 14 Or install both bulbs so that the ice contacts both bulbs when the bin is full FIGURE 3 15 Wiring for Single Thermostat Operation Dual Ice Type Only follow instructions below 1 Turn power off to the machine and check with volt meter to make sure panel is dead 2 Sele...

Page 36: ...ECK _____ 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 air cooled condenser ice storage bin ice spreader etc for proper installation CHECK _____ The applicable portion of the warranty registration start up report for proper completion C...

Page 37: ...be type vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 Solenoid valve 20 sometimes referred to as the A valve is open and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes throug...

Page 38: ...HEC Series Service Manual HOW YOUR TUBE ICE MACHINE WORKS 10 21 01 4 2 HEC Water Cooled Piping Schematic FIGURE 4 1 HEC Air Cooled Piping Schematic ...

Page 39: ...ess of the causes which open either thermostat switch See FIGURE 3 14 Illustration of the Bin Thermostat Bulb Installation With no divider in bin producing only ONE type ice When there is no partition in the bin for separating cylinder and crushed ice you need use only one bin thermostat and bulb By connecting wires 25 and 26 together on the same thermostat terminal and installing that thermostat ...

Page 40: ...n to stop the machine prior to ice backing up into the ice chute and jamming cutter Crushed Ice Preferred A special customized PLC can be programmed and furnished as an option to produce crushed ice first when the selector switch is in the Auto position This option will still allow the operator to select Cyl or Cru ice as desired but will produce crushed ice and satisfy that thermostat first then ...

Page 41: ...allows the liquid to be metered by the thermal expansion valve that opens and closes modulates as the temperature of the suction line dictates The evaporator floods with wet refrigerant that is in contact with the outside of the tubes that the ice making water is being circulated through The heat contained in this water is conducted through the wall of the tubes lowering the temperature of the wat...

Page 42: ...lean push button switch is set to Off position Button Out NOTE All valves are tagged with instructions _____ 7 Open compressor service valves 34 and 35 the two hand stop valves 90 in the thawing gas line 91 in the condenser return line and the hand stop valve 58 in the liquid line and hand stop valve 69 to the freezer pressure switch These valves are tagged to indicate that they were closed for sh...

Page 43: ...arge pressure increase immediately To change rotation reverse two 2 of the three 3 compressor wires L1 L2 and L3 at the control panel terminal block FIGURE 5 1 Solenoid Valves _____ 12 When the machine starts check water level in water pan 7 to determine whether or not water pump 6 is pumping water It may be necessary to stop and start the machine several times to expel air from the water pump imp...

Page 44: ... the freezer is clear of ice Its main purpose is to clear the freezer of liquid refrigerant and prevent possible refrigerant migration to the compressor while running the clean cycle It also can be used to check the units total refrigerant charge Total pumpdown is initiated by setting the selector switch to the Cyl position turn Ice switch to the Off position allow the machine to harvest if runnin...

Page 45: ...HEC Series Service Manual INITIAL START UP AND OPERATION 10 21 01 5 4 FIGURE 5 2 Piping Schematic Air Cooled ...

Page 46: ...HEC Series Service Manual INITIAL START UP AND OPERATION 10 21 01 5 5 FIGURE 5 3 Piping Schematic Water Cooled ...

Page 47: ...Compressor Contractor P 12A 7516E09000000 Pump Contactor 12A 7518E2000000 Auxiliary Contact CU 12A 7516E09000000 Cutter Contactor PLC 12A 7536M01000000 Programmable Controller FC 12A 7516E11000000 Fan Contactor Air cooled only R 12A 7517E18000000 Reversing Relay FU0 FU5 PLC Protection Fuses part of fuse block assembly TB 12A 7501E30000000 Terminal Block Assembly Fuses FU0 FU5 12A 7504E23000000 2 a...

Page 48: ...or breaking various circuits concerning cylinder or crushed ice production Energized during crushed ice production only FC Fan Contactor Cycles the fan motor s of air cooled condenser On and Off Activated by the condenser pressure switch Air cooled machines only SVI Service Indicator Switch For disabling the machine and entering a troubleshoot mode to identify a machine fault Opened for entering a...

Page 49: ...tart Push Button PB2 12A 7500E02000000 Manual Harvest Push Switch SS 12A 7500E07000000 Selector Switch S1 12A 7515E01000000 Cutter Overload Switch S2 12A 7515E07000000 Pump Overload Switch 1LT 12A 7520E10000000 Cylinder Light 2LT 12A 7520E10000000 Crushed Light 3LT 12A 7520E09000000 Cutter Overload Light 4LT 12A 7520E09000000 Pump Overload Light Note Components used in dual ice type machines only ...

Page 50: ...luminated when selector switch set in Auto position 3 LT Cutter Overload Illuminated when cutter overload switch S1 has tripped 4 LT Pump Overload Illuminated when pump overload switch S2 has tripped SS Selector Switch For the purpose of selecting the type of ice to be made either crushed Cru or cylinder Cyl Note Use Auto position only when using divided bin S1 Cutter Overload Switch Stops machine...

Page 51: ...ssure fault during thaw e High low pressure fault during partial pump down f High low pressure fault during total pump down 5 Automatic 2 hour delayed restart after being off from a Power failure b Power interruption c Compressor overload cutout d Low pressure fault e Long freeze fault f Short cycle fault 6 Built in adjustable thaw timer range 1 1 2 5 minutes 7 Closes A liquid feed solenoid valve ...

Page 52: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 6 FIGURE 6 3 Control Sequence Flow Chart ...

Page 53: ...trip Its normal time period is two hours Initiated by the following 1 Initial power up at the time of installation 2 Power restored after a power interruption or power failure 3 After running a Troubleshoot mode 4 After running a Clean mode 5 After running a Total Pumpdown mode 6 Machine faults such as a Cutter overload trip manual reset b Pump overload trip manual reset c High pressure cutout tri...

Page 54: ...discharge AC units only are open Initiated by the following 1 After the start up and standby modes are satisfied in sequence 2 At the termination of the harvest mode Harvest Mode Thaw Cycle The harvest mode is normally initiated at the termination of the freeze mode At this time the circulating water pump stops and the A liquid feed solenoid valve closes for a time period of seven seconds After se...

Page 55: ...ction of the total pumpdown mode is to transfer all the liquid refrigerant from the freezer evaporator into the receiver Total pumpdown is initiated as the first phase of and prior to entering the Clean mode Its main purpose is to clear the freezer of liquid refrigerant and prevent possible refrigerant migration to the compressor while running the Clean cycle It can also be used to check the units...

Page 56: ...vorable condition and possible cause damage to the compressor when returning to the freeze mode CAUTION After the total pumpdown and pushing the Start button the water pump can be started and stopped by simply pushing the Clean button on and off Note If the freezer and compressor suction pressure have come up enough to open the freezer pressure switch FPS2 and close low pressure safety switch 4PS ...

Page 57: ...ean button to the Off position 2 Set the Ice button to the Off position 3 Close the SVI switch 4 This will return the machine to the Start Up mode Output Light Fault Fault Description ll l l 10 High or low pressure cutout during freeze cycle ll l 11 High or low pressure cutout during harvest cycle ll ll 12 High or low pressure cutout during partial pumpdown ll l 13 High or low pressure cutout duri...

Page 58: ...t Description 0 Cylinder Ice Bin Stat Selector Switch 0 Flush Valve Special Order Only 1 Crushed Ice Bin Stat Selector Switch 1 A valve 2 Freezer Pressure Switch Manual Harvest 2 Compressor X valve air cooled machine 3 Start Switch 3 Reversing Relay 4 Clean Switch 4 Water Pump 5 Ice Switch 5 Cutter D valve 6 High Low Pressure Safety Switch 7 Service Indicator Switch TABLE 6 3 PLC Inputs Outputs ...

Page 59: ...hed Ice In 0 1 2 3 4 5 6 7 l l l l In 0 1 2 3 4 5 6 7 l l l l Out 0 1 2 3 4 5 l l Out 0 1 2 3 4 5 l l l Note Input 2 will be on at the start of the Harvest but will turn off as thaw gas pressure rises Note Input 2 will be on at the start of the Harvest but will turn off as thaw gas pressure rises S14 Partial Pumpdown S15 Total Pumpdown In 0 1 2 3 4 5 6 7 l l l In 0 1 2 3 4 5 6 7 l l l l l Out 0 1 ...

Page 60: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 14 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 6 Dual Ice Type Machine Off ...

Page 61: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 15 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 6A Single Ice Type Machine Off ...

Page 62: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 16 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 7 Dual Ice Type Freeze Cycle Cylinder Ice ...

Page 63: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 17 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 7A Single Ice Type Freeze Cycle ...

Page 64: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 18 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 8 Dual Ice Type Harvest Cycle Cylinder Ice ...

Page 65: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 19 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 8A Single Ice Type Harvest Cycle ...

Page 66: ...Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 20 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 9 Dual Ice Type Clean Cycle A Maintenance Operation ...

Page 67: ...HEC Series Service Manual ELECTRICAL CONTROLS THEIR FUNCTIONS 10 21 01 6 21 Use Copper Conductors Only Protected against primary single phase failure FIGURE 6 9A Single Ice Type Clean Cycle ...

Page 68: ... position The machine will begin a total pumpdown After total pumpdown the compressor will stop and only the water pump will be running 5 Push the Clean button to the Off position and the pump will stop 6 Shut off the water supply and drain the water tank flushing loose scale in the process 7 Close the water tank drain valve and fill tank with approximately six gallons of tap water Warm water can ...

Page 69: ...er 8 on top of the freezer The water distributors one in each tube may then be removed with pliers for cleaning Grasp the top of the distributor gently with pliers twist and pull up to remove the distributor After cleaning reinstall distributors firmly in each tube Water Tank The production of opaque ice usually indicates that the water in the water tank contains a concentrated amount of solids or...

Page 70: ...rature from pressure temperature chart corresponding to head pressure If this difference is more than 10 F cleaning is indicated because this difference indicates a good heat exchange is not being made If this difference is less than 8 F something other than a fouled condenser may be causing the high head pressure In normal operation this difference will stay between 5 F and 10 F regardless of wat...

Page 71: ...aks Mechanical cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser d Remove the cover plate on the side of the frame to expose the condenser end plate e Remove the nuts water plates and gaskets from both ends of the condenser If the gasket does not lift off with the end plate do...

Page 72: ...powerful enough to damage a tube if for any reason the cleaning tool should stick After one or two passes in each tube they should be flushed and inspected Often this is enough although some deposits require more In any case stop when a few places begin to show a copper color After cleaning wipe all foreign matter from the tube sheets and studs Reassemble as outlined on gasket installation instruc...

Page 73: ...oil level should be at a height of 1 4 to 1 2 of the sight glass but never out of sight above it Although the machine was shipped with the oil charge which was originally added for the test operation it may be necessary to add some oil when or if new refrigerant is added to the system An oil pump should be used to force any oil that may be required into the system Oil may be added to the compresso...

Page 74: ...7 Unusual noises Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes in the operation of the machine which may require maintenance long before a service situation arises An ounce of prevention...

Page 75: ...hecked system ______ leaks found repaired Compressor oil level i e 1 4 1 2 3 4 low high Gear reducer oil okay low PSIG low pressure switch set 20 psi PSIG high pressure switch set 300 psi Bin stat s installed and operate properly Make up water float valve adjusted okay Adjustable blowdown adjusted for clear ice F suction line superheat at TXV after at least two minutes into the freeze _____ F CYL_...

Page 76: ...n setting If it stops by high pressure cutout the switch will have to be reset manually Upon tripping the PLC will initiate the start up mode for two hours The machine will restart automatically at the end of two hours if the switch is reset or the machine can be started immediately by pushing the Start button Cutter or pump motor overload trips circuit breaker switches See Section 6 FIGURE 6 2 sw...

Page 77: ...sing hot refrigerant gas into freezer 2 during the freeze mode Clean or replace solenoid valve Check manual opening stem which should be at All In position See Solenoid Valve Section 9 FIGURE 9 13 Make up water float valve 12 stuck open or adjusted too high Check operation of float valve and replace if necessary See Float Valve Make Up Water Section 9 Low refrigerant charge usually insufficient wa...

Page 78: ... ice chute check angle of chute 30 minimum angle for cylinder ice 45 for crushed ice Ice may not contact bin thermostat control bulb to stop machine when bin is filled See Ice Bin Thermostat Section 9 and Bulb Installation Section 3 FIGURE 3 12 Ice fails to discharge from cutter area properly Ice mushy due to concentration of solids in water pan Drain and clean water tank Check blowdown during tha...

Page 79: ...e up water float valve 12 stuck open See Float Valve make up water Section 9 Water tank drain valve 39 open or leaking Close valve Warm condenser water entering water tank 7 through overflow connection 40 Pipe water outlet 24 and drain 25 separately to floor drain See Water Supply and Drain Section 3 Controls for regulating freezing and thawing cycles improperly set See Freezer Pressure Switch and...

Page 80: ...ine fault 10 11 12 or 13 has occurred Enter the troubleshoot mode and identify the last occurring fault See Fault Identity Section 6 Check High Low Pressure Switch Section 9 FIGURE 9 2 for improper setting too low opening pressure See Head Pressure Section 9 X discharge line solenoid valve not opening air cooled units only If the machine stops by low pressure cut out the switch will reset automati...

Page 81: ...e can be manually restarted by pushing the Start button or it will restart automatically after two hours Excessive temperature may be caused by gas leakage between suction and discharge valves of compressor valve plate Check for broken valve plate gaskets or valves High freezer superheat or high discharge rpessure can cause excessive heat HEC 10 and HEC 20 have built in motor overload and thermal ...

Page 82: ...e compressor crankcase heater is energized for at least two hours and there is no liquid refrigerant in the crankcase prior to running the machine A machine fault 16 has occurred NOTE If cutter motor circuit breaker pump motor circuit breaker compressor motor overload or thermal protection shuts the machine off HEC 30 and HEC 40 only the PLC will lose power and a power failure fault 16 will be ind...

Page 83: ... water level controlled by the float valve 12 regulates the quantity of blowdown during the thawing period An optional solenoid valve can be furnished in place of the drain valve to permit additional if required Float Valve make up water The make up float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank...

Page 84: ...inutes and at two minute intervals for at least two cycles Refer to the chart below for recommended superheat ranges 6 Adjust the valve only 1 4 turn at a time Close turn stem in to raise superheat Open turn stem out to lower superheat Monitor at least two cycles after each adjustment before adjust further Model Minimum Target Maximum HEC 10 7 8 10 HEC 20 5 6 8 HEC 30 7 8 10 HEC 40 8 10 11 TABLE 9...

Page 85: ...swab to remove the flux residue Use Emery cloth or a wire brush if necessary Freezer Pressure Switches The freezing time period for the production of crushed ice is controlled by the freezer pressure switch FPS1 located inside the control panel The freezing time period for cylinder ice is controlled likewise by the second switch FPS2 These switches were set at the factory to produce ice of recomme...

Page 86: ...e cylinder 1 16 diameter for 7 8 diameter ice and 1 8 diameter for 1 1 8 diameter ice This insures that the freezing cycle is not extended unnecessarily and eliminates a possible opaque core in the center of the ice When crushed ice is produced the freezer pressure switch FPS1 FIGURES 6 1 9 1 should be set to produce ice having a wall thickness of approximately 3 16 Note While making crushed ice i...

Page 87: ... setting Adjust the switch to the indicated pressure settings and test with an accurate gage to be sure the switch functions properly before installation Head Pressure The head pressure should be maintained at 190 210 psig during the freeze cycle This pressure can be checked at the test connection in the high pressure line near the high low pressure switch Air Cooled Units The condenser fan switch...

Page 88: ...tion If any of the 2 amp PLC output fuses FU0 FU5 are blown they must be replaced for that component to function Fuse Part 12A 7504E23000000 CAUTION In case of a power interruption or outage be sure the compressor crankcase is warm and there is no liquid refrigerant in the crankcase prior to restarting the machine manually except for Scroll compressor CAUTION Two control circuit fuses FU100 and FU...

Page 89: ...ee in a bin approximately 1 2 full of ice with the bin doors closed 3 Turning the adjustment screw clockwise raises the setting This adjustment makes the contacts open quicker at a higher temperature 4 Turn the adjustment screw counter clockwise lowers the setting This adjustment makes the contacts open slower at a lower temperature 5 Make sure the bulb is mounted firmly in the bin bracket after a...

Page 90: ...e time required to harvest the entire discharge of ice If it should be necessary to change the setting of the timer turn the adjustment screw clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment FIGURES 6 1 9 6 FIGURE 9 7 Ice Selector Switch Dual Ice Type Only Ice Selector Switch A 3 position rotary type switch marked Cru Auto Cyl is locate...

Page 91: ...upon completion of the harvest cycle Circulating Water Pump Motor The motor bearings are pre lubricated and sealed They require no further lubrication Pump should operate with the water level above the impeller housing The pump is equipped with a mechanical seal which is self addressing and requires no lubrication However the pump should not be operated unless circulating water The pump manufactur...

Page 92: ... bolts holding gear box mounting plate to the drive gear enclosure and lift out gear reducer and plate assembly 5 Remove drive gear from the reducer output shaft Two 1 4 20 x 1 1 2 long all thread bolts can be used for jacking screws in the two threaded holes of the drive gear 6 Remove the split hub bushing from the reducer shaft and remove the gear reducer from the mounting plate 7 Reassemble in ...

Page 93: ...Assembly may then be taken to a work bench for removal of cutter To remove the cutter from the water tank assembly perform the following 1 Remove the ice deflector by removing the hinge pin at the hub end 2 Remove the cutter disc assembly which is held onto the shaft by a roll pin The cutter can now be removed 3 Remove the cutter bearing bracket which is held in place by three 1 4 cap screws holdi...

Page 94: ...HEC Series Service Manual SERVICE OPERATIONS 10 21 01 9 12 FIGURE 9 8 Cutter Water Tank Assembly With Water Pump and Cutter Motor ...

Page 95: ...HEC Series Service Manual SERVICE OPERATIONS 10 21 01 9 13 FIGURE 9 9 Cutter Water Tank Parts ...

Page 96: ...HEC Series Service Manual SERVICE OPERATIONS 10 21 01 9 14 FIGURE 9 10 Cutter Drive Parts ...

Page 97: ...HEC Series Service Manual SERVICE OPERATIONS 10 21 01 9 15 FIGURE 9 11 Cutter Parts ...

Page 98: ...ervice Manual SERVICE OPERATIONS 10 21 01 9 16 NOTE Deflector door assembly and chute deflector may be removed if there is no divider in the bin see How Ice Is Stored Section 4 FIGURE 9 12 Ice Discharge Arrangement ...

Page 99: ...anually open the liquid feed A solenoid valve 20 by backing the stem out Close liquid outlet king valve 58 on the receiver 15R Put machine into total pumpdown as described above Removal Of Refrigerant From The Machine To transfer the refrigerant charge from the machine into a separate container proceed as instructed above under pumping down freezer This will isolate most of the refrigerant in the ...

Page 100: ...e compressor load When this current gets too high or is applied for an extended period the motor windings overheat resulting in a failure or burnout 2 Loss of Refrigerant The hermetic compressor motor is maintained at proper operating temperature by passing cool suction gas over the motor windings A loss of refrigerant can cause the winding to overheat resulting in a failure or burnout 3 High Head...

Page 101: ...er distributors are located in the distributing head 8 at the top of the freezer There are 78 distributors used in models having an S suffix i e Models HEC 10S HEC 20S HEC 30S and HEC 40S 48 distributors are used in models having an M suffix i e Models HEC 10M HEC 20M HEC 30M and HEC 40M These may require occasional or periodical cleaning to remove suspended solids and foreign particles accumulate...

Page 102: ...ting the machine after filling the water tank be sure that the water pump is circulating water It is possible that air may have collected in the pump impeller housing and the unit may have to be stopped and started several times to expel the air FIGURE 9 14 CPR Crankcase Pressure Regulating Valve CPR Crankcase Pressure Regulating Valve The CPR valve is designed to prevent overloading and liquid sl...

Page 103: ...rotective cover If there is sufficient refrigerant in the receiver a discharge pressure of 200 psig is maintained during the freeze and the system is free of noncondensables ice will release and be cleared from the freezer within 1 1 2 minutes Check several cycles after making adjustments HEC 10 HEC 20 HEC 30 HEC 40 55psig 55psig 55psig 50psig TABLE 9 2 CPR Valve Setting Converting from Cylinder I...

Page 104: ... HEC 30S 38 40 41 43 HEC 30M 35 37 39 41 HEC 40S 31 33 36 38 HEC 40M 25 27 31 33 TABLE 9 3 Recommended Freezer Pressure Settings FIGURE 9 16 Freezer Pressure Switch The bottom screw is used to set the Differential DO NOT ADJUST Turn top screw to adjust the pressure setting also referred to as the Range Clockwise increase pressure setting Counterclockwise decrease pressure setting ...

Page 105: ...ed Ice lbs HEC 10S 39 41 29 31 HEC 10M 37 39 27 29 HEC 20S 39 41 29 31 HEC 20M 37 39 27 29 HEC 30S 38 40 28 30 HEC 30M 36 38 26 28 HEC 40S 38 40 28 30 HEC 40M 36 38 26 28 TABLE 9 4 Recommended Ice Weights per cycle Single To Dual Ice Conversion Converting from single type to dual type ice consist of adding components rewiring and machine adjustments Consult factory for single to dual ice conversio...

Page 106: ...HEC Series Service Manual MODEL NUMBER STRUCTURE 10 21 01 10 1 10 Model Number Structure ...

Page 107: ...80 70 60 50 C HEC 10S 43 80 200 110 8 40 1 5 39 4 8 2 7 1 5 1 1 0 9 Y HEC 10M 40 80 200 110 8 54 1 5 39 4 6 2 6 1 4 1 0 0 8 L HEC 20S 44 80 200 100 8 33 1 5 39 7 2 4 0 2 2 1 6 1 3 I HEC 20M 39 80 200 100 8 37 1 5 39 6 9 3 9 2 1 1 5 1 2 N HEC 30S 39 80 200 100 8 21 1 5 39 14 7 8 4 5 9 4 7 3 8 D HEC 30M 36 80 200 100 8 23 1 5 39 14 3 8 2 5 7 4 4 3 6 E HEC 40S 32 80 200 100 10 14 1 5 39 25 1 14 7 9 5...

Page 108: ...6 34 1 98 113 5 190 2 210 2 120 1 138 0 229 0 247 0 0 9 2 24 0 31 1 6 5 6 7 33 5 36 1 100 117 2 195 9 216 2 124 3 142 0 235 0 254 0 2 10 2 25 6 32 9 7 5 7 7 35 6 38 1 102 120 9 201 8 222 3 128 5 146 0 242 0 261 0 4 11 2 27 3 34 9 8 5 8 8 37 4 40 4 104 124 7 207 7 228 5 132 9 151 0 249 0 269 0 6 12 3 29 1 36 9 9 6 9 9 39 4 42 6 106 128 5 213 8 234 9 137 3 156 0 256 0 276 0 8 13 5 30 9 38 9 10 8 11 ...

Page 109: ...in H2O psi 0 03612 Temperature F C 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 4 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 1...

Page 110: ...onate listed below have in general the same effect on the appearance of raw water ice and therefore in this rough tabulation can be grouped together Generally the sodium carbonates can be considered 1 1 4 times as objectionable as the sulfates and the chlorides about 3 4 as objectionable as the sulfates Therefore total the sulfates and chlorides separately and apply the factors Calcium Sulfate Cal...

Page 111: ...n 7 6 Compressor Motor Burnout 9 18 Compressor Motor Contactor 6 2 Compressor Motor O L CD OL 6 2 Compressor Motor Temp O L CD TS 6 2 Compressor Warranty 13 5 Condenser 1 8 3 12 Condenser Air cooled Cleaning 7 5 Condenser Air cooled Heat Rejection 3 10 Condenser Fan Contactor FC 6 2 Condenser Fan Switch 9 6 Condenser Piping 3 10 3 11 3 12 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled Ma...

Page 112: ...ss Switches FPS1 2 9 4 Fuses FU0 through FU5 6 2 Fuses FU100 and FU200 6 3 9 9 G Gear Reducer 7 6 9 10 H Harvest Cycle Wiring Schematics Dual Ice 6 18 Havest Cycle Wiring Schematics Single Ice 6 19 Harvest Mode 6 8 HE Model Structure 10 1 Head Pressure 9 6 Heater Crankcase 9 6 Heat Exchanger 5 4 5 High low Pressure Switch 9 5 History Tube Ice 1 1 Hub Cutter Drive Gear 9 13 9 14 I Ice Capacity Tabl...

Page 113: ...fety Symbols 1 2 Safety Valves First Arrival 2 1 Selector Switch SS 6 4 9 8 Servicing Operations 9 1 Shipping Papers 2 1 Single Ice Type 4 4 Single to Dual Ice Conversion 9 23 Solenoid Valves 5 2 9 19 Space Diagram Air cooled 3 7 Space Diagram Water cooled 3 6 Special Precautions 1 2 Stand by Mode 6 8 Start Push Button PB1 6 4 Start up Checklist 5 1 Start Up Mode 6 7 Start Up Report Front Pg Stora...

Page 114: ... Cooled 3 5 3 6 Water Quality 12 1 Water Tank 9 12 9 16 9 20 Water Tank Cover 9 12 9 13 9 16 Water Tank Maintenance 7 2 Water Tank Parts 9 12 9 13 9 16 Wiring and Electrical Connection 3 4 Wiring Schematic Clean Cycle Dual Ice 6 20 Wiring Schematic Clean Cycle Single Ice 6 21 Wiring Schematic Freeze Cycle Dual Ice 6 16 Wiring Schematic Freeze Cycle Single Ice 6 17 Wiring Schematic Harvest Cycle Du...

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