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P24AL & P34AL Service Manual

INDEX

12/2016

12-1

12. Index

A Brief History of Henry Vogt Machine Co. ---------------------- 1-1

Adding Refrigerant------------------------------------------------------5-6

Ammonia Specification by Grade ------------------------------------5-2

Ammonia (amount required) ------------------------------------------5-2

Ammonia Removal --------------------------------------------------- 9-17

Assembly Drawing P24AL --------------------------- 1-4, 1-5, 1-6, 1-7

Assembly Drawing P34AL ----------------------- 1-8, 1-9, 1-10, 1-11

Automatic Blowdown (Harvest Cycle) ------------------------------9-1

Auxiliary Controls or Equipment ----------------------------------- 3-18

Basic Product Warranty ------------------------------ inside back cover

Bearing Bracket and Cutter Disc Removal ------------------------ 9-10

Belt Tension ------------------------------------------------------------ 9-24

Belt Replacement ------------------------------------------------------ 9-24

Bin Level Control -------------------------------------------------------6-1

Blowdown ---------------------------------------------------------------9-1

Charging from Tank Truck --------------------------------------------5-3

Charging from Cylinders -----------------------------------------------5-3

Charging Refrigeration System (Precautions) ---------------- 1-3, 5-2

Charging Valve-Freezer (28) ----------------------------------------------

P24AL -------------------------------------------------------------1-4

P34AL -------------------------------------------------------------1-8

Check Valve (101) --------------------------------------------- 1-11, 9-22

Circulating Water Pump Motor ------------------------------------- 9-20

Cleaning Procedure (Ice Making Section) ---------------------------7-3

Cleaning Ice Making Section ------------------------------------------9-1

Compressor (Optional) -------------------------------------------------7-5

Compressor Inspection ----------------------------------------------- 9-23

Compressor Maintenance (Optional) ---------------------------------7-6

Compressor Loosing Oil Excessively ------------------------------ 8-10

Compressor Oil Changing ------------------------------------------- 9-23

Compressor Running Unloaded During Freeze ---------------------8-9

Compressor Servicing ------------------------------------------------ 9-24

Condenser Cleaning ----------------------------------------------------9-6

Control Circuit Protection ---------------------------------------------9-5

Control Panel ------------------------------------------------ 5-5, 6-2, 6-3

Control Panel Parts ---------------------------------------------- 6-2 , 6-3

Cooling Tower --------------------------------------------------------- 3-12

Cooling Tower/ Evap Condenser -------------------------------------7-5

Cooling Tower Piping Diagram --------------------------- 3-14, 13-15

Crushed Ice Production----------------------------------------------- 10-2

Current Unbalance ---------------------------------------------------- 3-17

Cutter Adapter Plate Installation ------------------------------------ 9-16

adjustment ------------------------------------------------------ 9-16

Cutter Assembly (P24AL) ------------------------------------------ 9-12

parts list -------------------------------------------------- 9-14, 9-15

Cutter Assembly Removal and Installation--------------------------9-9

Cutter Blade Replacement ------------------------------------------- 9-15

adjustment ------------------------------------------------------ 9-16

Cutter Disc Removal -------------------------------------------------- 9-10

Cutter Gear Reducer ---------------------------------------------- 7-7, 9-7

drive gear replacement ----------------------------------------- 9-7

gear reducer replacement -------------------------------------- 9-8

Cutter Height Adjustment --------------------------------------------- 9-3

Cutter Motor Starters ----------------------------------------------- 10-13

Cutter Ring Gear Replacement --------------------------------------- 9-7

Cutter Parts Weights --------------------------------------------------- 9-9

Cutter Shaft & Bearing Removal/Installation --------------------- 9-10

Description of Machine ----------------------------------------------- 2-1

Draining Oil Trap ----------------------------------------------------- 9-19

Drive Gear Replacement ---------------------------------------------- 9-7

Electrical Schematic, All Voltages 50-60 Hz. --------------------- 6-4

Electrical Controls------------------------------------------------------ 6-1

Float Switch ------------------------------------------------------------- 9-1

Float Switch Stop Valve (10A) --------------------------------------- 1-9

Float Valve (Make-Up Water) ---------------------------------------- 9-1

Flushing Water In ----------------------------------------------------- 3-11

Foundation -------------------------------------------------------------- 3-1

foundation layout for P24AL ----------------------------------- 3-4

foundation layout for P34AL ----------------------------------- 3-7

Freeze Period ------------------------------------------------------------ 4-1

Freeze Protection Diagram ------------------------------------ 3-14, 3-15

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) ---------------------------------------- 9-4

Freezer Purge Valve (76) --------------------------------------- 1-7, 1-10

Freezer Safety Valves (51) -------------------------------- 1-6, 1-9, 3-13

Freezer Timer ----------------------------------------------------------- 9-2

Gage Glass Stop Valve (31) ------------------------------------------ 1-6

Gear Reducer Replacement ------------------------------------------- 9-8

Hand Expansion Valve (17) ------------------------------ 1-4, 1-8, 9-2

Harvest Period ---------------------------------------------------------- 4-2

Head Pressure ----------------------------------------------------------- 8-8

High Compressor Discharge Temperature ------------------------- 8-11

High Discharge Pressure ---------------------------------------------- 8-8

Heat Rejection --------------------------------------------------------- 3-13

High Suction Pressure ------------------------------------------------- 8-9

How Your Tube-Ice Machine Works -------------------------------- 4-1

Summary of Contents for P-24AL

Page 1: ...12 2016 P 24AL P 34AL TUBE ICE MACHINE Service Manual 5000 ...

Page 2: ...ses 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 5...

Page 3: ...um 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 wa...

Page 4: ...VOGT TUBE ICE MACHINES P24AL P34AL Model Installation Service Manual and Parts Catalog 12A 4171L14 Vogt Ice LLC 1000 W Ormsby Avenue Suite 19 Louisville Kentucky 40210 800 853 8648 502 635 3000 Fax 502 634 0479 ...

Page 5: ...hine 2 1 Safety Tags and Labels 2 1 Model designation for P Series Ice Machine Figure 2 1 2 2 Storage prior to installation and start up 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Machine Room 3 1 Space Requirements 3 1 Foundation 3 1 Lifting Procedures 3 1 P24AL Space Diagram Figure 3 1 3 2 3 3 P24AL Foundation Layout Figure 3 2 3 4 P34AL Space Diagram Figure 3 3 3 5 3 6 P34AL Foundation Layout Figur...

Page 6: ...g Piping for Vogt P34AL and Central High Side Figure 3 16 3 23 Interconnecting Piping for 2 Vogt P34AL and Central High Side Figure 3 17 3 24 Interconnecting Piping for 3 Vogt P34AL and Central High Side Figure 3 18 3 25 Installation Review A Checklist 3 26 4 HOW YOUR TUBE ICE MACHINE WORKS Operating Features 4 1 Principle of Operation 4 1 Freeze Period 4 1 Harvest Period 4 2 Piping Nomenclature 4...

Page 7: ...rs Table 7 1 7 4 Average Hole Size in Tube Ice Table 7 2 7 4 Water Tank 7 4 Compressor optional 7 5 Compressor Maintenance Table 7 4 7 6 Oil Trap 7 6 Cutter Gear Reducer 7 6 8 TROUBLESHOOTING List of Symptoms 8 1 Machine Stopped 8 2 8 3 Freeze Up Due to Extended Freezing Period 8 4 Freeze Up Due to Ice Failing To Discharge 8 5 Low Ice Capacity 8 6 8 7 Poor Ice Quality 8 7 High Discharge Pressure 8...

Page 8: ...er Assembly Removal and Installation 9 9 Bearing Bracket and Cutter Disc Removal 9 10 Cutter Shaft and Bearing Removal 9 10 Cutter Shaft and Bearing Installation 9 10 Cutter Height Adjustment 9 11 Water Tank Installation 9 12 P24A Cutter Assembly Figure 9 5A 9 12 P24A Water Tank Assembly Figure 9 5B 9 13 P24A and P34A Cutter and Water Tank Part Nos 9 14 Cutter Ring Gear Replacement 9 15 Cutter Bla...

Page 9: ...2N 8ER ES UL Figure 10 2 10 3 Mitsubishi FX3GE 24MR PLC and FX2N 8ER ES UL Figure 10 3 10 4 Mitsubishi PLC Input Outputs Table 10 1 10 4 Wiring Schematic P24AL P34AL with Mitsubishi PLC Figure 10 4 10 5 Power Monitor 10 6 Power Monitor Figure 10 5 10 6 Power Monitor Parameter Limits Table 10 2 10 7 Parameter Adjustments 10 7 11 TABLES AND CHARTS P24AL Specifications Table 11 1 11 1 P34AL Specifica...

Page 10: ...P24AL P34AL Service Manual TABLE OF CONTENTS 12 2016 vi ...

Page 11: ...es are renowned for their long life giving many customers more than 35 years of dependable service Ask someone who owns one Preview All the skill in engineering and fabrication that we 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 ...

Page 12: ... 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 safet...

Page 13: ...of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it an...

Page 14: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 4 Figure 1 1 P24AL 1 Front Side Control Panel ...

Page 15: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 5 Figure 1 2 P24AL Right Side ...

Page 16: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 6 Figure 1 3 P24AL Back Side ...

Page 17: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 7 Figure 1 4 P24AL Left Side ...

Page 18: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 8 Figure 1 5 P34AL Front Side Control Panel ...

Page 19: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 9 Figure 1 6 P34AL Right Side ...

Page 20: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 10 Figure 1 7 P34AL Back Side ...

Page 21: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 11 Figure 1 8 P34AL Left Side ...

Page 22: ...P24AL P34AL Service Manual INTRODUCTION 12 2016 1 12 ...

Page 23: ...ion refrigerant liquid connection thaw gas connection make up water supply electrical connection and the proper refrigerant charge The machine has been partially factory tested prior to shipment and will require adjustment to meet the high side condensing unit operating conditions See Start up and Operation for the correct setting of the controls After factory pressure testing of the machine the m...

Page 24: ...t be stored or installed in an area that is subject to reach temperatures at or above 110 F 43 3 C Nominal Capacity T tons day 25T 25 tons day 50T 50 tons day 80T 80 tons day Product Variation Code A number or letter designator assigned to specific variations within a family series 000 or Blank Standard Product Consult factory for specific code interpretation Model Variation A letter assigned to i...

Page 25: ...ound 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 minimum foundat...

Page 26: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 2 Figure 3 1A P24AL Space Diagram Front View ...

Page 27: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 3 Figure 3 1B P24AL Space Diagram Side View ...

Page 28: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 4 Figure 3 2 P24AL Foundation Layout ...

Page 29: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 5 Figure 3 3A P34AL Space Diagram Front View ...

Page 30: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 6 Figure 3 3B P34AL Space Diagram Side View ...

Page 31: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 7 Figure 3 4 P34AL Foundation Layout ...

Page 32: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 8 Figure 3 5 Lifting Procedure for P24AL ...

Page 33: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 9 Figure 3 6 Lifting Procedure for P34AL ...

Page 34: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 10 Figure 3 7 Seismic Anchoring Detail for P24AL and P34AL Tube Ice Machines ...

Page 35: ...ply Drain and Refrigeration 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 a...

Page 36: ...eezer Table 3 2 shows the volume required to hold the refrigeration charge of the freezer and the hot gas required for the thaw cycle It is recommended that a heating coil be installed in the receiver to assure that the liquid ammonia is at saturated temperature at the start of each thaw period Note Additional storage volume may be required for the interconnecting piping Add volume of interconnect...

Page 37: ...t the condenser water pump from losing prime during off cycles Proper water treatment for the prevention of mineral and foreign matter accumulation in the condenser or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use The use of a 40 mesh strainer in the condenser water supply line is also recommended P24AL Cylinder P34AL Cylinder Suction Tem...

Page 38: ...usted 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 COOLING TOWER WATER COOLED CONDENSER 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 en...

Page 39: ...o the atmosphere in such a manner as to comply with local and national codes Specific requirements can be found in standards published by the International Institute of Ammonia Refrigeration IIAR Wiring and Electrical Connections WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work with the Tub...

Page 40: ...nected to the elapse time ET indicator in the control panel Figure 3 11 Power Supply Connections Voltage Unbalance Voltage unbalance can cause motors to overheat and fail Voltage unbalance between any two legs should be no greater than 2 Example Supply voltage 230 3 60 Voltage Readings AB 220 Volts BC 225 Volts Average 220 225 227 3 224 Volts AC 227 Volts AB 224 220 4 Volts Highest Deviation BC 22...

Page 41: ...or 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 1LT and the LIQUID FEED 2LT pilot lights will ill...

Page 42: ...ns listed in the Installation Review Checklist and all necessary valves have been opened for operation CAUTION Auxiliary Controls or Equipment When connecting other equipment such as high low pressure switch conveyor motors bin level control etc refer to the control panel wiring drawing for the proper connecting terminals and instructions See Figure 6 3 ...

Page 43: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 19 Figure 3 12 Interconnecting Piping for Vogt P24AL and Vogt 24AHS ...

Page 44: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 20 Figure 3 13 Interconnecting Piping for Vogt P24AL and Dedicated High Side ...

Page 45: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 21 Figure 3 14 Interconnecting Piping for Vogt P34AL and Dedicated High Side ...

Page 46: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 22 Figure 3 15 Interconnecting Piping for Vogt P24AL and Central High Side ...

Page 47: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 23 Figure 3 16 Interconnecting Piping for Vogt P34AL and Central High Side ...

Page 48: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 24 Figure 3 17 Interconnecting Piping for 2 Vogt P34AL and Central High Side ...

Page 49: ...P24AL P34AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 12 2016 3 25 Figure 3 18 Interconnecting Piping for 3 Vogt P34AL and Central High Side ...

Page 50: ... 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...

Page 51: ...h pressure gas which discharges through the oil separator then through the heat coil of the receiver when installed and to the condenser In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid passes through the liquid line through a strainer 43 liquid A solenoid valve 20 check valve 101 and hand expansion valve 17 At the hand e...

Page 52: ...30 seconds to spare before the next freezer period begins This is to prevent refreezing and to allow the ice moving augers etc to clear CAUTION 1 Control Panel 36 Oil Trap 1PG Suction Pressure Gauge 39 Water Tank Drain Valve 2PG Discharge Pressure Gauge 43 Strainer 2 Freezer 44 Receiver Drain Valve 5M Cutter Motor 46 Filter Drier 5R Gear Reducer 49 Freezer Suction Stop Valve or Regulator 6 Water P...

Page 53: ...P24AL P34AL Service Manual HOW YOUR TUBE ICE MACHINE WORKS 12 2016 4 3 Figure 4 1 Piping Schematic for P24AL ...

Page 54: ...P24AL P34AL Service Manual HOW YOUR TUBE ICE MACHINE WORKS 12 2016 4 4 Figure 4 2 Piping Schematic for P34AL ...

Page 55: ...lushing 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 and allowing dry gas to enter the suction side of the compressor The suction gas is then compressed and discharged once again completing the ...

Page 56: ...are attached 9 Reconfirm Rotation Check for 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 Refri...

Page 57: ... 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 an 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 cylind...

Page 58: ...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 psig to 200 psig maximum b Compressor oil pressure Mycom W Series 18 27 psig Vilter 450 Series 35 50 psig c Liquid level in receiver d Compressor oil level While charging the machine the low pre...

Page 59: ...pressure switch 2PS open the control panel door and reconnect wire 24 to the freezer pressure switch Open valve 29 and or receiver liquid feed valve 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 ready for start up and ice production Figure 5 1 Control Panel ...

Page 60: ...ts 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 freeze timer 1TR times out the switch will close and initiate the harvest cycle If a freezer pressure switch 2PS has been installed the su...

Page 61: ...h no hole To cease ice production manually allow the machine to complete the harvest period and start the freeze period When the LIQUID FEED light comes on at the beginning of the freeze period push the STOP button to cease ice production Thaw Gas Regulating and Suction Regulating Valve Adjustment The following is the procedure for regulating valve adjustment On dedicated compressor systems the su...

Page 62: ...P24AL P34AL Service Manual START UP OPERATION 12 2016 5 8 ...

Page 63: ...ween 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 h...

Page 64: ...od with pneumatic timer to delay the actual thawing process Energized during thawing 2CR Control Relay For making and breaking circuits during 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 1TR Freeze Timer Controls the length of ...

Page 65: ...WING 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 a...

Page 66: ...P24AL P34AL Service Manual ELECTRICAL CONTROLS 12 2016 6 4 Figure 6 3 Electrical Schematic for P24AL and P34AL all Voltages 50 60 Hz ...

Page 67: ...ols high 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 f...

Page 68: ...k 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 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 _____________ ...

Page 69: ...r 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 ope...

Page 70: ...sert 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 ri...

Page 71: ...ss add 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 press...

Page 72: ...re 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...

Page 73: ...ST button Always check the machine operation thoroughly after remedying the problem Be sure to correct the source or cause of the problem to prevent the problem from occurring again Symptom Page Machine stopped 8 2 Freeze up due to extended freeze period 8 4 Freeze up due to ice failing to discharge 8 5 Low ice capacity 8 6 Poor ice quality 8 7 High discharge pressure 8 8 Low discharge pressure 8 ...

Page 74: ... head pressure Check delay timer in part wind starts only Water pump cutter motor 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 r...

Page 75: ...mpressor 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 Net oil pressure range Mycom 17 28 psig Vilter 35 50 psig Defective control panel component such as 1PB ...

Page 76: ...s solenoid valve 18 leaking through during freeze if 2PS is used 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...

Page 77: ...ure these controls are working properly Cold prevailing wind can also be a factor Insufficient heat due to non condensables usually air in 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 th...

Page 78: ...d 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 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 pu...

Page 79: ...build up of mineral deposit on the sides and bottom of the tank and opaque ice production Also water distributors restricted 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 pre...

Page 80: ... The refrigerant will be cooler although the pressure will be high Air can be purged from the system by following instructions in Chapter 9 Purging Non Condensables Cooling tower or evaporative 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 required Check...

Page 81: ...om 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 opening stem is in the automatic screwed in position Repair ...

Page 82: ...ycom 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 oil...

Page 83: ...ive motor and repair or replace as needed Symptom High compressor discharge temperature Possible Cause Possible Remedy High head pressure Check gage accuracy and High discharge pressure Defective suction or discharge valves Feel the compressor heads for hot spots or one head running hot Replace worn or leaking valves Restriction in the discharge gas line Check all hand and check valves to make sur...

Page 84: ...P24A P34A Service Manual TROUBLESHOOTING 12 2016 8 12 ...

Page 85: ... 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 ...

Page 86: ...re 9 2 located inside the control panel This timer is a microprocessor based timer housed in a standard 15 terminal CYCL FLEX plug in case Time set points are entered into the unit using a sealed membrane keypad on the front of the unit Each digit in the setpoint is individually increased or decreased by pressing the appropriate keypad switch There is a mode annunciator in the display area on the ...

Page 87: ...on the left on the 9 to 0 transitions when using the pads The display will borrow from the digits on the left on the 0 to 9 transitions when using the pads On ranges 6 and 7 the display will carry on the 59 to 00 transition and borrow on the 00 to 59 transition of the two least significant digits When the desired setpoint is displayed touch the ENT key The new setpoint is entered all and keys beco...

Page 88: ...h corresponding time periods and water temperatures Also see Tables 11 5 or 11 6 Operating Vitals for typical settings When making adjustments allow two ice discharging cycles between adjustments Switch adjustment is as follows See Figure 9 3 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 indic...

Page 89: ...rgized 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 4 governs the ice thawing period It is locat...

Page 90: ...ion 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 gask...

Page 91: ...olding the drive gear to the split taper bushing 7 Using two of the same cap screws in the threaded holes of the bushing jack the gear off the bushing and remove both from the gear reducer shaft 8 Clean the split bushing and tapered hole of the new drive gear and insert the bushing into the drive gear making sure the tapers match 9 Slide the split hub and gear onto the keyed shaft with the key in ...

Page 92: ...h and slide the hub and gear onto the shaft 12 Position the hub on the shaft note measurements previously taken so the full width of the gear teeth will engage when assembled and tightened 13 Tighten the cap screws three or four progressively and uniformly around the hub checking the measurements and adjusting as necessary 14 Install the reducer and mounting plate assembly on the water tank bracke...

Page 93: ...he machine and will have to be disconnected from the tank at the pump inlet bolted flange before moving the water tank 6 Disconnect the ice discharge chute or hopper from the ice discharge opening of the water tank making sure the tank is free to be moved 7 Remove the mounting bolts from around the flange of the tank allowing the tank to be lowered to rest on its casters 8 P34A only the channel su...

Page 94: ...illed 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 5A for parts location and identification Cutter Shaft and Bearing Removal Note Use onl...

Page 95: ...r 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 lbs 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 deflector plate in the ice discharge opening 20 ...

Page 96: ...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...

Page 97: ...P24AL P34AL Service Manual SERVICING OPERATIONS 12 2016 9 13 Figure 9 5B P24A Water Tank Assembly ...

Page 98: ...4 x 1 4 x 3 3 16 S S 12A 2785S04000000 12A 2785S04000000 32 Cutter Adapter Plate 19T2010A1100 19T2010A05 33 Bearing 12A 2020M0200000 12A 2020M02000000 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 2210E01000000 12A 2210E01000000 39 Botto...

Page 99: ...cutter Make sure it is fully seated all the way against the machined shoulder of the cutter bank 9 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 11 Check and adjust cutter heig...

Page 100: ...l adjoin 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 Chapter 10 Pumpdown The function of the pum...

Page 101: ...valve Other valves may also be closed to isolate a particular area which may require 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 Refer to Chapters 1 2 and Append...

Page 102: ...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 Chapter 7 Water Cooled Condensers and Chapter 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 a...

Page 103: ...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 5 When a small amo...

Page 104: ...s 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 pre lubricated and sealed They require no further lubrication The pump should operate with the water level above the impeller hous...

Page 105: ...ession nut manually close the solenoid valve stem in until it protrudes about 1 8 out from the housing 7 Reopen stop valves 90 and check for leaks 8 Adjust the regulating valve to approximately 60 65 psig to the freezer pressure during harvest See Page 5 7 Figure 9 7 Thaw Gas Solenoid Valve Assembly The Liquid Feed Solenoid Valve 20 Figure 9 8 is opened and closed during the freezer cycle by the f...

Page 106: ... 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 Figure 9 8 Liquid Line Solenoid Valve Thaw Chamber Check Valve 101 Fig 9 9 This valve is closed during the freeze cycle to keep the t...

Page 107: ...e 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 ...

Page 108: ...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 1 Always use matched sets or banded belts for multiple belt applications 2 Too much tension shortens belt l...

Page 109: ...is the lowest tension at which the belts will not slip under the highest load condition b Check tension after the first two to four hours and again after 24 to 48 hours of operation then periodically thereafter c If a belt slips tighten it 8 Retighten motor hold down bolts after each adjustment Compressor Servicing Refer to your compressor manual for specific instructions regarding repair and serv...

Page 110: ...P24AL P34AL Service Manual SERVICING OPERATIONS 12 2016 9 26 ...

Page 111: ... 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 1 1 ...

Page 112: ...mmended 2 hours for package machines Figure 10 1 Mitsubishi E1012 Operator Interface The PLC provides a MACHINE FAULT indication with an alarm relay The PLC will log when the fault occurred time and date and where in the cycle the machine was when the fault occurred It will store the last 5 faults in history which can be accessed by pressing the HISTORY button on the interface until the FAULT HIST...

Page 113: ...olor and is distinguished from the red 240VAC or 120VAC control wiring The outputs are externally fused for 2A Outputs 1 and 2 are dry contacts used for high side control interlock and conveyor control Outputs 0 3 11 20 23 are relay type with 120V or 200 240 V connections The LED indicators on the right hand side of the Mitsubishi PLC indicate the power run and error status of the PLC When power i...

Page 114: ...ctor Switch Ice position 4 Water Pump motor starter 5 Freezer Pressure switch 5 Alarm 6 Compressor Motor fault 6 D sol defrost solenoid valve 7 Cutter Motor overload 7 Not used 10 Pump Motor overload 10 Float switch A sol liquid feed valve 11 Oil press safety 11 Cutter motor starter 12 High Low pressure safety 13 Not used 14 High Refrigerant Level HLC Freon Machine only 15 Not used Expansion Modul...

Page 115: ...P24AL P34AL Service Manual OPTIONS AND ACCESSORIES 12 2016 10 5 Figure 10 4 Wiring Schematic P24AL P34AL with Mitsubishi PLC ...

Page 116: ...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 Figure 10 5 Power Monitor The Display The display normally shows the AB BC CA line voltages If the unit is waiting on a timer that timer will be displayed The timer display may be switched off by pressing SELECT The LCD will then...

Page 117: ... OVERVOLTAGE flashes The value may be adjusted by pressing the up and down arrows Imbalance Voltage Tolerance in IMBALANCE flashes The value may be adjusted by pressing the up and down arrows Lockout Time in seconds SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the delay on break timer value Delay time in seconds and tenths of seconds RESP SECONDS flashes The...

Page 118: ...he new settings are saved in permanent memory when the display returns to displaying the line voltage The new settings may be verified by pressing the select button to sequence through the various parameters To prevent tripping on a 1 volt change the DTP 3 automatically calculates cut in voltages for the return from undervoltage conditions The cut out voltage is always based on user voltage and to...

Page 119: ...19 72 Connection Sizes Makeup water FPT 3 4 3 4 3 4 Tank drain FPT 2 2 2 Tank overflow FPT 3 3 3 Flush water FPT 3 4 3 4 3 4 Suction Flanged 3 3 3 Liquid feed FPT Socket 3 4 3 4 3 4 Thaw gas Flanged 2 2 2 Compressor HP KW FLA Dedicated only 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 at Pull down Bt...

Page 120: ... 50 189 50 189 50 189 Connection Sizes Makeup water FPT 1 1 1 Tank drain FPT 2 2 2 Flush water FPT 3 4 3 4 3 4 Tank overflow FPT 3 3 3 Suction Flanged 4 4 4 Liquid feed FPT Socket 1 1 1 Thaw gas Flanged 2 2 2 Compressor HP KW FLA Dedicated 125 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...

Page 121: ...5 34 5 60 5 20 90 4 08 4 27 3 97 5 10 5 34 4 96 Includes 25 blow down per cycle Table 11 3 P24AL 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 3...

Page 122: ...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 5 P24AL 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 123: ...2A 2117C03000000 12A 2117C03000000 Freezer pressure switch Asco PA16A 1 12A 2117T03000000 12A 2117T03000000 Transducer for above control Asco RE10A44 2 12A 7504E01000000 12A 7504E01000000 Fuse 10 amp 3 12A 7504E06000000 12A 7504E06000000 Fuse 15 amp 3 12A 7504E03000000 12A 7504E03000000 Fuse 20 amp 1 12A 7515E16000000 12A 7515E16000000 6 Amp Circuit Breaker 1 12A 7515E08000000 12A 7515E08000000 15...

Page 124: ...210 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 ...

Page 125: ... 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 8 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 126: ...P24AL P34AL Service Manual TABLES CHARTS 12 16 16 11 8 ...

Page 127: ... Crushed Ice Production 10 2 Current Unbalance 3 17 Cutter Adapter Plate Installation 9 16 adjustment 9 16 Cutter Assembly P24AL 9 12 parts list 9 14 9 15 Cutter Assembly Removal and Installation 9 9 Cutter Blade Replacement 9 15 adjustment 9 16 Cutter Disc Removal 9 10 Cutter Gear Reducer 7 7 9 7 drive gear replacement 9 7 gear reducer replacement 9 8 Cutter Height Adjustment 9 3 Cutter Motor Sta...

Page 128: ...side view 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 18 Normal Operating Vitals P24AL and P34AL 11 5 O Operating Features 4 1 Operating Tips 5 6 Operating Vitals P24AL and P34AL 11 5 Operating Weight 2 3 P P24AL heat rejection 3 13 make up water usage 11 4 normal operating vitals 11 5 specifications 11 2 P34AL heat rejection 3 13 make up wa...

Page 129: ... 2 Specifications for P34AL 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 start up 2 3 Stop Push Button 1PB 5 5 6 3 Suction Line Frosting to Compressor 8 12 Suction Regulating Valve 3 12 5 7 T Temperature Pressure Chart 11 7 Thaw Gas Check Valve 101 1 7 9 22 Thaw Gas Regul...

Page 130: ...P24AL P34AL Service Manual INDEX 12 2016 12 4 ...

Page 131: ...Appendix A ...

Page 132: ...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 133: ... 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 149: ...l damages due to its breach of any warranty herein contained or otherwise Without limitation to the foregoing in no event shall SELLER be liable for the loss of use of the product or for the loss of use of any other product process plant equipment or facilities of the PURCHASER whether partially or wholly due to defects in material and or workmanship and or design of SELLER S product and in no eve...

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