Vogt P-34AL-15 Service Manual Download

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P34AL-15 & P34ALOF-15 Service Manual

Options and Accessories

9/22/05

10-4

Figure 10-1b

Mitsubishi FX

-24MR PLC with FX

-2AD Analog Input Module

Inputs Description

Outputs

Description

Not used

C-sol (Suction solenoid valve)

Not used

High Side Control Interlock

Start / Manual Harvest Button (in parallel)

Conveyor Control Contact

Selector Switch (Clean position)

ET - Elapsed Timer

Selector Switch (Ice position) is series w/Bin control

2M – Water Pump motor starter

Freezer Pressure switch (package machines only)

5 Alarm

Compressor overload

6 Harvest

Light

Cutter Motor overload

D-sol (defrost solenoid valve)

Pump Motor overload

UN-sol (compressor unloader) – dedicated compressor

Oil Pressure safety

H-sol (water tank flush valve)

High / Low pressure safety

10 Freeze

light

Not used

Float switch / A-sol (liquid feed valve) & Liquid feed light

Not used

3M – Cutter motor starter (not on Cutterless machines)

Not used

SETUP SCREEN

AUTOSTRT 120M

Figure 10-2

Operator Interface for PLC

Summary of Contents for P-34AL-15

Page 1: ...P 34AL 15 P34ALOF 15 TUBE ICE MACHINE Service Manual 5000 9 22 05 ...

Page 2: ......

Page 3: ...is manual is intended as an informational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 502 635 3024 or 502 634...

Page 4: ...sary 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 floa...

Page 5: ...9 22 05 ...

Page 6: ...3000 Service 502 635 3510 Parts Your Local Distributor or the Tube Ice parts Department Call your local distributor first for all of your parts and service needs Since 1938 Manufacturers of Quality Tube Ice Machines ...

Page 7: ...GT TUBE ICE MACHINES Installation Service Manual and Parts Catalog 12A4171L20 P34AL 15 P34ALOF 15 Model Vogt Tube Ice 1000 W Ormsby Suite 19 Louisville Kentucky 40201 502 635 3000 FAX 502 634 0479 9 22 05 ...

Page 8: ......

Page 9: ...ction 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 Storage prior to installation and start up 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Machine Room 3 1 Space Requirements 3 1 Foundation3 1 Lifting Procedures 3 1 P34AL 15 Space Diagram FIGURE 3 1 3 2 P34ALOF 15 Space Diagram FIGURE 3 2 3 3 Typical Foundation Layout FIGURE 3 3 3 4 ...

Page 10: ... 3 15 3 19 Interconnecting Piping for 3 Vogt P34AL 15 and Central High Side FIGURE 3 16 3 20 Interconnecting Piping for 2 Vogt P34ALOF 15 and Central High Side FIGURE 3 17 3 21 Interconnecting Piping for 3 Vogt P34ALOF 15 and Central High Side FIGURE 3 18 3 22 Installation Review A Checklist 3 23 4 HOW YOUR TUBE ICE MACHINE WORKS Operating Features 4 1 Principle of Operation 4 1 Freeze Period 4 1 ...

Page 11: ...r Distributors 7 3 Water Distributors TABLE 7 1 7 4 Average Hole Size in Tube Ice TABLE 7 2 7 4 Water Tank 7 5 Water Cooled Condenser Cleaning optional 7 5 Cooling Tower Evap Condenser optional 7 5 Compressor optional 7 6 Compressor Maintenance TABLE 7 4 7 7 Oil Trap 7 7 Cutter Gear Reducer 7 7 8 TROUBLESHOOTING List Of Symptoms 8 1 Machine Stopped 8 2 8 3 Freeze Up Due To Extended Freezing Period...

Page 12: ...Gear Replacement 9 7 Gear Reducer Replacement 9 8 Water Tank and Cutter Parts Weights TABLE 9 3 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 Installation 9 12 Typical Cutter Assembly FIGURE 9 5A 9 13 Typic...

Page 13: ...9 25 Belt Tension 9 25 Belt Replacement 9 26 Compressor Servicing 9 26 10 OPTIONS AND ACCESSORIES Crushed Ice Production 10 2 Length of Ice 10 2 PLC Programmable Logic Controller 10 3 Reduced Voltage Cutter Motor Starter 10 13 11 TABLES AND CHARTS P34AL 15 Specifications TABLE 11 1 11 2 P34ALOF 15 Specifications TABLE 11 2 11 3 P34AL 15 Make up Water Usage TABLE 11 3 11 4 P34A Make up Water Usage ...

Page 14: ...P34AL 15 P34ALOF 15 Service Manual TABLE OF CONTENTS vi ...

Page 15: ...ore 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 means of production The machine s economic and reliable ope...

Page 16: ...osed 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 s...

Page 17: ...ase 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 i...

Page 18: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 4 FIGURE 1 1 P34AL 15 Front Side Control Panel ...

Page 19: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 5 FIGURE 1 2 P34AL 15 Right Side ...

Page 20: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 6 FIGURE 1 3 P34AL 15 Left Side ...

Page 21: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 7 FIGURE 1 4 P34ALOF 15 Front Side Control Panel ...

Page 22: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 8 FIGURE 1 5 P34ALOF 15 Right Side ...

Page 23: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 9 FIGURE 1 6 P34ALOF 15 Left Side ...

Page 24: ...P34AL 15 P34ALOF 15 Service Manual INTRODUCTION 9 22 05 1 10 ...

Page 25: ...ing plant requiring refrigerant suction connection 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 condenser unit operating conditions See Start up and Operation for the correct setting of the controls After...

Page 26: ...lbs day K 1000 s lbs day T tons day 03K 3000 lbs day 04K 4000lbs day Consult Specifications for Actual Capacity 03T 3 tons day 05T 5 tons day 10T 10 tons day 25T 25 tons day 50T 50 tons day 80T 80 tons day Electrical Codes 26 208 230 3 60 46 460 3 60 56 575 3 60 25 200 3 50 45 400 3 50 21 230 1 60 Refrigerant F R 22 A Ammonia H R 404a Type of Ice B Cylinder K Crushed D Dual Ice Cru Cyl L 1 1 2 Lon...

Page 27: ... and 3 2 for recommended minimum clearance 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 machine extra space will be required for the cleaning tools Foundation Refer to the space diagrams Figure 3 3 for recommended minimum foundation requirements The figures show anchor bolt ...

Page 28: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 2 ICE DISCHARGE FIGURE 3 1 P34AL 15 Space Diagram ...

Page 29: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 3 ICE DISCHARGE FIGURE 3 2 P34ALOF 15 Space Diagram ...

Page 30: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 4 FIGURE 3 3 Typical Foundation Layout ...

Page 31: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 5 FIGURE 3 4 Typical Lifting Procedure for P34AL 15 ...

Page 32: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 6 FIGURE 3 5 Seismic Anchoring Detail for Tube Ice Machines ...

Page 33: ...tion Connections See FIGURE 1 1 through 1 6 for locations Make Up Water In The water required for ice making must be potable water safe for human consumption and should be of the highest quality available The best way to determine water quality is to have a complete water quality analysis by a qualified laboratory It is advisable to install a particle filter in the make up and flushing water lines...

Page 34: ...oil be installed in the receiver to assure that the liquid ammonia is at saturated temperature at the start of each thaw period The receiver must be located inside a suitable building and must not be subjected to ambient temperatures below 50 F 10 C or above 110 F 43 3 C Note Additional storage volume may be required for the interconnecting piping Add volume of interconnecting piping to the values...

Page 35: ...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 P34AL 15 Cylinder P34ALOF 15 Cylinder Suc...

Page 36: ... with indoor sump Safety Valves Two safety pressure relief valves are an integral part of the packaged Tube Ice machine They are located on the suction accumulator of the freezer Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes Refer to the International Institute of Ammonia Refrigeration IIAR standard for specific requirements a...

Page 37: ...INDOOR SUMP CHECK VALVE Same flow rate to cooling tower Only enough water to maintain head pressure FIGURE 3 7 1 PUMP 3 WAY VALVE Better Freeze Protection COOLING TOWER WATER COOLED CONDENSER INDOOR SUMP CHECK VALVE Outdoor pump is off until indoor sump needs cooling FIGURE 3 8 2 PUMP 2 WAY VALVE Best Freeze Protection ...

Page 38: ...re attached to the structure on the front of the Tube Ice machine see FIGURE 3 9 Incoming 3 phase power will be connected at terminals L1 L2 L3 at the terminal block for operation of the Tube Ice machine and its controls Rotation checking of the cutter motor and water pump and auxiliary equipment is required see rotation check Also if one leg of the 3 phase power is higher or lower wild then it sh...

Page 39: ...is loose or dirty L2 and or L3 will have higher current Higher current causes more heat to be generated in the motor windings The maximum acceptable current unbalance is 10 Example Current Readings L1 96 Amps L2 91 Amps Average 96 91 98 3 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation L3 98 95 3 Amps Current Unbalance 100 x 4 95 4 2 Acceptable Rotation Check The cutter and pum...

Page 40: ...At the terminal block or at the power disconnect reverse wires L1 and L2 4 Make sure these terminals are tight and restore power to the machine 5 Perform rotation check again to confirm that it is correct CAUTION Do not attempt to start the machine until first making sure all conditions listed in the Installation Review Checklist and all necessary valves have been opened for operation CAUTION Auxi...

Page 41: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 15 FIGURE 3 11 Interconnecting Piping for Vogt P34AL 15 and Dedicated High Side ...

Page 42: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 16 C C C C C C FIGURE 3 12 Interconnecting Piping for Vogt P34AL 15 and Central High Side ...

Page 43: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 17 FIGURE 3 13 Interconnecting Piping for Vogt P34ALOF 15 and Central High Side ...

Page 44: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 18 FIGURE 3 14 Interconnecting Piping for Vogt P34ALOF 15 and Central Screw Compressor ...

Page 45: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 19 FIGURE 3 15 Interconnecting Piping for 2 Vogt P34AL 15 and Central High Side ...

Page 46: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 20 FIGURE 3 16 Interconnecting Piping for 3 Vogt P34AL 15 and Central High Side ...

Page 47: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 21 FIGURE 3 17 Interconnecting Piping for 2 Vogt P34ALOF 15 and Central High Side ...

Page 48: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 22 FIGURE 3 18 Interconnecting Piping for 3 Vogt P34ALOF 15 and Central High Side ...

Page 49: ...pply 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...

Page 50: ...P34AL 15 P34ALOF 15 Service Manual INSTALLING YOUR TUBE ICE MACHINE 9 22 05 3 24 ...

Page 51: ...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 expansion valve 17 the refrigerant expands from a saturated high pressure liquid state to...

Page 52: ...or the time required for all the ice to clear the freezer plus 30 seconds more CAUTION Make sure all the ice clears the freezer with at least 30 seconds to spare before the next freezer period begins This is to prevent refreezing and to allow the ice moving augers etc to clear CAUTION 1 Control Panel 36 Oil Trap 1PG Suction Pressure Gauge 39 Water Tank Drain Valve 2PG Discharge Pressure Gauge 43 S...

Page 53: ...P34AL 15 P34ALOF 15 Service Manual HOW YOUR TUBE ICE MACHINE WORKS 9 22 05 4 3 FIGURE 4 1 Piping Schematic for P34AL 15 ...

Page 54: ...P34AL 15 P34ALOF 15 Service Manual HOW YOUR TUBE ICE MACHINE WORKS 9 22 05 4 4 FIGURE 4 2 Piping Schematic for P34ALOF 15 ...

Page 55: ...e 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 cycle As ice continues to for...

Page 56: ... 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 condensables or other contaminants The machine will require a full charge of pure anhydrous ammonia Make sure it is from a reputable supplier who can and will furnish quality ammonia of Refrigeration or Federal Technical grade Gra...

Page 57: ...zer to the receiver Again make sure all the necessary valves are opened for operation and the compressor crankcase heater has been energized for a minimum for four hours Follow these instructions with caution 1 Using a approved for ammonia charging hose connect one end to the charging valve 28 in the liquid line near the freezer 2 Lay a full cylinder of anhydrous ammonia horizontally with the cyli...

Page 58: ...gerant from a refrigeration system into a cylinder can be very dangerous and is not recommended As the machine is being charged continually observe the following operating characteristics a Discharge pressure 175 psi to 200 psi maximum b Compressor oil pressure Mycom W Series 18 27 psi Vilter 450 Series 35 50 psi c Liquid level in receiver d Compressor oil level While charging the machine the low ...

Page 59: ...plished as follows 1 Make sure the crankcase oil temperature is approximately 100 F and there is no liquid ammonia in the compressor crankcase 2 Turn the Hand Auto switch 1SS to the Hand position and allow the water tank to refill MAKE SURE THE DRAIN VALVE IS CLOSED 3 If the compressor motor starter is wired to the control relay 3CR then push the green Start push button to start the compressor and...

Page 60: ...ral complete cycles of ice production to confirm the satisfactory operation of the machine IMPORTANT Complete the remaining part of the Warranty Registration Start Up Report and return it to the Tube Ice IMPORTANT Check the refrigerant level at the receiver liquid gage glass to make sure it is near the operating level mark Adding Refrigerant Add refrigerant while the machine is running by the foll...

Page 61: ...lve Adjustment The following is the procedure for regulating valve adjustment On dedicated compressor systems the suction regulating valve is not required However the compressor must unload by 50 or greater during the harvest or a hot gas bypass must be installed 1 Install gauge and gauge valve in gauge port of regulator 2 Turn high pressure stem down stream pressure on suction regulator into the ...

Page 62: ...P34AL 15 P34ALOF 15 Service Manual START UP OPERATION 9 22 05 5 8 ...

Page 63: ...iliary equipment fails Bin Level Control Included in the wiring schematic is provision for a bin level control BLC The NC contract of your control should be wired between terminals 8 9 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown However the machine will still need to be manually started to resume productio...

Page 64: ...ing freezing and thawing period 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 ...

Page 65: ... Thawing 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 independent...

Page 66: ...P34AL 15 P34ALOF 15 Service Manual ELECTRICAL CONTROLS 9 22 05 6 4 OPTIONAL 110 VOLT SECONDARY FIGURE 6 3 Typical Electrical Schematic all Voltages 50 60 Hz ...

Page 67: ...P34AL 15 P34ALOF 15 Service Manual ELECTRICAL CONTROLS 9 22 05 6 5 FIGURE 6 4 Optional PLC Electrical Schematic all Voltages 50 60 Hz ...

Page 68: ... controls 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...

Page 69: ...g Leak check entire system Check liquid refrigerant level in receiver Drained oil from oil trap Compressor crankcase heater working Compressor net oil pressure gage reading less suction 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 70: ...o be stopped and restarted to dispel air 9 Turn switch to Auto position to stop the pump Drain and flush the water tank Repeat cleaning as necessary 10 After cleaning fill the tank with fresh water start the pump again and circulate for 15 minutes 11 Stop the pump drain and flush the tank and again refill with fresh water 12 Remove the cover from the ice discharge opening and clean any area that m...

Page 71: ...t the distributor while pulling upward 3 Lift the distributor out of the hole To install the distributors 1 Insert one in each tube hole and seat firmly by using a short piece of pipe or conduit 2 Slide the pipe or conduit down over the vent tube and gently tap the distributor in place 3 Do not allow the distributor to be recessed below the top of the tube sheet To replace the cover 1 Replace wate...

Page 72: ...ry See Servicing Section Condenser Cooling Tower Evap Condenser optional 1 Bleed off valve The bleed off valve should be checked monthly to assure that is not blocked and that water is flowing as required If the unit is controlled by a water treatment system the bleed off valve may not be required 2 Strainer The pan or sump strainer is located in the bottom of the sump at the suction connection to...

Page 73: ...ssor manual for manufacturers recommended maintenance In starting and charging the unit the oil sight glass should be continually checked to make sure an adequate oil level is maintained The oil level should be 1 4 3 4 of the sight glass If the oil level drops below 1 4 of the glass add refrigeration oil as per the compressor manufacturer recommendations Never allow the oil level to be out of sigh...

Page 74: ...r which has an automatic return some oil will pass through the separator and eventually settle in the oil trap 36 which is offset from the base of the freezer This oil trap will have evidence of frost on its surface during the freeze cycle and may be more pronounced at the end of a normal freeze cycle just before the harvest Where there is oil in the trap there will not be frost Where there is fro...

Page 75: ...7 8 P34AL 15 P34ALOF 15 Service Manual MAINTENANCE 9 22 2005 CAUTION Follow all lockout and tag out procedures before servicing any electrical equipment CAUTION ...

Page 76: ...rvest 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...

Page 77: ...re 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 or defective ...

Page 78: ...pressor 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 1...

Page 79: ...aw gas 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 unload...

Page 80: ...e sure 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...

Page 81: ...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 pumping full...

Page 82: ...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 83: ...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 required Chec...

Page 84: ...ymptom 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 Rep...

Page 85: ...The 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 o...

Page 86: ...ient liquid refrigerant feed Check float and float switch solenoid valve and coil 20 in liquid line strainer and refrigerant level in receiver Water pump rotation incorrect or pump defective Check pump motor rotation Check for leaking pump seal or defective motor and repair or replace as needed Symptom High compressor discharge temperature Possible Cause Possible Remedy High head pressure Check ga...

Page 87: ...w 30 psi Use a by pass to relieve the pressure in the evaporator before opening the main suction valve Ensure that the compressor is unloading properly Defrost gas sourced from compressor discharge superheated gas Connect the defrost gas source to the receiver as recommended Use a by pass to relieve the pressure in the evaporator before opening the main suction valve Refrigerant contaminated with ...

Page 88: ...P34AL 15 P34ALOF 15 Service Manual TROUBLESHOOTING 9 22 05 8 13 ...

Page 89: ... the thaw mode The water level during the freeze mode should always be below the overflow piping to prevent excessive waste of cold water resulting in loss of ice capacity If it should become necessary to clean the float valve close the stop valve in the make up water line to the machine and remove the float valve After the valve has been cleaned and reinstalled check to ascertain if the proper wa...

Page 90: ...thickness is controlled by the freeze timer 1TR Figure 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 The...

Page 91: ...digit on the left on the 9 to 0 transitions when using the Δ 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 Δ and...

Page 92: ...gs with corresponding time periods and water temperatures Also see TABLE 11 8 11 9 Operating Vitals for typical settings When making adjustments allow two ice discharging cycles between adjustments Switch adjustment is as follows See Figure 9 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 ind...

Page 93: ...energized for a minimum of four 4 hours and no liquid refrigerant in the crankcase before restarting the machine When ready to restart the machine depress the Start button As usual initiate a harvest cycle if there is ice remaining in the freezer Check Amp draw through the breaker for excessive load or unbalance Thawing Timer The thawing timer 2TR Figure 9 4 governs the ice thawing period It is lo...

Page 94: ...ter piping and drain the condenser Generally additional water can be drained by loosening the cover heads and separating the covers from the condenser end 5 Remove the heads bolts and gasket completely 6 Inspect the tubes for excessive corrosion and possible ammonia leaks to determine whether or not further cleaning is feasible 7 Clean the inside of each tube as well as possible being careful not ...

Page 95: ...ews holding 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 ke...

Page 96: ...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 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 uniforml...

Page 97: ...iciently 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 tank and remove the circulating water tubing from the pump 5 P34A only the water pump is mounted to the structural frame of the machine and will have to be disconnected from the tank at...

Page 98: ...r disc from the tank Be sure the support arms are match marked for reassembly You may have to gently drive the support arms up or down to release them from the tank walls 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 ...

Page 99: ...r over the shaft and into the housing 10 With the top end of the shaft supported install the lower bearing on the shaft driving it down into the housing firmly against the housing shoulder 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 ...

Page 100: ...e the cutter to check all points If adjustment is necessary loosen the four side bolts and raise or lower each arm as needed Tighten the bolts securely to approximately 90 ft 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 boltholes 2 Push the water tank in and under the freezer alignin...

Page 101: ...P34AL 15 P34ALOF 15 Service Manual SERVICING OPERATIONS 9 22 05 9 13 Figure 9 5A Typical Cutter Assembly ...

Page 102: ...P34AL 15 P34ALOF 15 Service Manual SERVICING OPERATIONS 9 22 05 9 14 Figure 9 5B Typical Water Tank Assembly ...

Page 103: ...rew 3 8 16 x 1 12A 2215H6110000 43 Cap Screw 5 8 11 x 1 1 2 S S 4 12A 2215L11130000 44 Carriage Bolt 3 8 16x1 1 4 4 12A 2218H11120000 45 Mach Screw 3 8 16 x 2 Flat 8 12A 2226H11180000 46 Hex Nut 3 8 16 S S 12 12A 2240A11090000 47 Slotted Nut 1 14 NF S S 12A 2240E12160000 48 Lock washer 5 16 S S 12A 2250B10800000 49 Lock washer 3 8 S S 12A 2250B10900000 50 Lock washer 5 8 S S 12A 2250B11300000 51 1...

Page 104: ... 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 blades ar...

Page 105: ...o the edge of the blade See Figure 9 3 Using two C clamps to hold the adapter plate securely in place drill four 7 16 diameter holes through the adapter plate and through the cutter plate at the same time so they will adjoined properly 4 Countersink the holes in the adapter plate to make the bolt heads flush with the plate 5 Install bolts and spacers as illustrated and tighten securely Note the le...

Page 106: ...from the freezer pressure switch 2PS and insulate the end to prevent a short circuit 6 Restore power to the machine and start the water pump only to circulate warm water through the freezer 7 When the suction pressure increases to 70 psig or higher start the compressor and allow the machine to stop automatically by the low pressure switch at approximately 15 psig Lower pressure can be obtained by ...

Page 107: ...ks and 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...

Page 108: ...ints 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 that escapes the oil separator will pass through the receiver and to the freezer where it will settle in the oil trap 36 Indication of oil in the trap will be evident by the frost line At the end of a freeze cycle frost or ice will f...

Page 109: ... temperature A 5 CFM or larger vacuum pump is best 10 During evacuation add new oil to the compressor Also purge the receiver for non condensables 11 After evacuation break the vacuum by manually opening the liquid line solenoid valve and gradually opening the liquid line stop valve 29 or at the receiver letting liquid ammonia enter the freezer and raise the pressure 12 When the freezer suction pr...

Page 110: ...n that part of the line 3 Loosen the 1 4 tubing compression nut at the strainer slightly to purge that section of the thaw gas line and continue to purge until all pressure is relieved 4 Repair or replace the valve as needed making sure all connections are tight 5 With the valve manually opened stem out open slightly only one stop valve 90 and purge air from the line through the 1 4 tubing compres...

Page 111: ...iquid feed solenoid valve 2 Manually open screw stem in until only 1 8 protrudes and allow the liquid to flow to the freezer and clear this part of the line of liquid leaving only vapor 3 Close the other hand stop valve 29 downstream This will isolate the solenoid valve 4 Purge the remaining ammonia from this line through the strainer purge valve 75 5 Repair or replace the valve as needed making s...

Page 112: ...rm the water in the tank thereby improving the ice quality Repair or replace as follows 1 Turn off the water supply to this valve 2 Dismantle the valve and inspect for dirt etc and wear Reverse osmosis water can cause premature wear and erosion of the brass parts of this valve you may want to consider replacing the valve with a stainless steel valve 3 Repair or replace the valve as needed 4 Turn o...

Page 113: ... for foreign material such as sludge metal flakes burrs or anything that may look unusual indicating excessive wear or damage 6 Remove all remaining oil and wipe out the compressor with a lint free cloth The extent of internal inspection should be dependent on the degree of evidence of wear 7 Inspect and clean the oil strainer Cleaning can be accomplished with light oil diesel fuel or mineral spir...

Page 114: ... 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 make sure they are parallel and check the flywheel and motor sheave with a straight edge string or wire to make sure they are parallel and in the same plain Make adjustment as required 7 Adjust t...

Page 115: ...P34AL 15 P34ALOF 15 Service Manual Options and Accessories 9 22 05 10 1 10 Options and Accessories ...

Page 116: ... tank assembly for unrestricted access The result is that the ice is approximately 1 2 long and frozen only 3 16 1 4 thick A modification of this type is not one you would want to make every time a temporary change to crushed ice was wanted Contact your distributor for more information and complete details Length of Ice Ice length can be changed by increasing or decreasing the length of the spacer...

Page 117: ...ply for the unit can be 100 240VAC 50 60 Hz and is internally fused for 3A The inputs are 24VDC internally fused for 5 7mA and supplied by the PLC All 24VDC control wiring is blue in color and is distinguished from the red 240VAC 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 are relay...

Page 118: ...Switch Ice position is series w Bin control 4 2M Water Pump motor starter 5 Freezer Pressure switch package machines only 5 Alarm 6 Compressor overload 6 Harvest Light 7 Cutter Motor overload D sol defrost solenoid valve 10 Pump Motor overload UN sol compressor unloader dedicated compressor 11 Oil Pressure safety 7 H sol water tank flush valve 12 High Low pressure safety 10 Freeze light 13 Not use...

Page 119: ...P34AL 15 P34ALOF 15 Service Manual Options and Accessories 9 22 05 10 5 Figure 10 3 Wiring Schematic ...

Page 120: ...TART MODE POWER FAILURE Auto Restart On 120M Auto Restart Off With the ICE OFF CLEAN selector switch in the ICE positions the machine will begin a harvest cycle when the START button is pressed The machine starts in the harvest cycle to clear any ice from the freezer if a power failure has occurred HARVEST MODE The interface will display the current harvest time and the previous cycle harvest time...

Page 121: ...e compressor and water pump are running and the liquid feed valve A Valve is closed The pumpdown sequence will move most of the refrigerant from the freezer to the receiver for servicing operations If the MANUAL HARVEST button is pressed the Cutter and D Sol Thaw gas valve will come on This will clear the freezer of any ice that may have formed during the pumpdown It is recommended that the king v...

Page 122: ... pump clean cycle return the switch to the CLEAN position and press the START button C SETUP SCREEN CLEAN MODE CLEAN TIME M The machine will automatically exit the clean cycle after a 2 hour period At the completion of the clean cycle the interface will always return to the start up display requiring that the START button be pressed START MODE PRSS START BUTTN After pressing the START button the m...

Page 123: ... protection trips open The machine will stop immediately and the overload reset button located on the motor starter must be depressed B SILENCE ALARM A RESTART FAULT PUMP O L RESET B SILENCE ALARM A RESTART FAULT PUMP O L OL OK When the overload has been reset the interface will display OL OK It will be necessary to press A on the operator interface to restart the machine The cutter overload fault...

Page 124: ...n of either of these conditions A long cycle is defined as a freeze cycle that extends for a duration of one hour This could be caused by an open drain valve leaking hot gas valve or defective compressor The short cycle safety will stop the machine after three consecutive freeze cycles of less than five minutes duration Short cycling can be caused by a restriction in the liquid line inadequate mak...

Page 125: ...YR DLAY S CNVYR RUN S BLOWDOWN S CUTTR DLAY S HARVEST S SETUP SCREEN AUTOSTRT M CNVYR DLAY S CNVYR RUN S SUCT DLAY S BLOWDOWN S Note SUCT DLAY time delay opening of main suction valve used on cutterless machines To change the value of a variable scroll to that line press the SET button on the interface enter the new value using the numeric key pad and press ENTER to accept the new value Note When ...

Page 126: ...y taking an average of 5 scans then a freeze time calculated CALC FRZ 12 50 M AVG WTR TMP 70F SELCT SUC TMP 1 Three different equations will be entered to allow for 3 different freeze times based on three different suction temperatures Setup screen 3 4 B MONITOR SELCT SUC TMP 1 CALC FRZ 5 42M B MONITOR SELCT SUC TMP 2 CALC FRZ 6 60M B MONITOR SELCT SUC TMP 3 CALC FRZ 8 42M TIME User enters the des...

Page 127: ...3 C SETUP SCREEN 2 B NXT FORMULA PG SETUP SCREEN 3 T1 M1 B1 This screen is were the constants m1 b1 are entered for a given suction temp T1 Freeze cycle time will be determined using the linear equation y mx b For suction temp T1 Freeze Time m1 water temp b1 Note Constants m b must be whole numbers When creating a new curve using EXCEL multiply the calculated values by 1000 See example below A tre...

Page 128: ...p 5 10 15 Water Temp Freeze Time min Calc Time sec Water Temp Freeze Time min Calc Time sec Water Temp Freeze Time min Calc Time sec 50 4 4 264 50 5 4 323 50 6 9 413 60 4 7 282 60 5 7 344 60 7 3 440 70 5 0 300 70 6 1 365 70 7 8 467 80 5 3 318 80 6 4 386 80 8 2 494 90 5 6 336 90 6 8 407 90 8 7 521 m1 30 b1 2900 m2 35 b2 3630 m3 45 b3 4630 P24AL 1 1 4 Suction Temp 5 10 15 Water Temp Freeze Time min ...

Page 129: ...oad free turn off the power rotate the INITIAL TORQUE adjustment in the appropriate direction until the load just begins to move when power is first applied Start Time Adjustment The START TIME adjustment range is 1 2 to 30 seconds for a motor voltage from 10 to 100 of line voltage The higher the value of the INITIAL TORQUE the shorter the duration of the overall time period In most applications i...

Page 130: ...P34AL 15 P34ALOF 15 Service Manual Options and Accessories 9 22 05 10 16 ...

Page 131: ...P34AL 15 P34ALOF 15 Service Manual TABLES CHARTS 9 22 05 11 1 11 Tables Charts ...

Page 132: ...89 50 189 Connection Sizes makeup water FPT 1 1 2 1 1 2 1 1 2 tank drain FPT 2 2 2 tank overflow FPT 3 3 3 flush water FPT 3 4 3 4 3 4 suction Flanged 4 4 4 liquid feed FPT Socket 1 3 4 3 4 thaw gas Flanged 2 1 2 2 2 Compressor HP KW FLA Dedicated only 150 44 7 176 150 44 7 176 150 44 7 176 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 3 2 2 4 1 3 2 2 4 1 3 2 2 4 1 THR ...

Page 133: ...189 50 189 50 189 Connection Sizes makeup water FPT 1 1 2 1 1 tank drain FPT 2 2 2 flush water FPT 3 3 4 3 4 tank overflow FPT 3 4 3 3 suction Flanged 6 6 6 liquid feed FPT Socket 1 1 1 thaw gas Flanged 2 1 2 2 2 Compressor HP KW FLA Dedicated 150 44 7 176 150 44 7 176 150 44 7 176 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 3 2 2 4 1 2 1 5 3 2 2 1 5 3 2 THR Btu hr kW...

Page 134: ... 9 5 7 2 10 2 11 8 11 4 90 9 8 9 1 6 9 9 8 11 4 11 05 Includes 25 blowdown per cycle Table 11 3 P34AL 15 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 12 7 12 1 9 1 12 7 14 6 13 6 50 12 1 11 5 8 7 12 1 14 0 13 1 60 11 7 11 0 8 22 11 7 13 5 12 7 70 11 2 10 5 7 8 11 2 13 0 12 3 80 10 8 10 3 7 5 10 8 12 5 11 9 90 10 4 9 6 7 1 ...

Page 135: ...0 340 1231 8 6 8 2 7 8 7 3 6 9 U 1 1 2 26 53 180 66 24 303 333 910 5 7 5 4 5 2 4 9 4 6 Table 11 5 P34AL 15 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 27 56 180 63 60 175 205 129...

Page 136: ... 2 210 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...

Page 137: ...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 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 l...

Page 138: ...Appendix A ...

Page 139: ...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 140: ... 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 156: ... Ice Production 10 2 Current Unbalance 3 17 Cutter Adapter Plate Installation 9 18 adjustment 9 18 Cutter Assembly P24AL 9 14 parts list 9 15 9 16 Cutter Assembly Removal and Installation 9 10 Cutter Blade Replacement 9 17 adjustment 9 18 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 1...

Page 157: ... Gases 9 20 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 water usage 11 4 normal operating vitals 11 5 specifications 11 3 Piping and Drain Connections 3 11 Pipi...

Page 158: ...tarter 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 25 Thaw Gas Regulating Valve 18 1 5 1 9 9 23 9 24 5 7 Thaw Gas Stop Valve 90 1 5 1 9 Thawing Timer 2TR 9 5 Three...

Page 159: ...P24AL P34AL Service Manual INDEX 9 22 05 12 4 ...

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