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05TA Service Manual

MAINTENANCE

7/19/13

7-9

For The Manager Who Depends Upon This Machine For Efficient Operation.

“Preventive Maintenance” simply means that you or a delegated employee makes a daily visual
check of your Tube-Ice

®

machine. Here is what to look for and why:

Daily checklist:

1. Is the machine running or is the bin full

2. Bin doors kept closed

3. Thermostat bulb in bracket

4. Ice quality (clarity and uniformity)

5. Does all ice discharge during harvest

6. Cleanliness

7. Unusual noises

Why?

When you make these simple observations on a daily basis, you insure the smooth production

of ice for your facility. When you are aware of the proper operating conditions and observe them on
a daily basis, changes in these conditions can alert you to changes in the operation of the machine
which may require maintenance--long before a service situation arises.

“An ounce of prevention is worth a pound of cure!”

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Summary of Contents for P118F/HE100

Page 1: ...05TA TUBE ICE MACHINE Includes model P118F HE100 Manual Part Number 12A4171M06 Revision 3 Service Manual 5000 ...

Page 2: ...ormational 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 IMPORTANT To activate the machine warrant...

Page 3: ...ouisville Kentucky since 1880 Sales 800 853 8648 Service 502 635 3000 Parts Your Local Distributor Call your local distributor first for all of your parts and service needs Since 1880 Manufacturers of Quality Tube Ice Machines ...

Page 4: ...Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M06 05TA Model ...

Page 5: ...HINE Water Supply and Drain Sizes TABLE 3 1 3 1 Cooling Tower 3 2 Space Diagram Air Cooled Machine FIGURE 3 2A 3 3 Space Diagram Water Cooled Machine FIGURE 3 2B 3 4 Control Panel Power Connections FIGURE 3 3 3 5 Electrical Specifications TABLE 3 2 3 5 Phase Check Voltage and Current unbalance 3 6 Rotation Check 3 6 Air Cooled Condenser Installation Instructions 3 7 Pounds of R 22 404A to Add Vs L...

Page 6: ...URE 6 1 6 1 Control Panel Components Standard FIGURE 6 2 6 2 Control Panel Door w Power monitor option Standard FIGURE 6 2A 6 3 Control Panel Components CE Australian approval FIGURE 6 2B 6 4 Control Panel Components and Part Numbers TABLE 6 1 6 5 Description of Control Panel Component Function TABLE 6 2 6 6 Electrical Schematic All Voltages 50 60 Hz All Voltages FIGURE 6 3 6 7 Copeland Compressor...

Page 7: ...0 9 SERVICE OPERATIONS Adjustable Blowdown For Clearer Ice FIGURE 9 1 9 1 Automatic Blowdown Harvest Cycle 9 1 Float Valve Make Up Water 9 1 Float Switch 9 2 Hansen Refrigerant Float Switch FIGURE 9 2 9 2 Hand Expansion Valve 9 3 Freezer Pressure Switch 9 3 Freezer Pressure Switch Allen Bradley FIGURE 9 3 9 3 High Low Pressure Switch 9 4 High Low Pressure Switch FIGURE 9 4 9 4 Head Pressure 9 4 Wa...

Page 8: ...e 9 18 Refrigerant Leaks 9 18 Non Condensable Gases 9 18 Compressor Motor Burnout 9 19 Capacity Control Valve Compressor Unloader 9 20 Copeland Compressor Unloader Valve FIGURE 9 15 9 20 Loaded Operation Freeze Period 9 20 Unloaded Operation During Thaw Only 9 20 Cutter Motor 9 21 Cutter Gear Reducer 9 21 Water Tank Removal 9 22 Cutter Bearing Removal Installation 9 22 Cutter Assembly FIGURE 9 16 ...

Page 9: ...ABLE 11 1 11 2 05TA Specifications 380V 3Ph 50Hz TABLE 11 2 11 3 05TA Capacity Ratings TABLE 11 3 11 4 Condenser Water Usage TABLE 11 4 11 5 Make up Water Usage gpm TABLE 11 5 11 5 Normal Operating Vitals TABLE 11 6 11 5 Recommended Spare Parts List 11 6 Temperature Pressure Chart for Common Refrigerants TABLE 11 7 11 7 Conversion Factors English to Metric TABLE 11 8 11 8 Constants TABLE 11 9 11 8...

Page 10: ...05TA Service Manual TABLE OF CONTENTS vi ...

Page 11: ... customers more than 35 years of dependable service Ask someone who owns one Preview All the skill in engineering and fabrication that we have learned in over a century of experience is reflected in the 05TA model Tube Ice machines Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s e...

Page 12: ...inder valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary and illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation F...

Page 13: ...nderstand the operation of this machine and be aware of possible dangers These Safety Symbols will alert you when special care is needed Please heed DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates a strong possibility of a hazard and that an unsafe practice could result in severe personal injury WARNI...

Page 14: ...R MOTOR SOLENOID VALVE A FLARE 17 HAND EXPANSION VALVE 6 CIRCULATING WATER PUMP 28 CHARGING VALVE 1 4 12 MAKE UP WATER ICE DISCHARGE 20 LIQUID LINE FLOAT VALVE 43 STRAINER 1PG LOW PRESSURE GAGE 2PG HIGH PRESSURE GAGE 59 RECEIVER ACCESS VALVE 30 RECEIVER GAGE GLASS 18 THAW GAS SOLENOID VALVE VALVE D VALVE 50 RECEIVER SAFETY VALVE 31 RECEIVER GAGE GLASS STOP VALVE 51 FREEZER SAFETY VALVE 32 CONDENSE...

Page 15: ...IBUTING 6A WATER PUMP CHECK VALVE 16 THAWING CHAMBER 88 SUCTION ACCUMULATOR VALVE 7 WATER TANK 2 FREEZER 46 LIQUID LINE FILTER DRIER 35 COMPRESSOR DISCHARGE SERVICE 34 COMPRESSOR SUCTION SERVICE VALVE 13 HEAT EXCHANGER 25 WATER TANK DRAIN CONNECTION 1 FPT 3 COMPRESSOR 91 LIQUID RETURN STOP VALVE 15R RECEIVER ...

Page 16: ...ed Right Side View X VALVE 14 OIL SEPARATOR 58 LIQUID OUTLET STOP VALVE KING VALVE 55 DISCHARGE LINE STOP VALVE 4PS DUAL HIGH LOW PRESSURE SWITCH 41A CONDENSER PRESSURE CONTROL SWITCH 18S DEFROST PRESSURE SWITCH SOLENOID VALVE 53 COLD WEATHER DISCHARGE MUFFLER 48 COMPRESSOR ...

Page 17: ... PRESSURE GAGE 2PG HIGH PRESSURE GAGE 59 RECEIVER ACCESS VALVE 1 4 FLARE 30 RECEIVER GAGE GLASS 18 THAW GAS SOLENOID VALVE D 90 THAWING GAS STOP VALVE 15 CONDENSER 50 RECEIVER SAFETY VALVE 5 8 FLARE 52 CONDENSER SAFETY VALVE 1 CONTROL PANEL 94 OIL PRESSURE SWITCH 44 RECEIVER DRAIN VALVE 31 RECEIVER GAGE GLASS STOP VALVE 24 CONDENSER WATER 23 CONDENSER WATER INLET OUTLET 5R CUTTER GEAR REDUCER 22A ...

Page 18: ...DISCHARGE LINE WATER PUMP 6 CIRCULATING 16 THAWING CHAMBER 6A WATER PUMP CHECK VALVE 88 SUCTION ACCUMULATOR HEAT EXCHANGER 7 WATER TANK 2 FREEZER 46 LIQUID LINE FILTER DRIER 35 COMPRESSOR DISCHARGE SERVICE VALVE 34 COMPRESSOR SUCTION SERVICE VALVE 13 HEAT EXCHANGER 25 WATER TANK DRAIN CONNECTION 1 FPT 3 COMPRESSOR 91 LIQUID RETURN STOP VALVE 15R RECEIVER ...

Page 19: ...CTION 7 19 13 1 9 FIGURE 1 6 Assembly Water Cooled Right Side View DISCHARGE MUFFLER 48 COMPRESSOR 15 CONDENSER 14 OIL SEPARATOR 58 LIQUID OUTLET STOP VALVE KING VALVE PRESSURE SWITCH 4PS DUAL HIGH LOW SWITCH 18S DEFROST PRESSURE ...

Page 20: ...05TA Service Manual INTRODUCTION 7 19 13 1 10 ...

Page 21: ...lugs should be used whenever possible CAUTION The Tube Ice machine is top heavy Secure to avoid tipping CAUTION If a forklift is used make sure its capacity is sufficient The forks must be wide enough apart to prevent tipping sideways and must extend beyond the extremities of the frame base structure The machine needs to be bound in place to prevent tipping Safety Valves Safety pressure relief val...

Page 22: ...ator assigned to specific variations 000 or Blank Standard Product If unsure of the product code shown on your machine please consult the factory Model Variation A number assigned to indicate major variations within any one family series Basic Configuration P Package L Low side H High side Storage prior to installation or start up The machine must not be stored or installed in an area that may rea...

Page 23: ...e for satisfactory operation of the machine is 30 psig The maximum allowable pressure is 100 psig CAUTION Make up Water In Water Tank Drain Condenser Water In Condenser Water Out 1 2 MPT 1 FPT 1 1 4 FPT 1 1 4 FPT TABLE 3 1 Water Supply and Drain Sizes The condenser water outlet and water tank drain connections must be extended separately to an open drain or sump arranged for visible discharge Do n...

Page 24: ... bulb of 78 F is typical in the U S but many localities have design wet bulbs as low as 72 F or as high as 82 F The cooling tower water pump must be capable of delivering the required volume of water through the condenser Due to cooling tower location and pressure drop through water lines and water regulating valves the pump must be sized for each installation Refer to TABLE 11 1 for condenser wat...

Page 25: ...ON FIBER SEAL PART 12A 2600T01 ROTA LOCK FIELD CONNECTOR PART 12A 2396A0601 1 3 8 IDS X 1 3 4 12 THREADS F ROTA LOCK TEFLON FIBER SEAL PART 12A 2600T03 SHOWN FROM TOP OF ICE MACHINE 40 MINIMUM CLEARANCE FOR COMPRESSOR ACCESS 1 FPT DRAIN REAR OF UNIT 40 MINIMUM CLEARANCE FOR WATER TANK ACCESS 1 2 MPT MAKE UP WATER IN 30 MINIMUM CLEARANCE FOR CONDENSER CLEANING 12 MINIMUM CLEARANCE FOR INSTALLATION ...

Page 26: ...IT 85 1 1 4 FPT CONDENSER WATER OUT 1 1 4 FPT CONDENSER WATER IN 12 MINIMUM CLEARANCE FOR INSTALLATION AND ACCESS 11 3 4 32 60 6 5 8 7 1 2 30 MINIMUM CLEARANCE FOR CONDENSER CLEANING 40 MINIMUM CLEARANCE FOR WATER TANK ACCESS PROVIDE SUFFICIENT SPACE ICE DISCHARGE 1 2 MPT MAKE UP WATER IN 40 MINIMUM CLEARANCE FOR COMPRESSOR ACCESS FIGURE 3 2B Connections and Space Diagram Water Cooled Machine ...

Page 27: ...wing section Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 Connect the Ground wire to the Ground lug provided FIGURE 3 3 Control Panel Power Connections Water Cooled Air Cooled Standard Voltages F L A Min Ampacity Max Fuse F L A Min Ampacity Max Fuse 208 230 3ph 60 Hz 66 9 81 8 145 80 9 95 8 160 460 3ph 60 Hz 32 7 39 9 70 39 7 46 9 80 220 3...

Page 28: ...etween 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 225 224 1 Volts Voltage Unbalance 100 x 4 224 1 78 Acceptable AC 227 224 3 Volts Important If the supply voltage phase unbalance is more the 2 contact your local electric utility company Curre...

Page 29: ...ers There should be no intentional traps in liquid lines Trap volume should be kept to a minimum Long vertical rises should have traps every 20 feet Typical details are shown in FIGURE 3 6 7 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest 8 The discharge and l...

Page 30: ...dd vs Liquid Line Length 17 All piping must be done in accordance with applicable local and national codes Such codes may include The Safety Code For Mechanical Refrigeration ANSI B9 1 and The Code For Refrigerant Piping ANSI B31 5 18 The following installation guidelines are strongly suggested While they do not affect the machine warranty they may be required for safe operation and to comply with...

Page 31: ...190V 50 hz 3 ph 380V 50 hz 14 0 7 0 14 0 7 0 Weight lbs Net Shipping Operating Maximum flooded R 404a 625 805 680 635 815 690 Condenser Dimensions inches A Width B Length C Height D Leg centerline E Leg centerline F Clearance below 45 46 127 49 15 38 106 15 20 5 Recommended Line Sizes OD Liquid All lengths and orientations Discharge Gas Vertical Up all lengths Horiz or Down 75 ft Horiz or Down 75 ...

Page 32: ... 13 3 10 FIGURE 3 4 Condenser Dimensions Machine Bohn Part Vogt Part Coil Split P118 Standard BNHS02A015 8 12A2115B09 50 25 25 P118 High Ambient BNHS02A015 12 12A2115B10 50 25 25 Note Condensers listed above are 200 208 230V 50 60hz 400 460V 50 60hz available ...

Page 33: ...05TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 7 19 13 3 11 FIGURE 3 5 Condenser Field Piping Cold Weather Valve Kit ...

Page 34: ... Equivalent Feet Copper Tubing Type L 1 1 8 O D 1 3 8 O D 1 5 8 O D 2 1 8 O D Globe valve open 28 36 42 57 Angle valve open 15 18 21 28 90o Elbow 3 4 4 5 45o Elbow 1 5 2 2 2 5 Tee 90 turn through 6 8 9 12 Tee straight through 2 2 5 2 8 3 5 TABLE 3 5 Equivalent Feet Due To Friction FIGURE 3 6 Minimum Traps For Discharge Lines Note Each recommended line size is based on use of Type L copper tubing a...

Page 35: ...A Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 15 14 3 13 Air Cooled Condenser Wiring FIGURE 3 7 Wiring For BOHN BNHS02A015 8 BNHS02A015 12 with Cold Weather Valve and Two Fan 50 25 25 Condenser Split ...

Page 36: ... Valves Pressure relief valves are installed on the freezer receiver and the water cooled condenser These valves are designed to vent in emergency conditions This ensures vessel internal pressure does not exceed maximum allowable pressures Vent the relief valve outlet to a safe outdoor location in the approved manner away from people and building openings Vent line piping must have drain line at l...

Page 37: ...or the machine to make an additional discharge of ice AFTER the ice contacts the probe This will vary based on the size of the bin and the ice distribution system employed Note The probe should also be mounted on the back side of the bracket opposite of the front of the bin to reduce the possibility of damage from ice removal equipment The control panel is electrically connected so that the bin th...

Page 38: ...T button to set the Set point S1 will be blinking Use the up or down key to set the temperature at 38 F 4 Press the SET button to set the Differential DIF 1 will be blinking Use the up or down key to set the differential at 2 F 5 Select between C1 Cooling mode and H1 Heating mode Use the up or down key to select C1 Machine will shut off when temperature drops to 38 F and come on when temperature r...

Page 39: ...ply 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 et...

Page 40: ...05TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 3 7 14 3 18 BLANK PAGE ...

Page 41: ...r is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 The liquid feed solenoid valve 20 sometimes referred to as the A valve is open and the thawing gas solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes through the suction ...

Page 42: ...o spare before the next freeze period begins This is to prevent refreezing CAUTION Item No Description Item No Description 1 Control Panel 31 Gage Glass Stop Valve 1PG Suction Pressure Gauge 32 A C Condenser Service Connection 2PG Discharge Pressure Gauge 34 Compressor Suction Service Valve 2 Freezer 35 Compressor Discharge Service Valve 3 Compressor 37 Oil Charging Drain Valve 4PS Dual High Low P...

Page 43: ... G W A T E R 22 5R 7 WATER TANK 6 PUMP WATER TANK DRAIN 39 25 WATER OUT 23A WATER IN 5M CUTTER MOTOR LIQUID LINE THAW GAS 18 15 CONDENSER 15R 50 59 LIQUID RETURN LIQUID RETURN 4PS HI LO MUFFLER WATER IN 30 OIL RETURN 70 58 44 DISCHARGE 34 3 COMPRESSOR 31 31 WATER OUT 24 23 37 12 22A 22A 55 14 OIL SEP 1 DPS 18S 56 PANEL CONTROL 20 17 69 FIGURE 4 1 Water Cooled Piping Schematic ...

Page 44: ...ATER TANK 6 PUMP WATER TANK DRAIN 39 25 WATER OUT 23A WATER IN 5M CUTTER MOTOR LIQUID LINE THAW GAS 18 15R 50 59 LIQUID RETURN LIQUID RETURN 4PS LO HI MUFFLER 30 OIL RETURN 70 58 44 DISCHARGE 34 3 COMPRESSOR 31 31 12 15 CONDENSER 32 101 41A FAN 55 53 69 AIR FLOW 1PG 2PG 18S DPS 43 14 OIL SEP 6A 51 16 28 17 40 46 35 48 91 90 13 88 8 37 FIGURE 4 2 Air Cooled Piping Schematic ...

Page 45: ... and any remaining liquid droplets are removed by the accumulator and suction line heat exchanger The dry gas enters the compressor and is compressed then discharged to the condenser completing the cycle As the ice is formed in the freezer the suction pressure steadily reduces until it causes the freezer pressure switch contacts to close initiating the harvest period During the harvest period the ...

Page 46: ...valves 34 and 35 the hand stop valve 90 in the thawing gas line the receiver liquid return stop valve 91 in the condenser return line hand stop valve 58 in the liquid line hand stop valve 69 to the freezer pressure switch top and bottom float switch hand stop valves 22A and stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage gla...

Page 47: ...ition 2 Push the Start button to start the water pump 3 The pump can be stopped and started by the Stop and Start push buttons to purge the tubing of air 4 When there is good water flow turn the Clean Off Ice switch to Ice The machine will then start in a harvest thaw period with the compressor running 5 At the termination of the harvest period the machine will begin the freeze period NOTE Be sure...

Page 48: ...hould be observed in the gage glass on the receiver Adding Refrigerant When adding refrigerant use the following procedure 1 Make connection between charging valve and refrigerant cylinder using hose or pipe suitable for R 22 or R 404a service See instruction card attached to refrigerant cylinder 2 Open valve on R 22 or R 404a cylinder and purge air out of charging line at the charging valve conne...

Page 49: ...Do not use the Stop pushbutton or the machine disconnect for normal shutdown of the machine Throw the Disconnect only in an emergency or for safety when performing certain service or repairs to the machine The compressor crankcase heater is de energized when the disconnect is thrown The Start push button can be used to initiate a harvest cycle When it is pushed during a freeze cycle it will immedi...

Page 50: ...5 6 5TA Service Manual START UP AND OPERATION 7 19 13 Blank page ...

Page 51: ...05TA Service Manual ELECTRICAL CONTROLS 3 10 14 6 1 6 Electrical Controls FIGURE 6 1 Control Panel Standard SS PB1 PB2 ...

Page 52: ...05TA Service Manual ELECTRICAL CONTROLS 3 10 14 6 2 FIGURE 6 2 Control Panel Components Standard ...

Page 53: ... Manual ELECTRICAL CONTROLS 3 10 14 6 3 FIGURE 6 2A Control Panel Door Standard and Optional Power Monitor SWITCHES LOCATED ON OUTSIDE OF CONTROL PANEL DOOR OPTIONAL POWER MONITOR LOCATED ON BACK OF ENCLOSURE DOOR ...

Page 54: ...05TA Service Manual ELECTRICAL CONTROLS 3 10 14 6 4 FIGURE 6 2B Control Panel Components CE Australian Approved ...

Page 55: ...ly FC Air Cooled Only 12A7516E25 Condenser Fan Contactor 16 Amp 3 Pole 1 N O Aux Contact 208 240V Coil 12A7530E57UL Fan Manual Motor Starter 6 3 10 0A 400 460V 12A7530E58UL Fan Manual Motor Starter 10 0 16 0A 200 230V FPS 12A2117E04 Freezer Pressure Switch FU1 FU2 12A7504E18 Fuses 5A 600V Class CC Time Delay FU10 FU60 12A7504E29 Fuses 1A 600V Class CC Fast Acting For use w optional Power Monitor P...

Page 56: ... primary side of transformer on 400 460V machines FU10 FU60 Short circuit protection for power monitor Optional P Pump Motor Starter Manual motor starter and contactor Starts and stops pump motor Provides short circuit and over current protection Stops water pump motor in the event of a mechanical or electrical malfunction that results in excessive motor amperes PB1 Used to stop machine immediatel...

Page 57: ...05TA Service Manual ELECTRICAL CONTROLS 3 10 14 6 7 FIGURE 6 3 Electrical Schematic All Voltages 50 60 Hz ...

Page 58: ...05TA Service Manual ELECTRICAL CONTROLS 3 10 14 6 8 FIGURE 6 4 Compressor Schematic Detail All Voltages 50 60 Hz ...

Page 59: ...ng into it 4 Shut off water supply and drain water tank 7 by opening drain valve 39 Remove any loose sediment from tank 5 Close drain valve 39 and fill water tank approximately 15 gallons with warm water Close the petcock on the water pump during the cleaning period 6 Add 40 ounces 8 ounces per 3 gallons of Calgon ice machine cleaner or equivalent a food grade liquid phosphoric acid to water tank ...

Page 60: ... sanitizing solution to the water tank Install water box cover on water tank and allow sanitizing solution to circulate for at least 20 minutes 10 While circulating sanitizing solution open petcock valve adjustable blow down and allow solution to flow down the drain With petcock valve open allow water to circulate for a minimum of 3 minutes 11 Press Stop button to stop pump then drain and flush wa...

Page 61: ...over plate Open drain valve 39 Clean tank thoroughly by flushing out with a hose and scrubbing with a stiff brush Fill the water tank with fresh water When restarting the machine be sure that the water pump is circulating water It is possible that air may have collected in the pump impeller housing and the pump may have to be stopped and started several times to expel the air Water Cooled Condense...

Page 62: ...ndicated A restriction can occur with foreign matter in the condenser but it is also likely to be somewhere else in the system Draining Condenser Draining of water cooled condensers is recommended in preparation for the winter cold where units may be left exposed to ambient temperatures below 32 F Theoretically it is easy to drain a condenser In practice the problem can be complex Despite the fact...

Page 63: ...icking gasket replace the water plate and tap it on the outside face with a mallet or a block of wood After a few taps the gasket will spring free and will then slip off with the water end plate f Gaskets need only be rinsed in running water rust scale or dirt will not stick to gasket material A rag or soft brush is all that is required to remove any foreign matter Part II The inside of the water ...

Page 64: ... during the shutdown period If the level is low after start up it should begin to return after a short period of operation FIGURE 7 1 Copeland Discus Compressor 10HP The oil level should be checked frequently particularly during the start up operation to see that a sufficient amount of oil remains in the crankcase While it is important to observe the oil splash during operation the true level can ...

Page 65: ...uction service valve should be backseated to shut off pressure to the gauge port when connecting the oil pump Air should be purged from the oil pump discharge line by forcing some oil through the line before tightening the charging connection Cutter Gear Reducer The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the si...

Page 66: ...onsult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulation 4 Check water tank for solids to be removed 5 Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc for abnormal noise and or vibrations 6 Check oil level in gear reducer D Yearly in addition to weekly and monthly 1 Check entire system for lea...

Page 67: ...sed 3 Thermostat bulb in bracket 4 Ice quality clarity and uniformity 5 Does all ice discharge during harvest 6 Cleanliness 7 Unusual noises Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes...

Page 68: ...e cycle ________ ________ ________ _____ Cutter motor amps cutting ice ________ ________ ________ _____ Water pump amps ________ ________ ________ _____ AC condenser motor amps if applicable ________ ________ ________ _____ Crankcase heater heating _____ Refrigerant leak okay high low _____ Leak checked system ______ leaks found repaired _____ Compressor oil level i e 1 4 1 2 3 4 low high _____ Ge...

Page 69: ... it will then start in a thawing cycle Always check the machine thoroughly after remedying the problem to prevent the same cause from reoccurring Symptom Page Machine Won t Run 8 2 8 3 Freeze up Due To Extended Freeze Period 8 4 Freeze up Due To Ice Failing To Discharge 8 5 Low Ice Capacity 8 6 Low Compressor Oil Level 8 7 Poor Ice Quality 8 8 High Head Pressure Water Cooled Machines 8 9 High Head...

Page 70: ...rt of the compressor Check for broken cylinder head gasket or valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body Note Switch on 4D compressors without Coresense and 3D compressors with line break protection will reset automatically after the motor has cooled sufficiently 3 0 amp circuit breaker CB in the control panel trip...

Page 71: ...eration and motor amp draw If tripping repeats but ice is not jammed check the cutter bearing for wear the gear reducer for resistance and the motor for defect or single phasing Pump motor overload tripped Check voltage and overload range adjustment against motor rating Reset the switch set the Clean Off Ice selector switch to the Clean position and restart the machine by the Start push button Che...

Page 72: ...as solenoid valve 18 leaking through during the freeze cycle Check the manual opening stem to make sure it is in the automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Refrigerant float switch stuck Check to make sure the float switc...

Page 73: ... too short Check the thaw timer T which should be adjusted to allow all the ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Cutter or cutter disc does not turn Check cutter reducer and drive gear for proper operation and alignment Check for broken cutter disc or drive pin and replace as necessary Ice backs up into cutter or discharge opening jamming cutter Ice m...

Page 74: ...of freezer may be stopped up Remove freezer cover and clean the distributors See Water Distributors Section 7 Inadequate water for ice making Check water pressure 30 PSIG minimum recommended Check for a restriction in the water supply line or at the make up water float valve Make up water float valve 12 stuck open adjusted too high or water tank drain valve 39 open or leaking Repair replace or adj...

Page 75: ...f a freeze cycle Repair or replace defective parts Repeated short cycling refrigerant carrying oil out of compressor Usually caused by freeze up low refrigerant charge low head pressure faulty timer faulty pressure switch or expansion valve clogged Use process of elimination Worn piston rings This condition is hard to detect without dismantling the compressor and checking piston ring tolerances No...

Page 76: ...G is recommended minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain valve is closed Water pump rotation wrong direction Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Low refrigerant charge Check refrigerant level mark on the receiver and on the painted portio...

Page 77: ...en and clean as needed Non condensables usually air in system Check refrigerant tables for correct pressure temperature relation If non condensables are present Perform a total pumpdown let stand for at least 6 hours allowing non condensables to gather in the upper part of the receiver Evacuate the freezer and attach a recovery unit to the top receiver purge valve 59 Open the valve and recover the...

Page 78: ...fuse Replace fuse and reset switch If the condenser is split check the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted airflow Visually inspect condenser and clean as necessary Non condensables usually air in the system Fo...

Page 79: ... and causes an overflow of water which creates a siphon to remove a fixed amount of water from the tank Float Valve make up water The make up float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank during the freezing period so that there will be a quantity of by pass or blowdown only during the thaw mod...

Page 80: ...before the hand expansion valve Therefore when the refrigerant level in the freezer drops the float switch closes thereby energizing and opening the A liquid feed solenoid until sufficient level has been reached to open the float switch The float switch has a fixed 1 2 differential The float switch is installed at the correct height at the factory and should not need to be adjusted The float switc...

Page 81: ... F setting 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will be between 40 psi and 50 psi 3 After the machine is running the range adjustment top screw will have to be fine tuned to get the proper ice thickness Clockwise Thinner Ice Counter Clockwise Thicker Ice The freezing time can be such that a small percentage o...

Page 82: ...e setting Adjust the switch to the indicated pressure settings and test with an accurate gage to be sure the switch functions properly before installation Head Pressure The head pressure should be maintained at 190 210 psig for R 22 and 230 250 psig for R 404a during the freeze cycle This pressure can be checked at the test connection in the high pressure line near the high low pressure switch Wat...

Page 83: ...0 psig and Off at 230 psig for R 404a Higher settings may be necessary for 0 F and below ambient conditions to assure there is enough warm gas for ice harvesting FIGURE 9 5A Water Regulating Valve FIGURE 9 5B Condenser Fan Switch Vogt Part 12A2117F05 Cut In Adjusting Screw Set at 210 PSIG R 22 Set at 250 PSIG R 404A CW Lowers Setting Cut Out Adjusting Screw Set at 190 PSIG R 22 Set at 230 PSIG R 4...

Page 84: ...d on the stem seal nut FIGURE 9 6A X Solenoid Valve Sporlan ME34S290 Air cooled machines before August 2006 FIGURE 9 6B X Solenoid Valve Sporlan ME35S190 Air cooled machines only after August 2006 Table 9 1 Sporlan Valve Part s Vogt Sporlan Rebuild Kit Coil 12A4200A0904 ME34S290 12A4199V46 KS E34 12A2105C16 MKC 2 12A4200A09041 ME35S190 12A4199V56 KS E35 12A2105C28 MKC 1 Note Manual stem not shown ...

Page 85: ...RE 9 7B A Solenoid Valve Hansen Hansen 1 1 4 Solenoid Valve Vogt Part 12A4200A1001 Coil 208 230V Vogt Part 126229 Coil 208 230V Vogt Part 126229 Hansen 1 2 Solenoid Valve w strainer Vogt Part 12A4200A0606 Hansen Rebuild Kit HS7 Vogt Part 12A4199V52 Hansen Rebuild Kit HS8 Vogt Part 12A4199V51 ...

Page 86: ...A7509E12 To Oil Separator Oil Pump Screen Discharge Service Valve Sentronic Oil Pressure Safety Switch Compressor Unloader Oil Pump Oil Charging Connection 1 4 access fitting with shrader Suction Service Valve Oil Return shut off valve from oil separator Suction Screen Behind suction valve Discharge line from compressor Temprite Oil Separator Vogt Part 12A3025S14 Add 16 ounces of oil when installi...

Page 87: ... in the power supply to the module The time delay is not energized on opening of the high or low pressure switches There are two major components in the protection system 1 The protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resistance 2 The control module is a sealed e...

Page 88: ...h voltage Under no circumstances should a high potential test be made at the sensor terminals with the sensor leads connected to the solid state module Even though the power and pilot circuit leads are not connected the module can be damaged Note 4D 6D Compressors manufactured before March 2011 have Electronic Motor Protector FIGURE 9 10 Compressor Protection Wiring Compressor with Electronic Moto...

Page 89: ...power to deenergize the module Remove the jumper of Step 2 Remove wiring connections from the sensor and common terminals on the module control circuit terminal board b CAUTION Use Ohmmeter with a maximum of 9 VAC for checking The sensors are sensitive easily damaged and no attempt should be made to check continuity through them with other than an ohmmeter Any external voltage or current applied t...

Page 90: ...cause the heater output to be reduced thus increasing the time out period from two minutes to three or four minutes when low oil pressure conditions exist With the electronic clock the time out will always be the same As a result of the elimination of the capillary tube measuring system and a more precise timing circuit Sentronic will improve the overall reliability of the refrigeration system As ...

Page 91: ...hrow S P D T contact of Sentronic can be electrically isolated from the control circuit power supply and used to control a circuit with a different voltage Sentronic has a timing circuit that actually compares the amount of time with good oil pressure to that with insufficient oil pressure and has a memory that will shut the compressor down after a period of more than two minutes if the compressor...

Page 92: ...12A2117A05 585 1076 02 CoreSense Protection Module and Sensor 12A2117A07 943 0109 00 Oil safety sensor only For Sentronic Sentronic 3 or CoreSense 12A2117A0501 998 0162 00 Control Circuit Protection The electrical control circuit of the machine is protected by a 2 pole 3 amp circuit breaker If breaker trips the machine will immediately stop Before resetting the breaker open the disconnect switch t...

Page 93: ...ate FIGURE 9 12 Water Pump Cutter Gear Reducer The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil once a year The motor bearings are prelubricated and require no further lubrication For additional information refer to manufacturer s instructi...

Page 94: ...he adjustment screw clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment FIGURE 9 14B Thawing Timer Wiring Timer Part 12A7503E22 Syrelec Timer Orange Light indicates timer is timing Light indicates timer has timed out Time Base Set to min Scale Set to X1 Crouzet Timer White Light flashing when timing Light Solid when timed out Range Set to ...

Page 95: ...peration 2 Close the liquid stop valve 58 at the receiver 3 Open the water tank drain valve 39 partially to allow a continuous flow of warm make up water into the water tank and still maintain a good level in the tank An auxiliary supply of warm water not to exceed 100 F may be used if available Warmer water affords a more complete pumpdown 4 Start the machine and allow it to operate and complete ...

Page 96: ...e the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements WARNING Refrigerant Leaks In addition to testing the machine for leaks as instructed under Refrigerant Charge it is advisable to again make a le...

Page 97: ...rnout 3 High head pressure The system is designed to operate at 200 psig Excessive head pressure adds refrigerating load on the compressor which can cause the windings to overheat and result in a failure or burnout 4 Moisture Moisture in contact with refrigerant oil and the presence of heat will form hydrochloric or hydrofluoric acid The acid will destroy the insulation on the motor winding causin...

Page 98: ...ion pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may be used with the valve either energized or de energized without excessive compressor cycling FIGURE 9 15 Loaded Operation during freeze This capacit...

Page 99: ...Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 17 1 Turn power off and lock out disconnect 2 Remove motor from reducer 3 Loosen slightly the four bolts and nuts holding the gear reducer in place 4 Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove the reducer and mounting plate from the tank 5 Measure the distance between th...

Page 100: ...upport on the side of the tank 8 Loosen and remove the three cap screws from the bearing support ends and lift the support out of the water tank 9 Drive the 3 16 x 1 2 pin located in the side of the support hub in and through the bearing wall 10 Now the bearing can be pressed or driven out of the support hub 11 Try the new bearing on the cutter shaft to make sure it turns easily 12 Press or drive ...

Page 101: ...R PLATE 3 8 BOLTS FASTEN BEARING SUPPORT TO CUTTER HOUSING 12A4030R12 Gear Reducer 10 1 12A2250A108 Cut Washer 5 16 SS 12A2215G1108 Cap Screw 5 16 X 3 4 Hex Head SS 12A2160H0101 Hub for Cutter Drive Gear Gear Box Mounting Plate Bolted to Cutter Housing Assembly 19T4500S1805 19T2615D01 Drive Gear W Tapered Hole 19T2615D01 Drive Gear W Tapered Hole 12A2215F1112 Cap Screw 1 4 X 1 1 4 Hex Head SS 12A2...

Page 102: ...00G05 Cutter Housing Gasket 19T2025B0101 Cutter Bearing Support 19T2160C0202 Cutter Assembly Cutter ring gear cutter shaft 19T4090S04 Cutter Shaft 12B2020R01 Cutter Bearing 12A2010A12 Adapter Plate 1 1 1 4 ice 19T2163D0202 Cutter Disc Assembly 12A3040S01 Spiral Pin holds disc assembly to cutter shaft 1 4 X 1 1 2 long 12A3040S02 Spiral Pin holds cutter bearing in bearing support 3 16 X1 2 long 19T4...

Page 103: ...t be ample room around the machine for the water tank removal It is recommended that you have good quality water when attempting to produce crushed ice If the ice is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Refer to Technical Service Bulletin No 88 5 page 9 24 Also you should not attempt to produce crushed ice when the make up water te...

Page 104: ... are designed to vent in emergency conditions This ensures vessel internal pressure does not exceed maximum allowable pressures PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE BEFORE REPLACING RELIEF VALVE REVIEW REQUIREMENTS PER CURRENT LOCAL AND NATIONAL CODE VALVE REPLACEMENT SHOULD BE MADE BY PROPERLY TRAINED PERSONNEL ONLY NOTE IF REFIEF VALVE DISCHARGES VALVE MUST BE REPLACE...

Page 105: ...ted below have in general the same effect on the appearance of raw water ice and therefore in this rough tabulation can be grouped together Generally the sodium carbonates can be considered 1 1 4 times as objectionable as the sulfates and the chlorides about 3 4 as objectionable as the sulfates Therefore total the sulfates and chlorides separately and apply the factors Calcium Sulfate Calcium Chlo...

Page 106: ...05TA Service Manual SERVICE OPERATIONS 3 10 14 9 28 Blank ...

Page 107: ... 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 1 Power Monitor Voltage 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...

Page 108: ... and down arrows Lockout Time in seconds SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the delay on break timer value Delay time in seconds and tenths of seconds RESP SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the time that a fault is allowed before shutdown occurs Control mode ON OFF AUTO flashes The value may be adj...

Page 109: ... 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 tolerance settings while the cut in voltage is 3 closer to the nominal voltage setting This quality is sometimes referred to as hysterisis This is to help reduce oscillation that may occur on weak power distri...

Page 110: ... comes on and run time Automatic Restart after a Power Failure enable disable Auto restart time delay time before restarting recommended 2 hours for package machines The PLC provides Machine Fault indication with an alarm relay The PLC will log when the fault occurred time and date and were in the cycle the machine was when the fault occurred Machine Faults Compressor high discharge pressure Compr...

Page 111: ...or 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 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 indi...

Page 112: ... Bin control 4 Water Pump motor starter 5 Freezer Pressure switch 5 Alarm 6 Compressor overload for 4D 6D without CoreSense 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 s 11 CoreSense Oil press safety for comp without CoreSense 11 Cutter motor starter 12 High Low pressure safety 13 Not used 14 Not used 15 Not used ...

Page 113: ...05TA Service Manual 10 7 OPTIONS AND ACCESSORIES FIGURE 10 4 Wiring Schematic Mid Size Machine P112 P118 P18XT ...

Page 114: ...Blank page ...

Page 115: ...05TA Service Manual TABLES CHARTS 3 10 14 11 1 11 Tables Charts ...

Page 116: ... 1 8 1 1 8 1 1 8 Marley Cooling Tower 5 4821 4821 4821 dimensions LxWxH ft meters 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 shipping weight lbs Kg 740 336 740 336 740 336 operating weight lbs Kg 1340 608 1340 608 1340 608 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 24 4 HP KW FLA 3 2 2 ...

Page 117: ... 8 1 5 8 1 5 8 Marley Cooling Tower 5 4821 4821 4821 dimensions LxWxH ft meters 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 shipping weight lbs Kg 740 336 740 336 740 336 operating weight lbs Kg 1340 608 1340 608 1340 608 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 24 4 HP KW FLA 3 2 2 9 ...

Page 118: ...0 9965 9090 8655 66 11215 10320 9820 9895 9020 8590 67 11165 10240 9740 9825 8950 8515 68 11110 10160 9660 9755 8880 8445 69 11055 10080 9580 9685 8810 8375 70 11000 10000 9500 9615 8740 8305 71 10935 9920 9420 9545 8670 8235 72 10875 9840 9340 9475 8600 8165 73 10810 9760 9260 9405 8530 8095 74 10740 9680 9180 9335 8460 8025 75 10670 9600 9100 9265 8390 7955 76 10600 9520 9020 9195 8320 7885 77 1...

Page 119: ...ssure psig Discharge Pressure psig Harvest Times secs Ice per cycle Freeze Time minutes End of Freeze Average during Freeze First All Ice Total Average Water Temperature deg F R22 R404A R22 R404A Ice Out Harvest lbs 90 80 70 60 50 C 1 36 47 200 240 15 90 120 147 20 5 19 5 18 4 17 4 16 4 Y 1 1 4 33 44 200 240 15 90 120 152 22 9 21 5 20 3 19 3 17 9 60 L 1 1 2 30 40 200 240 15 120 150 170 26 1 24 6 2...

Page 120: ... 12A4200H0402P Make up water float valve Lead Free Plastic 1 12B2020R01 Cutter bearing 1 12A2600G15 Gasket for freezer cover 1 12A2600G05 Gasket for water tank 1 12A7509E12 Crankcase heater 100 W insertion type Discus Compressor 1 12D2590G08 Suction pressure gage R 22 1 12D2590G09 Discharge pressure gage R 22 1 12D2590G1 Suction pressure gage R 404A 1 12D2590G11 Discharge pressure gage R 404A 1 12...

Page 121: ...113 5 190 2 210 2 120 1 138 0 229 0 0 9 2 24 0 31 1 6 5 6 7 33 5 100 117 2 195 9 216 2 124 3 142 0 235 0 2 10 2 25 6 32 9 7 5 7 7 35 6 102 120 9 201 8 222 3 128 5 146 0 242 0 4 11 2 27 3 34 9 8 5 8 8 37 4 104 124 7 207 7 228 5 132 9 151 0 249 0 6 12 3 29 1 36 9 9 6 9 9 39 4 106 128 5 213 8 234 9 137 3 156 0 256 0 8 13 5 30 9 38 9 10 8 11 0 41 6 108 132 4 220 0 241 3 142 8 160 0 264 0 10 14 6 32 8 ...

Page 122: ... 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 ft3 8...

Page 123: ...h 9 5 Condenser Piping Cold Weather Valve Kit 3 11 Condenser Water Usage 11 5 Condenser Air cooled Cleaning 9 17 Condenser Air cooled Heat Rejection 3 9 Condenser Fan Switch CPS 9 5 Condenser Water Cooled Maintenance 7 3 Control Circuit Protection 9 14 Control Panel 6 1 Control Panel Parts 6 5 Control Relay CR 6 3 Cooling Tower 3 2 CoreSense 6 8 9 13 9 14 Crankcase Heater 7 6 9 14 Crushed Ice Prod...

Page 124: ...Piping Schematic Water cooled Air cooled 4 3 4 4 PLC Programmable Logic Controller 10 4 10 64 Poor Ice Quality 8 8 Power Connection 3 5 Power Monitor 10 1 10 2 10 3 Preventive Maintenance 7 8 Preventive Maintenance Program 7 10 Preview 1 1 Principle of Operation 4 1 Pumpdown 9 17 Pump Contactor 6 4 Q R R 22 HCFC 22 1 2 2 2 5 1 R 404a HFC SUVA HP62 1 2 2 2 5 1 Receipt of Machine 2 1 Receiver 4 1 Re...

Page 125: ...d Piping Schematic 4 3 Water Cooled Units 9 4 Water Distributors 7 3 Water Pump Motor 9 15 Water Quality 3 1 Water Regulating Valve 9 5 Water Supply and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 3 Water Tank 7 3 Water Tank Removal 9 22 Water Usage Condenser 11 5 Water Usage Make up 11 5 Wiring and Electrical Connection 3 5 Wiring Schematic Air Cooled Condenser 3 13 Wiring...

Page 126: ...05TA Service Manual INDEX 4 15 14 12 4 ...

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