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P18AL Service Manual

INDEX

3/6/07

11-1

11.

Index

A-Valve ----------------------------------------------------------- 4-1, 5-1

Accumulator ----------------------------------------------------- 4-1, 5-1

Adding Refrigerant --------------------------------------------------- 5-2

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

Ammonia – Machine Charge -------------------------------------- 5-2

Ammonia - Removal ------------------------------------------------ 9-5

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

Bearing, Cutter -------------------------------------------------------9-10

Bill of Lading ----------------------------------------------------------- 2-1

Bin, Level Control --------------------------------------------- 6-1, 8-2

Blowdown -------------------------------------------------------------- 3-3

Capacity Ratings ------------------------------------- 2-2, 10-2 –10-4

Centrifugal Pump ----------------------------------------------------- 9-4

Charging Refrigeration Systems --------------------------- 1-2, 5-2

Checklist, Daily-------------------------------------------------------- 7-2

Checklist, Installation Review ------------------------------------3-11

Chemical Cleaning --------------------------------------------------- 7-5

Circuit Breaker, Cutter ---------------------------------------------- 6-3

Circuit Breaker, Pump----------------------------------------------- 6-3

Circulating Water Pump Motor------------------------------------ 9-4

Clean/Off/Ice Selector Switch ------------------------------- 5-5, 6-1

Cleaning Procedure ------------------------------------------------- 7-3

Compressor------------------------------------------------------------ 7-7

Compressor Crankcase Heater----------------------------------3-11

Compressor Lubrication -------------------------------------------- 7-7

Compressor Unloading --------------------------------------------- 3-4

Condenser Cleaning------------------------------------------------- 7-5

Condenser, Water Cooled Maintenance ----------------------- 7-5

Control Circuit Protection------------------------------------------- 9-3

Control Panel ----------------------------------------------------- 6-2-6-3

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

Control, Relay (CR) -------------------------------------------------- 6-3

Cooling Tower--------------------------------------------------- 3-4, 7-7

Crankcase Heater ---------------------------------------------3-11. 7-3

Crushed Ice Production--------------------------------------------9-13

Cutter & Bearing Removal/Installation----------------- 9-10, 9-12

Cutter Drive Parts ---------------------------------------------------9-12

Cutter Gear Reducer ---------------------------------- 7-5, 9-9, 9-12

Cutter Motor --------------------------------------------- 9-3, 9-9, 9-12

Cutter, Assembly ----------------------------------------------------9-12

Cutter, Bearing -------------------------------------------------------9-12

Cutter, Bearing Support -------------------------------------------9-12

Cutter, Disc Assembly ---------------------------------------------9-12

Cutter, Drive Parts --------------------------------------------------9-12

Cutter, Gear Reducer ----------------------------------------9-9, 9-12

Cutter, Motor----------------------------------------------------9-9, 9-12

Cutter/Water Tank Assembly-------------------------------------9-12

Cutter/Water Tank Parts (crushed Ice) ------------------------9-13

Cutter/Water Tank Parts (cylinder ice)-------------------------9-12

D Valve (Thawing Gas ) -------------------------------------- 4-1, 4-2

Daily Check List------------------------------------------------------- 7-1

Drive gear ------------------------------------------------------------ 9-11

Electrical Connections, Customer-------------------------------- 3-9

Electrical Schematic All Voltages 50-60 Hz. ------------------ 6-5

Electrical, Controls --------------------------------------------------- 6-2

Enclosure --------------------------------------------------------------- 6-2

Energy Saving--------------------------------------------------------- 1-1

Float Switch ------------------------------------------------------- 1-7,9-3

Float Valve (Make-Up Water) ------------------------------------- 9-3

Foundation Layout --------------------------------------------------- 3-2

Freeze Period --------------------------------------------------------- 4-2

Freeze Timer ---------------------------------------------------- 4-2, 9-1

Freeze-Up Due To Extended Freezing Period---------------- 8-3

Freeze-Up Due To Ice Failing To Discharge ------------------ 8-3

Freezer ------------------------------------------------------------------ 4-1

Gear Reducer ------------------------------------------------------- 9-10

Hand Expansion Valve---------------------------------------- 1-5, 5-1

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

Heater, Crankcase ------------------------------------------- 3-11, 7-3

High Head Pressure ------------------------------------------------ 8-5

High/Low Pressure Switch ----------------------------------------- 6-1

History, Tube-Ice® --------------------------------------------------- 1-1

Hub, Cutter Drive Gear ------------------------------------------- 9-12

Ice Capacity ------------------------------------------------ 10-2 – 10-4

Ice-Making Section--------------------------------------------------- 7-3

Important Safety Notice--------------------------------------------- 1-2

Inspection, First Arrival---------------------------------------------- 2-1

Installation -------------------------------------------------------------- 3-1

Installation Review: A Checklist ------------------------------- 3-11

Introduction------------------------------------------------------------- 1-1

J, K

Low Compressor Oil Level ----------------------------------------- 8-6

Low Ice Capacity ----------------------------------------------------- 8-4

Low Pressure Switch ------------------------------------------------ 6-1

Lubrication------------------------------------------------------------- 7-6

Lubrication, Compressor ------------------------------------------- 7-7

Lubrication, Cutter Gear Reducer -------------------------------- 7-5

Summary of Contents for P18AL TUBE-ICE

Page 1: ...8 28 00 P18AL TUBE ICE MACHINE Manual Part Number 12A4171M09 Service Manual 5000 ...

Page 2: ...le additional expenses This manual is intended as an informational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX a...

Page 3: ...__ Hz machine not running Compressor crankcase heater on 12 hour minimum All valves opened or closed as tagged Solenoid valve stems in auto position System leak checked tight Auxiliary equipment overloads wired into control circuit Water supply and drains connected properly Sufficient make up water supply minimum 30 PSIG Instruction manual and warranty certificate left on site Name of person left ...

Page 4: ......

Page 5: ...3 6 07 TUBE ICE LLC located in Louisville Kentucky since 1880 Sales 800 853 8648 Parts and Service 502 635 3000 Since 1880 Manufacturers of Quality Tube Ice Machines ...

Page 6: ...Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M09 P18 Ammonia Lowside Model ...

Page 7: ...2 Rated Capacity 2 2 Vogt Model Nomenclature 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Machine Room 3 1 Lifting Procedures 3 1 Foundation Layout 3 2 Piping and Drain Connections TABLE 3 1 3 2 Make up Water In 3 3 Water Tank Drain 3 3 Water Tank Overflow 3 3 Water Tank Flush Valve 3 3 Receiver Table 3 2 3 3 Suction Pressure Regulator 3 4 Compressor Unloading 3 4 Safety Valves 3 4 Cooling Tower 3 4 Spa...

Page 8: ... Suction Gas Regulating Valve Adjustment 5 6 Shut down Procedure 5 6 Operating Tips 5 7 6 ELECTRICAL CONTROLS THEIR FUNCTIONS General Information 6 1 Control Panel Door Closed FIGURE 6 1 6 2 Control Panel Components and Part Numbers External TABLE 6 1 6 2 Control Panel Door Opened FIGURE 6 2 6 3 Control Panel Components and Part Numbers Internal TABLE 6 2 6 3 Description of Control Panel Component...

Page 9: ... 6 Machine Short Cycles Using Freeze Pressure Switch FPS Only 8 7 High Compressor Discharge Temperature 8 7 Suction Line Frosting To Compressor 8 7 9 SERVICE OPERATIONS Thawing Timer T FIGURE 9 1 9 1 Freeze Timer T2 9 1 Digital Timer Setting Procedure 9 1 Multi function Digital Freezer Timer FIGURE 9 2 9 2 Conveyor Timer T3 9 2 Flush Valve Timer T4 9 2 Make up Water Float Valve 37A 9 3 Refrigerant...

Page 10: ... 9 13 Crushed Ice Production 9 13 10 TABLES AND CHARTS P18AL Specifications 60 Hz TABLE 10 1 10 2 P18AL Capacity Ratings 7 8 Diameter Ice 1 Tube TABLE 10 2 10 3 P18AL Capacity Ratings 1 1 8 Diameter Ice 1 1 4 Tube TABLE 10 3 10 3 P18AL Capacity Ratings 1 3 8 Diameter Ice 1 1 2 Tube TABLE 10 4 10 4 P18AL Make up Water Usage TABLE 10 5 10 4 P18AL Normal Operating Vitals TABLE 10 6 10 5 Recommended S...

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 P18AL 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 ...

Page 12: ...ve and cylinder 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 o...

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

Page 14: ...P18AL Service Manual INTRODUCTION 3 6 07 1 4 FIGURE 1 1 P18AL Front View ...

Page 15: ...P18AL Service Manual INTRODUCTION 3 6 07 1 5 FIGURE 1 2 P18AL Back View ...

Page 16: ...P18AL Service Manual INTRODUCTION 3 6 07 1 6 FIGURE 1 3 P18AL Left View ...

Page 17: ...P18AL Service Manual INTRODUCTION 3 6 07 1 7 FIGURE 1 4 P18AL Right View ...

Page 18: ...P18AL Service Manual INTRODUCTION 3 6 07 1 8 ...

Page 19: ...ube Ice machine is a remote ice producing 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...

Page 20: ...fy that the correct model has been received Figure 2 1 Vogt Model Nomenclature Nominal Capacity 02K 2000 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...

Page 21: ...lectrical components of the Tube Ice machine are rated NEMA 1 The machine should not be located in a hazardous area or sprayed with water The machine should be installed in an area where water will not stand but will readily drain away from the machine See Space Diagram for clearances and utility connections FIGURE 3 1 Lifting Procedures CAUTION The approximate shipping weight of the machine is 2 ...

Page 22: ...lifting lug to meet local codes Piping and Drain Connections Figure 3 1 Water Connections and Refrigerant Connections shows locations and sizes for all connections on lowside CAUTION External shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 30 psig The maximum allowable pressure is 100 psig CAUTION Make up Water...

Page 23: ...This overflow line should not tie in with any other drain line except the water tank drain Unless water quality is superior do not discharge the overflow water to the cooling tower system This water contains additional dissolved solids left from the ice making process and can lead to excessive condenser fouling or cooling tower chemical usage It is recommended that a heat exchanger be used in plac...

Page 24: ...ention must be given to operating wet bulb conditions It is advisable to check with your local cooling tower distributor for their recommendations based on actual operating conditions in your area An average wet 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 volum...

Page 25: ...P18AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 3 6 07 3 5 FIGURE 3 1 Spacing and Connection Diagram ...

Page 26: ...P18AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 3 6 07 3 6 FIGURE 3 2 Piping Schematic Dedicated High Side ...

Page 27: ...P18AL Service Manual INSTALLING YOUR TUBE ICE MACHINE 3 6 07 3 7 FIGURE 3 3 Piping Schematic Central High Side ...

Page 28: ...er to TABLE 3 2 to properly size wiring connections A fused disconnect must be provided near the Tube Ice machine Connect 3 phase power to terminals L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of cutter motor and water pump is required see following section Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 ...

Page 29: ...ections Detail Standard Voltages F L A Minimum Ampacity Maximum Fuse 208 230 3ph 60 Hz 8 3 9 8 10 460 3ph 60 Hz 4 0 4 6 5 220 3ph 50 Hz 8 3 9 8 10 400 3ph 50 Hz 4 4 5 1 10 TABLE 3 2 Electrical Specifications Note Refer to Chapter 6 for a wiring schematic and electrical component layout and description ...

Page 30: ... 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 Current Unbalance Voltage unbalance w...

Page 31: ...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 32: ...mbers in this piping schematic The freezer 1 is a shell and tube type vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 5 Make up water is maintained by a float valve 29 in the water tank 13 The refrigerant float switch 23 opens and closes the liquid line solenoid valve 25 sometimes referred to as the A valve is open ...

Page 33: ...e consult the factory for information Harvest Period When the freeze timer T2 contact closes a control relay 1CR is energized The 1CR relay stops the water pump and starts the cutter motor The A solenoid valve 25 closes the D solenoid valve 18 opens and the thaw timer T is energized As the ice releases and drops through the rotating cutter and onto the cutter disc it is discharged through the side...

Page 34: ...P18AL Service Manual HOW YOUR TUBE ICE MACHINE WORKS 3 6 2007 4 3 FIGURE 4 1 P18AL Piping Schematic Dedicated High Side ...

Page 35: ...P18AL Service Manual HOW YOUR TUBE ICE MACHINE WORKS 3 6 2007 4 4 FIGURE 4 2 P18AL Piping Schematic Central System ...

Page 36: ...to rid the water tank of increased dissolved solids by flushing them out the overflow during the harvest thawing period The wet suction gas leaves the freezer and passes through the suction accumulator where liquid droplets are removed 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 f...

Page 37: ...ems should perform the operations described in this manual All local federal and EPA regulations must be strictly adhered to when handling ammonia R717 refrigerants See Material Safety Data Sheet MSDS Code5B81 83 for detailed information Charging From Tank Truck dedicated high side only The system may be charged by bulk from a tank truck and be pumped directly into the receiver through the drain v...

Page 38: ...ressor by using the green Start push button PB2 and the red Stop push button PB1 in sequence Correct compressor rotation is indicated by an arrow on the outer rim of the oil pump assembly opposite the shaft end of the compressor 9 Set the Clean Off Ice Switch SS to the Ice position allowing the circulating water pump to circulate water through the freezer 10 As the pressure continues to rise in th...

Page 39: ...cycle to dispel any ice made To initiate a harvest cycle close the charging valve and push the start manual harvest push button PB2 while the compressor is running This will initiate a harvest and another freeze cycle will start immediately following to continue the charging procedure Be sure to close the cylinder shut off valve during the harvest period and open it once the machine goes back into...

Page 40: ...ted by Stop and Start push buttons to purge the tubing of air 5 When there is good water flow turn the Clean Off Ice switch to Ice and the machine will then start in a harvest thaw period with the compressor running 6 At the termination of the harvest thaw period the machine will begin the freeze period 7 Observe the oil pressure the oil level the discharge pressure and listen for any unusual soun...

Page 41: ...ig slightly below the thaw gas regulator 6 After the machine has completed the harvest cycle and returned to the freeze cycle adjust the low pressure upstream pressure on the suction regulator to maintain the required freezer pressure For clear ice a minimum of 20 psig freezer pressure is required Shut down CAUTION The red Stop button should only be used for emergency shutdown For normal shutdown ...

Page 42: ...ean Off Ice selector switch to Off the machine will stop after the next harvest cycle Do not use the Stop push button 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 ...

Page 43: ...ll shutdown when any auxiliary equipment fails Bin Level Control Included in the wiring schematic is provision for a bin thermostat or bin level control BT The NC contact of your control should be wired between terminals 11 14 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown The machine will automatically resta...

Page 44: ...losed Symbol Vogt Part Component Description PB1 12A7500E57 Push Button Momentary Red PB2 12A7500E56 Push Button Momentary Green SS 12A7500E61 Selector Switch 3 Position T2 12A7503E52 Timer Digital Multi function 24 240V AC TABLE 6 1 Control Panel Components and Part Numbers External ...

Page 45: ... 63 1 0A 460V Only Cutter Manual Motor Starter 1 0 1 6A 400V Only ET 12B7503E20 12B7503E21 Timer Elapsed Din Rail Mount 220V 50 Hz Only Timer Elapsed Din Rail Mount 220V 60 Hz Only P 12A7530E56 12A7530E54 12A7530E55 Pump Manual Motor Starter 4 0 6 3A 200 208 230V Only Pump Manual Motor Starter 1 6 2 5A 460V Only Pump Manual Motor Starter 2 5 4 0A 400V Only T T3 T4 12A7503E22 12A7503E39 Timer Delay...

Page 46: ...d to stop machine immediately Should be used for emergency stopping only PB2 Used for starting machine or manually harvesting Will initiate a harvest cycle whenever pushed with the Clean Off Ice selector switch in the Ice position and machine operating in a freeze cycle SS Used to select operating mode of machine When in clean position only the water pump will run This allows cleaner to be circula...

Page 47: ...P18AL Service Manual ELECTRICAL CONTROLS 3 6 07 6 5 FIGURE 6 3 Electrical Schematic All Voltages 50 60 Hz ...

Page 48: ...P18AL Service Manual ELECTRICAL CONTROLS 3 6 07 6 6 ...

Page 49: ...ols high and low pressure switches oil pressure switch etc 2 Check cooling tower spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulation 4 Check water tank for solids to be removed 5 Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc f...

Page 50: ...sor 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 _____________ Compressor water out ____ F Tower fan cycles ___ On ___ Off Ice Production Check Test Cycle Make u...

Page 51: ...e sediment from tank 5 Close drain valve 28 and fill water tank approximately 27 gallons with warm water 6 Add 72 ounces 8 ounces per 3 gallons of Calgon ice machine cleaner a food grade liquid phosphoric acid to water tank during the refill period 7 Inspect the water distributors by looking through clean freeze cover If required remove the cover Clean and remove any solid particles from the distr...

Page 52: ...let to seat them in the freezer tubes Tube Size 1 1 1 4 1 1 2 Hole Size 1 16 1 8 Avg 1 8 3 16 Avg 1 4 3 8 Avg TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank contains a concentrated amount of solids or salts Remove cover plate Open drain valve 28 Clean tank thoroughly by flushing out with a hose and scrubbing with a stif...

Page 53: ...not be frost Where there is frost there will not be oil When the trap is 1 2 to 3 4 full of oil it should be drained The machine should be shutdown for at least 12 hours before attempting to drain oil from the trap Follow the procedure outlined in the service section Draining Oil Trap CAUTION Only qualified refrigeration service personnel familiar and experienced in the handling and use of anhydro...

Page 54: ...e motor manufacturer s recommendations 6 Fan bearings The fan bearings should be lubricated every six months Make sure the proper grade of grease is used normally conforms to NLCI Grade 2 and it is best to use a hand grease gun 7 Fan belts The fan belt tension should be checked weekly for the first two weeks of operation then monthly during continuous use The best tension for a V belt is the lowes...

Page 55: ...sure 35 50 psig Note Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pressure gage reading while the compressor is running Example Oil pressure gage reading 65 psig Suction pressure gage reading 40 psig Net Oil Pressure 25 psig The compressor oil should be changed at close intervals during initial break in operation and up to the first 1000 hours see Tabl...

Page 56: ...P18AL Service Manual MAINTENANCE 3 6 07 7 8 ...

Page 57: ...achine 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 3 Freeze up due to ice failing to discharge 8 3 Low ice capacity 8 4 Poor ice quality 8 5 High discharge pressure 8 5 Low discharge pressure 8 5 High suction pressure 8 6 ...

Page 58: ...eset the overload and restart by pushing the start push button PB2 Machine will start in a harvest Check voltage and amps against motor rating If tripping repeats but ice is not jammed check the gear reducer for resistance cutter bearings for wear drive gear and ring gear for proper engagement and reducer motor for defect or single phasing Bin level control optional open Adjust or replace control ...

Page 59: ...n each tube Thaw time too short T Adjust thaw timer T to allow all ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Replace defective timer See pressure regulating valve adjustment Thaw pressure to low The thaw gas regulator should be adjusted to increase the pressure in the freezer to 60 65 psi during a harvest Isolate and repair or replace the valve as needed I...

Page 60: ...ume Check compressor motor amp draw Check for belt slippage and tighten as needed Check for leaking compressor suction or discharge valves Refer to your compressor manual See other related symptoms Restriction in the refrigerant liquid line or float switch not operating properly Check for a partially closed valve or an obstruction at the strainer solenoid valve or hand expansion valve The liquid l...

Page 61: ... sure it is pumping enough water Check sump strainer screen and clean Check condenser pump direction of rotation Fan control out of adjustment Check adjustment Replace if defective Non condensable in system If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant will be cooler although the pressure will ...

Page 62: ...re requirements Possible Cause Possible Remedy Oil diluted with refrigerant Oil will be very foamy Check liquid feed control for overfeed problem Oil pressure regulating valve out of adjustment Adjust valve to increase oil pressure Turn stem in to increase out to decrease Compressor rotation incorrect Check rotation direction by arrow indication Reverse rotation if necessary Restriction strainer o...

Page 63: ...ir or replace as needed Symptom High compressor discharge temperature Possible Cause Possible Remedy High head pressure Check gage accuracy and High discharge pressure Defective suction or discharge valves Feel the compressor heads for hot spots or one head running hot Replace worn or leaking valves Restriction in the discharge gas line Check all hand and check valves to make sure they are fully o...

Page 64: ...P18AL Service Manual TROUBLESHOOTING 3 6 07 8 8 ...

Page 65: ...2 The freezing time period for the production of cylinder or crushed ice is controlled by the freeze timer mounted on the control panel door The timer was set at the factory to a default of 10 minutes The freeze time can be adjusted to compensate for water temperature and refrigeration system conditions Do not make adjustments until several ice discharging cycles have been made Digital Timer Setti...

Page 66: ...cessity for frequent flushing or cleaning of the water tank The primary purpose of the automatic blowdown is to remove accumulated salts and or solids from the water tank that accumulate during the freezing cycle This flushing action each cycle greatly reduces the total dissolved solids in the tank and results in clear ice production At the beginning of a harvest cycle a solenoid operated valve is...

Page 67: ...l 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 switch is installed at the position that provides highest capacity The correct height will produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30 F Hand Expansion V...

Page 68: ... 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 3 Allow the machine to operate and complete two freeze and harvest cycles 4 Stop the machine throw the electrical disconnect and lockout all power to the machine 5 Remove wire from freezer pressure switch if installed and insulate the...

Page 69: ... from the machine it may be purged into water which will absorb it Follow the purging instructions See Purging Non condensables Refrigerant Leaks Anhydrous ammonia leaks can be detected by odor sulfur stick soap solution or test paper The odor is normally noticed first and the location of the leak is found with soap or sulfur stick Soap solution can be purchased from your refrigeration supply hous...

Page 70: ...rs and other high pressure components It collects mostly in the coolest lowest velocity area of these components Evaporative condensers usually have purge points at the top of the outlet header of each circuit Receivers usually have a purge point at the top away from the inlet where it is coolest and the gas velocity is the lowest The freezer can be purged through the valve at the top of the sucti...

Page 71: ...l trap drain valve opened or unattended severe injury may result DANGER 5 When a small amount of liquid ammonia begins to spew out immediately close the valve 6 Remove the hose and install a plug in the valve DO NOT attempt to reuse any oil taken from the system unless it is properly reclaimed and meets the proper specifications Removing Excess Water from Ammonia If excessive water is in the ammon...

Page 72: ... solenoid valve and gradually opening the liquid line stop valve 24 or at the receiver letting liquid ammonia enter the freezer and raise the pressure 11 When the freezer suction pressure is up to at least 60 PSI manually close the liquid line solenoid valve and restore power to the machine 12 Open the compressor discharge valve oil return valve and all other valves that should be opened for norma...

Page 73: ...d remove the reducer and mounting plate from the tank 3 Measure the distance between the top of drive gear and the mounting plate for future reference 4 Remove the three cap screws from the gear and hub and install two 1 4 20 x 2 long all thread set or cap screws in the threaded holes of the drive gear These two screws can be used as jacking bolts to remove the gear from the tapered split hub 5 In...

Page 74: ...upport 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 the new bearing into the hub Be careful not damage the bearing surfaces the old bearing may be used as a driver 13 Drill a 3 16 hole through the bearing wall using the original hub hole as a pilot Ins...

Page 75: ...DIA X 1 2 LONG TYPE 304 SS 19 1 12A3050S0401 PIPE NIPPLE 3 4 ALL THREAD TYPE 304 S S 20 1 12A4030R15 GEAR REDUCER IN LINE 10 1 21 1 12A4078C04 SPLASH CURTAIN 22 4 12A4130S02 SPACER ADAPTOR PLATE 23 1 12A4200A0607 VALVES SOLENOID 3 4 FPT WITH 208 240V 50 60HZ COIL 24 1 12A4200G0807 VALVES BALL 1 NPT STAINLESS STEEL 37A 1 12A4200H0402 VALVE FLOAT 1 2 MPT LOCKNUT GASKET 37B 1 12A4200HP01 FLOAT STEM B...

Page 76: ...P18AL Service Manual SERVICE OPERATIONS 3 6 07 9 12 FIGURE 9 3 Cutter Water Tank Assembly ...

Page 77: ...7530E54 400V 50 Hz Change 1 Raise the freezer pressure switch setting to make ice 3 16 thick average 2 Reverse cutter direction 3 Reverse deflector Two people should normally accomplish this conversion process in 6 8 hours or less There must 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 i...

Page 78: ...P18AL Service Manual TABLES CHARTS 3 6 07 10 1 10 Tables Charts ...

Page 79: ...blowdown gpm m3 Hr 10 2 27 10 2 27 10 2 27 Connection Sizes makeup water FPT 1 2 tank drain FPT 1 flush solenoid valve FPT 3 4 overflow FPT 2 Compressor HP KW FLA HP KW FLA 30 22 4 105 minimum required Water Pump HP KW FLA HP KW FLA 2 0 2 6 5 6 Cutter Motor HP KW FLA HP KW FLA 0 5 0 7 1 9 THR at pulldown Btu hr kW 421 820 124 301 725 88 4 219 692 64 4 THR average Btu hr kW 337 456 98 8 241 380 70 ...

Page 80: ...n Required is for central plant operation and the tabulated value is based on 70 o make up water Table 10 2 Capacity Ratings for 1 Tube P18AL Capacity Ratings 1 1 8 Diameter Ice Suction Pressure psig 35 33 40 28 25 24 20 20 16 Suction Temp oF 21 4 20 0 16 6 15 0 11 3 10 0 5 5 5 0 0 0 Avg Ref Required tons 10 2 11 3 13 9 15 0 17 5 18 4 21 2 21 5 24 4 Compressor Capacity 11 4 12 8 16 1 17 7 21 3 22 ...

Page 81: ... 75 3 9 4 3 5 3 5 8 6 9 7 2 8 4 8 5 9 8 70 4 0 4 5 5 5 6 0 7 1 7 4 8 7 8 8 10 1 65 4 2 4 6 5 7 6 2 7 3 7 7 8 9 9 1 10 4 60 4 3 4 8 5 9 6 4 7 5 7 9 9 2 9 4 10 7 55 4 5 5 0 6 1 6 6 7 8 8 2 9 5 9 7 11 1 50 4 6 5 2 6 3 6 9 8 1 8 5 9 9 10 0 11 4 Average Refrigeration Required is for central plant operation and the tabulated value is based on 70 o make up water Table 10 4 Capacity Ratings for 1 1 2 Tube...

Page 82: ...17 5 15 5 13 5 13 0 12 0 50 L 1 1 2 18 54 190 65 40 120 160 235 24 22 21 5 21 20 HZ C 1 32 56 175 63 40 120 160 175 12 0 11 2 10 3 9 4 8 9 R 1 1 4 29 54 180 54 40 120 160 175 12 6 11 6 10 8 10 1 9 4 U 1 1 2 25 53 180 66 40 120 160 175 16 2 15 3 14 5 13 7 12 7 Table 10 6 Usual Operating Conditions RECOMMENDED SPARE PARTS LIST Vogt Model P18AL Tube Ice Machine QTY PART NUMBER DESCRIPTION 1 12A 7503E...

Page 83: ...0 1 229 0 190 1 138 0 0 9 2 24 0 31 1 6 5 33 5 15 6 6 7 100 117 2 195 9 216 2 124 3 235 0 196 1 142 0 2 10 2 25 6 32 9 7 5 35 6 17 1 7 7 102 120 9 201 8 222 3 128 5 242 0 203 3 146 0 4 11 2 27 3 34 9 8 5 37 4 18 6 8 8 104 124 7 207 7 228 5 132 9 249 0 210 2 151 0 6 12 3 29 1 36 9 9 6 39 4 20 3 9 9 106 128 5 213 8 234 9 137 3 256 0 217 2 156 0 8 13 5 30 9 38 9 10 8 41 6 21 9 11 0 108 132 4 220 0 24...

Page 84: ...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 10 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 ...

Page 85: ...tor 9 3 9 9 9 12 Cutter Assembly 9 12 Cutter Bearing 9 12 Cutter Bearing Support 9 12 Cutter Disc Assembly 9 12 Cutter Drive Parts 9 12 Cutter Gear Reducer 9 9 9 12 Cutter Motor 9 9 9 12 Cutter Water Tank Assembly 9 12 Cutter Water Tank Parts crushed Ice 9 13 Cutter Water Tank Parts cylinder ice 9 12 D D Valve Thawing Gas 4 1 4 2 Daily Check List 7 1 Drive gear 9 11 E Electrical Connections Custom...

Page 86: ...efrigerant Charge 3 6 5 2 Refrigerant Leaks 9 5 Refrigerant Leaks 5 1 Refrigerant Removal 9 5 Refrigeration System Review 5 1 Rotation Check 3 10 S Safety Notice 1 2 Safety Symbols and What They Mean 1 3 Safety Valves 2 2 Shipping Papers 2 1 Solenoid Valve 9 3 Space and Connection Diagram 3 5 Special Precautions 1 2 Start Push Button PB1 5 5 6 2 Starter Cutter Motor 6 3 Starter Pump Motor 6 3 Star...

Page 87: ...________ _________________ _________________ machine not running Compressor crankcase heater on 12 hour minimum Necessary hand valves opened as required Solenoid valve stems in auto position System leak checked tight Auxiliary equipment overloads wired into control circuit Compressor oil level _______ 1 4 glass min All water distributors in place visually inspected Water supply and drain lines ins...

Page 88: ...BLE OF CONTENTS ii Installer signature ____________________________________________ End user signature _________________________________ Please return to Tube Ice Division Henry Vogt Machine Co P O Box 1918 Louisville KY 40201 ...

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Vogt P18AL TUBE-ICE, Service Manual

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