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03TA Service Manual 
 

TABLE OF CONTENTS 

 

4/11/14 

iii

Page No. 

7.  MAINTENANCE

  

 

 

Ice-Making Section ........................................................................................................................................................ 7-1 

 

Cleaning Procedure ........................................................................................................................................................ 7-1 

                    

Sanitizing Procedure  ..................................................................................................................................................... 7-2     

 

Water Distributors ......................................................................................................................................................... 7-3 

 

Water Tank .................................................................................................................................................................... 7-3 

 

Water-Cooled Condensers, Checking Operation ........................................................................................................... 7-3 

 

Water-Cooled Condensers, Draining ............................................................................................................................. 7-4 

 

Water-Cooled Condenser Cleaning ............................................................................................................................... 7-4 

 

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

 

Compressor .................................................................................................................................................................... 7-6 

 

Cutter Gear Reducer ...................................................................................................................................................... 7-7 

 

Preventive Maintenance ................................................................................................................................................. 7-8 

 

 

Daily /Weekly / Monthly / Yearly Check List ......................................................................................................... 7-8 

 

 

Pressure Relief Valve Replacement Note ................................................................................................................ 7-8 

 

 

Note To Manager or Owner ..................................................................................................................................... 7-9 

 

 

Preventive Maintenance Program ............................................................................................................................ 7-10 

 

8.  TROUBLESHOOTING 

 

List Of Symptoms .......................................................................................................................................................... 8-1 

 

Machine Won’t Run ...................................................................................................................................................... 8-2, 8-3 

 

Freeze-Up Due To Extended Freezing Period ............................................................................................................... 8-4 

 

Freeze-Up Due To Ice Failing To Discharge ................................................................................................................. 8-5 

 

Low Ice Capacity ........................................................................................................................................................... 8-6 

 

Low Compressor Oil Level ............................................................................................................................................ 8-7 

 

Poor Ice Quality ............................................................................................................................................................. 8-8 

 

High Head Pressure (Water-Cooled) ............................................................................................................................. 8-9 

 

High Head Pressure (Air-Cooled) .................................................................................................................................. 8-10 

 

9.  SERVICE OPERATIONS 

 

Adjustable Blowdown (For Clearer Ice) ........................................................................................................................ 9-1 

Water Pump/ Blowdown Assembly, FIGURE 9-1 ........................................................................................................ 9-1 

 

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

 

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

 

Thermal Expansion Valve, FIGURE 9-2 ....................................................................................................................... 9-2 

 

Superheat / Checking Superheat    ................................................................................................................................. 9-2 

 

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 

 

Water-Cooled Units ....................................................................................................................................................... 9-4 

 

Air-Cooled Units ........................................................................................................................................................... 9-5 

 

Water Regulating Valve, FIGURE 9-5A ....................................................................................................................... 9-5 

 

Condenser Fan Switch, FIGURE 9-5B .......................................................................................................................... 9-5 

Summary of Contents for TUBE-ICE 03TA

Page 1: ...4 11 14 03TA TUBE ICE MACHINE Includes models HE60 P112F Part Number 12A4171M07 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: ...in Louisville Kentucky since 1880 Sales 800 959 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 12A4171M07 03TA Model Revision 3 0 ...

Page 5: ...in Installation 3 1 Setting the Ice Machine on the Bin 3 1 Ice Chute Location Machine Footprint FIGURE 3 1 3 1 Forklift and Blocks Method FIGURE 3 2 3 2 Forklift and Ropes or Lifting Strap Method FIGURE 3 3 3 3 Connections and Space Diagram Air Cooled Machine FIGURE 3 4 3 4 Connections and Space Diagram Water Cooled Machine FIGURE 3 5 3 5 Piping and Drain Connections 3 6 Water Supply and Drain Siz...

Page 6: ... YOUR TUBE ICE MACHINE WORKS Principle of Operation 4 1 Freeze Period 4 2 Harvest Period 4 2 Piping Nomenclature TABLE 4 1 4 2 Water Cooled Piping Schematic FIGURE 4 1 4 3 Air Cooled Piping Schematic FIGURE 4 2 4 4 5 START UP AND OPERATION Refrigeration System Review 5 1 Refrigerant Charge 5 1 Start Up Checklist 5 2 Start Up 5 3 Control Panel Switch Layout FIGURE 5 1 5 3 Adding Refrigerant 5 4 Ope...

Page 7: ...Won t Run 8 2 8 3 Freeze Up Due To Extended Freezing Period 8 4 Freeze Up Due To Ice Failing To Discharge 8 5 Low Ice Capacity 8 6 Low Compressor Oil Level 8 7 Poor Ice Quality 8 8 High Head Pressure Water Cooled 8 9 High Head Pressure Air Cooled 8 10 9 SERVICE OPERATIONS Adjustable Blowdown For Clearer Ice 9 1 Water Pump Blowdown Assembly FIGURE 9 1 9 1 Automatic Blowdown Harvest Cycle 9 1 Float ...

Page 8: ...Connections FIGURE 9 12B 9 12 Condenser Cleaning 9 13 Pump Down 9 13 Removal Of Refrigerant From Machine 9 13 Refrigerant Leaks 9 14 Non Condensable Gases 9 14 Compressor Motor Burnout 9 15 Capacity Control Valve Internal Construction 9 16 Copeland Compressor Unloader Valve FIGURE 9 13 9 16 Loaded Operation Freeze Period Unloaded Operation During Thaw Only 9 16 Component Removal and Replacement Op...

Page 9: ... 1 03TA Capacity Ratings TABLE 11 2 11 2 03TA Condenser Water Usage TABLE 11 3 11 3 03TA Make up Water Usage TABLE 11 4 11 3 03TA Normal Operating Vitals TABLE 11 5 11 3 Recommended Spare Parts List 11 4 Temperature Pressure Chart for Common Refrigerants TABLE 11 6 11 5 Conversion Factors English to Metric TABLE 11 7 11 6 Constants TABLE 11 8 11 6 12 INDEX ...

Page 10: ...5 24 11 Blank page ...

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 03TA 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: ...03TA Service Manual INTRODUCTION 4 21 14 1 4 FIGURE 1 1 Assembly Air Cooled Front View ...

Page 15: ...03TA Service Manual INTRODUCTION 4 21 14 1 5 FIGURE 1 2 Assembly Air Cooled Rear View ...

Page 16: ...03TA Service Manual INTRODUCTION 4 21 14 1 6 FIGURE 1 3 Assembly Air Cooled Right Side View ...

Page 17: ...03TA Service Manual INTRODUCTION 4 21 14 1 7 FIGURE 1 4 Assembly Water Cooled Front View ...

Page 18: ...03TA Service Manual INTRODUCTION 4 21 14 1 8 FIGURE 1 5 Assembly Water Cooled Rear View ...

Page 19: ...03TA Service Manual INTRODUCTION 4 21 14 1 9 FIGURE 1 6 Assembly Water Cooled Right Side View ...

Page 20: ...03TA Service Manual INTRODUCTION 4 21 14 1 10 BLANK ...

Page 21: ...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 valves a...

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: ...tice com registration htm Bin Installation Set the bin on solid level footing Inside the bin you will find the four legs Screw these legs to the bottom of the bin You can make MINOR leveling adjustments by using these legs as leveling screws as outlined in the manufacturer s instructions Setting the ice machine on the ice bin Once the ice storage bin is level the Tube Ice machine can be elevated a...

Page 24: ...wooden 2X4 s measuring 3 ft long pry bar Step 1 Position Tube Ice machine on forks Step 2 Stack wood blocks in each corner of the drip pan on top of the ice storage bin Step 3 Lift and set Tube Ice machine on wood blocks Step 4 Remove forklift Step 5 Stack 3 ft long 2X4 s beside drip pan overlapping front and back of bin Step 6 Using a pry bar with fulcrum on 2X4 s raise side of machine enough to ...

Page 25: ...ifting straps to bind forks to top angles Step 1 Remove front rear and top access panels Step 2 Position fork truck so that forks are resting flat on top angles of Tube Ice machine Step 3 Use the rope or straps to securely bind forks to the top angles CAUTION Be sure the bin is level and is set in its proper location See the space diagram FIGURE 6 CAUTION Step 4 Lift Tube Ice machine and set into ...

Page 26: ... PART 12A2600T01 9 11 16 TOP VIEW AIR COOLED CONDENSER LINE SHOWN LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW ALLOW 24 MINIMUM CLEARANCE BEHIND UNIT FOR CONDENSER LINE ACCES 3 4 FPT WATER TANK DRAIN CONNECTION LOCATED ON THE BACK OF UNIT 1 2 MPT MAKE UP WATER CONNECTION ALLOW 40 MINIMUM CLEARANCE FOR WATER TANK ACCES ALLOW 40 MINIMUM CLEARANCE FOR COMPRESSOR ACCES ALLOW 12 MINIMUM CLEARANCE ABOVE UN...

Page 27: ...EW FRONT VIEW RIGHT SIDE VIEW ALLOW 24 MINIMUM CLEARANCE BEHIND UNIT FOR CONDENSER LINE ACCES 3 4 FPT WATER TANK DRAIN CONNECTION LOCATED ON THE BACK OF UNIT 1 2 MPT MAKE UP WATER CONNECTION ALLOW 40 MINIMUM CLEARANCE FOR WATER TANK ACCES ALLOW 40 MINIMUM CLEARANCE FOR COMPRESSOR ACCES ALLOW 12 MINIMUM CLEARANCE ABOVE UNIT FOR INSTALLATION AND ACCESS 1 11 6 1 3 8 FIGURE 3 4B Connections and Space ...

Page 28: ...ut 1 2 MPT 3 4 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 not trap the water tank drain line as this will interfere with the operation of the automatic blowdown system A 20 mesh strainer supplied with the machine should be installed ...

Page 29: ...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 wate...

Page 30: ...ollowing 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 6 Control Panel Power Connections Standard Voltages Water Cooled Air Cooled F L A Min Ampacity Max Fuse F L A Min Ampacity Max Fuse 208 230 3ph 60 Hz 48 3 58 6 100 54 3 64 6 110 460 3ph 60 Hz 23 7 28 7 50 26 4 31 4 55 2...

Page 31: ...en 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 Current U...

Page 32: ...Typical details are shown in FIGURE 3 9 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 liquid lines must be insulated with 1 2 thick Armaflex insulation or equal 9 Use only ACR grade copper pipe Type L Recommended line sizes are shown in...

Page 33: ... 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 all applicable electrical and mechanical codes a Local electrical code must be checked for wiring method b The installer must provide a disconnect s...

Page 34: ...50 hz 14 0 7 0 14 0 7 0 Weight lbs Net Shipping Operating Maximum flooded R 404a 580 760 610 585 765 615 Condenser Dimensions inches See Fig 3 7 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 ft 7 8 1 ...

Page 35: ...INE 3 13 FIGURE 3 7 Condenser Dimensions Machine Bohn Part Vogt Part Coil Split P112 Standard BNHS02A011 12A2115B07 50 50 P112 High Ambient BNHS02A011 12 12A2115B08 50 50 Note Condensers listed above are 200 208 230V 50 60hz 400 460V 50 60hz available ...

Page 36: ...YOUR TUBE ICE MACHINE 4 21 14 3 14 Note Liquid return lines are customer supplied The Check Valve in the return line labeled Output Liquid Return Line is supplied with the condenser FIGURE 3 8 Condenser Field Piping 50 50 Coil Split ...

Page 37: ...er Tube O D Type L 5 8 7 8 1 1 8 1 3 8 1 5 8 2 1 8 Globe valve open 16 22 28 36 42 57 Angle valve open 9 12 15 18 21 28 90o Elbow 2 2 3 4 4 5 45o Elbow 1 1 1 5 2 2 2 5 Tee 90 turn through 4 5 6 8 9 12 Tee 90 straight through 1 1 5 2 2 2 5 2 5 2 8 3 3 5 TABLE 3 5 Equivalent Feet Due To Friction FIGURE 3 9 Minimum Traps For Discharge Lines Note Each recommended line size is based on use of Type L co...

Page 38: ...3TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 21 14 3 16 Air Cooled Condenser Wiring FIGURE 3 10 Wiring For BOHN BNHS02A011 BNHS02A011 12 with Cold Weather Valve and Two Fan 50 50 Condenser Split ...

Page 39: ...lves 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 low ...

Page 40: ... discharge opening of the chute 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 thermostat will stop the machine only upon the completion of a harvest period When both cylinder and crushed ice are produced and separately s...

Page 41: ...tton 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 reach...

Page 42: ... crushed ice With the switch set on Cru the machine will produce crushed ice If the switch is changed to Both Auto or Cyl within the first 5 minutes of a cycle the unit will revert immediately to the production of cylinder ice If an alternate bin level control is used it must be located in a position to stop the machine prior to ice backing up into the ice chute and jamming cutter Single Ice Type ...

Page 43: ...and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK ____ Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK ____ All field installed equipment augers conveyors cooling towers bin level controls etc fo...

Page 44: ...5 24 11 Blank page ...

Page 45: ...vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 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...

Page 46: ...vent refreezing CAUTION Item No Description Item No Description 1 Control Panel 32 A C Condenser Service Connection 2 Freezer 34 Compressor Suction Service Valve 3 Compressor 35 Compressor Discharge Service Valve 4PS Dual High Low Pressure Switch 37 Oil Charging Drain Valve 5M Cutter Motor 39 Water Tank Drain Valve 5R Gear Reducer 40 Automatic Water Tank Blowdown 6 Water Pump 41 Condenser Water Re...

Page 47: ...03TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 4 11 2014 4 3 FIGURE 4 1 Water Cooled Piping Schematic ...

Page 48: ...03TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 3 31 2014 4 4 FIGURE 4 2 Air Cooled Piping Schematic ...

Page 49: ...quid 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 liquid feed solenoid ...

Page 50: ...ons NOTE _____ 4 Open compressor service 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 and the stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage glass v...

Page 51: ...sition 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 sur...

Page 52: ...l should 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 co...

Page 53: ... 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 immed...

Page 54: ...5 24 11 Blank page ...

Page 55: ...03TA Service Manual ELECTRICAL CONTROLS 3 31 14 6 1 6 Electrical Controls FIGURE 6 1 Control Panel Standard SS PB1 PB2 ...

Page 56: ...03TA Service Manual ELECTRICAL CONTROLS 4 17 14 6 2 FIGURE 6 2 Control Panel Components Standard ...

Page 57: ... Manual ELECTRICAL CONTROLS 3 31 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 58: ...03TA Service Manual ELECTRICAL CONTROLS 3 31 14 6 4 FIGURE 6 2B Control Panel Components CE Australian Approved ...

Page 59: ...only 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...

Page 60: ... 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 61: ...03TA Service Manual ELECTRICAL CONTROLS 3 31 14 6 7 FIGURE 6 3 Electrical Schematic All Voltages 50 60 Hz ...

Page 62: ...03TA Service Manual ELECTRICAL CONTROLS 3 31 14 6 8 FIGURE 6 4 Compressor Schematic Detail All Voltages 50 60 Hz ...

Page 63: ...over opening 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 6 gallons with warm water Close the petcock on the water pump during the cleaning period 6 Add 16 ounces 8 ounces per 3 gallons of Nu Calgon ice machine cleaner or equivalent a food grade liquid phosphoric acid to...

Page 64: ...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 wat...

Page 65: ...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 Condenser Checking ...

Page 66: ...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 67: ...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 68: ...e 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 3D 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 b...

Page 69: ...rvice 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 side of the...

Page 70: ...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 71: ...ses 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 p...

Page 72: ...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 73: ... 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 74: ...ressor crankcase heater coils of relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and replace fuse Make sure there is no liquid refrigerant in the compressor crankcase prior to re starting the machine High Low safety pressure switch tripped If the machine stops by low pressure cutout the switch will reset automatically when the pressure...

Page 75: ...the cutter operation 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 Ice Clean switch to the Clean position and restart the machine by the Start push button Che...

Page 76: ...d 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 Float switch stuck or failed in the closed position Check to make sure the ...

Page 77: ...oo 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 mus...

Page 78: ...spicion of leakage Repair or replace the valve as needed Water distributors at top 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 a...

Page 79: ...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 80: ...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 81: ...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 82: ...set 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 Follow same procedure as s...

Page 83: ... 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 84: ...inutes and at two minute intervals for at least two cycles 5 Adjust the valve only 1 4 turn at a time Close turn stem in to raise superheat Open turn stem out to lower superheat Monitor at least two cycles after each adjustment before adjust further If the valve cannot be adjusted satisfactorily check the bulb insulation as follows 1 Remove the insulation from the sensing bulb 2 Loosen the bulb cl...

Page 85: ...ckwise 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 of the ice is frozen solid If so some ice from the top and bottom of the freezer should have a smal...

Page 86: ...clockwise to lower the 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 lo...

Page 87: ...t to the compressor FIGURE 9 6 Oil Separator Line to condenser Vogt Part 12A4200E1001 Adjusting Stem Set at 200 PSI R 22 Set at 235 PSI R 404A CW Lowers Setting 1 1 4 FPT Connection water connections Connected to High Side of Water Cooled Condenser 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 ...

Page 88: ...E 9 7C A Solenoid Valve Sporlan Sporlan 1 1 8 Solenoid Valve Vogt Part 12A4200A0904 Sporlan ME34S290 MANUAL STEM UNDER CAP IN TO OPEN OUT TO CLOSE AUTOMATIC Sporlan 5 8 Solenoid Valve Vogt Part 12A4200A0505 Sporlan ME19S290 Replacement Coil MKC 2 Vogt Part 12A2105C16 Rebuild Kit KS B19 E19 Vogt Part 12A4199V43 MANUAL STEM UNDER CAP IN TO OPEN OUT TO CLOSE AUTOMATIC Note Manual stem not shown Repla...

Page 89: ...ot operating It is de energized when the compressor is operating FIGURE 9 8 Copeland Discus Compressor 3D shown Oil Sightglass Vogt Part 12A7509E12 Crankcase Heater Oil Pump Screen Discharge Service Valve Sentronic Oil Pressure Safety Switch Compressor Unloader Oil Pump Suction Service Valve Oil Charging Connection 1 4 access fitting with shrader Oil Return shut off valve from oil separator Suctio...

Page 90: ...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 in the past all new and replac...

Page 91: ...row 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 10 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: ...e adjustment screw clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment FIGURE 9 12B 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 1...

Page 95: ...l ice and stop operation 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 opera...

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: ...nout 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 causing...

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 13 Loaded Operation during freeze This capacit...

Page 99: ...sary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 11 1 Turn power off and lockout 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 ...

Page 100: ... Before removing the bearing reference mark the location of the bearing support 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 be...

Page 101: ...r 18 12B2165M0101 Gear Reducer Mounting Bracket 19 12A2160H0101 Gear Hub 20 19T2615D01 Drive Gear 21 12A2240A1108 5 16 Hex Nut 22 12A2250B108 5 16 Lockwasher 23 12A2900M0508 Motor 1 2 Hp 208 230 460 3 50 60 Hz 24 12A2250A108 5 16 Cut Washer 25 12A2215G1108 5 16 X 3 4 Hex Head Cap Screw 26 12A2250B107 1 4 Lockwasher 27 12A2215F1112 1 4 Hex Head Cap Screw 29 19T1501S0505 Float Box Cover Assembly 30 ...

Page 102: ...03TA Service Manual SERVICE OPERATIONS 4 2 14 9 20 FIGURE 9 14 Cutter Water Tank and Drive Gear Assembly ...

Page 103: ...e may need to be adjusted by 1 3 psi to get the required thickness of ice This conversion process should normally be accomplished by two people in 1 2 hours or less It is recommended that you have good quality water when attempting to produce crushed ice If the ice is opaque and cloudy the cutter mechanism may become clogged restrict ice discharge and bind the cutter In addition you should not att...

Page 104: ...5 24 11 Blank page ...

Page 105: ... 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 106: ... 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 107: ... 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 108: ... 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 109: ...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 110: ... 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 111: ...03TA Service Manual 10 7 OPTIONS AND ACCESSORIES FIGURE 10 4 Wiring Schematic Mid Size Machine P112 P118 P18XT ...

Page 112: ...5 24 11 Blank page ...

Page 113: ...2 2 0 5 37 2 2 THR Btu hr kW 122 000 35 7 122 000 35 7 122 000 35 7 122 000 35 7 Marley Cooling Tower 5 4821 4821 4821 4821 dim LxWxH ft meters 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 shipping weight lbs Kg 650 336 650 336 650 336 650 336 operating weight lbs Kg 999 608 999 608 999 608 999 608 connections inlet x outlet NPT 4 x 4 4 x 4 4 x 4 ...

Page 114: ...469 6126 6096 5772 6339 6003 65 6187 5863 6434 6098 6063 5746 6306 5976 66 6155 5835 6401 6068 6032 5718 6273 5947 67 6122 5808 6367 6040 6000 5692 6240 5920 68 6089 5780 6333 6011 5967 5664 6206 5891 69 6057 5753 6299 5983 5936 5638 6173 5863 70 6024 5725 6265 5954 5904 5611 6140 5835 71 5997 5697 6237 5925 5877 5583 6112 5806 72 5969 5669 6208 5896 5850 5556 6084 5778 73 5942 5641 6180 5867 5823...

Page 115: ... 90 0 54 0 50 0 56 0 53 Includes 15 Blowdown Make up Water Usage gpm Table 11 4 Suction Pressure psig Discharge Pressure psig Harvest Times sec Ice per cycle Avg lbs Freeze Time minutes End of Freeze Average during Freeze First Ice All Ice Out Total Harvest Water Temperature o F R22 R404A R22 R404A 90 80 70 60 50 60 HZ CYL 1 33 45 200 240 15 90 120 63 15 5 14 5 13 4 12 4 11 4 1 1 4 32 44 200 240 1...

Page 116: ...age 6 3 CU P Starter 1 See Page 6 3 Compressor Contactor 1 12A2900M0508 Cutter motor 1 2 HP 2 12A4200H0401 Make up water float valve 1 12B2020R04 Cutter bearing 78 12B2185N11 Water Distributors 1 48 12B2185N21 Water Distributors 1 1 4 1 12A2600G01 Gasket for freezer cover 1 12A2600G12 Gasket for water tank 1 12A7509E12 Crankcase heater Copeland Discus Compressor 1 12A4200A0505 5 8 Liquid feed sole...

Page 117: ...210 2 120 1 138 0 229 0 247 0 0 9 2 24 0 31 1 6 5 6 7 33 5 36 1 100 117 2 195 9 216 2 124 3 142 0 235 0 254 0 2 10 2 25 6 32 9 7 5 7 7 35 6 38 1 102 120 9 201 8 222 3 128 5 146 0 242 0 261 0 4 11 2 27 3 34 9 8 5 8 8 37 4 40 4 104 124 7 207 7 228 5 132 9 151 0 249 0 269 0 6 12 3 29 1 36 9 9 6 9 9 39 4 42 6 106 128 5 213 8 234 9 137 3 156 0 256 0 276 0 8 13 5 30 9 38 9 10 8 11 0 41 6 44 9 108 132 4 ...

Page 118: ... 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 7 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 33 lbs ...

Page 119: ...9 5 Condenser Piping Cold Weather Valve Kit 3 14 Condenser Water Usage 11 3 Condenser Air cooled Cleaning 9 13 Condenser Air cooled Heat Rejection 3 12 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled Maintenance 7 5 Control Circuit Protection 9 10 Control Panel 6 1 Control Panel Parts 6 5 Control Relay CR 6 5 Cooling Tower 3 7 Crankcase Heater 7 6 9 7 Crushed Ice Production 9 21 Cutter Be...

Page 120: ...matic Water cooled 4 3 Piping Schematic Air Cooled 4 4 Poor Ice Quality 8 8 Power Connection 3 8 Power Monitor 10 1 Preventive Maintenance 7 1 Preventive Maintenance Program 7 10 Preview 1 1 Principle of Operation 4 1 Pump Down 9 13 Pump Motor Starter 6 5 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 Refrigerant Charge 5 1 Refrigerant Leaks 9 14 ...

Page 121: ...Units 9 4 Water Distributors 7 3 Water Pump Motor 9 10 Water Regulating Valve 9 5 Water Supply and Drain Water Cooled 3 6 Water Supply and Drains Air cooled 3 6 Water Tank 7 3 Water Tank Removal 9 18 Water Usage Condenser 11 3 Water Usage Make up 11 3 Wiring and Electrical Connection 3 6 Wiring Schematic Air Cooled Condenser 3 16 Wiring Schematic All Voltages 50 60 Hz 6 7 X X Valve 4 2 Y Z ...

Page 122: ...03TA Service Manual INDEX 4 21 14 12 4 ...

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