Vogt Tube-Ice HFO10 Service Manual Download Page 3

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Important Safety Information

Any improper attempt to repair major equipment may result in personal injury, property damage,

or loss of life. Before installing, operating, adjusting, or servicing the HFO10, please read this manual and
become familiar with its contents, understand the operation of this machine, and be aware of possible dangers.

Safety Symbols and What They Mean

Heed the following safety symbols, which may appear in this manual and/or on the machine.

Symbol

Meaning

Danger:

Indicates an immediate hazard and that special precautions are necessary to

avoid severe personal injury or death.

Warning:

Indicates a strong possibility of a hazard and that an unsafe practice could

result in severe personal injury.

Caution:

Indicates that hazards or unsafe practices could result in personal injury or

damage to product or property.

Summary of Contents for Tube-Ice HFO10

Page 1: ...Manual Part Number 12A4171M16 Vogt Ice LLC 1000 W Ormsby Ave Suite 19 Louisville KY 40210 USA Since 1880 Sales Service 1 502 635 3000 Parts Your Local Distributor SuperCare Technical 1 502 635 3510 or 1 502 635 3052 Service Manual 50 00 USD ...

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Page 3: ...re of possible dangers Safety Symbols and What They Mean Heed the following safety symbols which may appear in this manual and or on the machine Symbol Meaning Danger Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death Warning Indicates a strong possibility of a hazard and that an unsafe practice could result in severe personal injury C...

Page 4: ... or information is needed contact the factory by calling 1 502 635 3000 or faxing 1 502 635 3024 Please read this manual carefully before attempting installation operation or servicing of this professionally designed piece of equipment The SuperCare group at Vogt Ice LLC provides assistance for all customer service needs including part sales and warranty support SuperCare also conducts training sc...

Page 5: ...d only All valves opened or closed as tagged Solenoid valve stems in auto position System checked for leaks and none found all connections tight Auxiliary equipment overloads wired into control circuit Water supply and drains connected properly Sufficient makeup water supplied minimum 30 psig 2 bar Instruction manual and warranty certificate left onsite Name of person left with ___________________...

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Page 7: ...ssure Relief Valves 3 1 Machine Location 3 2 Equipment Storage 3 2 Rated Capacity 3 2 Chapter 4 Installation of the HFO10 4 1 Machine Connections 4 1 Equipment Layout and Service Access 4 5 Lifting Procedures 4 6 Equipment Anchoring 4 7 Piping and Drain Connections 4 8 Water Cooled Condenser Connections Water Cooled Machines Only 4 9 Cooling Tower Water Cooled Machines Only 4 9 Pressure Relief Val...

Page 8: ... Freeze Period 8 2 Freeze Up from Ice Failing to Discharge 8 3 Poor Ice Quality 8 4 Low Ice Capacity 8 4 High Head Pressure Water Cooled Machines 8 5 High Head Pressure Air Cooled Machines 8 6 Chapter 9 Servicing Operations 9 1 Adjustable Blowdown for Clearer Ice 9 1 Automatic Blowdown 9 1 Makeup Water Float Valve 9 1 Refrigerant Float Switch 9 2 Hand Expansion Valve 9 3 Freezer Pressure Switch Vo...

Page 9: ...tor 9 12 Cutter Gear Reducer 9 12 Cutter Motor Replacement 9 13 Cutter Gear Reducer Removal and Replacement 9 13 Water Tank Removal 9 14 Cutter and Bearing Removal and Reinstallation 9 14 Crushed Ice Production 9 16 Appendix A Optional Accessories A 1 Power Monitor Wagner Model DTP 3 A 1 The Display A 1 Adjustment of Parameters in Order of Display A 2 Appendix B Tables B 1 Appendix C Additional Do...

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Page 11: ...ice machines is to find the perfect balance between something that will work well in the application and be available for purchase for the foreseeable future Finding this balance has been Vogt s focus Vogt s long term refrigerant solution is HFO hydrofluoroolefin blends with similar properties as R134a These HFO based refrigerants have very low GWPs which are in line with the European Union F Gas ...

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Page 13: ...e of ice produced cylinder or crushed optional is determined by how the machine cutter is set up The unit will only stop when a thawing harvest period has been completed whether by the Clean Off Ice selector switch or the ice bin thermostat To stop the machine instantly push the Stop button To restart the machine push the Start button The Clean Off Ice selector switch must always be set in the Ice...

Page 14: ...te is located on the left side of the control panel The model number and machine description are located in the top left hand corner Figure 2 can be used to verify that the correct model has been received Figure 2 Vogt Model Nomenclature ...

Page 15: ...alve 8 Water Distributing Chamber 46 Filter Dryer 12 Makeup Water Float Valve 48 Muffler 13 Heat Exchanger 50 Receiver Safety Valve 15 Condenser 51 Freezer Safety Valve 15R Receiver 52 Water Regulating Stop Valve Water Cooled Only 16 Thawing Chamber 53 Cold Weather Solenoid Valve X A C Machines 17 Expansion Valve 55 Discharge Line Stop Valve For A C Machines 18 Thaw Gas Solenoid Valve D 56 Freezer...

Page 16: ...2 4 Figure 3 Water Cooled Piping Schematic ...

Page 17: ...2 5 Figure 4 Air Cooled Piping Schematic ...

Page 18: ...zer the filter dryer the liquid line solenoid valve A and then the expansion valve and capillary 10 At the expansion valve and capillary feed the refrigerant expands from a saturated liquid state of relatively high pressure to a very low pressure low temperature liquid 11 The float switch is wired to the liquid line solenoid valve A 12 The float switch energizes and de energizes the liquid line so...

Page 19: ...e on the circulating water pump discharge helps to rid the water tank of increased dissolved solids found in harder water by flushing them out of the overflow during water pump operation During the harvest period the water pump stops therefore all the water circulating in the freezer drops to the tank the tank level increases and the overflow will get rid of that extra water The overflow is a hole...

Page 20: ... to indicate refrigerant cylinder pressure The cylinder may be considered empty of liquid refrigerant when the gauge pressure is 25 psig 1 7 bar or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary release of refrigerant into the atmosp...

Page 21: ...n Checklist Inspect outer casings if provided Inspect piping and valves Inspect refrigerant sight glass for damage The machine was shipped with a full refrigerant charge stored and isolated in the receiver Visually check all lines for mechanical damage If a leak is suspected check all joints with a refrigerant leak detector supporting HFO blend refrigerants All leaks should be reported to Vogt Ice...

Page 22: ...there is no possibility of standing water but readily drain away from the machine Equipment Storage If the equipment must be stored before installation it should be indoors and protected from extreme temperatures and high humidity These conditions can deteriorate the various components used in the manufacture and assembly of the equipment This equipment contains the HFO refrigerant blend R513A und...

Page 23: ...al equipment are allowed to install or work on this Tube Ice machine Preparing the machine for operation requires connecting the following to the appropriate locations on the machine Electrical supply Makeup water supply Water blowdown drain Condenser water inlet and outlet The diagrams on the following pages show the basic connection locations and orientation of the HFO10 machine ...

Page 24: ...ure Gauge Vogt 450 Condenser Control Panel Transformer Liquid Outlet Stop Valve King Valve Heat Exchanger CSH Screw Compressor Circulating Water Pump Receiver Pressure Relief Valve Freezer Pressure Relief Valve Condenser Pressure Relief Valve Low Pressure Gauge ...

Page 25: ...ion Accumulator Condenser Water Regulating Valve Freezer Float Switch Hand Expansion Valve Freezer Refrigerant Charging Valve Liquid Line Solenoid Valve A Freezer Pressure Relief Valve Ice Discharge Thaw Gas Solenoid Valve D High Pressure 250 psig 17 2 bar Safety Mechanical Switch Condenser Pressure Relief Valve ...

Page 26: ...ceiver Sight Glass Receiver Thaw Gas Solenoid Valve D Receiver Drain Valve Condenser Water Regulating Valve Gear Reducer Thawing Gas Stop Valve Cutter Motor Makeup Water Float Valve 1 2 in DN 15 MPT Makeup Water Connection Low Pressure Transducer High Pressure Transducer ...

Page 27: ...g weight for the HFO10 is 5 200 lb 2 359 kg The HFO10 requires certain clearances around the unit for safety reasons and to provide access for servicing operations Figure 8 shows clearance requirements Figure 8 Connections and Clearance Diagram Water Cooled Machine ...

Page 28: ...rom the top to avoid tipping The machine frame has lifting lugs at each top corner for screw pin anchor shackle eyebolt and hook to be used for lifting purposes The lifting lugs should be used wherever possible Figure 9 HFO10 Lifting Diagram 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 extremit...

Page 29: ...n accordance with all local and federal codes and building regulations Figure 10 indicates anchor bolt hole locations in the bottom frame of this Tube Ice machine Consult local codes and regulations regarding seismic and wind load requirements Additional bracing may be required Figure 10 HFO10 Anchor Points ...

Page 30: ...ope 2 1 2 in DN 65 BSPP Europe The condenser water outlet and water tank drain connections must be extended to an open drain or sump arranged for visible discharge Do not allow water to be trapped in the water tank drain line because this will interfere with the operation of the automatic blowdown system Do not connect these lines into a pressure tight common header because warm condenser water ma...

Page 31: ... States but many localities have design wet bulb temperatures as low as 72 F 22 C or as high as 82 F 28 C All standard Vogt supplied cooling towers are sized for 78 F 25 C The cooling tower water pump must be capable of delivering the required volume of water through the condenser The pump must be sized for each installation which depends on cooling tower location pressure drop through water lines...

Page 32: ...d to work with high voltage electrical equipment If a relief valve discharges the valve must be replaced before putting the machine back into service Relief valves do not properly reseat after a discharge event Contact Vogt SuperCare Customer Service at 1 502 635 3000 or 1 800 853 8648 for replacement valves Wiring and Electrical Connections Warning Only service personnel experienced and certified...

Page 33: ... rotation should match the marking on the pump housing The pump must be primed by starting the machine in Clean mode and allowing it to run for several minutes To change the direction of rotation for the motors disconnect the power and reverse L1 and L3 incoming power wires at the motor contactor in the control panel Voltage Imbalance Voltage imbalance can cause motors to overheat and fail Voltage...

Page 34: ...x 4 95 4 2 Acceptable Ice Bin Thermostat Sensor An electronic thermostat a standard feature on every HFO machine automates the machine s various cycles To ensure proper protection for the machine or auxiliary equipment the thermostat s sensor must be positioned so that the ice will contact it when the bin is full The distance between the top of the ice bin and the sensor must allow space for the m...

Page 35: ... sized for fuses and for compliance to local and national codes Refer to the machine nameplate for minimum circuit ampacity and maximum fuse size All field installed equipment augers conveyors cooling towers bin level controls etc is properly installed The applicable portion of the Warranty Registration Start Up Form has been completed and sent back to Vogt Ice Check the oil level of the cutter ge...

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Page 37: ...tronic leak detector or by doing a bubble test Check that all water supply lines are open to the water tank and all water tank drain valves are closed Set the Ice Off Clean switch to the Ice position Close the exterior disconnect switch to energize the crankcase heater and check supply voltage against that on motor nameplate for compliance before switching on disconnect Start Up Procedure Initial ...

Page 38: ...wn of the machine Disconnect the machine 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 machine is shut down The Start button can be used to initiate a harvest period When it is pushed during a freeze period it will immediately initiate a harvest period Ice Quality Your HFO10 has been set up at t...

Page 39: ...according to the steps below 1 Connect the charging valve on the machine to the refrigerant cylinder using a hose or pipe suitable for R513A service Refer to the instruction card attached to the refrigerant cylinder 2 Open the valve on the refrigerant cylinder and purge air out of the charging line at the charging valve connection 3 Open the charging valve on the machine 4 The charging valve must ...

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Page 41: ...Vogt SuperCare Customer Service Table 5 Vogt 450 Controls Part List Item Vogt Part No Description Control Module 12A2117J04 Controller with two SPDT Output Relays Power Supply 12A2117J07 Power Supply Relay Module 12A2117J08 Output Module Low and High Pressure Transducers 12A2117J02 Pressure Transducer 0 500 psig 0 34 5 bar Bin Control Temperature Sensor 12A2117J03 Temperature sensor To provide pro...

Page 42: ...6 2 The following diagrams show the electrical details for the panel layouts control circuit and 3 phase power Figure 15 Panel Layout 50 Hz CE Machines Only ...

Page 43: ...6 3 Figure 16 Panel Layout 60 Hz Non CE Machines ...

Page 44: ...6 4 Figure 17 Electrical Schematic Control Circuit All Voltages 50 Hz ...

Page 45: ...6 5 Figure 18 Electrical Schematic Control Circuit All Voltages 60 Hz ...

Page 46: ...6 6 Figure 19 Electrical Schematic 3 Phase Power All Voltages 50 Hz ...

Page 47: ...6 7 Figure 20 Electrical Schematic 3 Phase Power All Voltages 60 Hz ...

Page 48: ... replacing and integrating the former standalone freezer pressure switch FPS the bin thermostat the low pressure safety the high pressure safety the defrost pressure switch DPS and the condenser pressure switch CPS Vogt 450 High Pressure Safety Backup ...

Page 49: ...6 9 Vogt 450 Low Pressure Transducer 0 500 psi 0 34 5 bar Sensor 1 Vogt 450 High Pressure Transducer 0 500 psi 0 34 5 bar Sensor 3 ...

Page 50: ...creen displays in order of appearance 1 The low pressure value Sensor 1 in psig 2 The bin temperature value Sensor 2 Fahrenheit can be changed to Celsius 3 The high pressure value Sensor 3 psig Figure 21 Vogt 450 Controller Display ...

Page 51: ...ith four modules connected linking the name of the switches in the Vogt 450 controller OUTR1 OUTR2 OUTR3 with the name of the actuator connected to the switches FPS2 BC2 Low Pressure Safety Figure 22 Front of Vogt 450 Figure 23 Vogt 450 Sensor Wiring ...

Page 52: ...6 12 To modify the setting to adjust the FPS DPS and CPS please follow the instructions below Freezer Pressure Switch FPS2 OUTR1 ...

Page 53: ...freezer pressure switch FPS2 except replace Step 2 with the following Setting Step 2 Action For Bin Level Control BC2 OUTR2 For Low Pressure Safety OUTR3 For High Pressure Safety OUTR4 For Defrost Pressure Switch DPS OUTR5 For Condenser Pressure Switch CPS OUTR6 ...

Page 54: ...quency drive VFD is a type of controller that drives an electric motor by varying the frequency and voltage of its power supply The VFD also has the capacity to control ramp up and ramp down of the motor during start or stop respectively Figure 24 VFD Starter Panel ...

Page 55: ...ically activated by the System 450 air cooled machines only Provides short circuit and over current protection Stops fan motors in the event of a mechanical or electrical malfunction that results in excessive motor amperes FU1 2 Overload and short circuit protection for control circuit and crankcase heater FU10 60 Short circuit protection for optional power monitor P Pump motor starter manual moto...

Page 56: ...l block which is numbered for multiple wire connections and ease of troubleshooting Y3 Compressor loader solenoid for 25 loaded condition Y4 Compressor loader solenoid for 100 loaded condition Table 7 Part List for VFD Starter Panel 50 Hz Only Item No Vogt Part No Description CB4 12A7515E09 3 phase Circuit Breaker 30 Amp 600V Feeds power to the main control panel for the water pump cutter and cond...

Page 57: ...7 Inspect the water distributors by looking through the transparent freezer cover It may be necessary to clean the cover before inspecting If required remove the cover Clean and remove any solid particles from the two orifices in each distributor Clean the rubber cover gasket and reinstall the cover 8 To run the pump only set the selector switch to the Clean position and press Start 9 For up to tw...

Page 58: ...tion to the water tank Install the water tank cover and allow the sanitizing solution to circulate for at least 20 minutes 11 While circulating the sanitizing solution open the adjustable blow down petcock valve and allow the solution to flow down the drain With the petcock valve open allow the water to circulate for at least 3 minutes 12 Press Stop to stop the pump 13 Drain and flush the water ta...

Page 59: ...e decrease in ice capacity To clean the water distributors 1 Shut down the machine and remove the freezer cover on the top of the freezer 2 Remove the water distributors one per tube with pliers 3 Use the pliers on the top part of the distributor with a twisting upward motion taking care not to damage the orifices or the distributor body 4 Soak the distributors in ice machine cleaner to remove min...

Page 60: ...te freezer cover is provided for visual inspection of the water box and water distributors located at the top of the freezer The cover should be removed and cleaned if it becomes coated with deposits Generally if this cover is coated with solids this is a major indicator that other water contact areas i e water tank and distributors also require cleaning Water Cooled Condensers The interval in whi...

Page 61: ... for a natural gravity flow of water Water is thus retained in the tube due to the surface tension between the tube and the water and the normal curvature between tube supports Experience shows that as much as 20 of the water in the condenser is retained To break the surface tension between the water and the tubes and to drain all tubes completely the condenser must be tilted a minimum of 5 degree...

Page 62: ...ag or soft bristle brush to clean the inside of the water end plates and the outer tube sheet surfaces Note Never use a wire brush or strong caustic on these surfaces These surfaces have been coated with a special material that will give years of protection against corrosion unless damaged 7 Flush the condenser tubes clear with air water or a piece of rag on the end of a stick or wire This will su...

Page 63: ...ight glass of the compressor crankcase should be watched carefully for the first hour to ensure that the proper amount of oil is remaining in the crankcase between the lines on the sight glass The oil level may be low on initial start up if electrical current to the crankcase heater was interrupted Figure 26 Front of the Machine Compressor Section Figure 27 Compressor Oil Section Opto electronical...

Page 64: ...rge oz ml R 513A Bitzer BSE 170 Polyol Ester Oil 305 30 Note The oil specified for this machine is very hygroscopic it attracts and holds water molecules from the surrounding environment and should be protected from the atmosphere to all extents possible If the compressor needs more oil use an oil pump To add oil remove the large refrigerant valve cap on the Oil Drain Fill valve in Figure 27 Backs...

Page 65: ...at may require maintenance long before a service situation arises The following schedule is suggested as a minimum Daily Checklist Is the machine running or is the bin full Bin doors are closed Thermostat bulb is in the bracket All ice discharges during harvest period Machine and components are clean No unusual noises Operating pressures suction discharge hot gas oil are within acceptable limits I...

Page 66: ...denser and cooling tower and check condenser tubes Inspect for damage by corrosion or scale Remove all rust from all equipment clean and paint Check all motors for shaft wear and end play Check operation and general condition of all electrical controls relays motor starters and solenoid valves Observe one complete ice making cycle record data and compare with the Warranty Registration Start Up For...

Page 67: ..._____ AC condenser motor amps if applicable ________ ________ ________ Crankcase heater heats oil Refrigerant leaks okay high low Leak checked entire system number of leaks found _____ Compressor oil level in sight glass 1 4 1 2 3 4 low high Gear reducer oil level correct level low level Low pressure switch setting psig _____ High pressure switch setting psig _____ Bin stat s installed and operati...

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Page 69: ...ower failure and intermittent power interruption Check electrical fused disconnect or circuit breaker supplying power to the machine If power has been off for a period of time make sure the compressor crankcase heater is energized the crankcase is warm 100 110 F 38 43 C and there is no liquid refrigerant in the crankcase before running the machine Push Start to initiate startup in a thawing period...

Page 70: ...e sure the bin thermostat bulb or level control is located properly in the bin Refer to Ice Bin Thermostat Sensor Defective component in control panel Check for open circuit Refer to Figure 12 to identify parts Replace defective part restart machine and check power supply and current draw Freeze Up from Extended Freeze Period Possible Causes Possible Solutions Freezer pressure switch setting too l...

Page 71: ...pening 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 mushy due to concentration of solids in the water tank Perform Cleaning Procedure and check automatic and adjustable blo...

Page 72: ...e Solutions Low refrigerant charge Check for and repair leaks Add refrigerant Restriction in liquid line Check for a partially closed valve or an obstruction at the dryer strainer solenoid valve or expansion valve The liquid line will normally have frost on the downstream side of a restriction especially as the suction pressure decreases Float switch stuck or failed in open position Make sure the ...

Page 73: ...t or replace valve Never adjust the valve stem as far open as it will turn because it will not close when the head pressure drops Insufficient water supply Check size of water line and pump output at the condenser Refer to the specification sheet for water requirements Check cooling tower sump level and makeup water supply Cooling tower needs maintenance Check cooling tower fan belt and tighten or...

Page 74: ...d 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 Dirty condenser causing restricted air flow Visually inspect condenser and clean as necessary Non condensables usually air in the system Follow same procedure as specified for removing n...

Page 75: ...evel and causes an overflow of water The overflow creates a siphon to remove a fixed amount of water 20 of tank capacity from the tank Makeup Water Float Valve The makeup water float valve maintains the proper pumping water level for ice making The valve is set to maintain an appropriate level high enough to prevent pump cavitation and low enough to prevent tank flooding in the water tank during t...

Page 76: ...diagrams This solenoid valve is located in the pipeline directly before the hand expansion valve When the refrigerant level in the freezer drops the float switch opens and de energizes this normally open solenoid valve until the liquid level in the freezer rises enough to close the float switch The float switch has a fixed 1 2 in 13 mm differential The float switch is installed at the correct heig...

Page 77: ...chine off if the compressor suction pressure drops below the cut out setpoint The factory setpoint for the low pressure safety is 5 psig 0 3 bar The cut in point where the output contacts close is 20 psig 1 4 bar High Pressure Safety Switch Vogt 450 The compressor s high pressure safety switch Output 4 of the Vogt 450 will shut the ice machine off if the compressor discharge pressure reaches the c...

Page 78: ...crew compressor motor is protected by an electronic motor protection module If this module fails it must be replaced Two different modules are used depending on how the compressor is powered If the machine does not have a variable frequency drive motor protection is provided by the Bitzer SE E1 module Vogt part number 12A2110P0505 If the machine is equipped with a variable frequency drive the moto...

Page 79: ...e same compressor load When this current becomes too high or is applied for an extended period the motor windings overheat resulting in a failure Loss of Refrigerant The semi hermetic compressor motor is maintained at proper operating temperature by passing cool suction gas over the motor windings A loss of refrigerant can cause the winding to overheat resulting in a failure or burnout High Head P...

Page 80: ...zed when the machine is not operating It is de energized when the compressor contactor is energized In case of a power interruption or crankcase heater failure the crankcase heater should be powered on for a minimum of 2 hours before restarting machine manually See Figure 26 and Figure 27 for location on the machine Oil Separator To handle all oil management needs an integrated oil separator is in...

Page 81: ... discharge of ice Should it become necessary to change the setting of the timer turn the adjustment screw clockwise to increase the time or counterclockwise to decrease the time After adjustment verify the new setting is at least 30 seconds longer than the time required for the last piece of ice to be discharged from the machine Figure 33 Thaw Timer Unit Set to min Power Light green Light blinks w...

Page 82: ... 4 Start the machine and allow it to operate for one harvest 5 During the harvest cycle remove the Thaw timer to prevent another thaw cycle 6 Allow the machine to operate until the low pressure relay on the Vogt 450 stops the machine at 5 psig 0 3 bar Set the correct pressure 7 Close the thawing gas stop valve the receiver liquid return stop valve the compressor suction valve and the compressor di...

Page 83: ...te of Test may indicate a loss of refrigerant due to a leak Always completely evacuate and recover the refrigerant from the vessel or tubing before repairs are attempted Non Condensable Gases Air and other non condensable gases in a refrigeration system are not desirable and can cause unsatisfactory machine performance Non condensable gas effects are Higher condensing pressure than what should mat...

Page 84: ...stem rotation is shown on the stem seal nut with an arrow as shown in Figure 35 Figure 35 Thaw Gas Solenoid Valve D Valve Table 11 shows replacement part numbers for the thaw gas solenoid valve Table 11 Thaw Gas Solenoid Valve D Replacement Pats Part Description Vogt Part Number Hansen HS4W Complete Valve Without Coil 12A4200A1204 Coil 126229 208 230V 50 60 Hz Rebuild Kit New Figure 36 Hansen Park...

Page 85: ...ch allows the ice machine to release all the ice in a timely manner during the harvest period The solenoids direct the flow of the oil being circulated within the compressor body to control the direction of the slide valve and the amount that it moves Only capacity control valves Y3 25 and Y4 100 are used for this compressor 100 Loaded Operation Freeze Period During the freeze period capacity valv...

Page 86: ...ers for the water pump and seal kit Table 13 Circulating Water Pump Parts Part Description Vogt Part Number Water Pump Seal Kit 12A4080S12 Water Pump 60 Hz 12A4020G01 Water Pump 50 Hz 12A4020G08 Cutter Gear Reducer The oil level for the gear reducer should be level with the plugged opening in the side of the gear housing If not this is evidence of a leak Use food grade oil and change oil once a ye...

Page 87: ...erclockwise Reverse two wires at the motor if necessary to change rotation direction Cutter Gear Reducer Removal and Replacement To remove the gear reducer follow the steps below refer to Figure 41 1 Turn the power off and lock out the disconnect 2 Remove the motor from the gear reducer 3 Slightly loosen the 4 bolts and nuts holding the gear reducer in place 4 Remove the four bolts holding the mou...

Page 88: ...m the machine 4 With a 1 4 in 8 mm or smaller punch reach into the ice discharge opening and drive the spiral pin out of the disc assembly Push or drive the disc off the shaft 5 Lift the cutter assembly out of the bearing surface of the cutter The surface should be smooth and free of nicks or burrs 6 Inspect the bearing for wear No side movement between the shaft and bearing should exist The beari...

Page 89: ...ive in the 3 16 in 5 mm pin through the drilled hole until it is flush with the outside wall of the cutter support hub Check that the pin does not extend into the surface inner diameter ID of the bearing 4 Slide the new bearing and cutter support onto the cutter shaft and check that it spins freely If the fit is tight carefully ream the inner surface ID of the bearing until it turns freely 5 Insta...

Page 90: ... mm or 1 1 2 in 38 mm can be converted to produce crushed ice with no loss in capacity Some changes are required to convert the machine for crushed ice production as noted below The following parts must be added to the machine Table 15 Cutter Parts Crushed Ice Option Part Description Vogt Part Number Crushed Ice Cutter Assembly 126413B 3 4 HP Cutter Motor 60 Hz 208 230V 460V 3 2A 1 6A 12A2900M0601...

Page 91: ...e is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Also you should not attempt to produce crushed ice when the makeup water temperature is below 50 F 10 C Colder water can cause a build up of ice fines in the tank and eventually result in short cycling Figure 42 Cutter Parts crushed ice option Figure 43 shows the various cutter parts for cy...

Page 92: ...ing changes must be made to the machine Raise the freezer pressure switch setting to make ice with an average thickness of 3 16 in 5 mm Reverse the rotational direction of the cutter motor Reverse the installation orientation of the ice deflector plate ...

Page 93: ...the 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 44 Power Monitor Voltage Monitor The Display The display normally shows phase A to B phase B to C and C to A line voltages If the unit is on a timer that timer will be displayed The timer display may be switched off by pr...

Page 94: ...alue may be adjusted by pressing the UP and DOWN arrows Lockout Time SECONDS Flashes This value may be adjusted by pressing the UP and DOWN arrows This is the delay on break timer value Delay Time RESP SECONDS Flashes This display shows time in seconds and tenths of seconds This value may be adjusted by pressing the UP and DOWN arrows This is the time that a fault is allowed before shutdown occurs...

Page 95: ...e 1 volt change the DTP 3 automatically calculates cut in voltages for the return from undervoltage conditions The cut out 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 referred to as hysteresis This is to help reduce oscillation that may occur on a weak power distribution system When the load ...

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Page 97: ... Ampacity 60 Hz WC AC Amps 54 95 54 95 54 95 50 Hz WC Amps 65 6 65 6 65 6 Water Requirements makeup 3 gpm m3 hr 3 0 0 68 3 0 0 68 3 0 0 68 condenser 4 gpm m3 hr 80 18 2 80 18 2 80 18 2 Connection Sizes makeup water MPT in DN mm 1 2 15 1 2 15 1 2 15 tank drain FPT in DN mm 1 25 1 25 1 25 condenser water inlet standard FPT in DN mm 2 50 2 50 2 50 condenser water outlet standard FPT in DN mm 2 1 2 65...

Page 98: ...HD06A044 of Fans HP 6 1 5 6 1 5 6 1 5 electrical data total KW FLA 11 5 42 11 5 42 11 5 42 inlet connection ODC in mm 2 1 8 54 2 1 8 54 2 1 8 54 outlet connection ODC in mm 2 1 8 54 2 1 8 54 2 1 8 54 shipping weight lb kg 2200 999 2200 999 2200 999 operating weight lb kg 1990 903 1990 903 1990 903 1 Nominal capacity is based on 70 F 21 C makeup water 100 F 38 C condensing temperature 70 F 21 C amb...

Page 99: ...540 19020 17520 N A 19781 18221 74 19320 17400 15900 N A 18096 16536 45 21500 19000 17500 N A 19760 18200 75 19150 17250 15750 N A 17940 16380 46 21440 18960 17460 N A 19718 18158 76 18980 17100 15600 N A 17784 16224 47 21380 18920 17420 N A 19677 18117 77 18810 16950 15450 N A 17628 16068 48 21320 18880 17380 N A 19635 18075 78 18640 16800 15300 N A 17472 15912 49 21260 18840 17340 N A 19594 1803...

Page 100: ...75 000 80 6 100 38 85 29 93 34 70 16 48 3 3 275 000 80 6 105 41 90 32 95 35 110 25 119 8 2 275 000 80 6 110 43 95 35 92 33 110 25 119 8 2 275 000 80 6 Table 20 Makeup Water Usage Makeup Water 10 gal 38 L cycle blowdown Cylinder Ice Crushed Ice Tube Size in mm Tube Size in mm Temp F C 1 25 1 1 4 32 1 1 2 38 1 25 1 1 4 32 1 1 2 38 40 4 2 56 6 50 2 25 5 72 2 19 5 56 3 00 7 62 2 62 6 65 2 54 6 45 50 1...

Page 101: ...135 15 105 150 175 13 7 12 1 10 9 10 6 10 3 1 1 2 in 13 135 15 105 150 175 13 3 11 8 10 6 10 3 10 0 Table 22 Normal Operating Criteria Metric Units Suction Pressure bar Discharge Pressure bar Harvest Times secs Ice per Cycle Freeze Time minutes End of Freeze Average During Freeze First All Ice Total Average Water Temperature deg C R513A R513A Ice Out Harvest Kg 32 26 7 21 15 6 10 50 60 Hz Cylinder...

Page 102: ...38 20 1 29 DPS Setting Open psig bar 42 2 9 42 2 9 42 2 9 Minimum Discharge Pressure psig bar 130 8 9 130 8 9 130 8 9 Maximum Discharge Pressure psig bar 140 9 6 140 9 6 140 9 6 Minimum Harvest Time 30 seconds out minutes 2 0 2 0 2 0 Maximum Harvest Time minutes 3 0 3 0 3 0 Low Pressure Safety Cutout cut out psig bar 5 0 34 5 0 34 5 0 34 Low Pressure Safety Cutout cut in psig bar 20 1 38 20 1 38 2...

Page 103: ...t 1 12A7518E31 Aux Contact 10 Amp 2 NO Side Mount 1 12A7518E32 Aux Contact 5 Amp 2 NO Top Mount 1 Harvest Timer 12A7503E22 Thawing Timer Delay On Make 100 240V 1 CR control relay UR unloader relay 12A7517E27 Control Relay 10 Amp 2 N O 2 N C 208 240V Coil 1 Control circuit fuses 12A7504E18 Fuse 5A 600V Time Delay Class CC rejection type 2 Cutter Tank Parts Water Pump 12A4020G01 Water pump 1 1 2HP 3...

Page 104: ...e A 12A4200A0604 RS RS valve with 230V coil 1 Thaw gas valve 12A4200A1204 Hansen valve Less coil 1 Thaw gas valve coil Hansen 126229 Coil Hansen 208 240V 1 Condenser Water regulating valve 12A4200E1402 Valve condenser water regulating 1 Compressor Parts Oil level control 12A2110P0507 Optical Oil level control 230V control power 1 Unloader coil 12A2110P0508 Coil Unloader 230V 8W 1 Crankcase Heater ...

Page 105: ...08 240V Coil 12A7530E52UL Cutter Manual Motor Starter 0 63 1 0A 460V 60 Hz 12A7530E53UL Cutter Manual Motor Starter 1 0 1 6A 400V 50 Hz 12A7530E54UL Cutter Manual Motor Starter 1 6 2 5A 200 208 230V 50 60 Hz ET 12B7503E17 Timer Elapsed Panel Mount 220V 50Hz 12B7503E18 Timer Elapsed Panel Mount 220V 60Hz FC Air Cooled Only 12A7516E27 Condenser Fan Contactor 30 Amp 3 Pole 1 N O Aux Contact 208 240V ...

Page 106: ... PM 12A7700P01 Power Monitor Universal Phase Protector Optional PF 12A7516E23 Power Failure Contactor 9 Amp 3 Pole 1 N O Aux Contact 208 240V Coil SS 12A7500E61 Selector Switch 3 Position 12A7500E77 Contact Block Mounting Latch 2 N O 1 N C T 12A7503E22 Thawing Timer Delay On Make 100 240V 12A7503E39 Timer Base 8 Pin Guarded Terminal TB1 N A Main Terminal Block Assembly ...

Page 107: ...7 82 96 7 96 7 123 187 3 187 3 1 9 8 9 7 42 41 7 41 7 83 98 4 98 4 124 190 190 2 10 4 10 3 43 42 8 42 7 84 100 2 100 2 125 192 8 192 8 3 10 9 10 9 44 43 8 43 8 85 102 102 126 195 6 195 6 4 11 5 11 4 45 44 9 44 9 86 103 8 103 8 127 198 4 198 4 5 12 1 12 46 46 46 87 105 7 105 7 128 201 3 201 2 6 12 7 12 6 47 47 1 47 1 88 107 5 107 5 129 204 2 204 1 7 13 3 13 2 48 48 2 48 2 89 109 4 109 4 130 207 1 2...

Page 108: ... Water Sensible Heat 1 BTU lb F 4 182 Joules kg C Ice Melting Effect 1 Ton Refrigeration 12 000 BTU hr 3 5 kw hr Atmospheric Pressure 14 7 psia 760 mmHg Weight of Water 62 4 lb ft3 1 000 kg m3 8 33 lb gal 1 gpm Water 3 79 L min 12 013 lb day 5 449 kg day Weight of Air 0 0749 lb ft3 0 0100 lb gal 1 Horsepower 2 545 6 BTU hr 46 watts 1 Kilowatt 1 34 horsepower 3 411 BTU hr Gravitational Acceleration...

Page 109: ... for your reference OSHA Standard The Control of Hazardous Energy Lockout Tagout 29 CFR 1910 147 R513A Safety Data Sheet Bitzer CSH Compressor Manual Water Conditioning Technical Service Bulletin 88 5 Compressor Oil BSE 170 Safety Data Sheet Gear Reducer Oil Safety Data Sheet ...

Page 110: ...Notes ...

Page 111: ...Notes ...

Page 112: ...Mid Size Machines HFO10 Service Manual Manual Part Number 12A4171M16 Vogt Ice LLC 1000 W Ormsby Ave Suite 19 Louisville KY 40210 USA Since 1880 ...

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