Vogt TUBE-ICE P-118F Service Manual Download Page 112

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P118F Service Manual

INDEX

1/6/09

12-1

12. Index

A Valves --------------------------------------------------------- 4-1, 5-1

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

Adding Refrigerant --------------------------------------------------- 5-4

Air - cooled Condenser Wiring (3 phase) --------------------3-12

Air-Cooled Condenser ---------------------------------------------9-10

Air-Cooled Condenser Data --------------------------------------- 3-8

Air-Cooled Condenser Installation ------------------------------- 3-6

Air-Cooled Piping Schematic-------------------------------------- 4-4

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

Allen-Bradley Switch------------------------------------------------- 9-3

Assembly Drawing , Air-Cooled---------------------- 1-4, 1-5, 1-6

Assembly Drawing , Water Cooled ----------------- 1-7, 1-8, 1-9

Automatic blowdown------------------------------------------------- 9-1

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

Bearing, Cutter -------------------------------------------------------9-16

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

Bin, Single Thermostat Wiring -----------------------------------3-12

Bin, Thermostat Installation---------------------------------------3-12

Blowdown -------------------------------------------------------------- 9-1

Burnout, Compressor ----------------------------------------------9-12

Capacity Ratings ----------------------------------------------------11-4

Capillary By-pass----------------------------------------------------- 9-2

Centrifugal Pump ----------------------------------------------------9-13

Charging Refrigeration Systems --------------------------------- 1-2

Check Valve ----------------------------------------------------------- 4-2

Checklist, Daily-------------------------------------------------------- 7-5

Checklist, Installation Review ------------------------------------3-13

Checklist, Start-up --------------------------------------------------- 5-2

Chemical Cleaning --------------------------------------------------- 7-4

Circuit Breaker, Cutter ---------------------------------------------- 6-2

Circuit Breaker, Pump----------------------------------------------- 6-2

Circulating Water Pump Motor-----------------------------------9-13

Clean/Ice Switch------------------------------------------------------ 6-2

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

Compressor------------------------------------------------------------ 7-3

Compressor Crankcase Heater----------------------------------- 9-5

Compressor Lubrication -------------------------------------------- 7-3

Compressor Motor Burnout---------------------------------------9-12

Compressor Unloader-------------------------------------- 9-13, 9-14

Compressor, Contactor --------------------------------------------- 6-2

Compressor, Motor Protection ------------------------------------ 9-6

Condenser Cleaning------------------------------------------------9-10

Condenser Fan Contactor (FC)----------------------------------- 6-2

Condenser Fan Switch---------------------------------------------- 9-5

Condenser Piping (Cold Weather Valve Kit) -----------------3-10

Condenser Water Usage -----------------------------------------11-5

Condenser, Air-cooled Cleaning --------------------------------9-10

Condenser, Air-cooled Heat Rejection ------------------------- 3-8

Condenser, Pressure Switch (CPS) ----------------------------- 9-5

Condenser, Water Cooled Maintenance ----------------------- 7-4

Control Circuit Protection----------------------------------------- 9-10

Control Panel ---------------------------------------------------------- 6-1

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

Control, Relay (CR) -------------------------------------------------- 6-2

Cooling Tower --------------------------------------------------------- 3-1

Crankcase Heater ---------------------------------------------- 7-3, 9-5

Crushed Ice Production------------------------------------------- 9-22

Cutter & Bearing Removal/Installation -----------------9-16, 9-17

Cutter Drive Parts -------------------------------------------------- 9-20

Cutter Gear Reducer ---------------------------------7-5, 9-10, 9-15

Cutter Motor---------------------------------------------------------- 9-15

Cutter, Assembly --------------------------------------------9-18, 9-19

Cutter, Bearing ------------------------------------------------------ 9-16

Cutter, Bearing Support------------------------------------------- 9-16

Cutter, Disc Assembly--------------------------------------9-18, 9-19

Cutter, Drive Parts ------------------------------------------------- 9-20

Cutter, Gear Reducer --------------------------------------------- 9-10

Cutter, Motor--------------------------------------------------------- 9-10

Cutter/Water Tank Assembly------------------------------------ 9-18

Cutter/Water Tank Parts (crushed Ice) ----------------------- 9-21

Cutter/Water Tank Parts (cylinder ice)------------------------ 9-19

Cylinder Head Sensor --------------------------------------------- 9-14

D Valve (Thawing Gas ) ------------------------------------ 4-1, 9-13

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

Drive gear ------------------------------------------------------------ 9-20

Electrical Connection ------------------------------------------------ 3-4

Electrical Schematic All Voltages 50-60 Hz. ------------------ 6-3

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

Enclosure --------------------------------------------------------------- 6-1

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

Equivalent Feet Due To Friction ---------------------------------- 3-9

Fan Contactor (FC) -------------------------------------------------- 6-2

Filter/Drier -------------------------------------------------------------- 4-1

Float Switch ------------------------------------------------------------ 9-2

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

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

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

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

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

Freezer Pressure Switch ------------------------------------------- 9-3

Fuses (FU1 and FU2) ----------------------------------------------- 6-2

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

Summary of Contents for TUBE-ICE P-118F

Page 1: ...P 118F TUBE ICE MACHINE Service Manual 5000 1 6 09 ...

Page 2: ...dditional 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 at 50...

Page 3: ...imum 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 installed and connected properly Compressor pump cutter and other motor direction of rotation correct Make up ...

Page 4: ......

Page 5: ...n 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 1 6 09 ...

Page 6: ......

Page 7: ...pection 2 1 Safety Valves 2 1 Machine Room 2 2 Storage prior to installation and start up 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Piping and Drain Connections TABLE 3 1 3 1 Cooling Tower 3 1 Space Diagram Water Cooled Machine FIGURE 3 1 3 2 Space Diagram Air Cooled Machine FIGURE 3 2 3 3 Wiring and Electrical Connection FIGURE 3 3 3 4 Voltage and Current unbalance 3 5 Rotation Check 3 5 Air Cooled ...

Page 8: ... Parts TABLE 6 1 6 2 Electrical Schematic All Voltages 50 60 Hz Across Line Start FIGURE 6 2 6 3 7 MAINTENANCE Ice Making Section 7 1 Cleaning Procedure 7 1 Water Distributors 7 2 Water Tank 7 2 Water Cooled Condenser Cleaning 7 2 Water Cooled Condenser Service FIGURE 7 1 7 3 Lubrication 7 3 Compressor 7 3 Cutter Gear Reducer 7 4 Preventive Maintenance 7 4 Daily Check List 7 5 Note To Manager Or O...

Page 9: ...ater Cooled Units 9 5 Air Cooled Units 9 5 Water Regulating Valve FIGURE 9 3A 9 5 Condenser Fan Switch FIGURE 9 3B 9 5 Compressor Crankcase Heater 9 5 Compressor Motor Protection 9 6 High Potential Testing 9 7 Field Troubleshooting 9 7 9 8 Electrical Installation Diagram FIGURE 9 4 9 8 Oil Pressure Safety Control 9 9 Oil Pressure Sensor 9 9 Oil Pressure Module 9 9 Thawing Timer FIGURE 9 5 9 10 Tha...

Page 10: ...RE 9 10 9 20 Cutter Water Tank Parts Crushed Ice FIGURE 9 11 9 21 Crushed Ice Production 9 22 10 OPTIONS AND ACCESSORIES PLC Programmable Logic Controller 10 2 Reduced Voltage Compressor Motor Starter 10 14 Power Monitor 10 17 11 TABLES AND CHARTS P118F Ratings 60 Hz 30 HP TABLE 11 1 11 2 P118F Ratings 50 Hz 35 HP TABLE 11 2 11 3 P118F Capacity Ratings TABLE 11 3 11 4 P118F Condenser Water Usage T...

Page 11: ...tomers 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 P118F 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 econ...

Page 12: ...der 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 Fai...

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: ...P118F Service Manual INTRODUCTION 1 6 09 1 4 FIGURE 1 1 Assembly Air Cooled Front View ...

Page 15: ...P118F Service Manual INTRODUCTION 1 6 09 1 5 FIGURE 1 2 Assembly Air Cooled Rear View ...

Page 16: ...P118F Service Manual INTRODUCTION 1 6 09 1 6 FIGURE 1 3 Assembly Air Cooled Right Side View ...

Page 17: ...P118F Service Manual INTRODUCTION 1 6 09 1 7 FIGURE 1 4 Assembly Water Cooled Front View ...

Page 18: ...P118F Service Manual INTRODUCTION 1 6 09 1 8 FIGURE 1 5 Assembly Water Cooled Rear View ...

Page 19: ...P118F Service Manual INTRODUCTION 1 6 09 1 9 FIGURE 1 6 Assembly Water Cooled Right Side View ...

Page 20: ...P118F Service Manual INTRODUCTION 1 6 09 1 10 ...

Page 21: ...tor All leaks should be reported to the Henry Vogt Machine Co to obtain authorization for repair CAUTION The approximate weight of the machine is 2975 pounds Always use equipment with adequate load carrying capacity CAUTION The machine frame has lifting lugs at each corner in the top for eyebolts and hooks to be used for lifting purposes if desired Lifting lugs should be used whenever possible CAU...

Page 22: ... the machine should not be located in a hazardous area or sprayed with water The machine should be installed on a drainable condensate drip pan or in an area where water will not stand but will readily drain away from the machine See Space Diagram for clearances and utility connections FIGURES 3 1 and 3 2 Storage prior to installation or start up The machine must not be stored or installed in an a...

Page 23: ...P118F Service Manual RECEIPT OF YOUR TUBE ICE MACHINE 1 6 09 2 3 ...

Page 24: ...t warm condenser water may back up into the water tank The condenser water outlet MUST be piped separately to the drain CAUTION Cooling Tower for water cooled machines only When selecting a cooling tower careful attention 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 i...

Page 25: ...P118F Service Manual INSTALLING YOUR TUBE ICE MACHINE 1 6 09 3 2 FIGURE 3 1 Space Diagram Water Cooled Machine ...

Page 26: ...P118F Service Manual INSTALLING YOUR TUBE ICE MACHINE 1 6 09 3 3 FIGURE 3 2 Space Diagram Air Cooled Machine ...

Page 27: ... on the Tube Ice machine WARNING FIGURE 3 3 Control Panel 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 termin...

Page 28: ...n on the other two legs Current follows the path of least resistance therefore if terminal connection L1 is loose or dirty L2 and or L3 will have higher current Higher current causes more heat to be generated in the motor windings The maximum acceptable current unbalance is 10 Example Current Readings L1 96 Amps L2 91 Amps Average 96 91 98 3 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highes...

Page 29: ...e they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest 5 The discharge and liquid lines must be insulated with 1 2 thick Armaflex insulation or equal 6 Horizontal runs in the discharge line should slope 1 4 per foot in the normal direction of flow away from the ice machine 7 Traps must be installed in discharge lines at the base of all vertical...

Page 30: ...allation 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 switch s adjacent to the condenser c Electrical connections between the condenser and the Tube Ice machin...

Page 31: ...60 hz 3 ph 190V 50 hz 3 ph 380V 50 hz 33 0 16 5 33 0 16 5 Weight lbs Net Shipping Operating Maximum flooded R 22 610 760 648 660 810 705 Condenser Dimensions inches A Width B Length C Height D Leg centerline E Leg centerline F Clearance below 28 3 4 180 1 8 41 5 8 27 147 5 8 14 5 8 28 3 4 180 1 8 41 5 8 27 147 5 8 14 5 8 Recommended Line Sizes OD Liquid All lengths and orientations Discharge Gas V...

Page 32: ...turn through tee 6 8 9 12 Tee straight through or sweep elbow 2 2 5 3 3 5 90 elbow or reducing tee straight through 3 4 4 5 TABLE 3 4 Equivalent Feet Due To Friction Courtesy Kramer Trenton Co Follow these procedures to make a tight joint 1 Silver solder or braze condenser tubing ends to the female Rota lock connectors 2 Remove dust caps if used making sure that component plastic seals are intact ...

Page 33: ...P118F Service Manual INSTALLING YOUR TUBE ICE MACHINE 1 6 09 3 10 FIGURE 3 5 Condenser Piping Cold Weather Valve Kit ...

Page 34: ...nual INSTALLING YOUR TUBE ICE MACHINE 1 6 09 3 11 65 F AMBIENT THERMOSTAT CLOSE AT 20 F AMBIENT THERMOSTAT CLOSE AT 65 F AMBIENT THERMOSTAT CLOSE AT 85 F FIGURE 3 6 Wiring For DD 311 and DD 361 Condenser 3 phase motors ...

Page 35: ... should be electrically installed between terminals 11 and 14 on the terminal block and the existing jumper wire 11 14 removed See your wiring schematic FIGURE 6 2 The location of the device in the bin is illustrated in FIGURE 3 7 Be sure to locate the level control device in the bin to allow space for the machine to make an additional discharge of ice after the ice contact the bulb or paddle One ...

Page 36: ...iance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK _____ All field installed equipment air cooled condenser ice storage bin ice bin level control etc for proper installation CHECK _____ The applicable portion of the warranty registration start up report for proper completion CHECK _____ The position of all toggle switches to assure ...

Page 37: ......

Page 38: ...1 6 09 ...

Page 39: ...reezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 Solenoid valve 20 sometimes referred to as the A valve is open and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 the heat exchanger 13 and to the compressor 3 Here the cool gas is compressed to ...

Page 40: ...xt freeze period begins This is to prevent refreezing CAUTION 1 Control Panel 31 Gage Glass Stop Valve 1PG Suction Pressure Gauge 32 A C Condenser Service Connection 2PG Discharge Pressure Gauge 34 Compressor Suction Service Valve 2 Freezer 35 Compressor Discharge Service Valve 3 Compressor 37 Oil Charging Drain Valve 4PS Dual High Low Pressure Switch 39 Water Tank Drain Valve 5M Cutter Motor 40 A...

Page 41: ...P118F Service Manual HOW YOUR TUBE ICE MACHINE WORKS 1 6 2009 3 FIGURE 4 1 Water Cooled Piping Schematic ...

Page 42: ...P118F Service Manual HOW YOUR TUBE ICE MACHINE WORKS 1 6 2009 4 FIGURE 4 2 Air Cooled Piping Schematic ...

Page 43: ...hanger 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 to close initiating the harvest period During the harvest period the thawing gas solenoid valve the D valve is open allowing the warm high pressure gas to enter the free...

Page 44: ...essor service valves 34 and 35 the hand stop valve 90 in the thawing gas line 91 in the condenser return line hand stop valve 58 in the liquid line hand stop valve 69 to the freezer pressure switch and stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage glass valves 31 on the receiver can be opened for liquid level observation b...

Page 45: ...on 3 Push the Start button to start the water pump 4 The pump can be stopped and started by Stop and Start push buttons or by the Ice Clean switch to purge the tubing of air 5 When there is good water flow turn the On Off switch On and the Ice Clean switch to Ice The machine will then start in a harvest thaw period with the compressor running 6 At the termination of the harvest thaw period the mac...

Page 46: ...he gage glass on the receiver Adding Refrigerant When adding refrigerant it is necessary for the following procedure to be followed 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 va...

Page 47: ... 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 in the off position The Start push button can be used to initiate a harvest cycle When it is pushed during a freeze cycle it will immediately initiate a harvest cycle When the machine is sto...

Page 48: ......

Page 49: ...1 6 09 ...

Page 50: ...P118F Service Manual ELECTRICAL CONTROLS 1 6 09 6 1 6 Electrical Controls FIGURE 6 1 Control Panel Cover Removed ...

Page 51: ...er Controls the time of the thawing period BC Bin Control Relay Stops and starts machine operation by action of optional bin thermostat BT FC Fan Contactor Cycles the fan motor s of air cooled condenser on and off Activated by the condenser pressure switch air cooled machines only TS1 Ice Clean Toggle Switch Two position toggle switch to operate machine in ice making mode or clean mode When in cle...

Page 52: ...P118F Service Manual ELECTRICAL CONTROLS 1 6 09 6 3 FIGURE 6 2 Electrical Schematic All Voltages 50 60 Hz ...

Page 53: ...iment from tank 5 Close drain valve 39 and fill water tank approximately 60 gallons with warm water Close the petcock on the water pump during the cleaning period 6 Add 160 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 th...

Page 54: ... 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 Condensers Checking Operation How often condensers need cleaning depends on so many...

Page 55: ...operated water valve If this difference is less than 5 F restricted water flow or a low supply pressure is indicated A restriction can occur with foreign matter in the condenser but it is also likely to be somewhere else in the system Draining Draining of water cooled condensers is recommended in preparation for the winter cold where units may be left exposed to ambients below 32 F Theoretically i...

Page 56: ...til it is considered clean e Flush the condenser according to directions f Install the water regulating valve and connecting piping Open the water supply stop valve and check for leaks Mechanical cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser d Remove the cover plate on the...

Page 57: ...arefully for the first hour to make certain the proper lubrication is being maintained The oil may become low in the crankcase on an initial start up if electrical current has been interrupted to the machine thus de energizing the compressor crankcase heater Before starting the machine again the heater should be energized for a time period of at least two hours to evaporate refrigerant that may ha...

Page 58: ...ith suitable leak detector for the first four weeks of operation 2 Check oil level and condition C Monthly in addition to weekly checks 1 Check calibration and operation of all controls high and low pressure switches oil pressure switch etc 2 Check cooling tower for scaling and algae consult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulat...

Page 59: ...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 60: ..._______ ________ _____ 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 _____ Gear reducer oil okay low _____ PSIG low pressure switch set _____ PSIG high pressure switch set _____ Bin stat s installed and oper...

Page 61: ... 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 62: ...kage between suction and discharge port of the compressor Check for broken cylinder head gasket or valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body One of the 2 5 amp control circuit fuses FU I or FU 2 in the control panel burnt out Check compressor crankcase heater coils of relays contactors starters solenoid valves and...

Page 63: ... 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 Ch...

Page 64: ...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 65: ...aw 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 mushy due to concentrati...

Page 66: ...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 water restriction in the supply line or at the make up water float valve Make up water float valve 12 stuck open adjusted too high or water tank drain valve 15 open or leaking Repair replace or adj...

Page 67: ...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 68: ...ded 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 portion of the gage...

Page 69: ...screen and clean as needed Non condensables usually air in system Check refrigerant tables for 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 vap...

Page 70: ...use Replace fuse and reset switch If the condenser is split check the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted air flow Visually inspect condenser and clean as necessary Non condensables usually air in the system Fo...

Page 71: ... siphoning vacuum is broken A vacuum break solenoid is installed on the blowdown piping to break the siphon at the end of the freeze cycle This valve is normally open and is only closed during the harvest cycle Earlier models did not utilize a siphon to achieve the desired blowdown during harvest Those models had a solenoid operated drain valve which would allow the water to drain from the tank du...

Page 72: ... 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 which provides highest capacity The correct height will produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30 F Hand Expansion Valve The hand expansion valve is located d...

Page 73: ...nitially setting an AB pressure switch which has not been previously adjusted 1 Turn the bottom screw differential approximately 1 2 turn to the Left counter clockwise The pointer arrow which is at the top middle of the switch will be at the F setting See FIGURE 9 1 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will b...

Page 74: ...roximately 3 16 High Low Pressure Switch The high low pressure switch HPS FIGURE 9 2 is a two pole dual function switch Located in the machine mounted to the frame near the compressor It protects the machine from possible damage due to abnormal pressure during operation CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming normal operation...

Page 75: ...wers the head pressure and decreasing the water flow raises the head pressure The valve is adjusted during the factory test The valve stem should not be opened as far as it will go or the valve will not close fully when the head pressure drops below its setting Air Cooled Units The condenser fan switch mounted to the frame lower right side FIGURE 9 3B CPS is used to regulate the head pressure This...

Page 76: ... the module The time delay is not energized on opening of the high or low pressure switches There are two major components in the protection system 1 The protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resistance 2 The control module is a sealed enclosure containing a r...

Page 77: ...is external to the solid state protection system If the compressor operates with the module bypassed but will not operate when the jumper wire is removed then the control circuit relay or triac in the module is open 4 If after allowing time for motor cooling the protector still remains open the motor sensors may be checked as follows a Disconnect control circuit power to deenergize the module Remo...

Page 78: ... below 2700 ohms resistance the compressor will run with the control circuit bypassed but will not run when connected properly the solid state module is defective and must be replaced The replacement module must be the same voltage and be compatible with the original module on the compressor FIGURE 9 4 ...

Page 79: ...t opens on low oil pressure and signals the Sentronic electronic control module to begin time out The same contact closes when proper oil pressure is present and stops the module time out Should oil pressure fall below 7 9 PSID for a period of two minutes the Sentronic module will open the control circuit using its Normally Closed N contact and shut the compressor off Approximate oil pressure can ...

Page 80: ... open the disconnect switch to machine and set the On Off switch to the off position If the machine was off for an extended time the crankcase heater must be energized for a minimum of two hours before restarting the machine When ready to restart the machine depress the Start button The machine will automatically return to a freeze cycle upon completion of the harvest cycle Condenser Cleaning See ...

Page 81: ...nother thaw cycle 6 Allow the machine to operate until the low pressure switch stops the machine 20 PSIG If a lower pressure is desired it can be accomplished by jumping the low pressure switch and starting and stopping the machine by the Start and Stop push buttons Continually observe the oil level to make sure the oil is not carried from the compressor while operating at a low pressure 7 Close t...

Page 82: ...ature See Water Cooled Condensers Section 7 Compressor Motor Burnout There are several causes of compressor motor burnout Some of these are described below 1 Low line voltage A compressor motor is designed to operate within the range of plus or minus 10 of its nameplate voltage Low voltage requires the motor windings to carry more current at the same compressor load When this current gets too high...

Page 83: ...s a spare When ordering a seal specify pump size type serial number and manufacturer s name as indicated on the nameplate Capacity Control Internal Valve Construction A schematic illustration of the internal valve operation is shown in Figure 9 7 In the normal full capacity operating position with the solenoid valve de energized the needle valve is seated on the lower port and the unloading plunge...

Page 84: ...suction pressure through the suction port Since the face of the plunger is open to the suction chamber the gas pressures across the plunger are equalized and the plunger is held in the open position by the spring Unloaded Operation during thaw only During the thaw cycle the solenoid coil is energized The needle valve is seated on the upper port and the unloading plunger chamber is exposed to disch...

Page 85: ...install the terminal cover 10 Check motor rotation to make sure the cutter turns in the proper direction Reverse two wires at the motor if necessary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 10 1 Turn power off and lock out disconnect 2 Remove motor from reducer 3 Loosen slightly the four bolts and nuts holding the gear reducer in p...

Page 86: ...en bolts holding the tank supports 7 The tank can then be removed to the side of the machine 8 Make sure the rubber gasket is in place and aligned properly when the tank is installed and bolted to the freezer Cutter And Bearing Removal Installation Refer to FIGURES 9 8 9 9 9 10 for parts identification and location 1 Turn off and lock out power to the machine 2 Remove the cutter motor from the red...

Page 87: ...iginal hub hole as a pilot Insert and drive the 3 16 pin flush with the outside of the hub making sure the pin doesn t extend beyond the inner surface of the bearing 14 Slide the new bearing and support onto the cutter shaft to make sure it spins freely If it is tight ream the bearing inner surface slightly until it turns free 15 Install the bearing support in the tank using the reference marks as...

Page 88: ...P118F Service Manual SERVICE OPERATIONS 1 6 09 9 18 FIGURE 9 8 Cutter Water Tank Assembly ...

Page 89: ...P118F Service Manual SERVICE OPERATIONS 1 6 09 9 19 FIGURE 9 9 Cutter Tank Parts cylinder ice ...

Page 90: ...P118F Service Manual SERVICE OPERATIONS 1 6 09 9 20 FIGURE 9 10 Cutter Drive Parts ...

Page 91: ...P118F Service Manual SERVICE OPERATIONS 1 6 09 9 21 FIGURE 9 11 Cutter Tank Parts crushed ice option ...

Page 92: ...version process should normally be accomplished by two people in 3 4 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 ice is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Refer to Technical Service Bulletin No...

Page 93: ...P118F Service Manual OPTIONS AND ACCESSORIES 1 6 09 10 1 10 Options and Accessories Reduced Voltage Compressor Motor Starters Page 10 2 Power Monitor Page 10 17 ...

Page 94: ...IME adjustment fully clockwise to 100 so that the longest starting time is obtained 2 Rotate the INITIAL TORQUE adjustment to midrange on the dial 50 to lower the starting torque 3 Start the motor If more or less torque is required to break the load free turn off the power rotate the INITIAL TORQUE adjustment in the appropriate direction until the load just begins to move when power is first appli...

Page 95: ...OTE The Line Voltage Limiter adjustment can reduce the motor terminal voltage to a level not less than the value of voltage determined by the START TORQUE adjustment If unable to lower the output voltage reduce the START TORQUE until an acceptable output is obtained Dual Ramp and Energy Saving Controls The soft starter has provisions for dual ramp soft starting however this feature is not used on ...

Page 96: ...low Replace power pole containing shorted SCR as required Motor growls when started and does not come up to speed Controller not finished ramping voltage Check to see that the unit has finished ramping the motor voltage If motor is coming up to speed to slowly decrease start time adjustment Make sure that Decel is not selected connection between Decel and Common on controller This will cause a per...

Page 97: ...edly to step through each menu item changing settings where required As you step through the Setup Menu the unit will remain on line monitoring your system and logging any faults in memory for you to review after you leave the setup mode The Setup LED will stay on during setup operations When you have passed the last parameter in the setup menu the setup LED will extinguish and you will be returne...

Page 98: ... Use the arrow keys to adjust the number of times the contactor will be operated in order to seal the contacts Setting retries to OFF means do not check load side Any input to the load inputs will be ignored Default is off Reset Mode Manual Automatic Choose whether to let the unit automatically reset or to wait for you to manually reset it The recommended setting is automatic because faults must b...

Page 99: ...me temperature conditions the LCD display may be dark or clear If this occurs simply use the arrow keys as described above to adjust the display to a visible condition LCD contrast adjustments are stored in the permanent memory and will remain constant once set Locking Out Setup Menu In some field installations it may be desirable to lock out unwanted changes from being made to the programmed para...

Page 100: ...essor contactor with 1 amp fused connections The connections labeled control should be wired to a 230 volt power source Com and Run connections should be wired in series with the system control circuit Note that specified connections are for P18XT models only Consult factory for other models Figure 10 6 Phase Protector wiring schematic ...

Page 101: ...e voltage too low and or phase missing Control LED does not go out when control is off CONTROL LED always on Control input is very sensitive Insure control voltage 2 volts for off condition System trips out on low or high line voltage FAULT LED flashes due to fault Check normal line voltage using READ feature Re adjust voltage range as required Output relay never turns on Control Mode setting is O...

Page 102: ...P118F Service Manual TABLES CHARTS 1 6 09 11 1 11 Tables Charts ...

Page 103: ...0 000 49 8 170 000 49 8 170 000 49 8 Marley Cooling Tower 5 4821 4821 4821 dimensions LxWxH ft meters 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 shipping weight lbs Kg 740 336 740 336 740 336 operating weight lbs Kg 1340 608 1340 608 1340 608 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 2...

Page 104: ...00 49 8 170 000 49 8 170 000 49 8 Marley Cooling Tower 5 4821 4821 4821 dimensions LxWxH ft meters 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 shipping weight lbs Kg 740 336 740 336 740 336 operating weight lbs Kg 1340 608 1340 608 1340 608 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 24 4...

Page 105: ... 10750 10150 10050 11180 10556 10452 9920 9585 9450 10317 9968 9828 64 10700 10100 10000 11128 10504 10400 9860 9530 9400 10254 9911 9776 65 10650 10050 9950 11076 10452 10348 9800 9475 9350 10192 9854 9724 66 10600 10000 9900 11024 10400 10296 9740 9420 9300 10130 9797 9672 67 10550 9950 9850 10972 10348 10244 9680 9365 9250 10067 9740 9620 68 10500 9900 9800 10920 10296 10192 9620 9310 9200 1000...

Page 106: ...3 15 1 170 000 100 75 93 19 1 170 000 100 80 94 25 2 170 000 100 85 94 37 5 170 000 105 90 95 68 15 170 000 110 95 100 68 15 170 000 Table 11 4 Make Up Water Usage gpm P118F Cylinder Ice Crushed Ice Make Up Water Tube Size Tube Size Temp F 1 1 1 4 1 1 2 1 1 1 4 1 1 2 40 1 15 1 10 1 09 1 19 1 15 1 14 50 1 10 1 05 1 04 1 14 1 09 1 09 60 1 04 0 99 0 98 1 08 1 02 1 02 70 1 00 0 94 0 93 1 03 0 98 0 97 ...

Page 107: ...3 17 9 60 L 1 1 2 31 70 195 150 15 90 120 170 26 1 24 6 23 2 22 0 20 5 HZ C 1 35 70 195 150 15 90 120 109 14 1 13 3 12 5 11 8 11 1 R 1 1 4 34 70 195 150 15 90 120 113 15 8 14 8 14 0 13 2 12 2 U 1 1 2 33 70 195 150 15 90 120 126 18 1 17 0 16 0 15 1 14 0 C 1 33 70 195 150 15 90 120 147 22 6 21 3 20 3 19 0 17 8 Y 1 1 4 32 70 195 150 15 90 120 152 24 4 23 2 21 8 20 4 19 1 50 L 1 1 2 31 70 195 150 15 9...

Page 108: ...0 60hz 1 12A 7530E12000000 Compressor motor starter 208 230v 50 60hz 1 12A 2900M05010000 Cutter motor 1 2 HP 2 12A 4200H04020000 Make up water float valve 1 12B 2020R01000000 Cutter bearing 1 12A 2600G07000000 Gasket for freezer cover 1 12A 2600G05000000 Gasket for water tank 1 12A 7509E12000000 Crankcase heater Copeland Discus Compressor 1 12C 2590G08000000 Suction pressure gage 1 12C 2590G090000...

Page 109: ...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 110: ...5 9 TF 32 C F TF 9 5 TC 32 Volume ft3 m3 2 8317e 2 gal U S m3 3 7854e 3 ft3 gal U S 7 48 TABLE 11 8 CONSTANTS Specific heat of Water 1 BTU lbm F Specific heat of Air 4 19 kJ kg C 0 24 BTU lbm F Tube Ice Density 32 35 lbs ft3 Ice Latent Heat 144 BTU hr Water Sensible Heat 1 BTU lb F Ice Melting Effect IME 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 lbs ft3 ...

Page 111: ...P118F Service Manual TABLES CHARTS 1 6 09 11 10 ...

Page 112: ...nser Fan Contactor FC 6 2 Condenser Fan Switch 9 5 Condenser Piping Cold Weather Valve Kit 3 10 Condenser Water Usage 11 5 Condenser Air cooled Cleaning 9 10 Condenser Air cooled Heat Rejection 3 8 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled Maintenance 7 4 Control Circuit Protection 9 10 Control Panel 6 1 Control Panel Parts 6 2 Control Relay CR 6 2 Cooling Tower 3 1 Crankcase Heater...

Page 113: ...ation Vitals 11 6 Optional Equipment Power Monitor 10 17 Optional Equipment Soft start Motor Controller 10 14 Overload Cutter 6 2 Overload Pump 6 2 P Pin Stainless Steel 9 18 Piping and Drain Connections 3 1 Piping Schematic Nomenclature 4 2 Piping Schematic Water cooled 4 3 PLC 10 2 Poor Ice Quality 8 8 Power Connection 3 4 Power Monitor 10 17 Preventive Maintenance 7 6 Preventive Maintenance Pro...

Page 114: ...ater Conditioning 3 1 Water Cooled Condenser 3 1 7 2 Water Cooled Condenser Cleaning 7 2 Water cooled Machine Installation 3 1 Water Cooled Piping Schematic 4 3 Water Cooled Units 9 5 Water Distributors 7 2 Water Pump Motor 9 13 Water Quality 3 1 Water Regulating Valve 9 5 Water Supply and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 3 Water Tank 7 2 Water Tank Removal 9 16 ...

Page 115: ...P118F Service Manual INDEX 1 6 09 12 4 ...

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