Home

P18AL Service Manual

Contents

1. 2 1 Solenoid Valve 9 3 Space and Connection Diagram 3 5 Special Precautions 1 2 6 19 07 P18AL Service Manual Start Push Button PB1 5 5 6 2 Starter Cutter Motor 6 3 Starter Pump Motor 6 3 Start Up 5 5 Start Up Checklist 3 11 Suction Cut Off Unloader 9 14 Symptoms Troubleshooting 8 1 T Telephone Number Vogt 1 1 Temperature Pressure 10 6 Thawing 4 1 Thawing Timer 6 3 9 1 Timer 6 3 9 1 Troubleshooting 8 1 U Unloading Compressor 3 4 V Vitals Operation 10 5 Warranty Basic inside back cove
2. AJR NIN DIN 38 352 656 774 332 818 40 36 9 685 805 35 1 851 42 388 715 838 370 885 61 44 407 745 870 919 64 3804 423 0 384 46 427 776 904 420 955 67 363 4 389 5 4340 395 48 447 807 939 433 992 708 481 8 3723 398 9 444 0 406 50 467 840 974 455 1029 742 45 6 381 5 4084 4490 4320 TABLE 10 7 pressures are in Ibs in gage psig oo O1 1 oo gt ojo A 02 AIC gt D A SES o N N 283 0 6 19 07 P18AL Service Manual REFERENCE INFORMATION CONVERSION FACTORS English to Metric To Convert Multiply by 9 2903e 2 6 416 e 4 1054 48 2546 2 1 34 Area Joule J BTU Hr 10 7 TABLES amp CHARTS Pressure Ibf ft Paschals Ibf in psi Paschals in Hg psi in psi 0 03612 Temperature F C 5 9 32 C F 9 5 32 Volume ft m 2 8317e 2 gal U S m 3 7854e 3 ft gal U S 7 48 TABLE 10 8 CONSTANTS Specific heat of Water Specific heat of Air Tube Ice Density Ice Latent Heat Water Sensible Heat Ice Melting Effect IME Kilowatt Gravitat
3. 7 2 Preventive Maintenance Program 7 1 Preview 1 1 Principle of Operation 4 1 Pump 9 4 Pump Starter 6 3 Pump 6 3 Q R R 717 Anhydrous Ammonia 1 2 2 1 5 1 9 5 Receipt of Machine 2 1 Receiver 3 3 Recommended Spare Parts List 10 5 Refrigerant Charge 3 6 5 2 Refrigerant Leaks 9 5 Refrigerant Leaks 5 1 Refrigerant Removal 9 5 Refrigeration System Review 5 1 Rotation 3 10 S Safety Notice 1 2 Safety Symbols and What They 1 3 Safety Valves 2 2 Shipping Papers
4. 1100 DNLLVSH 54 006 SIATY 4018 ANIT NOLLONS GIONS1CE SEVdAG NOLLADS ZNIISSYdAG ul A ANIT NOILONS TYNOLLdO 4 H31VAA LAM T CHEIVAA Ts _ HELWA 14 HENT LC 2 Zh CC Hosa aval SONY TA lt lt ANIT 001 LS lt lt BS 1 L ION Ce Sor zu a 011 ger a 0 gan d gee ar 9 244 Z TATY A ONIOUVHO MANIVULS ae E 9T A 5 lt 3ONVTH HT S OMVHL aN 0 I HANIVELS SIATY A SEITEN a a xis d 3 amp gt TANYA TOALNOS 6 x H ANTT CINOTT HOLMS IVOTI 1 AAZATAT lt 4 B E d 5 2 5 9 gt TOAN Ui E 5 8 9 E SONY die unsgdud o th Tw nd d o m 5 1 ANIT NOLLONS Z 5 t a AITAN B 5 9 L GION3TOS ANIT NIYAT 10 11 GHSNHOINOO
5. SNIIONIZITVOOS l XNIIZONVHOSIQa I 1 FIGURE 4 2 Schematic Central System iping P18AL P 6 19 2007 P18AL Service Manual 6 19 07 5 1 START UP AND OPERATION 5 Start Up and Operation Refrigeration System Review The refrigeration system uses anhydrous ammonia R 717 refrigerant Following the piping schematic Figure 3 2 or 3 3 you will see that during the machine s freeze cycle the compressor discharge gas goes through the oil separator to remove oil present in the discharge gas and return the oil to the compressor crankcase It is then discharged into the condenser and condensed into a liquid by the removal of heat by water passing through the condenser tubes A reservoir of liquid R 717 approximately 175 165 is accumulated in the receiver and is required for thawing purposes see Table 3 2 Liquid from the receiver flows through the strainer to the A solenoid valve 25 which opens and closes by action of the low side float switch 23 The liquid is then expanded through the hand expansion valve 9 and into the evaporator 1 freezer The cold wet R 717 refrigerant floods the evaporator and is in contact with the outside of the ice making tubes which water is being circulated through The heat contained in the water passes through the wall of the tubes lowering the temperature of the water causing it to freeze and form a long tube of ice that adheres to the inside of fr
6. 4 1 Gear Reducer 9 10 H Harvest Period cnn ccncccnen 4 2 Heater Crankcase High Head Pressure High Head Pressure 8 5 High Low Pressure Switch 6 1 History Tube Ice amp Hub Cutter Drive Gear 9 12 1 Capacity 10 2 10 4 Ice Making Section 7 3 Important Safety Notice Inspection First Arrival 2 1 Installation 3 1 Installation Review A Checklist 3 11 1 1 J K L Low Compressor Oil Level 8 6 Low Ice Capacity 8 4 Low Pressure Switch 6 1 Lubrication Lubrication Compressor 7 7 Lubrication Cutter Gear Reducer 7 5 11 2 INDEX M Machine Ratings 10 3 10 4 Machi
7. JATA NA AOLFAFAHS OLE SQI SL 5 891 SLT ACIS MO T 591 OST 1 VINOWAY ISHAUVH LAVLS LV ANALVYIANEL NOLLVAALVS LV SI VINOWJAV LVHL 55 OLGSONSAWOOSU TOD VINO 841 005 M lt ANIT CINOIT R SVD gt STATYA Ja L ANTT NOLLONS aT 5 A SATA ANIT NIVIKI g l HASNHANON ANIT FIGURE 4 1 P18AL Piping Schematic Dedicated High Side ONIZITWAOG ul 6 19 2007 P18AL Service Manual 4 4 HOW YOUR MACHINE WORKS 5 8c aolyadydas O18 54 cL 541 SEL 541052 VINOFUAV LAVLS NOILYAQLYS LY TINON LYHL JANSSY
8. 1868 8 INOIT 125 1285 LJ NE S GE z 1 1 IONII AONE HT SVOAMVHL 1 Hi LJ HANIVELS SHATV JSTTHH DVODSHDSESHd lt ANIT lt SNIISVO t l I pr 4 3 E B a ed d ta 9 d s HOLV 1008 2 T HON TT hi 5 E E E ANTT MOLLOAS 4 8 gt e 5 gt 8 2 cle 4015 NOLLODS 4 ANIT NOILONS Z HOT US ANIT S8 d 4d ol A ANTT NOLLONS ANTT NIVA LL HI3SNRSOINOO SANIT ANIT FIGURE 3 3 Piping Schematic Central High Side 1 22 07 3 8 INSTALLING YOUR TUBE ICE MACHINE Wiring and Electrical Connection WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage P18AL Service Manual electrical equipment should be allowed to install or work the Tube Ice machine WARNING Refer to TABLE 3 2 to properly size wiring connections A fused disconnect must be provided near the Tube Ice machine Connect 3 phase power to terminals L1 L2 L3 for
9. 7 4 Freezer nq HL EH EM 7 4 Other Maintenance Operations Cutter Gear nca dao 2 2 09 P18AL Service Manual 7 8 9 TABLE CONTENTS Page No MAINTENANCE Cont OUT A 7 5 Optional Maintenance Op rations Be tue 7 5 Water Cooled Condenser Cleaning ertt RM 7 5 Cooling Tower Evaporative Condenser ss 7 6 COMPr SSO PER A DEM UE 7 7 TROUBLESHOOTING LiStOPSYMPIOMS 8 1 Stopped s on MS sta asa E E Freeze Up Due Ice Failing Discharge LOW ICE Capacity Ar di Poor Ice High Discharge Pressure Check Gage Accuracy iii 8 5 Low Discharge Pressure Check Gage Accuracy inner 8 5 High Suction Pressure Check Gage Accuracy 8 6 Compressor Running Unloaded During Freeze Dedicated Compressor Only 8 6 Compressor Oil Pressure Low Check Gage 8 6 Compressor Loosing Oil 8 6 Machine Short Cycles Using Freeze Pressure Switch FPS Only ss 8 7 High Compressor Discharge Temp rature eee E 8 7 Suction Line Frosting To COIlpresSOE sor EORR HERPES Rr begin ettet 8 7 SERVICE OPERAT
10. MT 4 POWER GHSIDE SAFETY AUXILIARY HI OPTIONAL FREEZER PRESSURE SWITCH COMPRESSOR UN LOADER SOLENOID CONVEYOR TIMER CONTACT CUTTER AUXILIARY HIGH SIDE GN PUMP AUXILARY 9 CUSTOMER CONNECTIONS MAIN POWER GROUND FIGURE 3 5 Control Panel Field Connections Detail STARS Ampacity Fuse 10 5 220 3ph 50 Hz 9 8 10 400 3ph 50 Hz 5 1 10 TABLE 3 2 Electrical Specifications Note Refer to Chapter 6 for a wiring schematic and electrical component layout and description 1 22 07 3 10 Service Manual INSTALLING YOUR TUBE ICE MACHINE Phase Check CAUTION DO NOT attempt to start machine without priming pump and insuring proper rotation of both cutter and pump CAUTION Cutter and pump motor rotation are factory synchronized but must be checked at installation For ice production the cutter disc as viewed at the ice discharge opening should turn from left to right crushed rotation should be from right to left The pump rotation should match the marking on the pump housing The pump will need to be primed by starting the machine in the clean mode and allowing it to run for several minutes To change direction of rotation for both cutter and pump disconnect power and reverse L1 and L3 incoming power wires at the compressor motor contactor Voltage Unbalance Voltage unbalance can cause motors to overheat and fail The maximu
11. gt ANIT NOLLONS C ANIT UNIT ONIZITWNOG ul HHSNSONOO ANIT FIGURE 3 2 Schematic Dedicated High Side 1 22 07 3 7 INSTALLING YOUR TUBE ICE MACHINE P18AL Service Manual ALFA SNLLYTNO AIS AA OTIA AO HBIVAA Z OHNIVUM TIO 30VD OT HOLIMS IYOT LNVEZSOISIES SIATY A JATIA LAN T A HSIVAA 1 E T B 14 E E SOWVHOSKI ES SONVTd E AOLFTANNOOT 1 211 NMI aoLyavdas TO AISNAANOO Q SL 5 lt 54 SLT AGIS 2AO T SA OSZ VINOYUNV 50 LXVIS LV HANLY ANAL NOLLVSILLVS LV SI VINOJUT GdIQOIIIVHIlSunsgv Ol DNLLVSH VINOJUAU 54 006 Pr 1 lt lt INIT CINOIT m E
12. dal Tad WHZHdud HANIVELS V 7 ANSE Hd AGIS HOIH SONVTS C NIYAT TO DA NIVUC N31 V A em Sex p qE SATVA AN TAF 144 ET 22 2545 eee ds AOUFHOSIQ 7 aor NT 1 lt 1 lt MIS 20 n 259 5 Taga 5 Fone 4 28 NOISNVdX3 fm gt GOGHNIVHLS 1 1 5 9 JONY AVAL 1 NOILINS asas 5 AUTRE WOSSHudIWNOO ISHAHVH ONIANA SSAT WAD 05 OL 55 4 0 MV AVOINA HOLVAVAAHS TIO NIVEC 5 SQI SL 841 SLT HGIS AO I 541060 JO LAVLS LV AMALVYHANAL NOLLVSALVS SI VINOWWY CINOIT HINSSV OL TOD DNILVAH VINO WINY 841 005 ANIT H E ras S3ATVA m SVD MVELL
13. 9 12 Cutter Bearing Support 9 12 Cutter Disc Assembly Cutter Drive Parts 9 12 Cutter Gear Reducer 9 9 9 12 Cutter Motor Cutter Water Tank Assembly 9 12 Cutter Water Tank Parts crushed Ice 9 13 Cutter Water Tank Parts cylinder 9 12 11 1 INDEX D D Valve Thawing Gas 4 1 4 2 Daily Check List Drive gear E Electrical Connections Customer 3 9 Electrical Schematic All Voltages 50 60 Hz 6 5 Electrical Controls Enclosure 6 2 Energy Saving 1 1 Float Switch 1 7 9 3 Float Valve Make Up Water Foundation Layout 3 2 Freeze Period 4 2 4 2 9 1 Freeze Up Due To Extended Freezing Period 8 3 Freeze Up Due To Ice Failing To Discharge 8 3
14. 48 15 64 IN NIVIG 8 2 OT 48 1 01 m jl 8 5 OI SV 4S T 16 44 C I IOH 48 5 SNOLLVOO I LIOU 8 1 4 ab FE ANININ DNILNNOW v 8 8 5 BE 8 1 amp 8 8 OT HNVd d HIVINL 48 1 Ic 48 6 CC CIONH TOS 5 8 1 EEL NANNININ ZI 4 uS 8 RE YOA 8 5 8E FIGURE 3 1 Spacing and Connection Diagram 1 22 07 P18AL Service Manual 3 6 INSTALLING YOUR TUBE ICE MACHINE DNILV IOOIO AMOTIYIAO ANVL HAL VA 144 2 HATVA DNIDWVHO gunssdud SIGIS MO T M DNLLV IQ1O ITO HOLIMS LVOTA 0 IDUNA TA
15. CAUTION 6 19 07 P18AL Service Manual 6 19 07 5 3 START UP AND OPERATION Charging From Cylinders dedicated high side only The machine may also be charged from refrigerant cylinders To charge from cylinders the compressor will have to operate to transfer the ammonia from the freezer to the receiver Again make sure all the necessary valves are opened for operation and the compressor crankcase heater has been energized for a minimum of four 4 hours Follow these instructions with caution 1 2 10 11 Using approved for ammonia charging hose connect one end to charging valve 30 located on the freezer Lay full cylinder of anhydrous ammonia horizontally with the cylinder valve outlet pointing up to withdraw liquid and the bottom end raised about 2 higher than the top end Connect the other end of the charging hose to the cylinder valve It is recommended that a gage be attached to this line to indicate cylinder pressure Close the liquid line stop valve 24 or the receiver liquid feed valve Open charging valve 30 and carefully purge air from the charging hose Open the cylinder valve slowly checking for leaks the line and allow the suction pressure to build up to approximately 40 psig and check again for leaks the system Set the freeze timer T2 to maximum setting If the machine contains a pressure switch in place of the freeze timer disconnect and lock out the power open
16. Check for water leaks around the freezer cover and tighten nuts if needed 7 4 Service Manual MAINTENANCE Water Distribution System Water Distributors The water distributors are located under the freezer cover at the top of the freezer These distributors may require occasional or periodic cleaning to remove solids and foreign particles accumulated from the make up water The frequency of this cleaning operation will depend on the characteristics of the water supply The cleaning operation is needed when the inside diameter of a large proportion of the ice becomes irregular due to channeling of water or if some of the ice is opaque or if there is a noticeable decrease in ice capacity Tube Size 1 1 1 4 1 1 2 Number of Water Distributors 156 102 72 TABLE 7 1 Number of Water Distributors Per Tube Size To clean distributors stop the unit and remove the freezer cover on top of the freezer The water distributors one in each tube may then be removed with pliers for cleaning Use pliers on the distributor s top part with a twisting upward motion Use care when removing distributors to avoid distorting orifice holes or the body of the distributor The distributors can be soaked in ice machine cleaner to remove mineral buildup Rinse distributors thoroughly before reinstalling and tap lightly with a rubber mallet to seat them in the freezer tubes 11 4 11 2 Hole Size 1 16
17. Set the Clean Off Ice switch to the position Do not use the machine disconnect to stop the machine If the disconnect is used the crankcase heater will be de energized and liquid refrigerant will migrate to the compressor If in a freeze mode the machine will continue to run At the completion of the freeze cycle the machine will harvest and stop The completion of a cycle ensures that all ice is removed from the freezer to prevent refreeze when the machine is restarted If in a harvest the machine will complete the harvest and stop 6 19 07 P18AL Service Manual 5 7 START UP AND OPERATION Operating Tips If the operation of your machine is not controlled by a timer bin level control or some other mechanism to automatically start and stop ice production you should use ONLY the Clean Off Ice toggle switch to start and stop machine By turning the Clean Off Ice selector switch to the machine will stop after the next harvest cycle Do not use the Stop push button or the machine disconnect for normal shutdown of the machine Throw the Disconnect only in an emergency or for safety when performing certain service 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 immediately initiate a harvest cycle
18. 7 5 Circuit Breaker Cutter 6 3 Circuit Breaker Pump Circulating Water Pump Motor 9 4 Clean Off Ice Selector Switch 5 5 6 1 Cleaning Procedure 7 7 Compressor Crankcase Heater 3 11 Compressor Lubrication Compressor Unloading 3 4 Condenser Cleaning 7 5 Condenser Water Cooled Maintenance Control Circuit Protection 9 3 Control Panel 6 2 6 3 Control Panel Parts 6 2 6 3 Control Relay CR 6 3 Cooling Tower 3 4 7 7 Crankcase Heater Crushed Ice Production 9 13 Cutter amp Bearing Removal Installation 9 10 9 12 Cutter Drive Parts 9 12 Cutter Gear Reducer 7 5 9 9 9 12 Cutter Motor 9 3 9 9 9 12 Cutter Assembly 9 12 Cutter Bearing
19. eleeeejeee 2 4 22112012 6 3 6 19 07 FIGURE 6 2 Control Panel Door Opened Symbol Vogt Part Component Description 1CR 2CR 12A7517E28 Relay 10 3 NO INC 208 240V Coil 3CR 12 7515 21 Circuit Breaker 2 Pole 12A7530E54 Cutter Manual Motor Starter 1 6 2 5A 200 208 230V Only CU 12A7530E52 Cutter Manual Motor Starter 0 63 1 0A 460V Only 12 7530 53 Cutter Manual Motor Starter 1 0 1 6 400 Only ET 12B7503E20 Timer Elapsed Din Mount 220V 50 Hz Only 12B7503E21 Timer Elapsed Din Mount 220V 60 Hz Only 12A7530E56 Pump Manual Motor Starter 4 0 6 3A 200 208 230V Only P 12A7530E54 Pump Manual Motor Starter 1 6 2 5A 460V Only 12 7530 55 Pump Manual Motor Starter 2 5 4 0A 400V Only 15 12A7503E22 Timer Delay on make 220V TA 12A7503E39 Timer Base 8 Pin Guarded Terminal TB 19T7501E09 Terminal Block Assembly TABLE 6 2 Control Panel Components and Part Numbers Internal 6 4 Service Manual ELECTRICAL CONTROLS Symbol Component Description Relay for making and breaking various circuits during freezing and thawing ICR Energized during the thaw period Relay for making and breaking various circuits during freezing and thawing 2CR En
20. 226 19 246 187 4 203 0 3 0 N EI 2 o olo Co aa T amp Ni do co Ny S Di N N ojo ala Ou EN N RS ARS 11 01105 1 4 09 i EN ES m OR REN o NO COIN po O1 O1 AO 8 54 179 242 28 263 192 9 209 9 6 63 193 258 36 280 4 72 208 275 45 298 2 82 224 293 55 316 TIR NIN N 198 6 215 0 222 0 229 0 235 0 242 0 i 249 0 21 256 0 217 241 3 264 0 247 9 271 0 254 6 279 0 261 5 286 0 268 4 294 0 275 5 302 0 282 7 311 0 290 1 319 0 297 6 328 0 305 2 336 0 312 9 345 0 320 8 354 0 328 9 364 0 337 1 373 0 345 4 383 0 353 9 392 0 362 6 229 4 402 0 363 371 4 235 8 412 0 N EN 92 240 sit 65 335 2 102 256 329 75 356 4 112 273 85 374 6 123 291 369 96 394 8 135 09 10
21. 6 19 07 P18AL Service Manual ELECTRICAL CONTROLS 6 Electrical Controls Your packaged Tube Ice machine is equipped with cutter and pump motor starters CU and P and a transformer if required for the control circuit power The control panel and transformer are mounted on the machine front side see Figure 1 1 The control panel wiring schematic FIGURE 6 3 illustrates these components as well as provisions for auxiliary equipment which may be incorporated by the customer such as Fused Main power disconnect 2CR NO Highside On Auxiliary Contact T3 Conveyor On Timer When adding a high side unit or motor starters for auxiliary equipment be sure to incorporate the overload protection as indicated between terminals 2 12 This will assure that the machine will shutdown when any auxiliary equipment fails Bin Level Control Included in the wiring schematic is provision for a bin thermostat or bin level control BT The NC contact of your control should be wired between terminals 11 14 and the jumper wire removed as indicated Installation in this manner will allow the machine to finish the harvest period before shutdown The machine will automatically restart when the bin thermostat or bin control device is no longer in contact with the ice To insure that the machine does not restart set the Clean Off Ice toggle switch to the position Safety Switches The machine is not equipped with the followin
22. experience is reflected in the PISAL 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 economic and reliable operations have been proven over and over again in a network of varied types of installations throughout the world Furnished with your machine is the Certificate of Test the report of operating data that is a record of the unit s satisfactory operation on our factory test floor It is evidence of our desire to deliver to you the finest ice making unit ever made This manual is designed to assist you in the installation start up and maintenance of your unit Your Tube Ice machine will give you a lifetime of service when you install it maintain it and service it properly Please read your manual carefully before attempting installation operation or servicing of this professionally designed piece of equipment If you have additional questions please call your distributor Also feel free to phone the factory direct at 502 635 3000 or 1 800 853 8648 1 1 1 2 Service Manual INTRODUCTION Important Safety Notice This information is intended for use by individuals possessing adequate backgrounds of electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in personal injury and property damage The manufacturer
23. n T MS 3 4 Cooling To Wer i RUE RR NOUIS 3 4 Spacing and Connection Diagram FIGURE 3 1 3 5 Piping Schematic Dedicated High Side FIGURE 3 2 3 6 Piping Schematic Central High Side FIGURE 3 3 3 7 Wiring and Electrical Connection FIGURE 3 4 3 8 Control Panel Field Connections FIGURE 3 5 3 9 Electrical Specifications Table 3 2 cn ne 3 9 Phase 3 10 Volt se and Current 2 on RR 3 10 2 2 09 me P18AL Service Manual ii TABLE OF CONTENTS Page No 3 INSTALLING YOUR TUBE ICE MACHINE Cont NICHTS e dI CIERRE CH 3 11 4 HOW YOUR TUBE ICE MACHINE WORKS Principle OF Operation ede eret och enger det bo ie e ee eU ba d erede ied 4 1 Ereeze Period E E ENE A E ne 4 2 Harvest Period VE 4 2 Piping Nomenclature 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 Reylew 3 4 oie ue mad etieu dis 5 1 Refrigerant Charg ee e eR eR epe eR e tt re e 5 2 Ammonia Specification By Grade Table 5 1 5 eene o ae en 5 2 Sp cial Precautions er e pet ee eb rete e tee ded 5 2
24. 1 8 1 8 3 16 1 47 3 8 Avg Avg Avg TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank contains a concentrated amount of solids or salts Remove cover plate Open drain valve 28 Clean tank thoroughly by flushing out with a hose and scrubbing with a stiff brush It may be necessary to completely remove the water tank in order clean all surfaces The tank has casters to simplify removal After cleaning close drain reinstall tank if necessary and 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 Freezer Cover A clear polycarbonate 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 the freezer cover is coated with solids this is a prime indicator that the other areas i e water tank and distributors also require cleaning CAUTION The water distribution system is critical to proper machine operation Failure to maintain and clean water distribution components can result in improper machine operation and compressor failure CAUTION 6 19 07 6 19 07 P18AL Se
25. 19 07 SERVICE OPERATIONS FIGURE 9 4 Cutter Tank Parts Crushed Ice Production Your PI8AL Tube Ice machine is capable of producing crushed ice with no loss of capacity However there are certain changes to be made in order to convert to crushed ice production Add PANS Change 1 Cutter Assembly 12A6413A Cutter Motor 3 4 HP 12A2900M0601 60 Hz 1 HP 12A2900M0603 50 Hz Gear Reducer 5 1 Ratio 12A4030R12 Motor Starter 12A7530E55 208 230V 60 Hz 12A7530E54 460V 60 Hz 12 7530 56 200V 50 Hz or 12A7530E54 400V 50 Hz Raise the freezer pressure switch setting to make ice 3 16 thick average 2 Reverse cutter direction 3 Reverse deflector Two people should normally accomplish this conversion process in 6 8 hours or less There must be ample room around the machine for the water tank removal It is recommended that you have good quality water when attempting to produce crushed ice If the ice 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 make up water temperature is below 50 F 10 C Colder water can cause build up of ice fines in the tank and eventually result in short cycling PI8AL Service Manual 10 1 TABLES amp CHARTS 10 Tables amp Charts 6 19 07 10 2 Service Manual TABLES amp CHARTS P18AL SPECIFICAT
26. 3 16 1 4 thick Check and adjust thawing time Thawing should be 30 seconds longer than it takes for all the ice to clear the freezer Excessive ice chips in the water tank causing short cycling Check incoming water temperature 45 F minimum Check flushing valve to make sure ice chips are being melted and flowing out the tank overflow during the harvest cycle Compressor running unloaded or not pumping full volume Check compressor motor amp draw Check for belt slippage and tighten as needed Check for leaking compressor suction or discharge valves Refer to your compressor manual See other related symptoms Restriction in the refrigerant liquid line or float switch not Check for a partially closed valve or an obstruction at the operating properly strainer solenoid valve or hand expansion valve The liquid line will normally have frost on the downstream side of a restriction especially as the suction pressure decreases Low refrigerant charge causing re freeze Check the receiver gage glass mark for the proper level Check for and repair leaks Add refrigerant Warm make up water for ice making Capacity of the machine is proportional to ice making water temperature Warmer water will reduce the ice making capacity Refer to Section 11 Capacity Table Check float adjustment and water tank drain valve Excessively high head pressure Check cooling tower or evaporative condenser to make sure sufficient water is provided for cooling
27. Large Machines Model Number Serial Number This form must be filled out completely and signed by the customer in order to assure acceptance by Vogt Date of Start Up Form Completed By AC Condenser Model Number AC Condenser Serial Number Water Treatment System Yes L Manufacturer Model Bin Manufacturer Model Bin Capacity Ibs Distributor Company Name Phone Address City State Zip Service Company Company Name Phone Address City State Zip Customer location of equipment Company Name Phone Address City State Zip PRE OPERATION CHECK OPERATION CHECK Service Manual on hand Power Supply V PH HZ machine running Machine room suitable 50 F minimum 110 F maximum Pump cutter amp other motor direction of rotation correct Power Supply Hz machine running Cutter motor amps RLA Actual Compressor crankcase heater on 12 hour minimum Water pump amps Actual valves opened or closed as tagged Condenser motor amps if applicable Solenoid valve stems in auto position Incoming potable water temperature F System leak checked tight water distributors in place visually inspected Auxiliary equipment overloads wired into control circuit Make up water float valve operates properly L Water supply and drains connected properly Clear
28. When P18AL is attached to a central system a pressure regulator will be required see Figures 3 3 for location This regulator usually furnished by the purchaser must be a combination back pressure regulating and stop type valve The usual minimum pressure drop across this type valve is 2 psig therefore the valve must be set to maintain a freezer pressure at least 2 psi above the maximum general suction pressure Compressor Unloading When a PI8AL is attached to a dedicated compressor system unloading of the compressor will be required A minimum compressor unloading during the harvest cycle is 66 If the compressor can not be unloaded then a hot gas bypass to the suction line must be installed Safety Valves Two safety pressure relief valves are an integral part of the packaged Tube Ice machine They are located on the suction accumulator of the freezer Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes Refer to the International Institute of Ammonia Refrigeration IIAR standard for specific requirements and instructions Cooling Tower 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 in your area An average wet bulb of 78 F is typical in the U S but many localities have design wet bulbs as low a
29. a positive pressure 20 25 psig indicated on the freezer pressure gage when the machine is received The machine has been cleaned with ice machine cleaner and flushed so that the machine is ready for ice production Safety Tags and Labels Be sure to read and adhere to all special tags and labels attached to valves or applied to various areas of the machine They provide important information necessary for safe and efficient operation of your equipment The machine is available in three different tube sizes for producing ice 7 8 OD x 1 long 1 1 8 OD x 1 long or 1 3 8 OD x 1 long The ice is cut to length by a rotating breaker type cutter Ice can be produced up to 1 1 2 long by modifying the spacers under the adapter plates see Chapter 9 Ice Length for modifying instructions 2 2 P18AL Service Manual RECEIPT OF YOUR TUBE ICE MACHINE 6 19 07 Safety Valves Two safety pressure relief valves are an integral part of the low side Tube Ice machine Both are located on the top of the freezer Vent the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes Rated Capacity The Tube Ice machine is rated to produce a given amount of ice when operating under the proper conditions as specified in this manual see Section 10 for the operating specifications You should be prepared to handle the ice produced as it is discharged from the machine and move it to your storage or baggin
30. and the equipment is operational to cool the water Also see Symptom High Head Pressure Suction regulator out of adjustment or defective optional Check the freezer pressure and compare to the main suction pressure The suction regulator should regulate the freezer pressure and create 2 psi pressure drop across the valve Adjust pressure regulator Repair or replace defective valve Thawing gas solenoid valve 18 leaking through during freeze Check the manual opening stem to make sure it is in the cycle automatic position stem screwed in Check for leak by sound temperature difference and frost during a freeze cycle Close the stop valve 90 to confirm suspicion of leakage Repair or replace the valve 6 19 07 Service Manual 8 5 TROUBLESHOOTING Symptom Poor ice quality Possible Cause Possible Remed Excessive concentration of solids in the water tank usually Perform a cleaning procedure as well as removing the freezer indicated by a build up of mineral deposit on the sides and cover and cleaning the water distributors Make sure the bottom of the tank and opaque ice production Also water flushing valve 27 is functioning and the tank overflow piping distributors restricted is not restricted Insufficient water supply indicated by a low level in the tank Check water pressure 30 psig is recommended minimum Check for a water line restriction partially closed valve or defective make up water float valv
31. cooling tower chemical usage It is recommended that a heat exchanger be used in place of direct contact with condenser water Water Tank Flush Valve Flushing water blowdown is necessary to melt ice fines and flush dissolved solids from the water tank during the thawing harvest cycle This function is important and helps to maintain good ice quality If water quality is superior this blowdown can be reduced by installing a smaller orifice in the flushing outlet elbow Make sure there is enough flushing water to prevent the accumulation of excessive ice fines in the tank If make up and flushing water are from the same source they can be connected by a common line to the machine Receiver The receiver used to supply hot thaw gas must be sized adequately to provide sufficient thaw gas Table 3 2 shows the volume required to hold the refrigeration charge of the freezer and the hot gas required for the thaw cycle It is recommended that a heating coil be installed in the receiver to assure that the liquid ammonia is at saturated temperature at the start of each thaw period Note Additional storage volume may be required for the interconnecting piping Add volume of interconnecting piping to the values shown in Table 3 2 RECEIVER VOLUME Cubic Feet MODEL With Heating Coil With out Heating Coil PISAL TABLE 3 2 Receiver Volume Requirements 3 4 Service Manual INSTALLING YOUR TUBE ICE MACHINE Suction Pressure Regulator
32. if clogging is minimal TABLE 7 4 Compressor Maintenance The above maintenance is only a guide The compressor should be inspected anytime there is unusual noise damage is suspected or the oil becomes discolored The oil should be changed any time the compressor is opened For specific recommendations and instructions refer to the particular compressor manufacturer s manual 7 8 Service Manual MAINTENANCE 6 19 07 Service Manual 8 1 TROUBLESHOOTING 8 Troubleshooting Note Your machine s electrical system has several built in safety and overload protection features to stop operation when a single component fails or there is a problem from an outside source such a power supply Make sure all auxiliary equipment is connected to incorporate safety and overload circuits and protect all related equipment When the machine stops it must be manually restarted by pushing the green Start button The machine will restart in a harvest to clear any ice from the freezer before beginning another cycle Always check the machine operation thoroughly after remedying the problem Be sure to correct the source or cause of the problem to prevent the problem from occurring again Symptom Page Machine stopped 8 2 Freeze up due to extended freeze period 8 3 Freeze up due to ice failing to discharge 8 3 Low ice capacity 8 4 Poor ice quality 8 5 High discharge pressure 8 5 Low discharge pressure 8 5 High suction pr
33. level drops below 1 4 of the glass add refrigeration oil as per the compressor manufacturer recommendations Never allow the oil level to be out of sight above or below the sight glass when the compressor is operating CAUTION The crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compressor CAUTION During operation the specified net oil pressure should be maintained for proper lubrication and operation of the cylinder unloader mechanism Mycom N amp W Series net oil pressure 17 28 psig Vilter 450 Series net oil pressure 35 50 psig Note Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pressure gage reading while the compressor is running Example Oil pressure gage reading 65 psig Suction pressure gage reading 40 psig Net Oil Pressure 25 psig The compressor oil should be changed at close intervals during initial break in operation and up to the first 1000 hours see Table 7 4 below Note It is the owner s responsibility to make sure normal maintenance is initiated to insure that the compressor is not subjected to premature wear or failure due to neglect or lack of sufficient maintenance and care Maintenance Operation Bregueuey Ist Change oil 200 hr 500 hr 1500 hr 4000 hr Every 4000 hrs Clean suction strainer cloth 200 hr 500 hr Remove
34. needed to load the compressor cylinders and any further procedures to check the mechanical function of the unloader mechanism Possible Remedy Adjust timer or replace if defective See FIGURE 9 2 Check freezer pressure switch adjustment See FIGURE 9 1 for adjustment and TABLE 7 2 for average hole size Make sure all water distributors are in place one in each tube Adjust thaw timer T to allow all ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Replace defective timer See pressure regulating valve adjustment The thaw gas regulator should be adjusted to increase the pressure in the freezer to 60 65 psi during a harvest Isolate and repair or replace the valve as needed The head pressure should be maintained form 175 190 psi maximum 200 usually by a water regulating valve or fan cycling switch Check to make sure these controls are working properly Cold prevailing wind can also be a factor If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver and the refrigerant will be cooler although pressure will be high Air can be purged from the system by following the procedure in the Section 9 Purging Non Condensables The refrigerant level in the receiver should be near the operating mark at the end of a freezing cycle to provide enough volume of warm gas for harvesting DO NOT OVERFILL RECEIVER See Table 3 2 Check cu
35. not pumping efficiently Thaw gas valve 18 leaking through Suction Pressure to low Defective gage P18AL Service Manual Possible Remed Check compressor motor amp If the compressor is running unloaded the amperage will only be approximately 6096 of normal amp draw Refer to the compressor manual Make sure manual opening stem is in the automatic screwed in position Repair or replace defective parts Adjust suction regulator valve Check pressure with accurate gage and replace as necessary Symptom Compressor running unloaded during freeze dedicated compressor only Possible Cause Low oil pressure Unloader solenoid valve open Unloader mechanism not working properly Symptom Compressor oil pressure low check gages See Section 7 for compressor oil pressure requirements Possible Cause Oil diluted with refrigerant Oil pressure regulating valve out of adjustment Compressor rotation incorrect Restriction strainer oil filter pick up tube or oil passage Compressor thrust bearing installed upside down Symptom Compressor loosing oil excessively Possible Cause Non effective oil separator or float Liquid refrigerant in crankcase Compressor piston rings seized or broken Leaking shaft seal 6 19 07 Possible Remedy Check compressor net oil pressure Net oil pressure oil pressure gage reading less suction pressure Mycom z 17 28 psig Vilter 2 35 50 psig Refer to the compressor Adjustme
36. of cylinder or crushed ice is controlled by the freeze timer mounted on the control panel door The timer was set at the factory to a default of 10 minutes The freeze time can be adjusted to compensate for water temperature and refrigeration system conditions Do not make adjustments until several ice discharging cycles have been made Digital Timer Setting Procedure initial The following procedure is recommended for initially setting Syrelec timer which has not been previously adjusted 1 Press the valid and mode key simultaneously to set the time range Set at S Minutes and Seconds 2 Press the mode key only to move to the count mode Set at d down count 3 Press the mode key again to move to out mode setting Set at A for delay on break 4 Press valid to exit mode setup Set freeze time to 10 minutes by using the four round buttons 9 2 Service Manual SERVICE OPERATIONS The freezing time can be such that small percentage of the ice 1s frozen solid If so some ice from the top and bottom of the freezer should have small hole the center to insure that the freezing time has not been extended to where a loss in capacity would result It is preferable that the freezing cycle be such that a small diameter hole remains in the center of the ice cylinder 1 16 diameter for 7 8 diameter ice 1 8 diameter for 1 1 8 diameter ice 1 4 diameter for 1 3 8 diameter ice This insures that the freezing c
37. or seller cannot be responsible for the interpretation of this information nor can it assume any liability in connection with its use Special Precautions To Be Observed When Charging Refrigeration Systems Only technically qualified persons experienced and knowledgeable in the handling of anhydrous ammonia refrigerant R 717 and operation of refrigeration systems should perform the operations described in this manual All local federal and EPA regulations must be strictly adhered to when handling refrigerants If a refrigeration system is being charged from refrigerant cylinders disconnect each cylinder when empty or when the system is fully charged A gage should be installed in the charging line to indicate refrigerant cylinder pressure The cylinder may be considered empty of liquid R 717 refrigerant when the gauge pressure is 25 pounds 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 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 Failure to observe either of these precautions can result in transferring refrigerant from the system to the refr
38. production check of Registration Start up Report D Yearly in addition to weekly and monthly 1 2 3 4 5 6 7 8 Check entire system for leaks Drain water from condenser and cooling tower and check condenser tubes Check closely 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 Check freezing time ice release time and ice out time Change oil in gear reducer box once a year Lubricate compressor motor bearings 7 2 MAINTENANCE PREVENTATIVE MAINTENANCE FORM This form can be removed and duplicated for record keeping Date Model Serial P18AL Service Manual The following service performed and checked Hour meter reading Ambient temperature inside Make Up water float valve adjusted properly Water distributors clean and in place All drains freely draining Cleaned and flushed water tank Compressor oil changed Cleaned and inspected inside compressor crankcase Changed compressor oil filter Checked adjusted compressor belt tension or alignment Lubricate compressor motor bearings Check change cutter gear reducer oil Check adjust cutter drive gear meshing Leak check entire system Check liquid refrigerant level in receiver Drained oil from oil trap Compressor crankcase heater work
39. you see in parentheses refer to the numbers in this piping schematic The freezer 1 is a shell and tube type vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 5 Make up water is maintained by a float valve 29 in the water tank 13 The refrigerant float switch 23 opens and closes the liquid line solenoid valve 25 sometimes referred to as the A valve is open and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 1 passes through the suction accumulator and to the compressor Here the cool gas is compressed to a high temperature high pressure gas which discharges through the oil separator and into the condenser In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid goes through the accumulator boil out coil where it is gives up heat to the suction gas for compressor protection In addition this liquid is subcooled and carried to the Freezer 1 Liquid refrigerant from the accumulator flows through the thawing chamber of the freezer the liquid line stop valve 24 the liquid feed valve 25 and then the hand expansion valve 9 float switch 23 is wired to the A solenoid valve 25 The float switch energizes and de energizes the A solenoid in response to the level of refrigeran
40. 400 3 50 MACHINES ONLY GE 49151B0170 12A 7519E03 TRANSFORMER 1 0 KVA 60 HZ 260 3 60 MACHINES ONLY COMPRESSOR MOTOR 5 796180010 12A 2900 0508 12 4020608 OVERLOAD SAFETIES 220 FOR 208 250 5 60 amp 200 3 50 MOTOR LOCATED HIGHSIDE 1 9 1 84 0 92 FLA 5 6 5 4 2 7 FLA L4 TO 5 AND FROM L5 22 208 230 460 3 50 60 208 230 460 3 50 60 CU OL P OL 2 3 HIGHSIDE 22 SAFETY 3CR STOP PUSH 22 BUTTON PB1 120 0 4 12 4 7 cr START PUSH BUTTON PB2 NOTE FOR BIN THERMOSTAT REMOVE JUMPER FROM 1CR TERMINAL BLOCK 4 NUMBERS 11 amp 14 1 27 28 T ice O NOTE OPTIONAL FREEZE PRESSURE CLEAN OFF ICE SWITCH LOCATED SELECTOR AT HIGH SIDE SWITCH 4 55 CLEAN OFF ICE 14 9 i 16 SELECTOR SWITCH LA 5 55 15 208 219 3CR Q a ICE 0 32 CLEAN 15 16 10 SHOWN OFF POSITION 12 E 32 22 35 FS 35A A SOL COMPRESSOR UNLOADER LOCATED AT HIGHSIDE 1CR 34 UN SOL o o i CUTTER MOTOR cu STARTER FLUSH TIMER i CONVEYOR TIMER 13 5 12 14 37 38 W SOL FIGURE 6 3 Electrical Schematic All Voltages 50 60 Hz 6 6 P18AL Service Manual ELECTRICAL CONTROLS 6 19 07 6 19 07 P18AL Service Manual 7 1 MAINTENANCE 7 Maintenance Preventi
41. 5 2 02 1 94 89 2 14 1 93 1 86 2 49 2 25 2 16 70 2 35 2 12 2 04 2 74 2 47 2 38 60 2 42 2 16 2 09 2 84 2 53 2 43 50 2 49 2 21 2 14 2 92 2 58 2 49 40 2 56 2 25 2 19 3 00 2 62 2 54 6 19 07 Table 10 5 Make Up Water Usage gpm P18AL Service Manual Normal Operating Vitals P18AL Harvest Times Discharge Pressure psig secs End of End of First All Ice Total Thaw Ice Out Harvest 0 0 Table 10 6 Usual Operating Conditions Ice per cycle Average Ibs 175 175 175 10 5 TABLES amp CHARTS Freeze Time minutes Water Temperature deg F 89 89 RECOMMENDED 5 PARTS LIST Vogt Model P18AL Tube Ice Machine QTY PART NUMBER DESCRIPTION 1 12 7503 52 Freeze 1 12A 7503E22 Thawing Timer 1 12 7517 28 CR Relay 208 230V 50 60 Hz 1 12 7516 23 Starter Contactor 208 230V 50 60 Hz 1 12A 7530E54 CU Starter 208 230V 50 60 Hz 1 12A 7530E56 P Starter 208 230V 50 60 Hz 1 12A 2900M0501 Cutter Motor 1 2 HP 2 12 4200 0402 Make up Water Float Valve 1 12B 2020R01 Cutter Bearing 1 12 2600 07 Gasket Freezer Cover 1 12A 2600G05 Gasket for water tank 1 12 2590 17 Freezer and Thaw Gas Pressure Gage 1 12A 7500E22 Float Switch 1 12 6229 Coil Hansen Solenoid Valve TO ORDER SPARE PARTS PLEASE CONTACT YOUR DISTRIBUTOR 6 19 07 10 6 Service Manual TABLES amp CHARTS TEMP
42. 8 416 10 i46 328 410 120 439 14 174 367 454 144 483 100119 D OO E N 9 E A ag Co NIN D DICO CR 5 12 3 01100 Be s AJN MININ N T aja o 5 6 18 197 409 500 170 581 20 210 430 525 184 556 22 224 458 549 199 582 35 24 239 476 575 214 599 26 25 4 499 601 229 636 28 269 524 628 245 665 30 285 549 656 26 1 694 32 301 575 684 278 723 34 317 60 1 713 295 754 36 334 628 743 313 785 Co N EN m oc 00 88 NIN RICO OJN OI NIN oja 05 AR o ml oo A A T NO 02 02 Oo m ooo A N P O1 Em
43. ARNING Follow these instructions carefully Severe personal injury can result from improper discharge of refrigerant WARNING WARNING It is not recommended that refrigerant be transferred from a refrigeration system into a cylinder If such a transfer is made 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 If ammonia vapor is released from the machine it may be purged into water which will absorb it Follow the purging instructions See Purging Non condensables Refrigerant Leaks Anhydrous ammonia leaks can be detected by odor sulfur stick soap solution or test paper The odor is normally noticed first and the location of the leak is found with soap or sulfur stick Soap solution can be purchased from your refrigeration supply house or it can be made by mixing four parts water one part liquid soap and a few drops of Glycerin for better capillary attraction Apply soap solutions with a narrow brush or spray bottle to all joints welds or areas of suspicion The solution will form bubbles if there is a leak e Light the end of the sulfur stick and pass it around suspected points of leakage A white cloud will form where a leak is even if it is very small Moisten a strip of test paper an
44. Assembly 28 Water Tank Drain Valve 1 FPT 14 Freezer Purge Valve 29 Make up Water Inlet Valve 2 FPT 15 Lifting Lug 30 Refrigerant Charging Valve Piping Nomenclature TABLE 4 1 6 19 2007 4 3 P18AL Service Manual A d o HOW YOUR TUBE ICE MACHINE WORKS M DNILV 109 3IO cl ANVL HAL Ld CC aval NIV3G IO 0t x 57 N LT SIS MOT C HOLIMS LVOTA 8c 144 CT 6 3AT7VA Lda WE LE gt lt ANVL HAL VA 16441 lt 1 To HOLVIONOQ22V DRE ER 222255555 Sr 2222 25 zx ESI WHZUWud didi MSHIVHIS 92 J DER HENIVULS 01 81 Oc 91 ONY 1d E ANIT HOSSHudWOo ISSAHVH ONIANA SSHT MAO 05 OL 55 84 WOO VA 3605 NATIF C INNINININ ASL 13495 CSCINSIWIAOO I TIVLS X ANTT NOILONS X Cc
45. CA crt MACHINE Manual Part Number 12A4171M09 Service Manual 55000 NOTICE This manual 15 the property of the owner of this particular Tube Ice machine Model 0 It 15 to be left the premises with this machine at all times After start up it should be stored in a safe place where it can be readily available when needed for future reference in maintaining troubleshooting or servicing Failure to comply with this notice will result in unnecessary inconvenience and possible additional expenses This manual is intended as an informational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 502 635 3024 IMPORTANT The Warranty Registration Start Up Report found in the front of this manual is to be completed and returned to the factory promptly after the official start up Please return to TUBE LLC 1000 W Ormsby Ave Louisville KY 40210 Tube Ice L L C Vogt Order Number 1000 Ormsby Louisville 40210 502 635 3235 502 635 3024 THIS FORM MUST BE SENT VOGT TO ACTIVATE WARRANTY Warranty Registration Start Up Form Medium amp
46. Charging From Tank Truck dedicated high side only ss 5 2 Charging From Cylinders dedicated high side only ss 5 3 Charging Operating Characteristics ue rebote i tee e eH de fetten Start up Procedure e Eie ele bett o EU ote el E tee e ee eb ale 6 ES Thaw Gas Regulating and Suction Gas Regulating Valve Adjustment Sh t dowr Procedute eren ette ter e tette dte e e i eee Oper ting RII DoD e E 5 7 ELECTRICAL CONTROLS amp THEIR FUNCTIONS General Information te eei ba tede npe tud adiecto bt 6 1 Control Panel Door Closed FIGURE 6 1 6 2 Control Panel Components and Part Numbers External TABLE 6 1 6 2 Control Panel Door Opened FIGURE 6 2 6 3 Control Panel Components and Part Numbers Internal TABLE 6 2 6 3 Description of Control Panel Component Function TABLE 6 3 ue 6 4 Electrical Schematic All Voltages 50 60 Hz FIGURE 6 3 6 5 MAINTENANCE Preventive Maintenance sies eg eee 7 1 Preventive Maintenance nent e En NE 7 2 Ice Making Section e e emis a oto 7 3 1 7 3 Water Distribution System eere ett dee NUS DE ten eee etes 7 4 Water Distributors TABLE e die 7 4 Average Hole Size in Tube Ice TABLE 7 2 7 4 Water Tarik ae
47. ERATURE PRESSURE CHART FOR COMMON REFRIGERANTS DegF R 12 R 22 R 502 R 134a R 404A 717 MP 39 DegF 12 R 22 R 502 R 134a R 404A R 717 39 50 76 30 02 90 00 70 9 1 50 407 97 4 102 9 742 45 48 72 24 07 87 08 65 87 52 488 101 0 109 0 77 46 68 17 15 83 16 60 8 3 54 51 0 908 104 8 50 1 113 0 81 44 63 10 23 80 25 54 79 56 532 943 1086 523 1170 42 58 02 32 76 34 49 74 58 554 979 1124 55 0 1210 40 54 05 41 71 55 43 71 577 101 6 116 4 575 125 0 38 49 13 50 67 65 3 6 6 6 62 60 1 105 4 120 4 60 1 130 0 36 44 22 60 63 75 3 0 6 1 64 625 109 3 124 6 62 7 134 0 100 34 38 30 70 58 86 23 5 6 66 65 0 1132 128 8 65 5 139 0 104 32 33 40 81 53 97 16 5 2 68 67 6 1173 133 2 68 3 144 0 109 30 27 49 92 48 108 0 8 44 1 28 21 59 103 42 120 00 41 153 0 26 1 5 69 115 3 8 132 08 3 4 0 146 8 158 0 RETE 30 145 1 5 151 5 164 0 22 01 90 140 24 158 2 0 156 3 169 0 o6 101 15 3 1 8 171 3 161 2 174 0 18 13 113 167 11 185 166 2 180 0 1714 185 0 414 28 138 195 215 176 6 191 0 181 9 197 0 10 45 165
48. EXPANSION VALVE 5 ICE DISCHARGE 2 WATER TANK OVERFLOW doe CUTTER TANK ASSEMBLY 6 19 07 e FIGURE 1 2 P18AL Back View 1 6 Service Manual INTRODUCTION FREEZER PURGE VALVE 14 15 LIFTING LUG 2 SUCTION CONNECTION 16 17 FREEZER PRESSURE GAGE THAW GAS SOLENOID VALVE 18 30 REFRIGERANT CHARGING VALVE 19 THAW GAS PRESSURE GAGE STRAINER PURGE VALVE 20 21 STRAINER OIL TRAP FIGURE 1 3 P18AL Left View 6 19 07 Service Manual 1 7 INTRODUCTION 23 REFRIGERANT FLOAT SWITCH LIQUID LINE STOP VALVE 25 LIQUID LINE SOLENOID VALVE aL d Wis 1 FLUSH WATER SOLENOID VALVE 26 LIQUID LINE STRAINER 1 FPT WATER DRAIN VALVE 1 2 FPT MAKE UP 69 WATER FIGURE 1 4 P18AL Right View 6 19 07 1 8 Service Manual INTRODUCTION 6 19 07 6 19 07 P18AL Service Manual 2 1 RECEIPT OF YOUR TUBE ICE MACHINE 2 Receipt Of Your Tube Ice Machine Only service personnel experienced in ammonia refrigeration and qualified to work on high amperage electrical equipment should be allowed to install or service this Tube Ice machine Eye protection should be worn by all personnel working
49. IONS 60 Hz Tube Size inches cm 114 Qn 112 Gs Nominal Capacity Ibs day Kg day See Table 11 3 See Table 11 4 See Table 11 5 Overall Dimensions LxWxH inches meters 38 x 38 x 133 91973 38 x 38 x 133 7 97 3 4 38 x 38 133 7 97 3 4 Shipping Weight lbs Kg 3300 1497 Operating Weight bs Refrigerant Charge 8 717 7 Ibs Total FLA Maximum Fuse Minimum Ampacity 16 1 66 Central System 00000000 00000001 See Table 11 3 SeeTable114 See Table 11 3 See Table 11 4 See Table 11 5 makeup water gpm m Hi 3 0 069 10 2227 makeup water FPT tank drain flush solenoid valve F overflow FPT Compressor HP KW FLA HP KW FLA Water Pump HP KW FLA HP KW FLA Cutter Motor HP KW FLA HP KW FLA THR at pulldown Btwhr THR average 27577 37456 085 Vogt reserves right to change designs and specifications without notice 1 Refrigerant charge is for low side unit only Additional refrigerant required for high side and piping 2 Compressor requirement is based on 70 F makeup water 14 F suction temperature 100 F condensing temperature 70 F ambient and 25 gal cycle blowdown Compressor rpm s vary 3 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower 4 Makeup water is maximum value Actual usage may vary Table 10 1 6 19 07 Service Manual 10 3 TABLES amp CHARTS P18AL Capacity Ratin
50. IONS Thawing Timer T FIGURE teret e Mee ee HERO HU prenne 9 1 Freeze Timer 1 2 85 52 EH EO UR RT OUO DIRE EIER ERU 9 1 Digital Timer Setting Procedure eit eg den way rne e 9 1 Multi function Digital Freezer Timer FIGURE 9 2 ener nennen retener tenete tenens 9 2 Conveyor Timer ento hack bare eo b re po ptem ca ayes Flush Valve Timer T4 Make up Water Float Valve eee phe PR te eR MIR Re ee ne Io eeu eee 9 3 R friserant Eloat Switcl 23 ea EO RCM te eee 9 3 Hand Expansion 9 reve cape e e dne tU erede eere 9 3 Solenoid Valves 18725 in p C OT ERN RR OR EG NV IRR CANTE E EE ERR 9 3 Control Circuit Protection CBI hasr iie eere tee RN ette eee 9 3 Cutter Motor 3 Gear Reducer 4 LM IR 9 3 Circulating Water Pump iret eb Drm nt Me a 9 4 Pumpdown9 4 Pumpdown Procedure x nee ene ee e t tec ORO t ele c tee tts 9 4 R moval of Ammonia Refrig r nt i neon pem n aedes 9 5 Refrigerant Leaks a c essen MO e eb idet ve e eve etd beet bl EE voe 9 5 Non condensable Gases x i Re uve un rede du RE 9 6 Purging Non condensable Gases eno PUR EE Mn e On n ee edt Pret 9 6 P18AL Service Manual TABLE OF CONTENTS Page No 9 SERVICE OPERATIONS Cont Purging Procedure Non condensab
51. ONG TYPE 304 SS 19 1 124305050401 NIPPLE 3 4 ALL THREAD 304 S S 20 1 12A4030R15 GEAR REDUCER IN LINE 10 1 21 1 12A4078C04 SPLASH CURTAIN 22 4 1244130502 SPACER ADAPTOR PLATE 23 1 12A4200A0607 VALVES SOLENOID 3 4 WITH 208 240V 50 60HZ COIL 24 1 12A4200G0807 VALVES BALL 1 NPT STAINLESS STEEL 37A 1 12A4200H0402 VALVE FLOAT 1 2 MPT LOCKNUT amp GASKET 37B 1 12A4200HP01 FLOAT STEM BRASS 10 LONG 1 4 20 THRD BOTH ENDS 37C 1 12A4200HPO2 FLOAT 14 20 THRD 26 1 12B2020R01 UHMW CUTTER BEARING 27 1 19T2024B0101 BEARING SUPPORT BRACKET 28 1 19T2160C0202 CUTTER ASSEMBLY WITH CAST CUTTER 29 1 19T2163D0202 CUTTER DISC ASSEMBLY 30 1 19T4001S0642 FLOAT BOX COVER 31 1 19T4500S1809 WATER TANK ASSEMBLY 31A 1 19T4001S0230 ICE DEFLECTOR PLATE 31B 1 19 450051809 GEAR REDUCER MOUNTING ASSEMBLY 31C 6 12A2215F1107 SCREW 1 4 20 UNC 5 8 SS HEX HEAD 31D 6 2A2240A1107 1 4 20 UNC SS FULL 31E 6 2 2250 107 WASHER 1 4 SS 31F 6 12A2250B107 LOCK WASHER 1 4 SS 32 1 19 400150423 SPLASH CURTAIN MOUNTING PLATE 33 1 19T2010A12 ADAPTOR PLATE ICE LENGTH USED WITH CAST CUTTER 6 19 07 TABLE 9 1 Cutter Water Tank Parts List 9 12 Service Manual SERVICE OPERATIONS PS TT FIGURE 9 3 Cutter Water Tank Assembly 6 19 07 Service Manual 9 13 6
52. PERATION Start up CAUTION The crankcase heater should be energized for a MINIMUM of CAUTION 4 hours and the crankcase must be free of liquid before attempting to operate the compressor FIGURE 5 1 Bottom Of Control Panel Starting the machine in freeze mode NOTE machine will always start in the harvest mode when the Clean Off Ice selector switch is turned to Ice l 10 Make sure the crankcase oil temperature is approximately 100 F and there is no liquid ammonia in the crankcase Set the Clean Off Ice selector switch SS to the Clean position Push the Start button PB2 to start the water pump The pump can be stopped and started by Stop and Start push buttons to purge the tubing of air When there is good water flow turn the Clean Off Ice switch to Ice and the machine will then start in a harvest thaw period with the compressor running At the termination of the harvest thaw period the machine will begin the freeze period Observe the oil pressure the oil level the discharge pressure and listen for any unusual sounds The compressor should start unloaded and automatically start after several seconds of operation Set the thaw gas pressure regulator and or the suction regulator if used See Thaw Gas Regulator and Suction Regulator on page 5 7 for instructions Be sure to observe a minimum of four 4 cycles of ice production
53. able to install particle filter in the make up and flushing water lines to dirt sand rust or other solid particles prior to entering the water tank and contaminating the ice Be sure to size the filter large enough to meet the water demands of 15 GPM peak flow allowing for a restriction through the filter as it traps these particles Minimum required supply pressure 15 30 psig Water Tank Drain This valve and connection is for the purpose of flushing and draining the water tank of impurities foreign material and cleaning chemicals used during servicing It should be piped to an open drain or sump for visible discharge It can be tied in with the overflow line but no others Water Tank Overflow A 2 FPT connection on the side of the water tank is provided to carry away overflow water during the thawing harvest cycle This water contains ice fines accumulated during harvesting and dissolved solids accumulated during the freezing cycle Do not reduce the size of this line Three inches is needed to provide sufficient area for ice fines to be flushed out especially if the incoming flushing water is 55 F 13 C or below This overflow line should not tie in with any other drain line except the water tank drain Unless water quality is superior do not discharge the overflow water to the cooling tower system This water contains additional dissolved solids left from the ice making process and can lead to excessive condenser fouling or
54. achine is running it will shut down on completion of the next ice harvest period Remove ice from storage area or cover ice discharge opening to prevent water from splashing out and contaminating stored ice Shut off water supply and drain water tank 13 by opening drain valve 28 Remove any loose sediment from tank Close drain valve 28 and fill water tank approximately 27 gallons with warm water Add 72 ounces 8 ounces per 3 gallons of Calgon ice machine cleaner a food grade liquid phosphoric acid to water tank during the refill period Inspect the water distributors by looking through clean freeze cover If required remove the cover Clean and remove any solid particles from the distributor orifices two orifices in each distributor Clean the rubber cover gasket and reinstall the cover To run the pump only set the Clean Off Ice selector switch SS to the Clean position and press Start Circulate cleaning solution until deposits are dissolved or solution is neutralized Repeat cleaning if necessary Press Stop button to stop pump then drain and flush water tank with fresh water Open water supply to machine Drain and flush tank and then refill with fresh water Clean inside of ice storage area and remove any solution that entered during the cleaning process Remove cover if one was installed over opening into storage area Start ice making cycle by setting the Clean Off Ice SS switch to
55. ally The idea is to prevent ice from freezing in the tubes as much as possible while charging It may be necessary to initiate a short harvest cycle to dispel any ice made To initiate a harvest cycle close the charging valve and push the start manual harvest push button PB2 while the compressor is running This will initiate a harvest and another freeze cycle will start immediately following to continue the charging procedure Be sure to close the cylinder shut off valve during the harvest period and open it once the machine goes back into the freeze cycle When the liquid level in the receiver is near the pump down level and the freezer is down to 15 psi suction with little of no frost on the shell you can stop the charging procedure and disconnect the cylinder Make sure the charging valve is closed and the cylinder valve is closed before attempting to disconnect the cylinder Loosen the union in the charging line gradually to relieve the ammonia pressure slowly When charging is complete stop the machine disconnect and lock out the power If the machine contains a pressure switch open the control panel door and reconnect Open liquid line stop valve 24 and or receiver liquid feed valve and you will hear liquid refrigerant flowing through to the liquid solenoid valve 25 Turn main power disconnect to the on position and the machine is ready for start up and ice production 6 19 07 6 19 07 P18AL Service Manual 5 5 START UP AND O
56. and Drain Connections Figure 3 1 Water Connections and Refrigerant Connections shows locations and sizes for all connections on lowside CAUTION External shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 30 psig The maximum allowable pressure is 100 psig CAUTION Make up Water Tank Water Tank Water Tank Suction Liquid Thaw Gas Water In Drain Overflow Flush Valve Connection Connection Connection 1 2 FPT 1 FPT 2 FPT 3 4 FPT 2 Flange 3 4 Flange 1 1 4 Flange The water tank drain connection must be extended to an open drain or sump arranged for visible discharge Mating 4 bolt flange supplied with machine Mating 2 bolt flange supplied with machine TABLE 3 1 Water Supply and Drain Sizes CAUTION These lines must NOT be connected into a pressure tight common header due to the possibility that warm condenser water may back up into the water tank The condenser water outlet MUST be piped separately to the drain CAUTION 1 22 07 P18AL Service Manual 1 22 07 3 3 INSTALLING YOUR TUBE ICE MACHINE Make Up Water In The water required for ice making must be potable water safe for human consumption and should be of the highest quality available The best way to determine water quality 15 to have complete water quality analysis by qualified laboratory It is advis
57. atic when incorporating overloads This is necessary to provide proper protection for the Tube Ice machine and its component parts IMPORTANT Installation Review A Checklist Make a visual check to be sure these steps have been taken BEFORE continuing CHECK PRIOR TO OPENING VALVES check all joints for leaks which may have developed during shipment NOTE the machine was shipped with a positive pressure of 20 25 PSIG verify on the freezer pressure gage CHECK ____ The system is properly evacuated to 500 microns CHECK All refrigerant piping water supply 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 for proper installation CHECK The applicable portion of the warranty registration start up report for proper completion CHECK Cutter gear reducer oil level oil should run out of side pipe plug when removed CHECK The water distributors at top of freezer to make sure they are all in position CAUTION The compressor crankcase heater should be energized for a minimum of four hours and the oil temperature should be 100 110 F before attempting to start the compre
58. d ammonia release into the atmosphere CAUTION 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 Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant 5 4 Service Manual STAR UP AND OPERATION Transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended As the machine is being charged continually observe the following operating characteristics a Discharge pressure 175 psi to 200 psi maximum b Compressor oil pressure Mycom W Series 18 27 psi 450 Series 35 50 psi Other models will vary check manufacturer s specifications c Liquid level in receiver d Compressor oil level While charging the machine the low pressure switch will stop operation of the compressor at set point pressure The switch will automatically reset at the differential pressure at which time you can restart the machine some low pressure switches may be manual reset It is best to use warm water in the tank and open the tank drain valve somewhat to allow cold water to exit and warm water to enter continu
59. d pass it around the suspected area If the paper comes in contact with ammonia it will turn red Coils submerged in water or condenser cooling water may be tested by dipping a strip directly in the water If ammonia is present the paper will turn red Always remove refrigerant pressure from the vessel tubing or component part before repairs are attempted Note Sulfur sticks and test paper can be obtained from your ammonia supplier 9 6 6 19 07 P18AL Service Manual SERVICE OPERATIONS Non condensable Gases Satisfactory operation of the machine is not possible if non condensable gases usually air are present in the system Excessive condensing pressure is an indication of such gases Excessive condensing pressure in water cooled condensers may also be due to the accumulation of scale in the cooling coil or due to insufficient cooling water or excessive water temperature See Water Cooled Condensers Section 7 Purging Non Condensables Air and other non condensable gases in a refrigeration system are not desirable Purging air from your Tube Ice machine will greatly improve system performance and save money Non condensable gas effects are Higher condensing pressure than desired Greater electrical power consumption Reduced refrigeration capacity Longer than normal compressor running time Slow ice release and long thaw cycle PERD pas Air collects mostly in high pressure condensers receivers and other high pre
60. e Make sure the water tank drain 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 causing an ice out problem re Check refrigerant level mark on the receiver and on the painted freeze portion of the gage glass guard Be sure to keep the gage glass cocks closed when finished checking the level Adjust suction regulator valve Restriction in liquid line causing short freeze cycle Check for closed valve defective solenoid valve 25 float switch defective or strainer restricted The liquid line will normally have frost on the down stream side of a restriction especially as the suction pressure decreases Symptom High discharge pressure check gage accuracy Possible Cause Possible Remed Insufficient water flow through the cooling tower or condenser Check the condenser water pump to make sure it is pumping enough water Check sump strainer screen and clean Check condenser pump direction of rotation Check adjustment Replace if defective Non condensable in system If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant will be cooler although the pressure will be high Air can be purged from the system by following instructions in Section 9 Purging Non Condensables Cooling tower or evapora
61. e liquid line solenoid valve and restore power to the machine 12 Open the compressor discharge valve oil return valve and all other valves that should be opened for normal operation 13 When the receiver liquid level is near its normal operating level or the pressures are near equal and the compressor crankcase has warmed the compressor can be started and ice production resumed 14 After several cycles check the system for symptoms of excessive water and if necessary repeat the pumpdown and evacuation procedure Note whenever excessive water is present in the system the source should be identified and corrections made prior to further operation 6 19 07 Service Manual 9 9 SERVICE OPERATIONS Cutter Motor Removal Replacement The cutter motor s bearings are prelubricated and sealed and require no further lubrication If the motor needs replacing proceed as follows Sn 99 9 10 Turn power off and lock out disconnect Check terminals with volt meter to confirm power 15 off Remove motor terminal cover and disconnect wires Mark wires for ease of replacement Remove four cap screws around the motor flange and separate the motor from the reducer Watch for shaft key which must be reinstalled later Check the motor electrically to confirm it is defective Apply Anti Seize lubricant to the shaft of the replacement motor Position the shaft key in the motor key way align it with the reducer key
62. e rim of the cutter and the top of the tank flange Loosen the bearing support cap screws and drive the support arms up or down for the proper alignment Tighten the support screws securely and finish assembly of the cutter and cutter disc Install the tank and other parts reversing the procedure of removal P18AL Service Manual 9 11 SERVICE OPERATIONS ITEM NO QTY PART NO DESCRIPTION 1 1 12A2160H0101 CUTTER DRIVE GEAR 2 1 12A2215F1107 SCREW 1 4 20 5 8 55 HEAD 3 3 12A2215F1112 SCREW 1 4 20 1 1 4 55 HEAD 4 4 12A2215G111 SCREW 5 16 18 UNC X 1 SS HEX HEAD CAP 5 4 12A2215H111 SCREW 3 8 16 UNC X 1 SS HEX HEAD CAP 6 3 12A2215H1208 SCREW 3 8 24 NF X 3 4 SS HEX HEAD CAP 7 4 12A2226F1112 MACHINE SCREW FLAT HEAD 55 1 4 X 1 1 4 8 4 12A2240A1108 NUT 5 16 18 55 FULL HEX 9 6 12A2240A1307 NUT HEX 1 4 20NC S S HEAVY 10 1 12A2250A107 WASHER 1 4 SS 11 4 12A2250A108 CUT WASHER 5 16 SS 12 3 1242250 12 WASHER CUT 3 8 55 13 6 12A2250B107 LOCK WASHER 1 4 SS 14 4 12A2250B108 LOCK WASHER 5 16 55 15 1 12A2615D01 DRIVE GEAR TI 59 W O SMALL amp MID SIZE MACH 16 1 12A2900M0508 MOTOR 1 2 HP 208 230 3 60 17 1 12A3040801 SPRING 1 4 DIA X 1 1 2 LONG TYPE 304 SS 18 1 12A3040802 SPRING 3 16 DIA X 1 2 L
63. e tank and results in clear ice production At the beginning of a harvest cycle a solenoid operated valve is actuated which allows water to flow into the tank during the harvest cycle The valve is actuated by a timer that allows for adjustment of the amount of water discharged during the harvest period see figure 9 1 for settings The machine should be started and run initially with a 30 second blowdown period and gradually increased until clear ice is produced 6 19 07 P18AL Service Manual 6 19 07 9 3 SERVICE OPERATIONS Make up Water Float Valve 37A The make up float valve maintains the proper 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 blowdown only during the thaw mode The water level during the freeze mode should always be below the overflow piping to prevent excessive waste of cold water resulting in loss of ice capacity If it should become necessary to clean the float valve close the stop valve in the make up water line to the machine and remove the float valve After the valve has been cleaned and reinstalled check to ascertain if the proper water level is being maintained After the machine is stopped and the water in the tank seeks its normal level there should be no water flow through the float valve or overflow It is advisable to install a large area strainer in the water supply line to pro
64. e up water float valve or flushing valve stuck or opened Thaw gas solenoid valve 18 leaking through during freeze Compressor running unloaded Symptom Freeze up due to ice failing to discharge Possible Cause Freeze timer T2 set to long Extended freeze period if freezer pressure switch is used Thaw time too short T Thaw pressure to low Insufficient heat for thawing due to low condensing pressure Insufficient heat due to non condensables usually air in the system Insufficient heat due to low refrigerant charge Cutter or cutter disc does not turn Compressor not running unloaded during thaw cycle for dedicated high side only 8 3 TROUBLESHOOTING Possible Remed Adjust timer or replace if defective See FIGURE 9 2 Adjust switch or replace if defective Close repair or replace valve as needed The float valve should be adjusted low enough that water should not run out the tank overflow during the freeze cycle Check the manual opening stem to make sure it is in the automatic position stem screwed in Check for leakage by sound temperature difference and frost during the freeze cycle Leakage should stop by closing the hand stop valve downstream of thaw gas valve Isolate and repair or replace the valve as needed If the compressor is running unloaded the motor amp draw will only be 60 70 of the normal amp draw of a loaded compressor Refer to the compressor manual for normal oil pressure
65. eezer tubes Since the purest water freezes first the circulating water continues to wash the dissolved solids down into the sump area of the water tank The flushing valve helps to rid the water tank of increased dissolved solids by flushing them out the overflow during the harvest thawing period The wet suction gas leaves the freezer and passes through the suction accumulator where liquid droplets are removed allowing dry gas to enter the suction side of the compressor The suction gas is then compressed and discharged once again completing the cycle As ice continues to form in the freezer tubes the suction pressure steadily decreases when the freeze timer T2 times out the contact closes initiating the thaw harvest cycle Note Freezing time will vary depending on make up water temperature and thickness of ice produced The freeze timer 2 should be set to provide the correct time to produce ice at the required thickness under the current operating conditions During the harvest period the D thawing gas valve 18 opens and the compressor unloads when required allowing the warm high pressure gas from the receiver to enter the freezer As the tubes warm up to slightly above freezing approximately 40 F 5 C the ice inside the tubes releases and falls down onto the rotating cutter for sizing and discharging Harvesting requires about three minutes but can vary depending on ice thickness suction pressure discha
66. ergized during all operational modes 3CR Relay stops the machine when there is a power failure or interruption and must be manually re energized by hitting the start button CBI Overload and short circuit protection for the crankcase heater and the control circuit CU Stops cutter motor in the event of a mechanical or electrical failure that results in excessive motor amperes Indicates hours of machine operation Energized when compressor is operating Stops pump motor the event of a mechanical or electrical failure which results E in excessive motor amperes Used to stop machine immediately Should be used for emergency stopping only Used for starting machine or manually harvesting Will initiate a harvest cycle PB2 whenever pushed with the Clean Off Ice selector switch in the Ice position and machine operating a freeze cycle Used to select operating mode of machine When clean position only the water pump will run This allows cleaner to be circulated through the freezer without 55 making ice In the off position the machine will shut down after the completion of a freeze and harvest period In the ice position machine will cycle on and off based on a control signal 1 e bin thermostat or timer or run continuously until manually stopped by setting the switch to the Off position T Controls the duration of the thawing period T2 Control the duration of the
67. essure 8 6 Compressor running unloaded during freeze 8 6 Compressor oil pressure low 8 6 Compressor loosing oil excessively 8 6 Machine short cycles 8 7 High compressor discharge temperature 8 7 Suction line frosting to compressor 8 7 Contact your distributor first for technical service assistance about operation problems not covered in this manual Also feel free to contact the factory for additional service 502 635 3000 6 19 07 8 2 Service Manual TROUBLESHOOTING Symptom Machine Stopped Possible Cause Possible Remedy Power failure or interruption Check fused disconnect or circuit breaker supplying power to the machine If power has been off make sure the crankcase heater is energized and there is no liquid refrigerant in the compressor crankcase prior to restarting the compressor If ice is in the freezer initiate a manual harvest Circuit breaker for control circuit tripped Check compressor crankcase heater coils of relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and reset circuit breaker Make sure there is no liquid refrigerant in the compressor crankcase prior to restarting the machine Compressor motor starter overload tripped Check for a loose connection on all motor starter and motor terminals that could cause excessive amp draw Reset overload and restart the machine check amperage power supply and head pressure Check delay
68. freeze period T3 Controls the duration of conveyor operation T4 Controls the duration of the flush valve operation TB Numbered for multiple wire connections and ease of troubleshooting TABLE 6 3 Description of Control Panel Component Function 6 19 07 P18AL Service Manual 208 40 111 NORMALLY OPEN HIGHSIDE CONTROL CONTACT CU 100 101 NORMALLY OPEN CUTTER STARTER AUX CONTACT 120 121 NORMALLY OPEN PUMP STARTER AUX CONTACT 13 91 CONVEYOR TIMER TIMERS T HARVEST TIMER default 3 min DELAY ON MAKE TIMER T2 FREEZER TIMER default 10 min MULTIFUNCTION TIMER MODE DELAY ON MAKE 3 CONVEYOR TIMER default 4 min SINGLE SHOT TIMER T4 FLUSH VALVE TIMER default 2 min DELAY ON MAKE FUNCTION d COUNT DOWN T RANGE 5 SET POINT 10M 005 FUNCTION 6 19 07 INCOMING POWER gt J FUSED DISCONNECT SWITCH BY CUSTOMER _ 6 5 ELECTRICAL CONTROLS USE COPPER CONDUCTORS RATED 60 Bi 250V 3A T TORQUE TERMINAL SCREWS TO 12 2 13 4 LB IN CIRCUIT BREAKER CU 14 15 460 VOLT 12A 7519 02 L4 15 TRANSFORMER 1 0 KVA 50 Hz
69. g area promptly The machine nameplate is located on the front of the control panel The model number and machine description are located in the top left hand corner The following figure can be used to verify that the correct model has been received Nominal Capacity XXXX XXXX XXXX XXX 02K 2000 Ibs day K 1000 s Ibs day T tons day 03K 3000 Ibs day 04K 40001bs day Consult Specifications for Actual Capacity tons day OST 5 tons day 10T 10 tons day 25T 25 tons day Model Variation 50T 50 tons day A number assigned to indicate major 80T 80 tons day variations within any one family series Basic Configuration Package Refrigerant L Low side R 22 High side Type of Ice Cylinder 404 Crushed Dual Ice Cru amp Cyl L 1 1 2 Long Cylinder Tube Size in 1 4 s of an inch x 9 Lone Cvlind ong Cylinder 4 1 5 _ 1 1 4 6 2 1 1 2 8 2 Electrical Codes 26 208 230 3 60 Condenser Type 46 460 3 60 AC Air Cooled 56 575 3 60 WC Water Cooled 25 200 3 50 HP High Pressure Water Cooled 45 400 3 50 SW Sea Water 21 230 1 60 NC No Condenser Product Variation Codes An alphanumeric designator assigned to specific variations 000 or Blank Standard Product If unsure of the product code shown on you
70. g safeties and control switches however they can be wired into the control circuit e Dual High Low pressure switch 1PS to stop the machine if the compressor suction pressure goes too low 15 20 psi or the compressor discharge pressure goes too high 225 250 psi Consult factory for detailed installation information 6 1 6 2 ELECTRICAL CONTROLS 6 19 07 P18AL Service Manual of TUBEACE LLC Le AUTOMATIC SIZED ICE MACHINE SS 2 FIGURE 6 1 Control Panel Door Closed Symbol Vogt Part Component Description 1 12A7500E57 Push Button Momentary Red PB2 12A7500E56 Push Button Momentary Green SS 12A7500E61 Selector Switch 3 Position T2 12A7503E52 Timer Digital Multi function 24 240V AC TABLE 6 1 Control Panel Components and Part Numbers External P18AL Service Manual ELECTRICAL CONTROLS ICR 2CR 3 1 1 is 1 ET e zum EE 22252225250 leleleleeK 22201002 elelee 66666618
71. gs 7 8 Diameter Ice Suction Pressure psig Suction Temp F Avg Ref Required tons Compressor Capacity ICE CAPACITY tons 24 hrs Average Refrigeration Required is for central plant operation and the tabulated value is based 70 make up water Table 10 2 Capacity Ratings for 1 Tube P18AL Capacity Ratings 1 1 8 Diameter Ice Suction Pressure psig Suction Temp oF Avs Ref Required tons Compressor Capacity Average Refrigeration Required is for central plant operation and the tabulated value is based on 70 make up water Table 10 3 Capacity Ratings for 1 1 4 Tube 6 19 07 10 4 TABLES amp CHARTS P18AL Capacity Ratings 1 3 8 Diameter Ice Suction Pressure psig P18AL Service Manual Suction Temp F Avs Ref Required tons Compressor Capacity n Temp ICE CAPACITY tons 24 hrs Average Refrigeration Required is for central plant operation and the tabulated value is based on 70 make up water Table 10 4 Capacity Ratings for 1 1 2 Tube Cylinder Ice Crushed Ice Make Up Water Temp F Tube Size Tube Size 17 11 4 1127 17 11 4 11 2 90 1 93 1 74 1 68 2 2
72. heavy Lift from the top to avoid tipping CAUTION The machine body has a lifting lug on the top for an eyebolt and hook to be used for lifting purposes if desired A lifting lug should be used whenever possible If a forklift is used make sure its capacity is sufficient The machine needs to be lifted from the top to prevent tipping Do not lift the machine using the water box flange on the top of the freezer The water box flange is not designed to carry the machine load The flange could fail or bend causing damage or personal injury 3 2 Service Manual INSTALLING YOUR TUBE ICE MACHINE Foundation Layout CAUTION The approximate machine operating weight is 3 000 pounds CAUTION The machine foundation should be constructed from concrete or similar material in accordance with all local and federal OSHA codes and building regulations The minimum required foundation size is shown in Figure 3 1 The foundations height will vary depending on the auxiliary equipment selected by the customer to transport ice to a bin or hopper Adequate space should be allowed for removal of the water tank and servicing operations such as cleaning the water distributors Figure 3 1 indicates minimum mounting requirements Contact your local distributor for seismic anchoring requirements in your area Additional bracing may need to be added to the top of the machine mounted to the lifting lug to meet local codes Piping
73. heed DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates strong possibility of hazard and that an unsafe practice could result in severe personal injury WARNING CAUTION Means hazards or unsafe practices could result in personal injury or product or property damage CAUTION 6 19 07 1 4 Service Manual INTRODUCTION FREEZER i CONTROL PANEL CUTTER MOTOR 7 i CUTTER GEAR REDUCER TE m4 ou lt WATER PUMP On SS FIGURE 1 1 P18AL Front View 6 19 07 P18AL Service Manual WATER DISTRIBUTION CHAMBER 6 4 THEO 1 5 INTRODUCTION 7 FREEZER SAFETY VALVES 8 THREE WAY VALVE 10 THAW GAS STOP VALVE HAND
74. hich is self adjusting and requires no lubrication However the pump should not be operated unless circulating water The pump manufacturer recommends that a mechanical seal be as spare When ordering a seal specify pump size type serial number and manufacturer s name as indicated on the nameplate Pumpdown The function of the pumpdown is to transfer all the liquid refrigerant from the freezer evaporator into the receiver Pump down should only be performed when the freezer is clear of ice Its main purposes are To check the total refrigerant charge To perform service or repair work on the machine To winterize the machine To prepare the machine for disconnecting and moving Before cleaning Ale Pumpdown Procedure To perform pumpdown follow this procedure 1 With the machine running close the liquid feed stop valve nearest the receiver 2 Open the water tank drain valve 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 3 Allow the machine to operate and complete two freeze and harvest cycles 4 Stop the machine throw the electrical disconnect and lockout all power to the machine 5 Remove wire from freezer pressure switch if installed and insulate the end to prevent a short circuit 6 Res
75. ice Yes No L Sufficient make up water supply minimum 30 PSIG Hour meter in control panel connected and operating Instruction manual and warranty certificate left on site Suction Pressure End of freeze End of harvest Name of person left with Discharge Pressure End of freeze End of harvest Test Make up Water Freeze Time Harvest Time First Ice Out All Ice Out Avg Hole Ice Ice Cycle Temp Min Sec Min Sec Min Sec Min Sec Size Lb Per Harvest Lb Per 22211 Note Ice per day can be found ice harvest 1440 freeze time harvest time Remarks Technician Signature End User Signature I certify that I have performed all of the above procedures 8 28 00 TUBE LLC located in 1880 ince lle Kentucky s isvi Lou Sales 800 853 8648 Parts and Service 502 635 3000 ty Ice Machines Since 1880 Manufacturers of Quali Tube 2 2 09 Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M09 P18 Ammonia Lowside Model P18AL Service Manual TABLE OF CONTENTS TABLE OF CONTENTS Vogt MACHINES Model P18AL Page No 1 INTRODUCTION A Brief History Of Our 3 RO RE RUE RO AREE ORDRE TRIN nt ds 1 1 Vogt Energy Savings Tube Ice Machines ses 1 1 nn 1 1 Importa
76. igerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant CAUTION Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 120 F and should be stored in a manner to prevent abnormal mechanical shocks Also transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended CAUTION It is not recommended that refrigerant be transferred from a refrigeration system directly into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be connected to an approved recovery mechanism with a safety shutoff sensor to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements CAUTION 6 19 07 Service Manual 1 3 INTRODUCTION Safety Symbols amp What They Mean Prior to installation or operation of the Tube Ice machine please read this manual Are you familiar with the installation start up and operation of a Tube machine Before you operate adjust or service this machine you should read this manual understand the operation of this machine and be aware of possible dangers These Safety Symbols will alert you when special care is needed Please
77. ill be evident by the frost line At the end of a freeze cycle frost or ice will form on that part of the oil trap where oil is not present When frost is seen only on the top 1 4 to 1 2 of the oil trap the oil trap should be drained Do not allow the oil trap to fill completely with oil or it will cause loss of ice production and possible refrigerant floodback to the compressor Oil Trap Draining Procedure 1 Stop the machine and wait 12 hours or more 2 Attach a suitable hose to the oil trap drain valve 61 Make sure there are no kinks or restrictions in the hose 3 Open the valve slightly until oil begins to drain 4 Continually observe the oil flow being ready to close the valve quickly DANGER Do not leave the oil trap drain valve opened or unattended severe injury may result DANGER 5 When a small amount of liquid ammonia begins to spew out immediately close the valve 6 Remove the hose and install a plug in the valve DO NOT attempt to reuse any oil taken from the system unless it is properly reclaimed and meets the proper specifications Removing Excess Water from Ammonia If excessive water is in the ammonia it will cause frost on the suction line to the compressor and dilution of the oil This condition should not go uncorrected and the water needs to be removed Water Removal Procedure 1 Perform a total pumpdown of the freezer See Pumpdown page 9 4 2 A total pumpdown is accomplished whe
78. ing Compressor net oil pressure gage reading less suction LAE JE JEJE JE E E E TEE TE TE EE EE Motor amps Compressor Cutter Suction psig end of freeze 2 Suction psig end of thaw Compressor water out F Tower fan cycles Ice Production Check First Ice Out Comments Pump Discharge psig end of freeze Discharge psig end of thaw F Off Ice Per Harvest estimated Ice Ib Per Day estimated Name 2 2 09 2 2 09 Service Manual 7 3 MAINTENANCE Ice Making Section The ice making section of the Tube Ice machine should be cleaned at least twice a year more often if water conditions cause mineral build up Use an approved food grade ice machine cleaner The water pump is used to circulate the cleaner through the system by setting the Clean Off Ice selector switch to Clean to start the water pump and to Off to stop the water pump For complete instructions refer to the Cleaning Procedure attached to the equipment and duplicated here Cleaning Procedure 1 10 11 12 13 Before cleaning any Tube Ice machine make sure the crankcase heater is working properly When the crankcase heater is not working there is a possibility for refrigerant evaporated by warm circulating water to migrate to the compressor during the cleaning operation Set Clean Off Ice selector switch SS to position If the m
79. ional accel 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 Ibs ft 8 33 Ibs gal 1 gpm water 12013 Ib day Weight of air 0 0749 Ibs ft 0 0100 Ibs gal 1 Horsepower 2545 6 BTU hr 1 BTU Ibm F 4 19 kJ kg 0 24 BTU Ibm F 32 35 Ibs ft 144 BTU hr 1 BTU Ib F 1 34 horsepower 9 81 m sec TABLE 10 9 6 19 07 P18AL Service Manual 6 19 07 11 Index A A Valve 4 1 5 1 Accumulator Adding Refrigerant 5 2 Ammonia Specification by Grade 5 2 Ammonia Machine Charge Ammonia Removal 9 5 B Basic Product Warranty inside back cover Bearing Cutter 9 10 Bill of Lading Bin Level Control 6 1 8 2 Blowdown 3 3 Capacity Ratings 2 2 10 2 10 4 Centrifugal Pump Charging Refrigeration Systems 1 2 5 2 Checklist Daily 7 2 Checklist Installation Review Chemical Cleaning
80. ive Freeze up Clogged water distributors Lack of water for making ice Lack of sufficient liquid refrigerant feed Water pump rotation incorrect or pump defective Symptom High compressor discharge temperature Possible Cause High head pressure Defective suction or discharge valves Restriction in the discharge gas line Internal relief valve leaking Symptom Suction line frosting to compressor Possible Cause Liquid refrigerant overfeed Refrigerant contaminated with water Possible Remed Adjust switch or replace if defective See Freeze up due to extended freezer period and Freeze up due to ice failing to discharge Clean water distributors Check water tank for sufficient water level Check for restriction in water line defective float valve open drain valve excessive ice chips or low water pressure and correct Check float and float switch solenoid valve and coil in liquid line strainer and refrigerant level in receiver Check pump motor rotation Check for leaking pump seal or defective motor and repair or replace as needed Possible Remed Check gage accuracy and High discharge pressure Feel the compressor heads for hot spots or one head running hot Replace worn or leaking valves Check all hand and check valves to make sure they are fully opened and not stuck Repair or replace as needed Check the compressor manual to see if your compressor is so equipped Replace accordingly P
81. le 9 6 Draining the eo Ret uve ERR one i en 9 7 Oil Trap Draining Procedure e 9 7 Removing Excess Water From Ammonia 9 7 10 11 Water Removal Procedure iai tette eo mote neben deii e be c ne bete Cutter Motor Removal Replacement Cutter Gear Reducer Removal Replacement 9 9 Water Removals ER Undo eme Ans 9 9 Cutter and Bearing Removal Installation seen 9 10 Cutter Water Tank Parts List TABLE 9 1 9 11 Cutter Water Tank Assembly FIGURE 9 3 en e e 9 12 Cutter Tank Parts FIGURE 9 4 E 9 13 Cr shed Ice Production uc iren D HE ertt bei a h e erect p e eee es 9 13 TABLES AND CHARTS Specifications 60 Hz TABLE 10 1 10 2 Capacity Ratings 7 8 Diameter Ice 1 Tube TABLE 10 2 ss 10 3 Capacity Ratings 1 1 8 Diameter Ice 1 1 4 Tube TABLE 10 3 10 3 Capacity Ratings 1 3 8 Diameter Ice 1 1 2 Tube TABLE 10 4 10 4 Make up Water Usage TABLE 10 5 P18AL Normal Operating Vitals TABLE 10 6 diner R commended Spare Parts 18 2 E D ee eid eed Temperature Pressure Char
82. m voltage unbalance between 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 Unbalance Voltage unbalance will cause a current unbalance but a current unbalance does not necessarily mean that a voltage unbalance exists A loose terminal connection or a buildup of dirt or carbon on one set of contacts would cause a higher resistance on that leg than on the other two legs Current follows the path of least resistance therefore if terminal connection 1 1 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 12 91 Amps Average 96 91 98 3 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation Current Unbalance 100 x 4 95 4 2 Acceptable L3 98 95 3 Amps 1 22 07 Service Manual 3 11 INSTALLING YOUR TUBE ICE MACHINE Startup Checklist IMPORTANT Be sure to follow the wiring schem
83. n there is no frost or ice on the freezer or oil trap and the freezer pressure is below that pressure relative to the surrounding temperature Refer to the Temperature Pressure chart for ammonia 3 With the freezer pressure below 25 PSIG attach a hose to the oil trap drain valve and extend the other end into a container 5 gallon bucket etc 4 Open the drain valve a little and drain out the oil and water that is present 5 Continue to drain oil water and purge the freezer and compressor to 0 PSIG 9 8 6 19 07 P18AL Service Manual SERVICE OPERATIONS 6 Close the compressor discharge stop valve and the oil return valve Make sure the power 15 disconnected and locked out 7 the compressor oil remove the compressor side cover and clean the inside of all oil and foreign matter and reinstall the side cover 8 Connect a vacuum pump or pumps to the freezer and compressor and evacuate them to 2000 microns or below while maintaining 60 F 10 c or higher room temperature 5 or larger vacuum pump 18 best 9 During evacuation add new oil to the compressor Also purge the receiver for non condensables 10 After evacuation break the vacuum by manually opening the liquid line solenoid valve and gradually opening the liquid line stop valve 24 or at the receiver letting liquid ammonia enter the freezer and raise the pressure 11 When the freezer suction pressure is up to at least 60 PSI manually close th
84. ndling of anhydrous ammonia refrigerant and operation of refrigeration systems should perform the operations described in this manual local federal and EPA regulations must be strictly adhered to when handling ammonia R717 refrigerants See Material Safety Data Sheet MSDS Code5B81 83 for detailed information Charging From Tank Truck dedicated high side only The system may be charged by bulk from a tank truck and be pumped directly into the receiver through the drain valve Follow these instructions with caution 1 Using a ammonia approved charging hose connect one end to the drain charging valve in the bottom of the high pressure receiver 2 Connect the other end of the charging hose to the tank truck It is best to have a gage in this line to indicate pressure 3 Open the drain charging valve and the fill valve from the tank truck 4 While observing the sight glass on the high pressure receiver fill the receiver to the proper volume 5 Make sure the charging valve is closed and the cylinder valve is closed before attempting to disconnect the hose Use caution when disconnecting the charging hose it will contain liquid ammonia and should be disposed of in accordance with local state and federal safety and environmental rules CAUTION Do NOT attempt to bulk charge the machine through the freezer charging valve 30 The freezer will not hold the full charge without exposing the compressor to serious damage
85. ne 3 1 Machine Won t Run 8 2 Maintenance Program 7 1 Maintenance Program Form 7 2 Make Up Water 3 2 8 8 10 4 Manual Harvest Push 5 7 6 4 Metric Conversion 10 7 N NEMA 3 1 Nomenclature Piping Schematic 4 2 Non Condensable Gases 9 6 Normal Operating Vitals 10 6 Operating Tips 5 7 Operation 10 5 P Pin Stainless Steel 9 11 Piping and Drain Connections 3 2 Piping Schematic Central System 4 4 Piping Schematic Dedicated High Side 4 3 Piping Schematic Nomenclature 4 2 Poor Ice 8 5 Power Connection 3 9 Preventive Maintenance
86. ng gear and drive Make sure all bolts are tightened securely and there is no excessive gear noise when the cutter motor is running Water Tank Removal DOI Oe la Turn off and lock out power to the machine Turn off water supply and disconnect lines from the tank Drain the tank and disconnect pump suction tube and drain line tubing and water lines Disconnect the ice discharge chute Loosen bolts holding the tank to the cutter assembly until the tank rests on the casters Remove cutter motor and gear reducer together Hang on machine frame to support and secure Loosen bolts holding the tank supports The tank can then be removed to the side of the machine Make sure the rubber gasket is in place and aligned properly when the tank is reinstalled and bolted to the freezer 9 10 SERVICE OPERATIONS 6 19 07 P18AL Service Manual Cutter And Bearing Removal Installation Refer to FIGURES 9 3 amp 9 4 for parts identification and location A 10 11 12 13 14 15 16 17 18 Turn off and lock out power to the machine Remove the cutter motor from the reducer Remove the water tank assembly and then the cutter assembly With 1 4 or slightly smaller punch reach in through the ice discharge opening drive the spiral pin out of the disc hub and cutter shaft and push or drive the disc off the shaft Lift the cutter assembly out of the bearing surface of the cutter The surface should be smo
87. non flammable non toxic degreasing agent or commercial detergent and water CAUTION Follow all lock out and tag out procedures before servicing any electrical equipment CAUTION Maintenance Operation Start Up Monthly Six Months Shutdown Clean debris from unit Clean strainer and flush sump X Check fan and pump rotation Clean spray nozzles Check belt tension Check for noise vibration Check adjust make up water valve Check adjust bleed rate Check lubricate fan bearings Lubricate motor base adj Screw Drain sump and piping Maintenance Operation Clean debris from unit X Clean strainer and flush sump X X Check fan and pump rotation X Clean spray nozzles Check belt tension X Check for noise vibration X Check adjust make up water valve X Check adjust bleed rate Check lubricate fan bearings X Lubricate motor base adj Screw Drain sump and piping TABLE 7 3 Cooling Tower Maintenance Schedule 6 19 07 P18AL Service Manual 7 7 MAINTENANCE Compressor optional This section is only a guide consult the compressor manual for manufacturers recommended maintenance In starting and charging the unit the sight glass should be continually checked to make sure an adequate oil level is maintained The oil level should be 1 4 3 4 of the sight glass If the oil
88. nt Check solenoid coil to make sure it is not energized If valve is stuck open replace valve Refer to compressor manual loaded manually manual for Pressure Mycom compressor can be Possible Remedy Oil will be very foamy Check liquid feed control for overfeed problem Adjust valve to increase oil pressure Turn stem in to increase out to decrease Check rotation direction by arrow indication rotation if necessary Clean strainer or restriction in passage or replace filter The Mycom compressor thrust bearing on the shaft seal end has an oil passage hole that has to be in the proper position when installing the thrust bearing Hole up for WA and series Mycom compressor Refer to your compressor manual Reverse Possible Remedy The oil separator will normally return a good portion of oil leaving the compressor if it is working properly Check the oil float and return line to see it is not restricted Check liquid feed to make sure it is not overfeeding and that the solenoid valve 25 is not leaking through when the machine is stopped Check compressor efficiency If rings are seized or broken replace defective parts A few drops per minute is okay replace the seal If ammonia is leaking P18AL Service Manual 6 19 07 8 7 TROUBLESHOOTING Symptom Machine short cycles using freeze pressure switch FPS only Possible Cause Freezer pressure switch FPS set too low or defect
89. nt Safety 1 2 Special Precautions Be Observed When Charging Refrigeration Systems esee 1 2 Safety Symbols and What They Mean 1 3 Assembly Drawing Model PI8AL FIGURES 1 1 1 2 1 3 amp 1 4 1 4 to 1 7 2 RECEIPT OF YOUR TUBE ICE MACHINE Inspection 2 1 Description of Reine ren tien nn fn enter lies 2 1 Safety Fagsvand Labels ete Rs et e tiat eb etes 2 1 Safety LIT X 2 2 Rated Capacity eem ee Ne Mt 2 2 Vogt Model me nets inner ee 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Machine ROOM en En rein nn 3 1 Lifts Procedutes 552228 IN ASR tied E ND A 3 1 Foundation pe e i OR RB 3 2 Piping and Drain Connections TABLE 3 1 3 2 Make up Water In Water Tank Drain Water Tank Overflow een RENI E eode e RO e EC RE RR eee NR TO te 3 3 Water Tank Flush Valve cogs cies ap ER Re 3 3 Receiver Fable g ERR 3 3 Suction Pressure Regulator t d b be eee ele 3 4 Conipressor Unlo ding eie Oe mu ree e 3 4
90. on or around the Tube Ice machine It is very important that you are familiar with and adhere to all local state and federal etc ordinances and laws regarding the handling storing and use of anhydrous ammonia An approved ammonia mask should be readily available for use in an emergency and all personnel should be aware of its location and proper use CAUTION Inspection As soon as you receive your machine inspect it for any damage If damage is suspected note it on the shipper s papers 1 the trucker s Bill of Lading Immediately make a separate written request for inspection by the freight line s agent Any repair work or alteration to the machine without the permission of the Tube Ice LLC can void the machine s warranty You should also notify your Vogt distributor or the factory Description Of Machine Vogt low side Tube Ice machine is a remote ice producing plant requiring refrigerant suction connection refrigerant liquid connection thaw gas connection make up water supply electrical connection and the proper refrigerant charge The machine has been partially factory tested prior to shipment and will require adjustment to meet the high side condenser unit operating conditions See Start up and Operation for the correct setting of the controls The machine is evacuated and charged with nitrogen gas pressure for shipment This prevents air or moisture from entering the system during transit There should be
91. onal control device consult the factory for information Harvest Period When the freeze timer T2 contact closes a control relay 1CR is energized The relay stops the water pump and starts the cutter motor The A solenoid valve 25 closes the D solenoid valve 18 opens and the thaw timer T is energized As the ice releases and drops through the rotating cutter and onto the cutter disc it is discharged through the side opening of the water tank The harvest timer T is to be set for the time required to discharge all the ice plus 30 seconds longer usually 2 to 2 1 2 minutes CAUTION Make sure all the ice clears the freezer with at least 30 seconds to spare before the next freeze period begins This is to prevent refreezing CAUTION 1 Freezer 16 Suction Connection 2 Flange 2 Control Panel 17 Freezer Pressure Gage 3 Cutter Motor 18 Thaw Gas Solenoid Valve 4 Cutter Gear Reducer 19 Thaw Gas Pressure Gage 5 Water Pump 20 Strainer Purge Valve 6 Water Distribution Chamber 21 Strainer 7 Freezer Safety Valves 22 Oil Trap 8 Three Way Valve 23 Refrigerant Float Switch 9 Hand Expansion Valve 24 Liquid Line Stop Valve 10 Thaw Gas Stop Valve 25 Liquid Line Solenoid 11 Ice Discharge 26 Liquid Line Strainer 12 Water Tank Overflow 27 FPT 27 Flush Water Solenoid Valve 13 Cutter Tank
92. operated with floating type diaphragms For satisfactory operation be sure that the manual opening stem is in the closed or automatic position This means the stem is backed all the way out Correct direction of stem rotation should be labeled on the stem seal nut Control Circuit Protection CB1 The electrical control circuit of the machine is protected by a 3 amp circuit breaker If breaker should open the machine will immediately stop Before resetting the breaker check power to the 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 Cutter Motor 3 Gear Reducer 4 The gear reducer supplied requires no lubrication It is lubricated from the original manufacturer for life Do not attempt to lubricate the gear reducer The motor bearings are also prelubricated and require no further lubrication Circulating Water Pump Motor 5 The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water level above the impeller 9 4 6 19 07 P18AL Service Manual SERVICE OPERATIONS housing to prevent cavitation or loss of prime The pump 1s equipped with a mechanical seal w
93. operation of the Tube Ice machine and its controls Rotation checking of cutter motor and water pump is required see following section Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 Connect the Ground wire to the Ground lug provided 2 2 2 1 22 07 22l 722222222222222222822 5 5 99929965 eeeleejeleeeleeeleee 2 12 27 22 90 1 VV E 8 EB E B E 3 E 08 eo pud Pr 8 ER 33 ES 8 3 8 B 83 48 ME 9 CUSTOMER MAIN POWER GROUND CONNECTIONS Control Panel Field Connections P18AL Service Manual 3 9 INSTALLING YOUR TUBE ICE MACHINE bleed T Bleeleellelsleelee eeleelelelele 1 1 2112 27 22 34 90 91 24 LI L2 T3 HSE
94. ossible Remedy Check float switch to make sure it is functioning properly Replace if defective Check solenoid valve 25 to make sure itis not leaking through Repair or replace if defective Test refrigerant or oil for water contamination Completely pump the freezer out pumpdown and blow excess water out through the oil trap drain valve Refer to Service Section 9 Removing Excess Water 8 8 P18AL Service Manual TROUBLESHOOTING 6 19 07 P18AL Service Manual 6 19 07 9 1 SERVICE OPERATIONS 9 Service Operations Thawing Timer T The thawing timer governs the ice thawing period It is located inside the control panel FIGURE 6 1 It 15 started by action of the freeze timer T2 which energizes the 1 relay This timer is set prior to shipment for approximately a two minute period Set the thawing period for at least 30 seconds longer than the time required to harvest the entire discharge of ice If it should be necessary to change the setting of the timer turn the adjustment screw clockwise to increase the time or counter clockwise to decrease the time Check thaw time after each adjustment TIME RANGE ADJUSTMENT DIAL LIGHT INDICATES THAT TIMER IS TIMED OUT LIGHT INDICATES THAT TIMER IS TIMING SCALE SELECTION SWITCH OPTION X1 OR 1 TIME BASE SELECTION SWITCH OPTION MINUTES OR SECONDS FIGURE 9 1 Timer Settings Freeze Timer T2 The freezing time period for the production
95. oth and free from nicks or burrs Inspect the bearing for wear There should be no side movement between the shaft and bearing and the bearing thrust flange should be no thinner than 3 16 it is 1 4 thickness new Before removing the bearing reference mark the location of the bearing support on the side of the tank Loosen and remove the three cap screws from the bearing support ends and lift the support out of the water tank Drive the 3 16 x 1 2 pin located in the side of the support hub in and through the bearing wall Now the bearing can be pressed or driven out of the support hub Try the new bearing on the cutter shaft to make sure it turns easily Press or drive the new bearing into the hub Be careful not damage the bearing surfaces the old bearing may be used as a driver Drill a 3 16 hole through the bearing wall using the original 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 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 Install the bearing support in the tank using the reference marks as a guide Slide the cutter and shaft into the bearing and check the cutter alignment By laying a straight edge across the tank top flange there should be 0 to 1 16 clearance between th
96. pting to drain oil from the trap Follow the procedure outlined in the service section Draining Oil Trap CAUTION Only qualified refrigeration service personnel familiar and experienced in the handling and use of anhydrous ammonia R717 should be authorized to perform the Draining Oil Trap procedure CAUTION Optional Maintenance Operations The following sections outline some general guidelines for service of auxiliary equipment Always follow the instructions provided by equipment manufacturers when performing service operations or scheduled maintenance Water Cooled Condenser Cleaning optional As water evaporates from a cooling tower the solid impurities remain and must be flushed from the system to prevent a scale build up in the condenser and cooling tower This can be accomplished by a continuous bleed off valve located in the pump discharge line The valve should be adjusted to bleed off an equal amount of water that is evaporated If water hardness 15 very high a higher bleed off rate or chemical treatment may be required Consult you local water treatment company for recommendations If after a period of time scale has formed inside the tubes mechanical cleaning may be necessary See Servicing Section Condenser Cooling Tower Evaporative Condenser optional 7 6 Service Manual 6 19 07 MAINTENANCE 1 Bleed off valve The bleed off valve should be checked monthly to assure that i
97. r Water Conditioning 3 3 Water Cooled Condenser 7 5 Water Cooled Condenser Cleaning 7 5 Water Distributors 7 4 Water Pump Motor 9 4 Water Quality 3 1 Water Supply and Drain Connections 3 2 Water 7 4 Water Tank Removal 9 9 Water Usage Make up 10 4 Wiring and Electrical Connection 3 9 Wiring Schematic All Voltages 50 60 Hz 6 5 X Y Z
98. r machine please consult the factory Figure 2 1 Vogt Model Nomenclature 1 22 07 P18AL Service Manual 3 1 INSTALLING YOUR TUBE ICE MACHINE 3 Installing Your Tube Ice Machine Only service personnel experienced and certified in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on this Tube Ice machine WARNING Important Notice The Warranty Registration Start Up Form must be completed and returned to Vogt Tube Ice to initiate and assure a full warranty A postage paid envelope is provided or you may fax the report to 800 770 8648 Machine Room The machine must be located inside a suitable building and must not be subjected to ambient temperatures below 50 F 10 C or above 110 F 43 3 C Heat from other sources sunlight furnaces condenser etc and unusual air current may affect the operation of the machine and should be avoided The electrical components of the Tube Ice machine are rated NEMA 1 The machine should not be located in a hazardous area or sprayed with water The machine should be installed in an area where water will not stand but will readily drain away from the machine See Space Diagram for clearances and utility connections FIGURE 3 1 Lifting Procedures CAUTION The approximate shipping weight of the machine is 2 300 pounds Always use equipment with adequate load carrying capacity The Tube Ice machine is top
99. rge pressure thawing gas temperature and distance from the receiver to the freezer IMPORTANT It is a good idea and will be profitable for you to observe and become familiar with the proper operating characteristics of your Tube Ice machine It will help you to recognize and correct minor irregularities as they occur in order to help prevent major problems ounce of prevention is worth a pound of cure IMPORTANT 5 2 Service Manual STAR UP AND OPERATION Refrigerant Charge Prior to charging the machine with anhydrous ammonia R 717 make sure the system is leak tight and free of non condensables or other contaminants The machine will require a full charge of pure anhydrous ammonia Make sure it is from a reputable supplier who can and will furnish quality ammonia of Refrigeration or Federal Technical grade Minimum Maximum Maximum Maximum Non Re Content Content x PEE Content ED Fertilizer 99 99 50 5000 PPM SPPM PPM 99 98 150 PPM 3 PPM 2 Reference Ammonia Data Book Chapter 1 General Information NOTE Do not use Fertilizer grade ammonia TABLE 5 1 Ammonia Specification By Grade Total ammonia R 717 charge required Dedicated System 500 165 Evaporator only 250 Ibs Special precautions to be observed when charging refrigeration systems Only technically qualified persons experienced and knowledgeable in the ha
100. rvice Manual 7 5 MAINTENANCE Other Maintenance Operations Cutter Gear Reducer The oil level of the gear reducer should be checked monthly or when there is any evidence of leakage The correct level is indicated by the pipe plug in the side of the gear housing The oil should run out of the hole when the plug is taken out If low add oil through one of the top plugged holes A high grade lubricant such as Mobil 600W or SAE 140 gear oil should be used The oil should be changed annually Drain the oil and flush the gear case with mineral spirits Drain the mineral spirits completely and refill with the proper oil Note If a USDA high food grade lubricant is desired use Chevron FM Lubricating Oil 460X CAUTION Follow all lock out and tag out procedures before servicing any electrical equipment CAUTION Oil Trap Although the compressor is equipped with an oil separator which has an automatic return some oil will pass through the separator and eventually settle in the oil trap 22 which is offset from the base of the freezer This oil trap will have evidence of frost on its surface during the freeze cycle and may be more pronounced at the end of a normal freeze cycle just before the harvest Where there is oil in the trap there will not be frost Where there is frost there will not be oil When the trap is 1 2 to 3 4 full of oil it should be drained The machine should be shutdown for at least 12 hours before attem
101. s 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 4 for condenser water requirements The water piping for the cooling tower and the installation of the pump must be in accordance with the manufacturer s instructions Proper water treatment for the prevention of mineral and foreign matter accumulation in the condenser or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use The condenser water pump should be sized on GPM required for condenser at 80 ft total discharge head for a typical installation However due to cooling tower location and pressure drop through water lines the water pump should be sized for each installation If the condenser inlet water temperature is expected to be below 75 F 24 C a water regulating valve should be installed in the condenser water inlet line and adjusted to maintain a head pressure of not less than 175 psig 1 22 07 3 5 INSTALLING YOUR MACHINE P18AL Service Manual 143 8 LP 4V SCT Lda 9 1 SVD NOILONS
102. s not blocked and that water is flowing as required If the unit is controlled by a water treatment system the bleed off valve may not be required 2 Strainer The pan or sump strainer is located in the bottom of the sump at the suction connection to the pump The strainer should be inspected monthly and kept clean Do not operate the unit without the strainer in place 3 Make up water float valve This valve should be checked monthly for proper operation and adjustment It should be adjusted to maintain a water level below the overflow and high enough to prevent the pump from cavitating when the system is in operation 4 Spray nozzles The spray nozzles should be checked monthly to make sure none are restricted and the spray pattern is complete and even 5 Pump motor and fan motor The motors should be checked and or lubricated every six months according to the motor manufacturer s recommendations 6 Fan bearings The fan bearings should be lubricated every six months Make sure the proper grade of grease is used normally conforms to NLCI Grade 2 and it is best to use a hand grease gun 7 Fan belts The fan belt tension should be checked weekly for the first two weeks of operation then monthly during continuous use The best tension for a V belt is the lowest tension at which the belt will not slip under its full load Never use dressing on V belts Keep belts and grooves clean and free of oil grease and foreign material Clean with
103. ssor CAUTION 1 22 07 P18AL Service Manual 6 19 2007 4 1 HOW YOUR TUBE ICE MACHINE WORKS 4 How Your Tube Ice Machine Works Principle Of Operation For a detailed description of the functions of each control panel component see Section 6 Operation of the machine is controlled by Clean Off Ice Start and Stop switches located in the control panel of the freezing unit Automatic operation 15 controlled by the freeze timer or an optional ice bin thermostat which will automatically stop and start the ice maker by the level of the ice the storage bin The control wiring 15 arranged so that the unit will stop only upon the completion of a thawing period whether by action of the Clean Off Ice switch in the Off position by the completion of a timed cycle or by the ice bin thermostat Clean Off Ice switch must always be set in the Ice position during normal ice making operation It is set in the Clean position only when the equipment is to be cleaned as outlined in the Cleaning Procedure Section 7 and instructions attached to the machine If it should become necessary to instantly stop the machine push the Stop button To restart the machine push the Start button FIGURES 4 1 amp 4 2 illustrate the piping diagram of the refrigerant and water circuits of the Tube machines with numbers for easy reference Throughout this manual the numbers
104. ssure components It collects mostly in the coolest lowest velocity area of these components Evaporative condensers usually have purge points at the top of the outlet header of each circuit Receivers usually have a purge point at the top away from the inlet where it is coolest and the gas velocity is the lowest The freezer can be purged through the valve at the top of the suction line but should be done only during the thaw cycle or after the system has been idle at least two hours Purging Procedure Follow this procedure when purging 1 Connect a suitable hose to the purge valve and place the other end in water 2 Open slightly the purge valve and allow air to escape 3 Air will appear as bubbles in the water rising to the surface 4 The larger the bubbles the more air is escaping 5 DO NOT leave the purge hose unattended 6 When air bubbles are reduced to a minute size smaller than 1 16 it can be considered that most of the air has escaped and purging can be ceased at this point 7 Additional purging can be done at other purge points 8 When purging is completed close the valve disconnect the hose and install a plug in the purge valve Service Manual 9 7 6 19 07 SERVICE OPERATIONS Draining the Oil Trap After many hours of operation the oil which escapes the oil separator will pass through the receiver and to the freezer where it will settle in the oil trap 22 Indication of oil in the trap w
105. sure it opens during harvest time Check Liquid feed valve 25 to make sure it is feeding during a freeze If the machine stops by high pressure cutout the switch will have to be manually reset after the pressure drops below the cut in setting Check the head pressure during the next freeze cycle Low oil pressure tripped OPS located on compressor Manually reset the switch after the switch heater cools Check the crankcase oil level 1 4 3 4 full Add oil if below 1 4 glass before attempting to restart the machine Restart the machine and check net oil pressure net oil pressure oil pump line pressure minus crankcase suction pressure Net oil pressure range Mycom 17 28 psig Vilter 35 50 psig Defective control panel component such as 1PB SS 1CR T See FIGURE 6 3 Wiring Schematic and check for open circuit Refer to FIGURES 6 1 and 6 2 Control Panel to identify parts Check for loose wires Replace defective part restart machine check power supply and current draw Fused disconnect for pump or cutter motor blown Check for loose connection on all terminals replace fuse and check amp draw against fuse rating Check voltage and current unbalance Section 3 Replace fuse if blown Symptom Freeze up due to extended freeze period 6 19 07 P18AL Service Manual 6 19 07 Possible Cause Freeze timer T2 set to long Freezer pressure switch FPS set too low or defective optional Water tank drain valve mak
106. t for Common Refrigerants TABLE 10 7 Conversion Factors English to Metric TABLE 10 8 ss Constant 10595 054 56 A AR AR T ue INDEX P18AL Service Manual 6 19 07 INTRODUCTION 1 Introduction TUBE ICE LLC A Brief History Of Our Company Henry Vogt Machine Co was founded as a small machine shop in Louisville Kentucky in 1880 In 1938 Vogt built the first Tube Ice machine and revolutionized the ice making industry Our first sized ice machine quickly replaced the old can ice plants which required much hard labor and large amounts of floor space for freezing cutting and crushing ice by hand Today TUBE ICE LLC carries on the tradition as one of the world s leading producers of ice making equipment Vogt Energy Saving Tube Ice Machines Are Cost Effective Today Vogt Tube Ice machines enjoy a well earned reputation as the most energy efficient dependable ice making equipment in the world Using as little as one half to one third the energy required by competitors icemakers Tube Ice machines produce the same amount of ice in restaurants sports arenas packing plants and wholesale operations around the globe at great savings In addition Tube Ice machines are renowned for their long life giving many 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
107. t in the freezer The cold liquid refrigerant enters the freezer where it absorbs heat from the circulating water This cool gas is pulled out of the freezer at the suction outlet thereby completing the circuit 4 2 Service Manual HOW YOUR TUBE ICE MACHINE WORKS The freezing period is completed by action of the freeze timer in the control panel or an optional freezer pressure switch The water pump 5 is stopped and solenoid valve A 25 is closed The thawing period then begins The thaw gas solenoid valve 18 sometimes referred to as the D valve is opened the cutter motor 3 is started and the harvest timer T is activated Warm gas from the receiver is discharged into the freezer through valve 18 thereby slightly thawing the outer edge of the ice which drops on the rotating cutter for sizing See Freezer Period and Harvest Period for more detailed description of operation Freeze Period The Tube Ice is frozen inside the stainless steel tubes in the freezer 1 by the direct application of refrigerant to the shell side outside of the tubes The ice is produced from constantly recirculating water during the freeze period As the ice thickness increases the freezer suction pressure decreases At a set time the freeze timer initiates the harvest period The harvest period may also be controlled by means of a freezer pressure switch that can be adjusted to get the correct thickness of ice this is an opti
108. tect the float valve from dirt or solids in the water that would necessitate frequent cleaning A strainer of 40 mesh screen is usually satisfactory Refrigerant Float Switch 23 The float switch is installed on a header assembly that is attached to the freezer shell Valves are provided for isolation of the float switch assembly if replacement or servicing is necessary The float switch closes as the level of refrigerant in the freezer rises and opens as the level falls The float switch is connected to the A solenoid valve coil This is the solenoid valve directly before the hand expansion valve Therefore when the refrigerant level in the freezer drops the float switch closes thereby energizing and opening the A liquid feed solenoid until sufficient level has been reached to open the float switch The float switch has a fixed 1 2 differential The float switch is installed at the correct height at the factory and should not need to be adjusted The float switch is installed at the position that provides highest capacity The correct height will produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30 F Hand Expansion Valve 9 The hand expansion valve is located directly after the solenoid valve This valve should be set at a point where the float switch is open for a length of time approximately equal to the time it is closed Solenoid Valves 18 25 All solenoid valves are pilot
109. the control panel door and disconnect the freezer pressure switch then turn the power back on Check compressor rotation by starting and stopping the compressor momentarily Jog the compressor by using the green Start push button PB2 and the red Stop push button PB1 in sequence Correct compressor rotation 15 indicated by an arrow on the outer rim of the oil pump assembly opposite the shaft end of the compressor Set the Clean Off Ice Switch SS to the Ice position allowing the circulating water pump to circulate water through the freezer As the pressure continues to rise in the freezer start the compressor and pump the ammonia into the receiver Make sure water is circulating through the condenser and freezer tubes The machine will make ice during the process and care should be taken not to freeze the ice solid If necessary harvest the ice and repeat the process If a refrigeration system is being charged from refrigerant cylinders disconnect each cylinder when empty or when the system is fully charged A gage should be installed in the charging line to indicate refrigerant cylinder pressure The cylinder may be considered empty of liquid R 717 refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the hose from the cylinder Loosen the union in the refrigerant charging line carefully to avoid liqui
110. timer in part wind starts only Water pump cutter motor conveyor motor overload tripped Check for loose connection on all terminals that could cause excessive amp draw Reset the overload and manually run that particular motor to check actual voltage and amperage against motor rating Freezer water pump motor overload P tripped Check for loose terminal connections and or blown fuse reset the overload and restart by pushing the start push button 2 Machine will start in a harvest Check voltage and amperage against motor rating during freeze Confirm proper rotation Cutter motor overload CU tripped Check for loose terminal connections and or blown fuse Clear all ice that may have jammed cutter Reset the overload and restart by pushing the start push button PB2 Machine will start in a harvest Check voltage and amps against motor rating If tripping repeats but ice is not jammed check the gear reducer for resistance cutter bearings for wear drive gear and ring gear for proper engagement and reducer motor for defect or single phasing Bin level control optional open Adjust or replace control as required If bin level control is not used make sure jumper wire from 11 to 14 is installed at the terminal block High Low pressure safety switch tripped optional If the machine stops by low pressure cutout the switch will reset automatically when the pressure rises to the cut in setting Check thaw gas valve 18 to make
111. tive condenser requires maintenance Check fan motor and fan belts for proper operation and tension Check spray nozzles tubes sump and sump screen for accumulation of mineral deposit and clean as required Check tower blowdown and chemical treatment if applicable Dirty condenser tubes Visually inspect the condenser tubes to see if there is any build up of mineral deposits which would reduce the cooling effect of the tubes and water Clean chemically or mechanically as applicable Symptom Low discharge pressure check gage accuracy Possible Cause Possible Remedy Fan cycling switch out of adjustment or defective Check adjustment Replace if defective Compressor running unloaded or not pumping efficiently Check compressor motor amp If the compressor is running unloaded the amperage will only be approximately 6096 of normal amp draw FLA Refer to the compressor manual Ambient temperature low and prevailing winds blowing Shield tower from prevailing winds to prevent excessive through tower cooling Install an indoor sump Too much cold water circulating through condenser Install a water regulating valve in the water line form the condenser and control flow by receiver pressure Make sure manual opening stem is in the automatic screwed in position Repair or replace defective parts 6 19 07 8 6 TROUBLESHOOTING Symptom High suction pressure check gage accuracy Possible Cause Compressor running unloaded or
112. to confirm the satisfactory operation of the machine Complete the remaining part of the Warranty Registration Start Up Report and return it to the TUBE LLC 5 6 P18AL Service Manual STAR UP AND OPERATION Thaw Gas Regulating and Suction Regulating Valve Adjustment The following is the procedure for regulating valve adjustment On dedicated compressor systems the suction regulating valve 15 not required However the compressor must unload by 50 or greater during the harvest or a hot gas bypass must be installed 6 19 07 1 2 Install gauge gauge valve in gauge port regulator Turn high pressure stem down stream pressure on suction regulator into the milled flats do not turn milled flats into packing nut Start the machine and initiate a harvest Adjust thaw gas regulator to build pressure to 60 65 psig 1 turn is approximately 13 psig Adjust downstream high pressure stem on suction regulator to begin regulating at 59 64 psig slightly below the thaw gas regulator After the machine has completed the harvest cycle and returned to the freeze cycle adjust the low pressure upstream pressure on the suction regulator to maintain the required freezer pressure For clear ice a minimum of 20 psig freezer pressure is required Shut down CAUTION The red Stop button should only be used for emergency shutdown For normal shutdown use the Clean Off Ice button CAUTION
113. tore power to machine and start the water pump circulate warm water through the freezer 7 When the suction pressure increases to 70 psig or higher start the compressor and allow the machine to stop automatically by the low pressure switch at approximately 15 psig Lower pressure can be obtained by jumping out the pressure switch Remove all power from the machine before opening the control panel cover With the pressure switch jumped out the machine can be manually started and stopped Do not operate the machine below 2 psig 8 When the desired pumpdown is obtained close the thawing gas stop valve and the compressor discharge line stop valve Other valves may also be closed to isolate a particular area that may require attention 9 To perform a total pumpdown it may be necessary to apply heat directly to the oil trap in order to boil off the liquid ammonia and oil mixture P18AL Service Manual 9 5 6 19 07 SERVICE OPERATIONS Removal of Ammonia Refrigerant from the Machine Liquid ammonia can be removed from the machine through the receiver drain valve Refer to Sections 1 2 and Appendix A for special warnings and instructions regarding the handling of ammonia Make sure you are familiar with and technically qualified to handle anhydrous ammonia refrigerant WARNING Approved recovery equipment hoses gages and refrigerant containers must be used to comply with all local and federal EPA regulations WARNING W
114. tter gear reducer and drive gear for proper operation and alignment Check for broken gear teeth or sheared shaft key Replace defective parts Check compressor motor Amp draw During the thaw cycle the compressor motor Amp draw should be 60 7096 of normal amp draw during the freeze cycle Check compressor unloader solenoid coil to make sure it is energized and the valve is opening during the thaw cycle 8 4 Service Manual TROUBLESHOOTING Symptom Low ice capacity Suspicions of low ice capacity should be confirmed by accurate calculations of actual ice product Significant losses can occur due to melting and off fall through augers and other ice handling equipment 1 Time the total cycle freeze time thaw time 2 Catch all the ice at the ice discharge opening of the machine for that cycle 3 Weight the total amount of ice caught Lbs ice per cycle Cycle time minutes X 1440 Ibs production per 24 hours Note divide seconds by 60 to get decimal equivalent More than one cycle should be caught and weighed to get an accurate average Possible Cause Possible Remedy Inadequate water for ice making Water pressure of 30 psig minimum is required to assure proper water supply Check water pressure Check for a restriction in the incoming line or at the make up water float valve Freeze timer Freezer pressure switch or thaw timer out of Check hole size in Tube Ice See TABLE 7 2 Crushed ice adjustment should be
115. ve Maintenance A careful inspection of the Tube Ice machines refrigeration system for leaks and correct operational functions at time of installation will start 165 long satisfactory life of service In order to insure this degree of dependability systematic maintenance program 15 recommended Therefore the following schedule 15 suggested as minimum A Daily 1 Check operating pressures suction discharge oil 2 Check ice quality 3 Check ice out time maintain 30 seconds of continued harvest after last ice is out 4 Check compressor oil level 5 Check refrigerant operation level 6 Check frost pattern on freezer shell and oil trap 7 Check make up water float valve adjustment B Weekly in addition to daily checks 1 Check for leaks after 400 hours or four weeks of operation 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 spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulation 4 Check water tank for solids to be removed 5 Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc for abnormal noise and or vibrations 6 Check oil level in gear reducer 7 Check one complete freeze thaw cycle record data and compare with
116. way and install the motor Make sure the key stays in Install the four cap screws to hold the motor in place on the reducer Connect the wires and install the terminal cover 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 Removal Replacement To remove the gear reducer proceed as follows Turn power off and lock out disconnect 1 Remove motor from reducer Loosen slightly the four bolts and nuts holding the gear reducer in place Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove the reducer and mounting plate from the tank Measure the distance between the top of drive gear and the mounting plate for future reference Remove the three cap screws from the gear and hub and install two 1 4 20 x 2 long all thread set or cap screws in the threaded holes of the drive gear These two screws can be used as jacking bolts to remove the gear from the tapered split hub In necessary the split hub can be removed by driving a screw driver in the split and sliding the hub off the shaft The new gear reducer can then be installed by reversing the removal procedure Be sure the gear and hub is properly positioned on the shaft so it will have a full vertical mesh with the cutter ring gear Final gear meshing should be adjusted so there is only a slight amount of play between the ri
117. ycle is not extended unnecessarily and eliminates a possible opaque core in the center of the ice 1 2 6 Digital Readout Legend 1 Power supply symbol 2 Closed control contact symbol 3 Flashing symbol during time delay row RUN 4 Current value readout 4 digits 1111 5 Unit of time N SH 6 Separation of units of time 7 Operating Modes 8 Increasing Up or Decreasing Down 9 Time range 10 Changeover relay status symbol NC Normally Closed NO Normally Open PEST 12 Configuration Validation 13 Incrementation of T 13 14 Display of time pre selection 4 digits FIGURE 9 2 Multi function Digital Freeze Timer SVG Conveyor Timer T3 An added feature of your machine is a conveyor timer This timer can be used to control the duration of operation of a conveyor or screw Flush Valve Timer T4 A feature of this machine is the automatic blowdown which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water tank The primary purpose of the automatic blowdown is to remove accumulated salts and or solids from the water tank that accumulate during the freezing cycle This flushing action each cycle greatly reduces the total dissolved solids in th

Download Pdf Manuals

Related Search

Related Contents

Point of View GeForce GTX 670 ''TGT Performance Boost'' DualFan NVIDIA GeForce GTX 670 2GB  Tower Fan STV 45 A1 - Lidl Service Website  Philips DVD+R DR8S8J05C    EVGA 100-BP-3788-B9 hardware cooling accessory  HM-162B取扱説明書[基本編] 付属品について 登録商標  Flume 1.3.0 User Guide - Apache Flume  Télécharger le mode d`emploi de Sanyo PLC  Navman Marine  Sony VAIO VGN-TZ31MN/N Travel with Style  

Copyright © All rights reserved. Failed to retrieve file