Vogt P18FXT, Service Manual

Page 1: ...10TA TUBE ICE MACHINE Includes model P18FXT Manual Part Number 12A4171M08 Revision 3 Service Manual 5000 ...

Page 2: ...ormational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 502 635 3024 IMPORTANT To activate the machine warrant...

Page 3: ...ouisville Kentucky since 1880 Sales 800 959 8648 Service 502 635 3000 Parts Your Local Distributor Call your local distributor first for all of your parts and service needs Since 1880 Manufacturers of Quality Tube Ice Machines ...

Page 4: ...Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M08 10TA Model ...

Page 5: ...ng and Drain Connections TABLE 3 1 3 1 Water Cooled Condenser Connections FIGURE 3 1 3 2 Cooling Tower 3 2 Space Diagram Air Cooled Machine FIGURE 3 2A 3 3 Space Diagram Water Cooled Machine FIGURE 3 2B 3 4 Wiring and Electrical Connection FIGURE 3 3 3 5 Electrical Specifications TABLE 3 2 3 5 Phase Check Voltage and Current unbalance 3 6 Rotation Check 3 6 Air Cooled Condenser Installation Instru...

Page 6: ...tor FIGURE 6 2A 6 3 Control Panel Components CE Australian Approved FIGURE 6 2B 6 4 Control Panel Components and Part Numbers TABLE 6 1 6 5 Control Panel Part Descriptions TABLE 6 2 6 6 Electrical Schematic All Voltages 50 60 Hz Across Line Start FIGURE 6 3 6 7 3 Phase Power Electrical Schematic All Voltages 50 60 Hz FIGURE 6 3A 6 8 Compressor Schematic Detail All Voltages 50 60 Hz FIGURE 6 4 6 9 ...

Page 7: ... 1 9 1 Automatic Blowdown Harvest Cycle 9 1 Float Valve Make Up Water 9 1 Float Switch 9 2 Hansen Float FIGURE 9 2 9 2 Hand Expansion Valve 9 3 Freezer Pressure Switch 9 3 Freezer Pressure Switch Allen Bradley FIGURE 9 3 9 3 Capillary Bypass 9 4 High Low Pressure Switch 9 4 High Low Pressure Switch FIGURE 9 4 9 4 Head Pressure 9 5 Water Cooled Units 9 5 Air Cooled Units 9 5 Water Regulating Valve ...

Page 8: ...ring Thaw Only 9 16 Circulating Water Pump Motor FIGURE 9 12 9 17 Cutter Gear Reducer FIGURE 9 13 9 17 Component Removal and Replacement Operations 9 18 Cutter Gear Reducer 9 18 Water Tank Removal 9 19 Cutter Bearing Removal Installation 9 19 Cutter Assembly FIGURE 9 14 9 20 Cutter Parts Cylinder Ice FIGURE 9 15 9 20 Cutter Drive Parts FIGURE 9 16 9 21 Crushed Ice Production FIGURE 9 17 9 22 Defro...

Page 9: ... TABLES AND CHARTS cont Normal Operating Vitals TABLE 11 6 11 4 Recommended Spare Parts List 11 5 Temperature Pressure Chart for Common Refrigerants TABLE 11 7 11 6 Conversion Factors English to Metric TABLE 11 8 11 7 Constants TABLE 11 9 11 7 12 INDEX ...

Page 10: ...10TA Service Manual TABLE OF CONTENTS vi BLANK ...

Page 11: ... customers more than 35 years of dependable service Ask someone who owns one Preview All the skill in engineering and fabrication that we have learned in over a century of experience is reflected in the 10TA model Tube Ice machines Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s e...

Page 12: ...linder 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 ...

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

Page 14: ...VE 90 CONTROL PANEL 1 FAN CONTROL SWITCH 41A COMPRESSOR 3 LIQUID OUTLET STOP VALVE KING VALVE 58 CIRCULATING WATER PUMP 6 LOW PRESSURE TEST CONNECTION HIGH PRESSURE TEST CONNECTION HIGH LOW PRESSURE SWITCH 4PS OIL PRESSURE SWITCH 94 HIGH PRESSURE GAGE 2PG LOW PRESSURE GAGE 1PG HEAT EXCHANGER 13 WATER TANK 7 ...

Page 15: ...2 VALVE 21 FREEZER PRESSURE STOP VALVE 69 FREEZER 2 SUCTION ACCUMULATOR 88 FLOAT SWITCH 22 LIQUID FEED SOLENOID VALVE A1 VALVE 20 HAND EXPANSION VALVE 17 FREEZER REFRIGERANT CHARGING VALVE 28 CHECK VALVE 101 SAFETY RELIEF VALVE 51 CONDENSER SERVICE CONNECTION 32 LIQUID RETURN STOP VALVE 91 OIL RETURN STOP VALVE 70 1 FPT WATER TANK DRAIN ...

Page 16: ... Side View RECEIVER DRAIN VALVE 44 GEAR REDUCER 5R CUTTER MOTOR 5M 1 2 MPT MAKE UP WATER CONNECTION COLD WEATHER SOLENOID VALVE X VALVE 53 OIL SEPARATOR 14 MAKE UP WATER FLOAT VALVE 12 THAWING GAS SOLENOID VALVE D VALVE 18 RECEIVER SIGHT GLASS 30 SAFETY RELIEF VALVE 50 RECEIVER 15R ...

Page 17: ...UID OUTLET STOP VALVE KING VALVE 58 COMPRESSOR 3 CONDENSER 15 CONTROL PANEL 1 CIRCULATING WATER PUMP 6 LOW PRESSURE TEST CONNECTION HIGH PRESSURE TEST CONNECTION OIL PRESSURE SWITCH 94 HIGH LOW PRESSURE SWITCH 4PS HIGH PRESSURE GAGE 2PG LOW PRESSURE GAGE 1PG HEAT EXCHANGER 13 THAWING GAS STOP VALVE 90 H L ...

Page 18: ...D VALVE A2 VALVE 21 FREEZER 2 HAND EXPANSION VALVE 17 FREEZER REFRIGERANT CHARGING VALVE 28 LIQUID FEED SOLENOID VALVE A1 VALVE 20 FLOAT SWITCH 22 FREEZER PRESSURE STOP VALVE 69 SUCTION ACCUMULATOR 88 FILTER DRIER 46 1 FPT WATER TANK DRAIN OIL RETURN STOP VALVE 70 LIQUID RETURN STOP VALVE 91 SAFETY RELIEF VALVE 51 ...

Page 19: ...ft Side View THAWING GAS SOLENOID VALVE D VALVE 18 CONDENSER WATER REGULATING VALVE 41 MAKE UP WATER FLOAT VALVE 12 GEAR REDUCER 5R RECEIVER DRAIN VALVE 44 RECEIVER SIGHT GLASS 30 CUTTER MOTOR 5M 1 2 MPT MAKE UP WATER CONNECTION OIL SEPARATOR 14 SAFETY RELIEF VALVE 50 RECEIVER 15R ...

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

Page 21: ...d Lifting lugs should be used whenever possible CAUTION The Tube Ice machine is top heavy Secure to avoid tipping CAUTION If a forklift is used make sure its capacity is sufficient The forks must be wide enough apart to prevent tipping sideways and must extend beyond the extremities of the frame base structure The machine needs to be bound in place to prevent tipping Safety Valves Two safety press...

Page 22: ...lbs day T tons day 03K 3000 lbs day 04K 4000lbs day Consult Specifications for Actual Capacity 03T 3 tons day 05T 5 tons day 10T 10 tons day 25T 25 tons day 50T 50 tons day 80T 80 tons day Electrical Codes 26 208 230 3 60 46 460 3 60 56 575 3 60 25 200 3 50 45 400 3 50 21 230 1 60 Refrigerant F R 22 A Ammonia H R 404a Type of Ice B Cylinder K Crushed D Dual Ice Cru Cyl L 1 1 2 Long Cylinder X 2 Lo...

Page 23: ...er 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 In Water Tank Drain Condenser Water In Condenser Water Out 1 2 MPT 1 FPT 2 FPT 2 1 2 FPT TABLE 3 1 Water Supply and Drain Sizes The condenser water outlet and water tank drain connections must be extended to an open drain or sump arra...

Page 24: ...ating conditions in your area An average wet bulb of 78 F is typical in the U S but many localities have design wet bulbs as low as 72 F or as high as 82 F The cooling tower water pump must be capable of delivering the required 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 instal...

Page 25: ...1 WATER TANK DRAIN LOCATED ON RIGHT SIDE REAR LEFT SIDE FRONT ROTALOCK FIELD CONNECTOR PART 12A2396A0501 1 1 4 12 THREADS F X 1 1 8 IDS ROTA LOCK TEFLON SEAL PART 12A2600T01 ROTALOCK FIELD CONNECTOR PART 12A2396A0601 1 3 4 12 THREADS F X 1 3 8 IDS ROTA LOCK TEFLON SEAL PART 12A2600T03 FIELD ATTACHMENT AIR COOLED CONDENSER TUBING TOP VIEW PROVIDE SUFFICIENT SPACE ICE DISCHARGE 40 MINIMUM CLEARANCE ...

Page 26: ...TLET 2 CONDENSER WATER INLET 1 WATER TANK DRAIN LOCATED ON RIGHT SIDE 2 4 3 4 1 1 1 2 11 5 8 10 ICE DISCHARGE 1 2 MPT MAKE UP WATER CONNECTION 12 MINIMUM CLEARANCE FOR INSTALLATION AND ACCESS REAR LEFT SIDE FRONT 1 3 1 8 4 5 10 4 40 MINIMUM CLEARANCE FOR WATER TANK ACCESS 40 MINIMUM CLEARANCE FOR COMPRESSOR ACCESS 6 3 8 FIGURE 3 2B Connections and Space Diagram Water Cooled Machine ...

Page 27: ...Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 Connect the Ground wire to the Ground lug provided FIGURE 3 3 Control Panel Power Connections Standard Voltages Water Cooled Air Cooled F L A Min Ampacity Max Fuse F L A Min Ampacity Max Fuse 208 230 3ph 60 Hz 112 3 138 6 245 140 3 166 6 275 460 3ph 60 Hz 56 2 69 3 125 70 2 83 3 140 220 3ph 50 H...

Page 28: ...tween 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 Curren...

Page 29: ...al risers There should be no intentional traps in liquid lines Trap volume should be kept to a minimum Long vertical rises should have traps every 20 feet Typical details are shown in FIGURE 3 6 7 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest 8 The discharge...

Page 30: ... accordance with applicable local and national codes Such codes may include The Safety Code For Mechanical Refrigeration ANSI B9 1 and The Code For Refrigerant Piping ANSI B31 5 18 The following installation guidelines are strongly suggested While they do not affect the machine warranty they may be required for safe operation and to comply with all applicable electrical and mechanical codes a Loca...

Page 31: ...14 0 Weight lbs Net Shipping Operating Maximum flooded R 404a 1210 1520 1265 Condenser Dimensions inches See Fig 3 7 A Width B Length C Height D Leg centerline E Leg centerline F Clearance below 45 46 233 16 49 15 38 106 15 3 20 5 Recommended Line Sizes OD Liquid All lengths and orientations Discharge Gas Vertical Up all lengths Horiz or Down 75 ft Horiz or Down 75 ft 1 3 8 1 5 8 1 5 8 2 1 8 Conne...

Page 32: ...LLING YOUR TUBE ICE MACHINE 4 14 14 3 10 FIGURE 3 4 Condenser Dimensions Machine Bohn Part Vogt Part Coil Split P18XT BNHS04A029 12A2115B11 50 50 Note Condensers listed above are 200 208 230V 50 60hz 400 460V 50 60hz available ...

Page 33: ...10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 14 14 3 11 Note Condenser return lines supplied by customer check valve supplied by Vogt FIGURE 3 5 Condenser Field Piping Cold Weather Valve Kit ...

Page 34: ...ivalent Feet Copper Tubing Type L 1 1 8 O D 1 3 8 O D 1 5 8 O D 2 1 8 O D Globe valve open 28 36 42 57 Angle valve open 15 18 21 28 90o Elbow 3 4 4 5 45o Elbow 1 5 2 2 2 5 Tee 90 turn through 6 8 9 12 Tee straight through 2 2 2 5 2 5 2 8 3 3 5 TABLE 3 5 Equivalent Feet Due To Friction FIGURE 3 6 Minimum Traps For Discharge Lines Note Each recommended line size is based on use of Type L copper tubi...

Page 35: ...10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 14 14 3 13 Air Cooled Condenser Wiring FIGURE 3 7 Wiring For BOHN BNHS04A029 with Cold Weather Valve and Four Fans 50 50 Condenser Split ...

Page 36: ...f Valves Pressure relief valves are installed on the freezer receiver and the water cooled condenser These valves are designed to vent in emergency conditions This ensures vessel internal pressure does not exceed maximum allowable pressures Vent the relief valve outlet to a safe outdoor location in the approved manner away from people and building openings Vent line piping must have drain line at ...

Page 37: ...r the machine to make an additional discharge of ice AFTER the ice contacts the probe This will vary based on the size of the bin and the ice distribution system employed Note The probe should also be mounted on the back side of the bracket opposite of the front of the bin to reduce the possibility of damage from ice removal equipment The control panel is electrically connected so that the bin the...

Page 38: ...T button to set the Set point S1 will be blinking Use the up or down key to set the temperature at 38 F 4 Press the SET button to set the Differential DIF 1 will be blinking Use the up or down key to set the differential at 2 F 5 Select between C1 Cooling mode and H1 Heating mode Use the up or down key to select C1 Machine will shut off when temperature drops to 38 F and come on when temperature r...

Page 39: ...ply and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK ____ Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK ____ All field installed equipment augers conveyors cooling towers bin level controls et...

Page 40: ...10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 4 14 14 3 18 BLANK PAGE ...

Page 41: ...and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 the heat exchanger 13 and to the compressor 3 Here the cool gas is compressed to a high temperature high pressure gas which discharges through the oil separator 14 and into the condenser 15 In the condenser heat is removed and the gas is conde...

Page 42: ...e 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 Control Panel 30 Receiver Sight Glass 1PG Suction Pressure Gauge 31 Gage Glass Stop Valve 2PG Discharge Pressure Gauge 32 A C Condenser Service Connection 2 Freezer 34 Compressor Suction Service Valve 3 Compressor 35 Compressor Discharge Service Valve 4PS ...

Page 43: ...10TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 4 14 2014 4 3 FIGURE 4 1 Water Cooled Piping Schematic ...

Page 44: ...10TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 4 14 2014 4 4 FIGURE 4 2 Air Cooled Piping Schematic ...

Page 45: ... dry gas enters the compressor and is compressed then discharged to the condenser completing the cycle As the ice is formed in the freezer the suction pressure steadily reduces until it causes the freezer pressure switch to close initiating the harvest period During the harvest period the thawing gas solenoid valve the D valve is open allowing the warm high pressure gas to enter the freezer This h...

Page 46: ...valves 34 and 35 the hand stop valve 90 in the thawing gas line the receiver liquid return stop valve 91 in the condenser return line hand stop valve 58 in the liquid line hand stop valve 69 to the freezer pressure switch top and bottom float switch hand stop valves 22A and stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage gla...

Page 47: ... circulated for a minimum of five 5 minutes to prime the pump purge the tubing of air and lubricate the cutter bearing Note If pump is already primed skip steps 1 3 4 When there is good water flow turn the Clean Off Ice selector switch to Ice The machine will then start in a harvest thaw period with the compressor running 5 At the termination of the harvest thaw period the machine will begin the f...

Page 48: ...ne is restarted 4 If in a harvest the machine will complete the harvest and stop 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 Off the machine will stop a...

Page 49: ...e is pumped down a liquid level should be observed in the gage glass on the receiver Refrigerant Charging Procedure 1 Make connection between charging valve and refrigerant cylinder using hose or pipe suitable for R 22 or R 404a service See instruction card attached to refrigerant cylinder 2 Open valve on cylinder and purge air out of charging line at the charging valve connections 3 Open charging...

Page 50: ...10TA Service Manual START UP AND OPERATION 4 14 14 5 6 BLANK ...

Page 51: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 1 6 Electrical Controls FIGURE 6 1 Control Panel SS PB1 PB2 ...

Page 52: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 2 FIGURE 6 2 Control Panel Components Standard ...

Page 53: ... Manual ELECTRICAL CONTROLS 4 14 14 6 3 FIGURE 6 2A Control Panel Door Standard and Optional Power Monitor SWITCHES LOCATED ON OUTSIDE OF CONTROL PANEL DOOR OPTIONAL POWER MONITOR LOCATED ON BACK OF ENCLOSURE DOOR ...

Page 54: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 4 FIGURE 6 2B Control Panel Components CE Australian Approved ...

Page 55: ...ed Panel Mount 220V 60Hz FC Air Cooled Only 12A7516E27 Condenser Fan Contactor 30 Amp 3 Pole 1 N O Aux Contact 208 240V Coil 12A7530E58UL Fan Manual Motor Starter 10 0 16 0A 400 460V 50 60hz 12A7530E63UL Fan Manual Motor Starter 23 0 32 0A 200 208 230V 50 60hz FPS 12A2117E04 Freezer Pressure Switch FU1 FU2 12A7504E18 Fuses 5A 600V Class CC Time Delay FU10 FU60 12A7504E29 Fuses 1A 600V Class CC Fas...

Page 56: ... FU10 60 Short circuit protection for optional Power Monitor P Pump Motor Starter Manual motor starter and contactor Starts and stops pump motor Provides short circuit and over current protection Stops water pump motor in the event of a mechanical or electrical malfunction that results in excessive motor amperes PB1 Used to stop machine immediately Should be used for emergency stopping only PB2 Us...

Page 57: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 7 FIGURE 6 3 Control Circuit Electrical Schematic All Voltages 50 60 Hz ...

Page 58: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 8 FIGURE 6 3A 3 Phase Power Electrical Schematic All Voltages 50 60 Hz ...

Page 59: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 9 FIGURE 6 4 Compressor Schematic Detail All Voltages 50 60 Hz ...

Page 60: ...10TA Service Manual ELECTRICAL CONTROLS 4 14 14 6 10 BLANK ...

Page 61: ...ver opening into it 4 Shut off water supply and drain water tank 7 by opening drain valve 39 Remove any loose sediment from tank 5 Close drain valve 39 and fill water tank approximately 15 gallons with warm water Close the petcock on the water pump during the cleaning period 6 Add 40 ounces 8 ounces per 3 gallons of Nu Calgon ice machine cleaner or equivalent food grade liquid phosphoric acid to w...

Page 62: ...sanitizing solution to the water tank Install water box cover on water tank and allow sanitizing solution to circulate for at least 20 minutes 10 While circulating sanitizing solution open petcock valve adjustable blow down and allow solution to flow down the drain With petcock valve open allow water to circulate for a minimum of 3 minutes 11 Press Stop button to stop pump then drain and flush wat...

Page 63: ...r 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 Tube Size 1 1 1 4 1 1 2 Hole Size 1 16 1 8 Avg 1 8 3 16 Avg 1 4 3 8 Avg TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank...

Page 64: ...fter the above possibilities have been eliminated determine the temperature difference between the water leaving the condenser and the refrigerant condensing temperature saturation temperature from pressure temperature chart corresponding to head pressure If this difference is more than 10 F cleaning is indicated because this difference indicates a good heat exchange is not being made If this diff...

Page 65: ...ical cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser d Remove the cover plate on the side of the frame to expose the condenser end plate e Remove the nuts water plates and gaskets from both ends of the condenser If the gasket does not lift off with the end plate do not try t...

Page 66: ...il may become low in the crankcase on an initial start up if electrical current has been interrupted to the machine thus de energizing the compressor crankcase heater Before starting the machine again the heater should be energized for a time period of at least two hours to evaporate refrigerant that may have condensed in the crankcase during the shutdown period If the level is low after start up ...

Page 67: ...auge port when connecting the oil pump Air should be purged from the oil pump discharge line by forcing some oil through the line before tightening the charging connection Cutter Gear Reducer The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil...

Page 68: ...tment 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 production check of R...

Page 69: ...sed 3 Thermostat bulb in bracket 4 Ice quality clarity and uniformity 5 Does all ice discharge during harvest 6 Cleanliness 7 Unusual noises Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes...

Page 70: ...e cycle ________ ________ ________ _____ Cutter motor amps cutting ice ________ ________ ________ _____ Water pump amps ________ ________ ________ _____ AC condenser motor amps if applicable ________ ________ ________ _____ Crankcase heater heating _____ Refrigerant leak okay high low _____ Leak checked system ______ leaks found repaired _____ Compressor oil level i e 1 4 1 2 3 4 low high _____ Ge...

Page 71: ... it will then start in a thawing cycle Always check the machine thoroughly after remedying the problem to prevent the same cause from reoccurring Symptom Page Machine Won t Run 8 2 8 3 Freeze up Due To Extended Freeze Period 8 4 Freeze up Due To Ice Failing To Discharge 8 5 Poor Ice Quality 8 6 Low Ice Capacity 8 7 Low Compressor Oil Level 8 8 High Head Pressure Water Cooled Machines 8 9 High Head...

Page 72: ...itch on 4D 6D compressors without Coresense and 3D compressors with line break protection will reset automatically after the motor has cooled sufficiently Compressor cylinder head temperature switch trips The thermal switch will reset automatically after the motor has cooled sufficiently Excessive temperature may be caused by gas leakage between suction and discharge port of the compressor Check f...

Page 73: ...eck the cutter operation and motor amp draw If tripping repeats but ice is not jammed check the cutter bearing for wear the gear reducer for resistance and the motor for defect or single phasing Pump motor overload tripped Check voltage and overload range adjustment against motor rating Reset the switch set the Ice Clean switch to the Clean position and restart the machine by the Start push button...

Page 74: ...e 18 leaking through during the freeze cycle Check the manual opening stem to make sure it is in the automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Float switch stuck or failed in the closed position Check to make sure the float ...

Page 75: ...o short Check the thaw timer T which should be adjusted to allow all the ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Cutter or cutter disc does not turn Check cutter reducer and drive gear for proper operation and alignment Check for broken cutter disc or drive pin and replace as necessary Ice backs up into cutter or discharge opening jamming cutter Ice mush...

Page 76: ...ded minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain valve is closed Water pump rotation wrong direction Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Low refrigerant charge Check refrigerant level mark on the receiver and on the painted portion of the gage...

Page 77: ...of freezer may be stopped up Remove freezer cover and clean the distributors See Water Distributors Section 7 Inadequate water for ice making Check water pressure 30 PSIG minimum recommended Check for a water restriction in the supply line or at the make up water float valve Make up water float valve 12 stuck open adjusted too high or water tank drain valve 15 open or leaking Repair replace or adj...

Page 78: ...f a freeze cycle Repair or replace defective parts Repeated short cycling refrigerant carrying oil out of compressor Usually caused by freeze up low refrigerant charge low head pressure faulty timer faulty pressure switch or expansion valve clogged Use process of elimination Worn piston rings This condition is hard to detect without dismantling the compressor and checking piston ring tolerances No...

Page 79: ... sump screen and clean as needed Non condensables usually air in system Check refrigerant tables for pressure temperature relation If non condensables are present Perform a total pumpdown let stand for at least 6 hours allowing non condensables to gather in the upper part of the receiver Evacuate the freezer and attach a recovery unit to the top receiver purge valve 59 Open the valve and recover t...

Page 80: ...ce fuse and reset switch If the condenser is split check the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted air flow Visually inspect condenser and clean as necessary Non condensables usually air in the system Follow same...

Page 81: ...ater which creates a siphon to remove a fixed amount of water from the tank Make up Water Float Valve Part No 12A4200H0402P The make up float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank during the freezing period so that there will be a quantity of by pass or blowdown only during the thaw mode The ...

Page 82: ...enoid valve directly before the hand expansion valve Therefore when the refrigerant level in the freezer drops the float switch opens thereby de energizing the normally open liquid feed solenoid until sufficient level has been reached to close 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 ...

Page 83: ... 2 1 Turn the bottom screw differential approximately 1 2 turn to the Left counter clockwise The pointer arrow which is at the top middle of the switch will be at the F setting 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will be between 40 psi and 50 psi 3 After the machine is running the range adjustment top screw ...

Page 84: ... possible damage due to abnormal pressure during operation CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming normal operation CAUTION The LOW pressure cut in should be set at 40 psig and the cutout set at 20 psig for R 22 The LOW pressure cut in should be set at 52 psig and the cutout set at 28 psig for R 404a NOTE After tripping at th...

Page 85: ...e switch located on the right hand front of machine It controls the operation of the condenser fan motor s through a contactor FC FIGURE 6 2 located in the control panel The switch is set to cycle the fan motor s On at 210 psig and Off at 190 psig for R 22 and On at 250 psig and Off at 230 psig for R 404a Higher settings may be necessary for 0 F and below ambient conditions to assure there is enou...

Page 86: ...ly to the module The time delay is not energized on opening of the high or low pressure switches There are two major components in the protection system 1 The protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resistance 2 The control module is a sealed enclosure containin...

Page 87: ...h voltage Under no circumstances should a high potential test be made at the sensor terminals with the sensor leads connected to the solid state module Even though the power and pilot circuit leads are not connected the module can be damaged Note 4D 6D Compressors manufactured before March 2011 have Electronic Motor Protector FIGURE 9 6 Compressor Protection Wiring Compressor with Electronic Motor...

Page 88: ...power to deenergize the module Remove the jumper of Step 2 Remove wiring connections from the sensor and common terminals on the module control circuit terminal board b CAUTION Use Ohmmeter with a maximum of 9 VAC for checking The sensors are sensitive easily damaged and no attempt should be made to check continuity through them with other than an ohmmeter Any external voltage or current applied t...

Page 89: ... the use of a Copeland approved oil pressure safety switch Failure to use an approved oil pressure safety switch will be considered as misuse of the compressor and can adversely affect warranty replacement of the compressor should a lubrication connected failure occur FIGURE 9 7A Sentronic Oil Pressure Safety Control Sentronic Sensor 2D 3D 4D 6D compressors before March 2011 The same oil pressure ...

Page 90: ... of a trip When the reset button is depressed it magnetically pulls the Sentronic relay s armature to its original reset position Sentronic needs no voltage present to reset Coresense Protection Discus compressors manufactured after March 2011 will be supplied with CoreSense Protection CoreSense replaces the Sentronic Oil Pressure Safety Module on all Discus compressors and the Electronic Motor Pr...

Page 91: ...ower is supplied to terminals L1 L2 L3 of the control panel the crankcase heater is energized when the machine is not operating It is de energized when the compressor contactor is energized Control Circuit Protection Part No 12A7504E1 The electrical control circuit of the machine is protected by a 2 Pole 3A circuit breaker If the breaker should open the machine will immediately stop Before resetti...

Page 92: ...tting of the timer turn the adjustment screw clockwise to increase the time or counter clockwise to decrease the time Verify time after each adjustment FIGURE 9 9B Thawing Timer Wiring Syrelec Timer Orange Light indicates timer is timing Light indicates timer has timed out Time Base Set to min Scale Set to X1 Crouzet Timer White Light flashing when timing Light Solid when timed out Range Set to 1 ...

Page 93: ...ent another thaw cycle 6 Allow the machine to operate until the low pressure switch stops the machine 20 PSIG If a lower pressure is desired it can be accomplished by jumping the low pressure switch and starting and stopping the machine by the Start and Stop push buttons Continually observe the oil level to make sure the oil is not carried from the compressor while operating at a low pressure 7 Cl...

Page 94: ...sor motor burnout Some of these are described below 1 Low line voltage A compressor motor is designed to operate within the range of plus or minus 10 of its nameplate voltage Low voltage requires the motor windings to carry more current at the same compressor load When this current gets too high or is applied for an extended period the motor windings overheat resulting in a failure or burnout 2 Lo...

Page 95: ...ns the stem is backed all the way out Correct direction of stem rotation should be labeled on the stem seal nut FIGURE 9 10A Thawing Gas Solenoid Valve D Valve FIGURE 9 10B Liquid Feed Solenoid Valve A1 A2 Valve Hansen 1 1 4 Solenoid Valve Part No 12A4200A1001 Hansen Rebuild kit HS8 Part No 12A4199V51 Hansen 1 2 Solenoid Valve Part No 12A4200A0604 208 230V coil Part No 126229 Hansen Rebuild Kit HS...

Page 96: ...scharge and suction pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may be used with the valve either energized or de energized without excessive compressor cycling FIGURE 9 11 Copeland Compressor Unloade...

Page 97: ...cated on the nameplate FIGURE 9 12 Circulating Water Pump Cutter Gear Reducer Part No 12A4030R12 The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil once a year The motor bearings are prelubricated and require no further lubrication For additi...

Page 98: ...if necessary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 16 1 Turn power off and lockout disconnect 2 Remove motor from reducer 3 Loosen slightly the four bolts and nuts holding the gear reducer in place 4 Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove the reducer and mounting plate from t...

Page 99: ...new 7 Before removing the bearing reference mark the location of the bearing support on the side of tank 8 Loosen and remove the three cap screws from the bearing support ends and lift the support out of the water tank 9 Drive the 3 16 x 1 2 pin located in the side of the support hub in and through the bearing wall 10 Now the bearing can be pressed or driven out of the support hub 11 Try the new b...

Page 100: ...NG PART NO 12A3040S02 CUTTER SUPPORT PART NO 12A2025B0102 UHMW CUTTER BEARING PART NO 19T2160C0201 CUTTER ASSEMBLY FOR CYLINDER ICE PART NO 19T2160C0202 ADAPTOR PLATE FOR CAST CUTTER PART NO 19T2010A12 FIGURE 9 14 Cutter Assembly FIGURE 9 15 Cutter Parts cylinder ice FREEZER CUTTER BEARING 47 GASKET DRIVE PIN FOR BEARING BEARING SUPPORT BRACKET CUTTER HOUSING DRIVE PIN FOR CUTTER DISC CUTTER DISC ...

Page 101: ... S 12A4030R12 GEAR REDUCER GEAR REDUCER MOUNTING PLATE BOLTED TO CUTTER HOUSING ASSEMBLY 19T4500S1805 19T2615D01 DRIVE GEAR WITH TAPERED HOLE 12A2215G1108 CAP SCREW 5 16 X 3 4 HEX HEAD S S 12A2250A108 CUT WASHER 5 16 S S 12A2160H0101 HUB SPLIT FOR CUTTER DRIVE GEAR 12A2215F1112 CAP SCREW 1 4 X 1 1 4 HEX HEAD S S 12A2250B107 LOCK WASHER 1 4 S S ...

Page 102: ...er 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 ...

Page 103: ... are designed to vent in emergency conditions This ensures vessel internal pressure does not exceed maximum allowable pressures CUT IN CLOSE ADJUSTING SCREW SET AT 90 PSIG CW LOWERS SETTING Vogt Part 12A2117B03 CUT OUT OPEN ADJUSTING SCREW SET AT 95 PSIG CW RAISES SETTING CE Approved machine Vogt Part 12A2117B03CE PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE BEFORE REPLACING RE...

Page 104: ...listed below have in general the same effect on the appearance of raw water ice and therefore in this rough tabulation can be grouped together Generally the sodium carbonates can be considered 1 1 4 times as objectionable as the sulfates and the chlorides about 3 4 as objectionable as the sulfates Therefore total the sulfates and chlorides separately and apply the factors Calcium Sulfate Calcium C...

Page 105: ... machine is ordered with this option the power monitor can be factory set to customer specifications The Vogt Part number for a power monitor retrofit kit is 12A7700K01 FIGURE 10 1 Power Monitor Voltage Monitor The Display The display normally shows the AB BC CA line voltages If the unit is waiting on a timer that timer will be displayed The timer display may be switched off by pressing SELECT The...

Page 106: ... and down arrows Lockout Time in seconds SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the delay on break timer value Delay time in seconds and tenths of seconds RESP SECONDS flashes The value may be adjusted by pressing the up and down arrows This is the time that a fault is allowed before shutdown occurs Control mode ON OFF AUTO flashes The value may be adj...

Page 107: ... To prevent tripping on a 1 volt change the DTP 3 automatically calculates cut in voltages for the return from undervoltage conditions The cut out voltage is always based on user voltage and tolerance settings while the cut in voltage is 3 closer to the nominal voltage setting This quality is sometimes referred to as hysterisis This is to help reduce oscillation that may occur on weak power distri...

Page 108: ... comes on and run time Automatic Restart after a Power Failure enable disable Auto restart time delay time before restarting recommended 2 hours for package machines The PLC provides Machine Fault indication with an alarm relay The PLC will log when the fault occurred time and date and were in the cycle the machine was when the fault occurred Machine Faults Compressor high discharge pressure Compr...

Page 109: ...or 3A The inputs are 24VDC internally fused for 5 7mA and supplied by the PLC All 24VDC control wiring is blue in color and is distinguished from the red 240VAC or 120VAC control wiring The outputs are externally fused for 2A Outputs 1 and 2 are dry contacts used for high side control interlock and conveyor control Outputs 0 3 11 20 23 are relay type with 120V or 200 240 V connections The LED indi...

Page 110: ... Bin control 4 Water Pump motor starter 5 Freezer Pressure switch 5 Alarm 6 Compressor overload for 4D 6D without CoreSense 6 D sol defrost solenoid valve 7 Cutter Motor overload 7 Not used 10 Pump Motor overload 10 Float switch A sol liquid feed valve s 11 CoreSense Oil press safety for comp without CoreSense 11 Cutter motor starter 12 High Low pressure safety 13 Not used 14 Not used 15 Not used ...

Page 111: ...10TA Service Manual 10 7 OPTIONS AND ACCESSORIES FIGURE 10 4 Wiring Schematic Mid Size Machine P112 P118 P18XT ...

Page 112: ...10 8 10TA Service Manual OPTIONS AND ACCESSORIES BLANK ...

Page 113: ...75 000 73 3 275 000 73 3 275 000 73 3 Marley Cooling Tower 5 4822 4822 4822 dim LxWxH ft meters 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 shipping weight lbs Kg 650 295 650 295 650 295 operating weight lbs Kg 1260 571 1260 571 1260 571 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 24 4...

Page 114: ...75 000 73 3 275 000 73 3 Marley Cooling Tower 5 4822 4822 4822 dim LxWxH ft meters 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 4 x 5 x 6 5 1 2x1 5x2 0 shipping weight lbs Kg 650 295 650 295 650 295 operating weight lbs Kg 1260 571 1260 571 1260 571 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 24 4 HP KW FLA 3 ...

Page 115: ... 16740 21174 18970 17410 65 20300 18200 16700 21112 18928 17368 20300 18200 16700 21112 18928 17368 66 20240 18160 16660 21050 18886 17326 20240 18160 16660 21050 18886 17326 67 20180 18120 16620 20987 18845 17285 20180 18120 16620 20987 18845 17285 68 20120 18080 16580 20925 18803 17243 20120 18080 16580 20925 18803 17243 69 20060 18040 16540 20862 18762 17202 20060 18040 16540 20862 18762 17202 ...

Page 116: ...gpm Suction Pressure psig Discharge Pressure psig Harvest Times secs Ice per cycle Freeze Time minutes End of Freeze Average during Freeze First All Ice Total Average Water Temperature deg F R22 R404A R22 R404A Ice Out Harvest lbs 90 80 70 60 50 C 1 34 45 200 240 15 120 150 235 17 9 16 0 14 4 13 9 13 5 Y 1 1 4 32 42 200 240 15 120 150 245 21 0 18 8 17 0 16 6 16 2 60 L 1 1 2 28 38 200 240 20 120 15...

Page 117: ...50 60hz 1 12A2900M0508 Cutter motor 1 2 HP 3 ph 2 12A4200H0402P Make up water float valve Lead Free Plastic 1 12B2020R01 Cutter bearing 1 12A2600G15 Gasket for freezer cover 1 12A2600G05 Gasket for water tank 1 12A7509E12 Crankcase heater 100W Insert type Copeland Discus Compressor 1 12C2590G08 Suction pressure gage R22 1 12C2590G09 Discharge pressure gage R22 1 12C2590G1 Suction pressure gage R40...

Page 118: ... 1 138 0 229 0 190 1 0 9 2 24 0 31 1 6 5 6 7 33 5 15 6 100 117 2 195 9 216 2 124 3 142 0 235 0 196 1 2 10 2 25 6 32 9 7 5 7 7 35 6 17 1 102 120 9 201 8 222 3 128 5 146 0 242 0 203 3 4 11 2 27 3 34 9 8 5 8 8 37 4 18 6 104 124 7 207 7 228 5 132 9 151 0 249 0 210 2 6 12 3 29 1 36 9 9 6 9 9 39 4 20 3 106 128 5 213 8 234 9 137 3 156 0 256 0 217 2 8 13 5 30 9 38 9 10 8 11 0 41 6 21 9 108 132 4 220 0 241...

Page 119: ...5 9 TF 32 C F TF 9 5 TC 32 Volume ft3 m3 2 8317e 2 gal U S m3 3 7854e 3 ft3 gal U S 7 48 TABLE 11 8 CONSTANTS Specific heat of Water 1 BTU lbm F Specific heat of Air 4 19 kJ kg C 0 24 BTU lbm F Tube Ice Density 32 35 lbs ft3 Ice Latent Heat 144 BTU hr Water Sensible Heat 1 BTU lb F Ice Melting Effect IME 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 lbs ft3 ...

Page 120: ...10TA Service Manual TABLES CHARTS 7 2 14 11 8 BLANK ...

Page 121: ... Condenser Piping Cold Weather Valve Kit 3 9 Condenser Water Usage 11 4 Condenser Air cooled Cleaning 9 5 Condenser Air cooled Heat Rejection 3 8 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled 3 2 7 4 Control Circuit Protection 9 11 Control Panel Parts 6 5 6 6 Control Relay CR 6 2 6 4 6 5 6 6 Cooling Tower 3 2 CoreSense 6 9 9 10 9 11 Crankcase Heater 7 6 9 11 Crushed Ice Production 9 22 ...

Page 122: ...nnections 3 1 Piping Schematic Air cooled 4 4 Piping Schematic Nomenclature 4 2 Piping Schematic Water cooled 4 3 PLC Programmable Logic Controller 10 4 10 6 Poor Ice Quality 8 6 Power Connection 3 5 Power Monitor 10 1 Preventive Maintenance 7 8 Preventive Maintenance Program 7 8 Preview 1 1 Principle of Operation 4 1 Pump Down 9 12 Pump Overload Protection 6 2 6 4 6 5 6 6 Pump Contactor 6 2 6 4 6...

Page 123: ... Water Cooled Units 9 5 Water Distributors 7 3 Water Pump Motor 9 17 Water Quality 3 1 Water Regulating Valve 9 5 Water Supply and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 4 Water Tank 7 4 Water Tank Removal 9 19 Water Usage Condenser 11 4 Water Usage Make up 11 4 Wiring and Electrical Connection 3 5 Wiring Schematic Air Cooled Condenser 3 12 Wiring Schematic All Voltage...

Page 124: ...10TA Service Manual INDEX 5 30 14 12 4 ...