Vogt TUBE-ICE 05TA Service Manual Download

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05TA Service Manual

INDEX

8/13/01

12-1

12. Index

A Valve (Liquid Feed) ---------------------------------- 4-1, 5-1, 9-12

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

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

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

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

Air-Cooled Condenser Data -----------------------------------------3-9

Air-Cooled Condenser Installation ----------------------------------3-7

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

Air-Cooled Units--------------------------------------------------------9-4

Allen-Bradley Switch --------------------------------------------------9-2

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

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

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

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

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

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

Bin, Single Thermostat Wiring------------------------------------ 3-13

Bin, Thermostat Installation---------------------------------------- 3-13

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

Burnout, Compressor ----------------------------------------------- 9-11

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

Centrifugal Pump ---------------------------------------------------- 9-12

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

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

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

Checklist, Installation Review ------------------------------------- 3-14

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

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

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

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

Circulating Water Pump Motor------------------------------------ 9-12

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

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

Compressor -------------------------------------------------------------7-5

Compressor Crankcase Heater -------------------------------------9-4

Compressor Lubrication ----------------------------------------------7-5

Compressor Motor Burnout ---------------------------------------- 9-11

Compressor Unloader----------------------------------------------- 9-13

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

Compressor, Motor Protection --------------------------------------9-5

Condenser Cleaning------------------------------------------- 7-4, 9-10

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

Condenser Fan Switch -----------------------------------------------9-4

Condenser Piping (Cold Weather Valve Kit)------------------- 3-11

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

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

Condenser, Air-cooled Heat Rejection ----------------------------3-9

Condenser, Pressure Switch (CPS) -------------------------------9-4

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

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

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

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

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

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

Crankcase Heater ------------------------------------------------7-5, 9-4

Crushed Ice Production --------------------------------------------9-20

Cutter & Bearing Removal/Installation---------------------------9-15

Cutter, Assembly -----------------------------------------------------9-17

Cutter, Bearing--------------------------------------------------------9-15

Cutter, Bearing Support --------------------------------------------9-15

Cutter, Disc Assembly -------------------------------------- 9-17, 9-19

Cutter, Drive Parts ---------------------------------------------------9-18

Cutter, Gear Reducer --------------------------- 7-4, 9-9, 9-14, 9-18

Cutter, Motor ----------------------------------------------------------9-14

Cutter Assembly------------------------------------------------------9-17

Cutter Parts (crushed Ice) -----------------------------------------9-19

Cutter/Water Tank Parts (cylinder ice)--------------------------9-17

D Valve (Thawing Gas) -------------------------------------- 4-1, 9-12

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

Drive gear--------------------------------------------------------------9-18

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

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

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

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

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

Equivalent Feet Due To Friction ----------------------------------3-10

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

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

Float Switch ------------------------------------------------------------ 9-1

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

Foundation Layout ---------------------------------------------------- 3-4

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

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

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

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

Freezer Pressure Switch -------------------------------------------- 9-2

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

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

Hand Expansion Valve ----------------------------------------------- 9-1

Harvest Period --------------------------------------------------------- 4-2

Head Pressure --------------------------------------------------------- 9-4

Summary of Contents for TUBE-ICE 05TA

Page 1: ...12 08 00 05TA TUBE ICE MACHINE Includes model P118F HE100 Manual Part Number 12A4171M06 Revision 1 Service Manual 5000 ...

Page 2: ...dditional expenses This manual is intended as an informational tool for the installation operation maintenance troubleshooting and servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 50...

Page 3: ...d entire system including AC condenser if applicable AC condenser cold weather temperature setting s Solenoid ________ Fan________ AC condenser installed above machine Yes No Approx _____ft AC condenser line length in equivalent feet ____________ AC condenser properly piped all lines insulated Bin control s installed properly Instruction manual and warranty certificate left on site Name of person ...

Page 4: ...Vogt Tube Ice Machines Installation Service Manual and Parts Catalog 12A4171M06 05TA Model ...

Page 5: ...OUR TUBE ICE MACHINE Piping and Drain Connections TABLE 3 1 3 1 Space Diagram Air Cooled Machine FIGURE 3 1 3 2 Space Diagram Water Cooled Machine FIGURE 3 2 3 3 Wiring and Electrical Connection FIGURE 3 3 3 4 Electrical Specifications TABLE 3 2 3 4 Phase Check Voltage and Current unbalance 3 5 Rotation Check 3 5 Air Cooled Condenser Installation Instructions 3 6 Pounds of R 22 to Add Vs Liquid Li...

Page 6: ...ts and Part Numbers TABLE 6 1 6 3 Electrical Schematic All Voltages 50 60 Hz Across Line Start FIGURE 6 3 6 4 Compressor Schematic Detail All Voltages 50 60 Hz FIGURE 6 4 6 5 7 MAINTENANCE Preventive Maintenance 7 1 Preventive Maintenance Form 7 2 Ice Making Section 7 3 Cleaning Procedure 7 3 Water Distribution System 7 4 Water Distributors 7 4 Number of Water Distributors Per Tube Size TABLE 7 1 ...

Page 7: ...s 9 2 Freezer Pressure Switch 9 2 9 3 Freezer Pressure Switch Allen Bradley FIGURE 9 1 9 2 High Low Pressure Switch 9 3 High Low Pressure Switch FIGURE 9 2 9 3 Head Pressure 9 4 Water Cooled Units 9 4 Air Cooled Units 9 4 Water Regulating Valve FIGURE 9 3A 9 4 Condenser Fan Switch FIGURE 9 3B 9 4 Compressor Crankcase Heater 9 5 Compressor Motor Protection Electronic 9 5 High Potential Testing 9 6 ...

Page 8: ... Gear Reducer 9 14 Water Tank Removal 9 15 Cutter Bearing Removal Installation 9 15 Cutter Assembly FIGURE 9 8 9 16 Cutter Parts Cylinder Ice FIGURE 9 9 9 17 Cutter Drive Parts FIGURE 9 10 9 18 Crushed Ice Production 9 19 10 OPTIONS AND ACCESSORIES PLC Programmable Logic Controller 10 2 Reduced Voltage Compressor Motor Starter 10 14 Power Monitor 10 17 11 TABLES AND CHARTS P118F Ratings 60 Hz 30 H...

Page 9: ...ving 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 experience is reflected in the 05TA 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 ma...

Page 10: ...der valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary and illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Fai...

Page 11: ...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 12: ...LVE 5M CUTTER MOTOR 4PS DUAL HIGH LOW PRESSURE SWITCH 44 RECEIVER DRAIN VALVE 2PG HIGH PRESSURE GAGE 1PG LOW PRESSURE GAGE 31 RECEIVER GAGE GLASS STOP VALVE 18 THAW GAS SOLENOID VALVE D VALVE 30 RECEIVER GAGE GLASS 88 SUCTION ACCUMULATOR HEAT EXCHANGER 31 RECEIVER GAGE GLASS STOP VALVE 1 CONTROL PANEL 90 THAWING GAS STOP VALVE 101 CHECK VALVE 32 CONDENSER SERVICE CONNECTION 59 RECEIVER PURGE VALVE...

Page 13: ... 01 1 5 FIGURE 1 2 Assembly Air Cooled Rear View 35 COMPRESSOR DISCHARGE 3 COMPRESSOR 15R RECEIVER 13 HEAT EXCHANGER 48 COMPRESSOR 91 LIQUID RETURN STOP VALVE 2 FREEZER 46 LIQUID LINE 34 COMPRESSOR SUCTION 25 WATER TANK DRAIN 7 WATER TANK ...

Page 14: ...nual INTRODUCTION 8 13 01 1 6 FIGURE 1 3 Assembly Air Cooled Right Side View 53 COLD WEATHER SOLENOID 55 DISCHARGE LINE STOP VALVE VALVE X VALVE 34 LIQUID OUTLET STOP VALVE KING VALVE 22 FLOAT SWITCH 14 OIL SEPARATOR ...

Page 15: ...RE 5M CUTTER MOTOR 4PS DUAL HIGH LOW PRESSURE SWITCH 44 RECEIVER DRAIN VALVE 2PG HIGH PRESSURE GAGE 1PG LOW PRESSURE GAGE 31 RECEIVER GAGE GLASS STOP VALVE 18 THAW GAS SOLENOID VALVE D VALVE 30 RECEIVER GAGE GLASS 88 SUCTION ACCUMULATOR HEAT EXCHANGER 31 RECEIVER GAGE GLASS STOP VALVE 1 CONTROL PANEL 90 THAWING GAS STOP VALVE 15 CONDENSER 59 RECEIVER PURGE VALVE 1 4 FLARE 50 RECEIVER SAFETY VALVE ...

Page 16: ...d Rear View 91 LIQUID RETURN STOP VALVE SERVICE VALVE 2 FREEZER 15R RECEIVER 13 HEAT EXCHANGER 48 COMPRESSOR DISCHARGE 46 LIQUID LINE FILTER DRIER 3 COMPRESSOR 7 WATER TANK MUFFLER 48 COMPRESSOR DISCHARGE SERVICE VALVE 48 COMPRESSOR SUCTION 48 WATER TANK DRAIN CONNECTION 1 FPT ...

Page 17: ...05TA Service Manual INTRODUCTION 8 13 01 1 9 FIGURE 1 6 Assembly Water Cooled Right Side View 22 FLOAT SWITCH 58 LIQUID OUTLET STOP VALVE 14 OIL SEPARATOR KING VALVE ...

Page 18: ...he top for eyebolts and hooks to be used for lifting purposes if desired 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...

Page 19: ...t Model Nomenclature Nominal Capacity 02K 2000 lbs day K 1000 s 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 Cy...

Page 20: ...tion 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 1 1 4 FPT 1 1 4 FPT TABLE 3 1 Water Supply and Drain Sizes The condenser water outlet and water tank drain connections must be extended to an open drain or sump arranged for visible discharge Do not trap the water tank drain line a...

Page 21: ...05TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 8 13 01 3 2 FIGURE 3 1 Connections and Space Diagram Air Cooled Machine ...

Page 22: ...05TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 8 13 01 3 3 FIGURE 3 2 Connections and Space Diagram Water Cooled Machine ...

Page 23: ... L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of cutter motor and water pump is required see following section Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 Connect the Ground wire to the Ground lug provided FIGURE 3 3 Control Panel Power Connections Water Cooled Air Cooled Standard Voltages F L A Min Am...

Page 24: ...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 25: ... 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 7 7 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest 8 The discharge and liquid lines must be in...

Page 26: ...vs Liquid Line Length 17 All piping must be done in 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 al...

Page 27: ...50 hz 3 ph 380V 50 hz 33 0 16 5 33 0 16 5 Weight lbs Net Shipping Operating Maximum flooded R 404a 610 760 648 660 810 705 Condenser Dimensions inches A Width B Length C Height D Leg centerline E Leg centerline F Clearance below 28 3 4 180 1 8 41 5 8 27 147 5 8 14 5 8 28 3 4 180 1 8 41 5 8 27 147 5 8 14 5 8 Recommended Line Sizes OD Liquid All lengths and orientations Discharge Gas Vertical Up all...

Page 28: ...anual INSTALLING YOUR TUBE ICE MACHINE 8 13 01 3 9 FIGURE 3 4 Condenser Dimensions Condenser pictured DD 231 Note Dash lines indicate customer supplied piping FIGURE 3 5 Condenser Field Piping Cold Weather Valve Kit ...

Page 29: ... Equivalent 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 5 2 8 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 tubing a...

Page 30: ...nser tubing ends to the female Rota lock connectors 2 Remove dust caps if used making sure that component plastic seals are intact 3 Wipe off connector and spud threaded surfaces with a clean cloth to prevent the inclusion of dirt or any foreign material in the system 4 Connector coupling nut should be screwed onto Rota lock spud using the proper amount of torque Spud Size Amount of Torque 7 8 50 ...

Page 31: ...d foreign matter accumulation in the condenser or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use Ice Bin Thermostat Sensor Optional An electronic ice bin thermostat may be added to automatically cycle machine operation To assure proper protection for the machine or auxiliary equipment the sensor of the ice bin thermostat must be located so...

Page 32: ...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 33: ...l 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 coolin...

Page 34: ...the numbers in this piping schematic The freezer 2 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 6 Make up water is maintained by a float valve 12 in the water tank 7 The liquid feed solenoid valve 20 sometimes referred to as the A valve is open and the thawing gas solenoid valve 18 someti...

Page 35: ... 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 Item No Description Item No Description 1 Control Panel 31 Gage Glass Stop Valve 1PG Suction Pressure Gauge 32 A C Condenser Service Connection 2PG Discharge Pressure Gauge 34 Compressor Suction Service Valve 2 Freezer 35 Compresso...

Page 36: ...ANEL 56 1PG CIRCULATING WATER 22 5R 7 WATE R TANK 6 PUMP WATER TANK 39 25 WATER OUT 23A WATER IN 5M CUTTER MOTOR LIQUID LINE 18 15 CONDENSER 15R RECEIVER 50 59 LIQUID LIQUID RETURN 4PS HI LO MUFFLER 14 OIL SEP WATER IN 30 OIL RETURN 70 58 44 DISCHARGE 34 31 31 6A 51 16 28 40 46 35 94 48 91 90 52 41 13 88 WATER OUT 24 23 37 12 17 69 20 ...

Page 37: ...ematic DISCHARGE 2 FREEZER CONTROL 56 1PG 2PG 20 7 WATER TANK 6 PUMP 39 25 WATER OUT 23A WATER IN 5M CUTTER LIQUID LINE THAW GAS 18 15R 50 ETURN 4PS HI LO MUFFLE 14 OIL SEP OIL RETURN 70 44 DISCHARGE 34 3 COMPRESSOR 6A 51 17 40 46 94 48 91 90 13 88 37 12 15 CONDENSER 32 101 41A FAN VALVE X 69 FLOW ...

Page 38: ... 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 39: ...s 34 and 35 the hand stop valve 90 in the thawing gas line the receiver liquid return stop valve 91 in the condenser return line hand stop valve 58 in the liquid line hand stop valve 69 to the freezer pressure switch and stop valve 70 in the oil return line These valves are tagged to indicate that they were closed for shipping purposes Gage glass valves 31 on the receiver can be opened for liquid ...

Page 40: ...the water pump 4 The pump can be stopped and started by Stop and Start push buttons or by the Ice Clean switch to purge the tubing of air 5 When there is good water flow turn the On Off switch On and the Ice Clean switch to Ice The machine will then start in a harvest thaw period with the compressor running 6 At the termination of the harvest thaw period the machine will begin the freeze period Be...

Page 41: ...d in the gage glass on the receiver Adding Refrigerant When adding refrigerant it is necessary for the following procedure to be followed 1 Make connection between charging valve and refrigerant cylinder using hose or pipe suitable for R 22 or R 404a service See instruction card attached to refrigerant cylinder 2 Open valve on R 22 or R 404a cylinder and purge air out of charging line at the charg...

Page 42: ...normal shutdown of the machine Throw the Disconnect only in an emergency or for safety when performing certain service or repairs to the machine The compressor crankcase heater is de energized when the disconnect is thrown The Start push button can be used to initiate a harvest cycle When it is pushed during a freeze cycle it will immediately initiate a harvest cycle When the machine is stopped wi...

Page 43: ...05TA Service Manual ELECTRICAL CONTROLS 8 13 01 6 1 6 Electrical Controls FIGURE 6 1 Control Panel Cover Removed ...

Page 44: ...ole 1 NO Aux Contact 208 240V Coil P 12A7530E56 Manual Motor Starter 4 0 6 3 Amps PF 12A7516E23 Power Failure Contactor 9 Amp 3 Pole 1 NO Aux Contact 208 240V Coil FC 12A7516E26 Condenser Fan Contactor 23 Amp 3 Pole 1 NC Aux Contact 208 240V Coil Air cooled Machines ONLY FPS 12A2117E04 Freezer Pressure Switch 12A7503E22 Thawing Timer Delay On Make 220V T 12A7503E39 Timer Base 8 Pin Guarded Termina...

Page 45: ...s a power outage the machine must be manually restarted by pushing the Start button FC Cycles the fan motor s of air cooled condenser on and off Activated by the condenser pressure switch Air cooled Machines ONLY FPS Regulates the ice thickness by reading freezer pressure and initiating the thaw period at the set point T Controls the time of the thawing period ET Indicates hours of machine operati...

Page 46: ...05TA Service Manual ELECTRICAL CONTROLS 8 13 01 6 4 FIGURE 6 2 Electrical Schematic All Voltages 50 60 Hz ...

Page 47: ... sediment from tank 5 Close drain valve 39 and fill water tank approximately 60 gallons with warm water Close the petcock on the water pump during the cleaning period 6 Add 160 ounces 8 ounces per 3 gallons of Calgon ice machine cleaner a food grade liquid phosphoric acid to water tank during the refill period 7 Inspect the water distributors by looking through clean freeze cover If required remov...

Page 48: ...ng the machine be sure that the water pump is circulating water It is possible that air may have collected in the pump impeller housing and the pump may have to be stopped and started several times to expel the air Water Cooled Condensers Checking Operation Scheduled maintenance for water cooled condensers is based primarily on the operating conditions found at the machine The condenser should be ...

Page 49: ... water flow or a low supply pressure is indicated A restriction can occur with foreign matter in the condenser but it is also likely to be somewhere else in the system Draining Draining of water cooled condensers is recommended in preparation for the winter cold where units may be left exposed to ambient temperatures below 32 F Theoretically it is easy to drain a condenser In practice the problem ...

Page 50: ...g valve and connecting piping g Open the water supply stop valve and check for leaks Mechanical Cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser d Remove the cover plate on the side of the frame to expose the condenser end plate e Remove the nuts water plates and gaskets from...

Page 51: ... 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 it should begin to return after a short period of oper...

Page 52: ...ith suitable leak detector for the first four weeks of operation 2 Check oil level and condition C Monthly in addition to weekly checks 1 Check calibration and operation of all controls high and low pressure switches oil pressure switch etc 2 Check cooling tower for scaling and algae consult water treatment suppliers for corrective measures 3 Check water distributors in freezer for scale accumulat...

Page 53: ...ses Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes in the operation of the machine which may require maintenance long before a service situation arises An ounce of prevention is worth a p...

Page 54: ...____ ________ _____ AC condenser motor amps if applicable ________ ________ ________ _____ Crankcase heater heating _____ Refrigerant leak okay high low _____ Leak checked system ______ leaks found repaired _____ Compressor oil level i e 1 4 1 2 3 4 low high _____ Gear reducer oil okay low _____ PSIG low pressure switch set _____ PSIG high pressure switch set _____ Bin stat s installed and operati...

Page 55: ... it will then start in a thawing cycle Always check the machine thoroughly after remedying the problem to prevent the same cause from reoccurring Symptom Page Machine Won t Run 8 2 8 3 Freeze up Due To Extended Freeze Period 8 4 Freeze up Due To Ice Failing To Discharge 8 5 Low Ice Capacity 8 6 Low Compressor Oil Level 8 7 Poor Ice Quality 8 8 High Head Pressure Water Cooled Machines 8 9 High Head...

Page 56: ... between suction and discharge port of the compressor Check for broken cylinder head gasket or valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body One of the 2 5 amp control circuit fuses FU I or FU 2 in the control panel burnt out Check compressor crankcase heater coils of relays contactors starters solenoid valves and tha...

Page 57: ...k 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 C...

Page 58: ...oid valve 18 leaking through during the freeze cycle Check the manual opening stem to make sure it is in the automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Float switch stuck or failed in the closed position Check to make sure th...

Page 59: ... too 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 m...

Page 60: ...of freezer may be stopped up Remove freezer cover and clean the distributors See Water Distributors Section 7 Inadequate water for ice making Check water pressure 30 PSIG minimum recommended Check for a restriction in the water supply line or at the make up water float valve Make up water float valve 12 stuck open adjusted too high or water tank drain valve 15 open or leaking Repair replace or adj...

Page 61: ...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 62: ...G is recommended minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain valve is closed Water pump rotation wrong direction Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Low refrigerant charge Check refrigerant level mark on the receiver and on the painted portio...

Page 63: ...en and clean as needed Non condensables usually air in system Check refrigerant tables for correct pressure temperature relation If non condensables are present Perform a total pumpdown let stand for at least 6 hours allowing non condensables to gather in the upper part of the receiver Evacuate the freezer and attach a recovery unit to the top receiver purge valve 59 Open the valve and recover the...

Page 64: ...fuse Replace fuse and reset switch If the condenser is split check the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted airflow Visually inspect condenser and clean as necessary Non condensables usually air in the system Fo...

Page 65: ...eck 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 drain by pass It is advisable to install a large area strainer in the water supply line to protect the float valve from dirt or solids in the water which would necessitate frequent cleaning A strainer o...

Page 66: ...e bottom screw differential approximately 1 2 turn to the Left counter clockwise The pointer arrow which is at the top middle of the switch will be at the F setting See FIGURE 9 1 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will be between 40 psi and 50 psi See FIGURE 9 1 3 After the machine is running the range adj...

Page 67: ...d in the machine mounted to the frame near the compressor It protects the machine from possible damage due to abnormal pressure during operation CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming normal operation 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 shoul...

Page 68: ...lve will not close fully when the head pressure drops below its setting Air Cooled Units The condenser fan switch mounted to the frame lower right side FIGURE 9 3B CPS is used to regulate the head pressure This is an adjustable pressure 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 1 located in the control p...

Page 69: ...nce 2 The control module is a sealed enclosure containing a relay or triac transformer and several electronic components Leads from the internal motor sensors are connected to the module as shown on the wiring diagrams While the exact internal circuitry is quite complicated basically the module senses the change in resistance of the sensors As the motor temperature rises or falls the resistance al...

Page 70: ...e 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 to the sensors may ...

Page 71: ... control module to precisely measure oil pump differential pressure The main advantage of Sentronic is the elimination of the traditional capillary tubes bellows and pressure connections that mechanical pressure switches require to measure differential oil pressure These require careful handling and are known to be a source of leaks in refrigeration systems ...

Page 72: ...or a period of two minutes the Sentronic module will open the control circuit using its Normally Closed N contact and shut the compressor off Approximate oil pressure can be measured in the field Oil pumps are furnished with a Schrader valve mounted on the oil pump discharge port To measure oil pressure subtract crankcase pressure from discharge oil pressure Tripping of the oil pressure safety swi...

Page 73: ... open the disconnect switch to machine and set the On Off switch to the off position If the machine was off for an extended time the crankcase heater must be energized for a minimum of two hours before restarting the machine When ready to restart the machine depress the Start button The machine will automatically return to a freeze cycle upon completion of the harvest cycle Condenser Cleaning See ...

Page 74: ...nother thaw cycle 6 Allow the machine to operate until the low pressure switch stops the machine 20 PSIG If a lower pressure is desired it can be accomplished by jumping the low pressure switch and starting and stopping the machine by the Start and Stop push buttons Continually observe the oil level to make sure the oil is not carried from the compressor while operating at a low pressure 7 Close t...

Page 75: ...ature See Water Cooled Condensers Section 7 Compressor Motor Burnout There are several causes of compressor motor burnout Some of these are described below 1 Low line voltage A compressor motor is designed to operate within the range of plus or minus 10 of its nameplate voltage Low voltage requires the motor windings to carry more current at the same compressor load When this current gets too high...

Page 76: ... all the way out Correct direction of stem rotation should be labeled on the stem seal nut FIGURE 9 6A D Solenoid Valve FIGURE 9 6B A Solenoid Valve Circulating Water Pump Motor The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water level above the impeller housing The pump is equipped with a mechanical seal that is self adjusting...

Page 77: ...ion pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may be used with the valve either energized or de energized without excessive compressor cycling FIGURE 9 7 Loaded Operation during freeze This capacity...

Page 78: ...install the terminal cover 10 Check motor rotation to make sure the cutter turns in the proper direction Reverse two wires at the motor if necessary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 10 1 Turn power off and lock out disconnect 2 Remove motor from reducer 3 Loosen slightly the four bolts and nuts holding the gear reducer in p...

Page 79: ...n be removed to the side of the machine 8 Make sure the rubber gasket is in place and aligned properly when the tank is installed and bolted to the freezer Cutter and Bearing Removal Installation Refer to FIGURES 9 8 9 9 9 10 for parts identification and location 1 Turn off and lock out power to the machine 2 Remove the cutter motor from the reducer 3 Remove the water tank assembly and then the cu...

Page 80: ... pin flush with the outside of the hub making sure the pin doesn t extend beyond the inner surface of the bearing 14 Slide the new bearing and support onto the cutter shaft to make sure it spins freely If it is tight ream the bearing inner surface slightly until it turns free 15 Install the bearing support in the tank using the reference marks as a guide 16 Slide the cutter and shaft into the bear...

Page 81: ...05TA Service Manual SERVICE OPERATIONS 8 13 01 9 17 FIGURE 9 8 Cutter Assembly FIGURE 9 9 Cutter Parts cylinder ice ...

Page 82: ...05TA Service Manual SERVICE OPERATIONS 8 13 01 9 18 FIGURE 9 10 Cutter Drive Parts ...

Page 83: ...05TA Service Manual SERVICE OPERATIONS 8 13 01 9 19 FIGURE 9 11 Cutter Parts crushed ice option ...

Page 84: ...version process should normally be accomplished by two people in 3 4 hours or less There must be ample room around the machine for the water tank removal It is recommended that you have good quality water when attempting to produce crushed ice If the ice is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Refer to Technical Service Bulletin No...

Page 85: ...05TA Service Manual OPTIONS AND ACCESSORIES 8 13 01 10 1 10 Options and Accessories PLC Programmable Logic Controller Page 10 2 Power Monitor Page 10 14 ...

Page 86: ...C internally fused for 5 7mA All 24VDC control wiring is blue in color and is distinguished from the red 240VAC control wiring The outputs are externally fused for 2A Outputs 0 1 and 2 are dry contacts used for sequencing and conveyor control Outputs 3 11 are relay type with 200 240 V connections FIGURE 10 1 shows the Mitsubishi PLC installed in the 05TA The LED indicators on the right hand side o...

Page 87: ...nt of a malfunction or fault The PLC will alert the user in the event of the following conditions high or low pressure short cycling three consecutive freeze cycles five minutes or less in duration long cycle a freeze cycle lasting more than 60 minutes water pump overload cutter motor overload compressor overload loss of oil pressure power failure Cutter Delay PLC equipped machines delay start of ...

Page 88: ...ce production in lbs over a period of time This value can be reset to zero by the user The operator interface shown in FIGURE 10 1 provides two 16 character lines of text which are used to report faults operating conditions and programming information to the user The keypad is used to enter or modify values in the PLC Operation of the interface is menu driven Basic directions for operation are dis...

Page 89: ...time and the previous cycle harvest time during the harvest cycle C SET UP SCREEN B RESET CYCLE HARVEST PREV HRVST Upon completion of the harvest cycle the machine will begin the freeze cycle The interface will display the current freeze time and the previous cycle freeze time during the freeze cycle C SET UP SCREEN B RESET CYCLE FREEZE PREV FREEZ Upon completion of the freeze cycle the machine wi...

Page 90: ... will also appear upon completion of a clean cycle or after a fault has been detected and reset The words PUMPED DOWN YES will appear if the machine is pumped down C SET UP SCREEN B RESET CYCLE PRESS START PUMPED DOWN YES When the switches are in the ON and CLEAN positions the machine will begin a clean cycle after completing the current ice making cycle The interface will display the time that th...

Page 91: ...er pump overload protection trips open The machine will stop immediately and the overload reset button located on the motor starter must be depressed B SILENCE ALARM A FOR RESTART FAULT PUMP O L PUMP OL RESET B SILENCE ALARM A FOR RESTART FAULT PUMP O L PUMP OL OK When the overload has been reset the interface will display PUMP OL OK It will be necessary to press A on the operator interface to res...

Page 92: ...ditions A long cycle is defined as a freeze cycle that lasts for a period of one hour An open drain valve leaking hot gas valve or defective compressor could cause this The short cycle safety will stop the machine after three consecutive freeze cycles of less than five minutes duration Short cycling can be caused by a restriction in the liquid line inadequate make up or circulating water or a defe...

Page 93: ... and press ENTER The only variables that can be changed from this screen are the harvest time blowdown time conveyor run time and conveyor delay time The last two lines of the display report total cycles and run time of the machine Pressing A on the operator interface while in the set up screen will allow you to access a second set up screen where the autostart and the timed freeze cycle features ...

Page 94: ... set up screen Pressing B from this screen will call the second monitor screen The second monitor screen displays the previous total cycle time lbs of ice produced per cycle and lbs of ice produced per day based on the last cycle time The screen is shown below C SET UP SCRN ICE DAY LBS PREV CYCLE ICE CYCLE LBS The user can set the pounds of ice per cycle from this screen The capacities and ice pro...

Page 95: ...05TA Service Manual OPTIONS AND ACCESSORIES 8 13 01 10 11 FIGURE 10 3 Control Panel Parts ...

Page 96: ...he fan motor s of air cooled condenser on and off Activated by the condenser pressure switch air cooled machines only TS1 Ice Clean Toggle Switch Two position toggle switch to operate machine in ice making mode or clean mode When in clean position only the water pump will run This allows cleaner to be circulated through the freezer without making ice TS2 On Off Toggle Switch Two position switch us...

Page 97: ...05TA Service Manual OPTIONS AND ACCESSORIES 8 13 01 10 13 FIGURE 10 4 Wiring Schematic ...

Page 98: ... line monitoring your system and logging any faults in memory for you to review after you leave the setup mode The Setup LED will stay on during setup operations When you have passed the last parameter in the setup menu the setup LED will extinguish and you will be returned to the SYSTEM ON LINE display NOTE The power monitor has no on and off switch so the unit will power up a few seconds after p...

Page 99: ...set from the manual mode To reset from a fault condition in the manual mode press and hold the fault button for two seconds Default is manual reset Control Mode This setting allows you to select the control source Pressing the arrow keys in this setup mode takes you through ON OFF and EXTERNAL The normal setting would be EXTERNAL With the control set to EXTERNAL the unit will respond to the signal...

Page 100: ...s it may be desirable to lock out unwanted changes from being made to the programmed parameters This can be achieved by using the lock feature The setup menu can be viewed but not changed when the lock is on TO LOCK out operator adjustments Hold the FAULT key down until FAULTS CLEARED appears on the Display While holding the FAULT key down press the ARROW UP key once This will turn the Setup Lock ...

Page 101: ...ressor contactor with 1 amp fused connections The connections labeled control should be wired to a 230 volt power source Com and Run connections should be wired in series with the system control circuit Note that specified connections are for 05TA models only Consult factory for other models FIGURE 10 6 Phase Protector wiring schematic ...

Page 102: ...e voltage too low and or phase missing Control LED does not go out when control is off CONTROL LED always on Control input is very sensitive Insure control voltage 2 volts for off condition System trips out on low or high line voltage FAULT LED flashes due to fault Check normal line voltage using READ feature Re adjust voltage range as required Output relay never turns on Control Mode setting is O...

Page 103: ...05TA Service Manual TABLES CHARTS 8 14 01 11 1 11 Tables Charts ...

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

Page 105: ...ndenser outlet ODC 1 5 8 1 5 8 1 5 8 Marley Cooling Tower 5 4821 4821 4821 dimensions LxWxH ft meters 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 5x 4 x 6 5 1 5x1 2x2 0 shipping weight lbs Kg 740 336 740 336 740 336 operating weight lbs Kg 1340 608 1340 608 1340 608 fan HP KW FLA 1 0 8 3 6 1 0 8 3 6 1 0 8 3 6 Tower Pump flow gpm m3 Hr 78 17 7 78 17 7 78 17 7 TDH minimum ft m 80 24 4 80 24 4 80 2...

Page 106: ...0 12022 10982 10379 10982 10032 9481 11421 10433 9860 64 11480 10480 9940 11939 10899 10338 10906 9956 9443 11342 10354 9821 65 11400 10400 9900 11856 10816 10296 10830 9880 9405 11263 10275 9781 66 11320 10320 9820 11773 10733 10213 10754 9804 9329 11184 10196 9702 67 11240 10240 9740 11690 10650 10130 10678 9728 9253 11106 10118 9624 68 11160 10160 9660 11606 10566 10046 10602 9652 9177 11026 10...

Page 107: ...3 15 1 170 000 100 75 93 19 1 170 000 100 80 94 25 2 170 000 100 85 94 37 5 170 000 105 90 95 68 15 170 000 110 95 100 68 15 170 000 Table 11 4 Make Up Water Usage gpm 05TA Cylinder Ice Crushed Ice Make Up Water Tube Size Tube Size Temp F 1 1 1 4 1 1 2 1 1 1 4 1 1 2 40 1 15 1 10 1 09 1 19 1 15 1 14 50 1 10 1 05 1 04 1 14 1 09 1 09 60 1 04 0 99 0 98 1 08 1 02 1 02 70 1 00 0 94 0 93 1 03 0 98 0 97 8...

Page 108: ...7 4 9 10 Condenser Fan Contactor FC 6 2 Condenser Fan Switch 9 4 Condenser Piping Cold Weather Valve Kit 3 11 Condenser Water Usage 11 5 Condenser Air cooled Cleaning 9 10 Condenser Air cooled Heat Rejection 3 9 Condenser Pressure Switch CPS 9 4 Condenser Water Cooled Maintenance 7 4 Control Circuit Protection 9 9 Control Panel 6 1 Control Panel Parts 6 2 Control Relay CR 6 2 Cooling Tower 3 1 Cra...

Page 109: ...verload Pump 6 2 P Pin Stainless Steel 9 17 9 19 Piping and Drain Connections 3 1 Piping Schematic Nomenclature 4 2 Piping Schematic Water cooled 4 3 PLC 10 2 Poor Ice Quality 8 8 Power Connection 3 5 Power Monitor 10 14 Preventive Maintenance 7 6 Preventive Maintenance Program 7 8 Preview 1 1 Principle of Operation 4 1 Programmable Logic Controller 10 2 Pump Down 9 10 Pump Overload 6 2 Pump Conta...

Page 110: ...allation 3 1 Water Cooled Piping Schematic 4 3 Water Cooled Units 9 4 Water Distributors 7 2 Water Pump Motor 9 12 Water Quality 3 1 Water Regulating Valve 9 4 Water Supply and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 3 Water Tank 7 2 Water Tank Removal 9 15 Water Usage Condenser 11 5 Water Usage Make up 11 5 Wiring and Electrical Connection 3 5 Wiring Schematic Air Cool...

Page 111: ...05TA Service Manual INDEX 8 13 01 12 4 ...

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