Vogt 03TA Service Manual
03TA
®
TUBE-ICE
MACHINE
(Includes models HE60 & P112F)
Service Manual
$50
00
NOTICE
This manual is the property of the owner of this particular Tube-Ice®
machine.
Model #____________________ Serial #____________________.
It is to be left on the premises with this machine at all times. After startup, 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 ICE, LLC
1000 W. Ormsby Ave.
Louisville, KY 40210
Tube Ice L.L.C.
Vogt Order Number: ____________________
1000 W. Ormsby
Louisville, KY 40210
(502) 635-3235
FAX #502-635-3024
THIS FORM MUST BE SENT TO
VOGT TO ACTIVATE WARRANTY
Warranty Registration / Start-Up Form
(Medium & 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 No Manufacturer: ____________________ Model: ________________________
Bin Manufacturer: _______________________ Model: _________________________ Bin Capacity: _______ lbs.
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
Machine room suitable 50°F minimum, 110°F maximum
Power Supply ______ V _____ PH _____ HZ (machine not running)
Crankcase heater on for 2 hours minimum, prior to start
All valves opened or closed as tagged
Water supply and drains connected properly
Sufficient make-up water supply (minimum 30 PSIG)
Leak checked 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 left with: __________________________________
Test
Cycle
#1
#2
#3
#4
Make-up Water
Temp
Note: Ice lb. per day can be found by:
Freeze Time
Min/Sec
Harvest Time
Min/Sec
harvestper lb. ice
+ me)harvest ti time(freeze
First Ice Out
Min/Sec
1440×
Power Supply ______ V _____ PH _____ HZ (machine running)
Compressor oil level, i.e. 1/4 – 1/2 – 3/4: ______
Compressor, pump , cutter & other motor direction of rotation correct
Compressor amps (Start of freeze cycle) L1_____ L2_____ L3_____
Cutter motor amps RLA__________ Actual __________
Water pump amps RLA__________ Actual __________
Condenser motor amps (if applicable) _________
Incoming potable water temperature: _____°F
All water distributors in place (visually inspected)
Make-up water float valve adjusted properly
Clear ice Yes No
Bin control(s) operate(s) properly to stop and start machine with ice
on them
Hour meter in control panel connected and operating
Suction Pressure: End of freeze ________ End of harvest ________
Discharge Pressure: End of freeze ________ End of harvest ________
All Ice Out
Min/Sec
OPERATION CHECK
Avg. Hole
Size
Ice
Lb. Per Harvest
Lb. Per Day
Remarks:
Ice
Technician Signature: ___________________________ End User Signature:_____________________________
I certify that I have performed all of the above procedures.
03TA Service Manual
Page No.
1. INTRODUCTION
A Brief History of Our Company............................................................................................................................1-1
Vogt Energy-Savings Tube-Ice® Machines.............................................................................................................1-1
Preview .............................................................................................................................................................1-1
Important Safety Notice..........................................................................................................................................1-2
Special Precautions To Be Observed When Charging Refrigeration Systems ..........................................................1-2
Safety Symbols and What They Mean ....................................................................................................................1-3
Assembly Drawing Model 03TA Air-Cooled, FIGURES 1-1, 1-2, & 1-3................................................................. 1-4, 1-5, 1-6
Assembly Drawing Model 03TA Water-Cooled, FIGURES 1-4, 1-5, & 1-6 ............................................................1-7, 1-8, 1-9
TABLE OF CONTENTS
Vogt
i
TABLE OF CONTENTS
®
TUBE-ICE® MACHINES
Model 03TA
2. RECEIPT OF YOUR TUBE-ICE MACHINE
Inspection .............................................................................................................................................................2-1
Safety Valves ......................................................................................................................................................... 2-1
Machine Room.......................................................................................................................................................2-2
Storage (prior to installation and start-up).............................................................................................................. 2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Bin Installation ......................................................................................................................................................3-1
Setting the Ice Machine on the Bin......................................................................................................................... 3-1
Ice Chute Location/Machine Footprint, FIGURE 3-1 ..............................................................................................3-1
Forklift and Blocks Method, FIGURE 3-2.............................................................................................................. 3-2
Forklift and Ropes or Lifting Strap Method, FIGURE 3-3.......................................................................................3-3
Connections and Space Diagram (Air-Cooled Machine), FIGURE 3-4....................................................................3-4
Connections and Space Diagram (Water-Cooled Machine), FIGURE 3-5................................................................ 3-5
Piping and Drain Connections................................................................................................................................3-6
Water Supply and Drain Sizes, TABLE 3-1 ............................................................................................................ 3-6
Cooling Tower.......................................................................................................................................................3-6
Wiring and Electrical Connection........................................................................................................................... 3-7
Control Panel Power Connections, FIGURE 3-6.....................................................................................................3-7
Electrical Specifications, TABLE 3-2.....................................................................................................................3-7
Phase Check ..........................................................................................................................................................3-8
Voltage Unbalance................................................................................................................................................. 3-8
Current Unbalance.................................................................................................................................................3-8
Air-Cooled Condenser Installation Instructions....................................................................................................... 3-9
Pounds of R-22 To Add Vs. Liquid Line Length, TABLE 3-3.................................................................................3-10
Air-Cooled Condenser Data ...................................................................................................................................3-11
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TABLE OF CONTENTS
Condenser Dimensions (Condenser Pictured: DD-231), FIGURE 3-7 .....................................................................3-12
Condenser Field Piping (Cold Weather Valve Kit), FIGURE 3-8............................................................................ 3-12
Condenser Equivalent Line Size Worksheet ...........................................................................................................3-13
Equivalent Feet Due To Friction, TABLE 3-5 ........................................................................................................3-13
Minimum Traps For Discharge Lines, FIGURE 3-9................................................................................................3-13
Air-Cooled Condenser Wiring................................................................................................................................3-14
Wiring for #DD-231 & #DD-261 Condenser, FIGURE 3-10...................................................................................3-14
Air-Cooled Connections.........................................................................................................................................3-14
Rota-lock Connector Torque Ratings, TABLE 3-6.................................................................................................. 3-14
Ice Bin Thermostat Sensor Installation ...................................................................................................................3-15
Ice Bin Thermostat Location, FIGURE 3-11........................................................................................................... 3-15
Programming the Electronic Ice Bin Thermostat ..................................................................................................... 3-16
4. HOW YOUR TUBE-ICE MACHINE WORKS
Principle of Operation ............................................................................................................................................ 4-1
Freeze Period ......................................................................................................................................................... 4-2
Harvest Period....................................................................................................................................................... 4-2
Piping Nomenclature, TABLE 4-1..........................................................................................................................4-2
Water-Cooled Piping Schematic, FIGURE 4-1........................................................................................................4-3
Air-Cooled Piping Schematic, FIGURE 4-2 ............................................................................................................ 4-4
03TA Service Manual
Page No.
5. START-UP AND OPERATION
Refrigeration System Review................................................................................................................................. 5-1
Refrigerant Charge.................................................................................................................................................5-1
Start-Up Checklist .................................................................................................................................................5-2
Start-Up .............................................................................................................................................................5-3
Control Panel Switch Layout, FIGURE 5-1............................................................................................................5-3
Adding Refrigerant ................................................................................................................................................5-4
Operating Tips ....................................................................................................................................................... 5-5
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Control Panel (Cover Removed), FIGURE 6-1 .......................................................................................................6-1
Description of Control Panel Parts, TABLE 6-1......................................................................................................6-2
Electrical Schematic All Voltages 50-60 Hz. (Across Line Start), FIGURE 6-2....................................................... 6-3
7. MAINTENANCE
Ice-Making Section................................................................................................................................................ 7-1
Cleaning Procedure ................................................................................................................................................ 7-1
Water Distributors .................................................................................................................................................7-2
Water Tank............................................................................................................................................................ 7-2
Water-Cooled Condensers, Checking Operation .....................................................................................................7-2
Water-Cooled Condensers, Draining ......................................................................................................................7-3
Water-Cooled Condenser Cleaning.........................................................................................................................7-4
Lubrication ............................................................................................................................................................7-5
03TA Service Manual
TABLE OF CONTENTS
Page
No.
Compressor......................................................................................................................................................7-5
Cutter Gear Reducer ........................................................................................................................................7-6
Preventive Maintenance.........................................................................................................................................7-6
Daily Check List ..............................................................................................................................................7-7
Note To Manager or Owner.............................................................................................................................. 7-7
Preventive Maintenance Program .....................................................................................................................7-8
8. TROUBLESHOOTING
List Of Symptoms.................................................................................................................................................. 8-1
Machine Won’t Run...............................................................................................................................................8-2, 8-3
Freeze-Up Due To Extended Freezing 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) ......................................................................................................................8-9
High Head Pressure (Air-Cooled)........................................................................................................................... 8-10
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9/28/98
9. SERVICE OPERATIONS
Adjustable Blowdown (For Clearer Ice) .................................................................................................................9-1
Automatic Blowdown (Harvest Cycle)....................................................................................................................9-1
Float Valve (Make-Up Water)................................................................................................................................9-1
Float Switch...........................................................................................................................................................9-1
Hand Expansion Valve...........................................................................................................................................9-2
Freezer Pressure Switch.........................................................................................................................................9-2
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................................................................................................................................. 9-5
High Potential Testing......................................................................................................................................9-6
Field Troubleshooting ......................................................................................................................................9-6
Electronic Module & Compressor Terminal Board Connections, FIGURE 9-4 ..................................................9-7
Sentronic Oil Pressure Safety Control ....................................................................................................................9-8
Oil Pressure Sensor .......................................................................................................................................... 9-8
Oil Pressure Module ........................................................................................................................................9-8
Thawing Timer, FIGURE 9-5................................................................................................................................. 9-9
iv
TABLE OF CONTENTS
Thawing Timer...................................................................................................................................................... 9-9
Control Circuit Protection ......................................................................................................................................9-9
Condenser Cleaning...............................................................................................................................................9-9
Air-Cooled Condenser............................................................................................................................................9-9
Cutter Gear Reducer ..............................................................................................................................................9-9
Pump Down...........................................................................................................................................................9-10
Removal Of Refrigerant From Machine .................................................................................................................. 9-10
Refrigerant Leaks...................................................................................................................................................9-11
Non-Condensable Gases.........................................................................................................................................9-11
Compressor Motor Burnout .................................................................................................................................... 9-11
Solenoid Valve ......................................................................................................................................................9-12
Solenoid Valve (“D” Valve), FIGURE 9-6A........................................................................................................... 9-12
Solenoid Valve (“A” Valve), FIGURE 9-6B...........................................................................................................9-12
Circulating Water Pump Motor ..............................................................................................................................9-12
Capacity Control Valve (Internal Construction)...................................................................................................... 9-13
Copeland Compressor Unloader Valve, FIGURE 9-7..............................................................................................9-13
Loaded Operation (Freeze Period)....................................................................................................................9-13
Unloaded Operation (During Thaw Only) ......................................................................................................... 9-13
Component Removal and Replacement Operations ................................................................................................. 9-14
Cutter Motor....................................................................................................................................................9-14
Cutter Gear Reducer ........................................................................................................................................9-14
Water Tank......................................................................................................................................................9-15
Cutter & Bearing..............................................................................................................................................9-15
Cutter/Tank Assembly Nomenclature, TABLE 9-1................................................................................................. 9-16
Cutter, Water Tank & Drive Gear Assembly, FIGURE 9-8.....................................................................................9-17
Water Tank & Pump Assembly, FIGURE 9-9......................................................................................................... 9-18
Crushed Ice Production ..........................................................................................................................................9-18
03TA Service Manual
Page No.
10. OPTIONS AND ACCESSORIES
PLC (Programmable Logic Controller) .................................................................................................................. 10-2
Power Monitor ...................................................................................................................................................... 10-14
11. TABLES AND CHARTS
03TA Ratings (60 Hz., 7.5 HP), TABLE 11-1 ........................................................................................................11-2
03TA Ratings (50 Hz., 10 HP), TABLE 11-2 .........................................................................................................11-3
03TA Capacity Ratings, TABLE 11-3 ....................................................................................................................11-4
03TA Condenser Water Usage, TABLE 11-4 .........................................................................................................11-5
03TA Make-up Water Usage, TABLE 11-5............................................................................................................11-5
03TA Normal Operating Vitals, TABLE 11-6 ........................................................................................................11-5
Recommended Spare Parts List..............................................................................................................................11-6
Temperature - Pressure Chart for Common Refrigerants, TABLE 11-7...................................................................11-7
Conversion Factors: English to Metric, TABLE 11-8..............................................................................................11-8
Constants, TABLE 11-9.........................................................................................................................................11-8
03TA Service Manual
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 icemaking 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.
1-1
INTRODUCTION
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
experience is reflected in the 03TA 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.
®
®
9/28/98
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.
1-2
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 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 refrigerant 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-22 or R- 404a
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.
03TA Service Manual
! 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.
! CAUTION !
Always store cylinders containing refrigerant in a cool place. They should never be exposed to
temperatures higher than 125 °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 !
9/28/98
03TA Service Manual
Safety Symbols & 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-Ice
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 heed.
! DANGER !
Indicates an immediate hazard and that special precautions
are necessary to avoid severe personal injury or death.
! DANGER !
1-3
INTRODUCTION
®
! WARNING !
Indicates a strong possibility of a 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 !
9/28/98
1-4
INTRODUCTION
03TA Service Manual
9/28/98
FIGURE 1-1
Assembly (Air-Cooled)
Front View
03TA Service Manual
1-5
INTRODUCTION
9/28/98
FIGURE 1-2
Assembly (Air-Cooled)
Rear View
1-6
INTRODUCTION
03TA Service Manual
9/28/98
FIGURE 1-3
Assembly (Air-Cooled)
Right Side View
03TA Service Manual
1-7
INTRODUCTION
9/28/98
FIGURE 1-4
Assembly (Water Cooled)
Front View
1-8
INTRODUCTION
03TA Service Manual
9/28/98
FIGURE 1-5
Assembly (Water Cooled)
Rear View
03TA Service Manual
1-9
INTRODUCTION
9/28/98
FIGURE 1-6
Assembly (Water Cooled)
Right Side View
03TA Service Manual
RECEIPT OF YOUR TUBE-ICE MACHINE
2. Receipt Of Your Tube-Ice Machine
! WARNING !
Only service personnel experienced in refrigeration and qualified
to work with high voltage electrical equipment should be allowed
to install or work on this Tube-Ice® machine.
! WARNING !
Inspection As soon as you receive your machine, inspect it for any damage. If damage is suspected,
note it on the shipper’s papers (i.e., 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 TUBE ICE, LLC can void the machine’s warranty.
The machine was shipped with a full charge of refrigerant stored in the receiver. Visually check all
lines for mechanical damage. If a leak is suspected, check all joints with a Halogen Leak Detector.
All leaks should be reported to TUBE ICE, LLC to obtain authorization for repair.
2-1
! CAUTION !
The approximate weight of the machine is 2000 pounds. Always use
equipment with adequate load carrying capacity.
! CAUTION !
The machine frame has lifting lugs at each corner in the top for eyebolts and hooks to be used for
lifting purposes if desired. Lifting lugs should be used whenever possible.
! 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 pressure relief valves are an integral part of the packaged Tube-Ice
machine. One is located in the low-side of the system on the freezer, and one is in the high side of the
system on the receiver. Vent each of the pressure relief valves to the atmosphere in such a manner as
to comply with local and national codes.
®
9/28/98
2-2
RECEIPT OF YOUR TUBE-ICE MACHINE
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 currents may affect the operation of the machine
and should be avoided. The electrical components of the Tube-Ice® machine are rated NEMA 1.
Therefore, the machine should not be located in a hazardous area or sprayed with water. The
machine should be installed on a drainable condensate drip pan or in an area where water will not
stand but will readily drain away from the machine. See Space Diagram for clearances and utility
connections, FIGURES 3-1 and 3-2.
Storage (prior to installation or start-up) The machine must not be stored or installed in an area
that may reach temperatures 115°F (46.1°C) or above.
This equipment contains HCFC-22 or HFC-404a refrigerant under pressure.
Do not store in an area exposed to temperatures above 115°F (46°C)
or in direct sun at temperatures above 105°F (40°C).
03TA Service Manual
! CAUTION !
! CAUTION !
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03TA Service Manual
4'-2"
PLAN
MINIMUM BIN OPENING - 6 1/2" x 6 1/2"
MAXIMUM BIN OPENING - 7" x 7"
FRONT OF MACHINE
3-1
INSTALLING YOUR TUBE-ICE® MACHINE
3. Installing Your Tube-Ice
! WARNING !
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 !
®
Machine
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.
Bin Installation Set the bin on solid, level footing. Inside the bin you will find the four legs.
Screw these legs to the bottom of the bin. You can make MINOR leveling adjustments by using
these legs as leveling screws, as outlined in the manufacturer’s instructi ons.
Setting the ice machine on the ice bin Once the ice storage bin is level, the Tube -Ice
machine can be elevated and placed on the bin top. Using the dimensions in FIGURE 3 -1 below,
mark the machine footprint on the bin top by measuring over from the ice chute opening.
®
ICE BIN
CHUTE SIZE - 5 5/8" X 5 5/8"
6 1/2"
6 1/2"
2'-3 1/16"
2'-5"
1'-2 1/4"
FIGURE 3-1
Ice Chute Location/Machine Footprint
8/23/01
3-2
INSTALLING YOUR TUBE-ICE® MACHINE
03TA Service Manual
FIGURES 3-2 & 3-3 illustrate two methods of lifting & setting Tube - Ice? machine on an ice storage bin.
! CAUTION !
The approximate weight of the machine is 2000 pounds.
Always use equipment with adequate load-carrying capacity.
! CAUTION !
REMOVE CASINGS FROM MODEL HE60
BEFORE PLACING MACHINE ON BIN
CONTROL PANEL
& SWITCH BOX
TUBE-ICE MACHINE
WOOD BLOCKS
TWO (2) EACH CORNER
ICE STORAGE BIN
FIGURE 3-2
Forklift-&-Blocks Method
You need:
??forklift truck with adequate load and height capacities
??(8) 2X4 wood blocks 8 in. long
??(2) wooden 2X4’s measuring 3-ft. long
??pry bar
Step 1. Position Tube-Ice? machine on forks.
Step 2. Stack wood blocks in each corner of the drip pan on top of the ice storage bin.
Step 3. Lift and set Tube-Ice? machine on wood blocks.
Step 4. Remove forklift.
Step 5. Stack 3-ft. long 2X4’s beside drip pan, overlapping front and back of bin.
Step 6. Using a pry bar with fulcrum on 2X4’s, raise side of machine enough to remove TOP wood
blocks.
! CAUTION !
Do not remove top AND bottom blocks at the same time.
! CAUTION !
Step 7. Repeat steps 5 and 6 on other side.
Step 8. With machine sitting on one (1) block under each corner, repeat steps 5, 6, and 7 remove
remaining blocks. Drip pan flanges may bend slightly.
Step 9. Straighten bent drip pan flanges.
Step 10. Check alignment of ice chute to bin opening.
8/23/01
03TA Service Manual
BEFORE PLACING MACHINE ON BIN
INSTALLING YOUR TUBE-ICE® MACHINE
REMOVE CASINGS FROM MODEL HE60
ROPE OR STRAPS
TUBE-ICE MACHINE
ICE STORAGE BIN
3-3
FIGURE 3-3
Forklift-&-Rope or Lifting Straps Method
You need:
??extra head room
??forklift with adequate load and height capacities
??1/2” rope or four lifting s traps to bind forks to top angles
Step 1. Remove front, rear, and top access panels.
Step 2. Position fork truck so that forks are resting flat on top angles of Tube -Ice®
machine.
Step 3. Use the rope or straps to securely bind forks to the top angles.
! CAUTION !
Be sure the bin is level and is set in its proper location.
See the space diagram, FIGURE 6.
! CAUTION !
Step 4. Lift Tube-Ice® machine and set into drip pan of bin.
Step 5. Remove rope or straps and fork truck.
Step 6. Check alignment of ice chute to bin opening.
8/23/01
8/23/01
INSTALLING YOUR TUBE-ICE
3-4
Connections and Space Diagram (Air Cooled Machine)
®
MACHINE
FIGURE 3-4
03TA Service Manual
8/23/01
03TA Service Manual
Connections and Space Diagram (Water Cooled Machine)
FIGURE 3-5
INSTALLING YOUR TUBE-ICE
®
MACHINE
3-5
3-6
Condenser
INSTALLING YOUR TUBE-ICE® MACHINE
Piping and Drain Connections
Figure 3-4 (Air Cooled) and 3-5 (Water Cooled) show locations and sizes for all connections.
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.
Make-up
Water In
1/2” MPT 3/4” FPT 1 1/4” FPT 1 1/4” FPT
* 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, as this will interfere
with the operation of the automatic blowdown system. A 20 mesh strainer, supplied with the
machine, should be installed in the supply line to the condenser.
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.
Cooling Tower.
For water cooled machines only. When selecting a cooling tower, careful attention must be given to
operating wet bulb conditions. It is advisable to check with your local cooling tower distributor for
their recommendations based on actual operating conditions 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 deliveri ng 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.
! CAUTION !
! CAUTION !
Water Tank
Drain*
Condenser
Water In
TABLE 3-1
Water Supply and Drain Sizes
! CAUTION !
! CAUTION !
03TA Service Manual
Water Out*
8/23/01
03TA Service Manual
INSTALLING YOUR TUBE-ICE® MACHINE
Wiring and Electrical Connection
! WARNING !
Only service personnel experienced in refrigeration and qualified to work with high voltage
electrical equipment should be allowed to install or work on the Tube-Ice® machine.
! WARNING !
Refer to TABLE 3-2 below 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 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.
3-7
8/23/01
FIGURE 3-6
Control Panel Power Connections
Water Cooled Air Cooled
Standard Voltages
208/230, 3ph, 60 Hz 66.9 81.8 145 76.9 91.8 155
460, 3ph, 60 Hz 32.7 39.9 70 37.2 44.4 75
200, 3ph, 50 Hz 73.3 89.8 160 83.3 99.8 170
400, 3ph, 50 Hz 37.2 45.4 80 42.2 50.4 85
F.L.A. Min.
Ampacity
Max. Fuse F.L.A. Min.
Ampacity
Max. Fuse
TABLE 3-2
3-8
INSTALLING YOUR TUBE-ICE® MACHINE
Phase Check
DO NOT attempt to start machine without priming pump
and insuring proper rotation of both cutter and pump.
Refer to FIGURE 3-1 & 3-2 (space diagram) for connection locations.
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 maximum 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 L1 is loose or
dirty, L2 and/or L3 will have higher current. Higher cu rrent causes more heat to be generated in the
motor windings.
The maximum acceptable current unbalance is 10%.
Example:
Current Readings: L1 = 96 Amps
L2 = 91 Amps Average = (96 + 91 + 98)/3 = 95Amps
L3 = 98 Amps
(L1) 96-95 = 1 Amps
(L2) 95-91 = 4 Amps (Highest Deviation) % Current Unbalance = 100 x (4/95) = 4.2%
“Acceptable”
(L3) 98-95 = 3 Amps
8/23/01
03TA Service Manual
Electrical Specifications
! CAUTION !
! CAUTION !
03TA Service Manual
INSTALLING YOUR TUBE-ICE® MACHINE
Air-Cooled Condenser Installation Instructions
! WARNING !
These installation guidelines must be followed to obtain
reliable operation from air cooled ice machines.
IF THESE GUIDELINES ARE NOT FOLLOWED THE
COMPRESSOR WARRANTY WILL NOT BE HONORED.
! WARNING !
1. Use only Vogt approved condensers. Any exceptions to this policy must be obtained in writing
from Vogt prior to installation and operation of the ice machine.
2. Outdoor condensers must be installed with vertical air flow. Indoor condensers used for heat
recovery may be installed with either horizontal or vertical air flow.
3. The condenser must be mounted above the ice machine.
4. Horizontal runs in the liquid return line should slope 1/4” per foot with liquid refrigerant draining
freely in the direction of normal operating flow (back to the ice machine) with no traps in the
liquid line.
5. Horizontal runs in the discha rge line should slope 1/4” per foot in the normal direction of flow
(away from the ice machine).
6. Traps must be installed in discharge lines at the base of all vertical 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 -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 insulated with 1/2” thick Armaflex insulation or equal.
9. Use only ACR grade copper pipe, Type L. Recommended line sizes are shown in TABLE 3-3.
10. For field attachment instructions, see FIGURE 3-4.
11. Distance between ice machine and condenser must not exceed 150 equivalent feet. Refer to
Condenser Equivalent Line Size worksheet (see TABLE 3 -4 ).
12. Condensers must be provided with a cold weather valve kit per FIGURE 3-8. These valves allow
one-half of the condenser to be disabled in cold weather. Running the ice machine with one-half
of the condenser in cold weather makes it easier to maintain minimum necessary condensing
pressure particularly in windy conditions.
13. Condensers with multiple fans must be provided with a thermostat to turn off unneeded fans in
cold weather. Turning off unneeded fans reduces on-off cycling of the fan(s) and allows for a
steadier condensing pressure and more consistent warm gas for ice harvesting.
3-9
8/23/01
3-10
INSTALLING YOUR TUBE-ICE® MACHINE
14. When extreme cold conditions are expected or encountered (temperatures below 0?F and wind
greater than 15 MPH), it may be necessary to install a protective enclosure around the condenser.
Apparatuses such as louvers may also be used for varying conditions. Contact the factory for
suggestions.
15. After installation, the field installed lines are to be evacuated to a vacuum of 500 microns or less
and held for at least one hour. After the vacuum pump is removed, vacuum should hold at 500
microns or less for at least 5 minutes.
16. The machine is shipped with a full operating charge of refrigerant sufficient to fill the condenser
and connecting lines. If the condenser piping is longer than 50 feet (one way), additional R -22 or
R-404a may need to be added to retain enough refrigerant in the receiver for thawing purposes
(see table. Refer to the operating level mark on the receiver and charge accordingly. Each 1” of
liquid level in the receiver equals approximately 5.5 pounds of R -22 or R-404a.
Liquid Line Size 75 ft. 100 ft. 125 ft. 150 ft.
1/2” none None None 2
5/8” none 2 4 6
7/8” none 4 8 12
1-1/8” none 6 12 18
Pounds of R-22 to Add vs. Liquid Line Length
17. All piping must be done in accordance with applicable local and national codes. Su ch 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. Local electrical code must be checked for wiring method.
b. The installer must provide a disconnect switch(s) adjacent to the condenser.
c. Electrical conn ections between the condenser and the Tube- Ice® machine require
minimum 12 ga. wire.
d. All electrical fittings and components exposed to the weather must be suitable for
outdoor installation.
The design total heat rejection for each Tube -Ice® machine, the recommended air -cooled condenser,
and condenser physical and electrical data are shown on the next page. Specified energy efficiency
ratings of the ice machines are based on use of the recommended condenser and approved piping
practices.
Recommended condensers provide the indicated total heat rejection at 90?F ambient, 100?F
condensing. Tube Ice, LLC is not responsible for head pressure problems if other than the
recommended condensers are used. For continuous operation at ambient temperature above 105 ?F,
consult the factory about using a larger condenser.
03TA Service Manual
TABLE 3-3
8/23/01
03TA Service Manual
Ice Machine Model 03TA 03TA
Electrical Frequency, Hz. 60 50
Recommended Condenser DD-231 DD-231
Total Heat Rejection (BTU/hr) 128,100 128,100
Fans:
Number
HP, Each
Total CFM
Full Load Amps (FLA):
3 ph., 208/230V, 60 hz.
3 ph., 460V, 60 hz.
3 ph., 200V, 50 hz.
3 ph., 380V, 50 hz.
Locked Rotor Amps (LRA):
3 ph., 208/230V, 60 hz.
3 ph., 460V, 60 h z.
3 ph., 200V, 50 hz.
3 ph., 380V, 50 hz.
Weight, lbs.:
Net
Shipping
Operating (Maximum flooded) R-404a
Condenser Dimensions, inches (See Fig. 3-7)
A (Width)
B (Length)
C (Height)
D (Leg centerline)
E (Leg centerline)
F (Clearance below)
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.
Connections (Cond. & Ice Mach.):
Liquid (ODF)
Discharge Gas (ODF)
3
1/2
15,000
6.0
3.0
--
--
19.8
9.8
--
--
400
500
430
41 3/8”
105”
36 1/8”
40 3/8”
94”
11 3/4”
1 1/8”
1 1/8”
1 1/8”
1 3/8”
1 1/8”
1 3/8”
TABLE 3-4
Air-Cooled Condenser Data
3-11
INSTALLING YOUR TUBE-ICE® MACHINE
3
1/2
15,000
--
--
6.0
3.0
--
--
19.8
9.8
400
500
430
41 3/8”
105”
36 1/8”
40 3/8”
94”
11 3/4”
1 1/8”
1 1/8”
1 1/8”
1 3/8”
1 1/8”
1 3/8”
8/23/01
3-12
INSTALLING YOUR TUBE-ICE® MACHINE
03TA Service Manual
FIGURE 3-7
Condenser Dimensions (Condenser pictured: DD-231)
Note: Dash lines indicate customer supplied piping.
8/23/01
FIGURE 3-8
Condenser Field Piping (Cold Weather Valve Kit)
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