Vogt HES-20 Service Manual
HES Series Service Manual
Table Of Contents
Models HES-20, HES-30 & HES-40
Page No.
1. INTRODUCTION
A Brief History of Our Company ................................................................................................................ 1-1
®
Vogt Energy-Saving Tube-Ice
Preview .................................................................................................................................................... 1-1
Important Safety Notice............................................................................................................................... 1-2
Special precautions to be observed when charging refrigeration systems ................................................... 1-2
Safety Symbols & What They Mean ........................................................................................................... 1-3
2. RECEIPT OF YOUR TUBE-ICE® MACHINE
Inspection ................................................................................................................................................... 2-1
Machines................................................................................................... 1-1
TABLE OF CONTENTS
i
Safety Valves............................................................................................................................................... 2-2
Machine Room ............................................................................................................................................ 2-2
Storage .................................................................................................................................................... 2-2
3. HOW YOUR TUBE-ICE® MACHINE WORKS
Principle of Operation ................................................................................................................................. 3-1
Air Cooled Piping Diagram, FIGURE 3-1 .................................................................................................. 3-2
Water Cooled Piping Diagram, FIGURE 3-2.............................................................................................. 3-2
Piping Schematic Nomenclature.................................................................................................................. 3-3
How Ice Is Stored
Bin Control Sensor Installation, FIGURE 3-3 ............................................................................................. 3-4
Storing Ice ................................................................................................................................................... 3-4
Ice Bin Capacity .......................................................................................................................................... 3-4
When Ice Bin Thermostats Are Not Used ................................................................................................... 3-5
Single Ice .................................................................................................................................................... 3-5
Dual Ice .................................................................................................................................................... 3-5
Crushed Ice Preferred .................................................................................................................................. 3-5
4. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Control Panel, FIGURE 4-1A ..................................................................................................................... 4-1
Control Panel with Hoffman Enclosure, FIGURE 4-1B.............................................................................. 4-1
Control Panel Part Numbers, TABLE 4-1 ................................................................................................... 4-2
Description of Control Panel Parts .............................................................................................................. 4-3
Wiring and Electrical Connections, FIGURE 4-2 ....................................................................................... 4-5
Electrical Specifications, TABLE 4-2 ......................................................................................................... 4-5
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TABLE OF CONTENT
Page No.
4. ELECTRICAL CONTROLS & THEIR FUNCTIONS (Cont.)
PLC Features & Functions........................................................................................................................... 4-6
PLC Display, FIGURE 4-3.......................................................................................................................... 4-6
PLC Inputs & Outputs, TABLE 4-3 ..................................................................................................... 4-6
PLC Start-Up Mode ............................................................................................................................. 4-7
PLC Stand-By Mode ............................................................................................................................ 4-7
PLC Freeze Mode ................................................................................................................................ 4-7
PLC Harvest Mode............................................................................................................................... 4-7
PLC Partial Pump-Down Mode............................................................................................................ 4-7
PLC Partial Pump-Down Time, TABLE 4-4........................................................................................ 4-7
PLC Total Pump-Down Mode.............................................................................................................. 4-7
PLC Clean Mode.................................................................................................................................. 4-8
PLC Fault Mode ................................................................................................................................... 4-8
PLC Fault Codes, TABLE 4-5 ............................................................................................................. 4-8
Copeland Performance Alert ....................................................................................................................... 4-9
Copeland Performance Alert wiring, FIGURE 4-4 ..................................................................................... 4-9
Copeland Performance Alert Codes & Lockout Configuration, TABLE 4-6 .............................................. 4-9
Machine Fault Startup Sequence, FIGURE 4-5........................................................................................... 4-10
Fault Indicator / Selector Switch Location, FIGURE 4-6............................................................................ 4-10
Dual Ice Machine (200V/208-230V) Wiring Schematic, FIGURE 4-7 ...................................................... 4-11
Single Ice Machine (200V/208-230V) Wiring Schematic, FIGURE 4-8 .................................................... 4-12
Single Ice Machine (Dual voltage -50hz) Wiring Schematic, FIGURE 4-9 ................................................ 4-13
Single Ice Machine (400V/460V) Wiring Schematic, FIGURE 4-10 ......................................................... 4-14
Air Cooled Condenser Wiring Schematic (Single Fan – 50/50 Split), FIGURE 4-11................................. 4-15
Air Cooled Condenser Wiring Schematic (Single Fan – 50/25/25 Split), FIGURE 4-12............................ 4-16
Air Cooled Condenser Wiring Schematic (Dual Fan – 50/50 Split), FIGURE 4-13 ................................... 4-17
5. MAINTENANCE
Ice-making Section...................................................................................................................................... 5-1
Cleaning Procedure ..................................................................................................................................... 5-1
Sanitizing Procedure.................................................................................................................................... 5-2
Water Distributors, FIGURE 5-1................................................................................................................. 5-4
Water Distributors, Freezer Cover, Gasket Part #'s, TABLE 5-1 ................................................................ 5-4
Water Tank.................................................................................................................................................. 5-5
Drip Pan .................................................................................................................................................... 5-5
Water Cooled Condensers ........................................................................................................................... 5-5
Draining the Condenser ............................................................................................................................... 5-6
Chemical Cleaning the Condenser............................................................................................................... 5-6
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Page No.
5. MAINTENANCE (Cont.)
Mechanical Cleaning the Condenser ........................................................................................................... 5-6
Part I..................................................................................................................................................... 5-6
Part II ................................................................................................................................................... 5-7
Replacement Gaskets, TABLE 5 -2............................................................................................................. 5-7
Air-Cooled Condenser Cleaning.................................................................................................................. 5-8
Compressor Oil............................................................................................................................................ 5-8
Cutter Gear Reducer Oil .............................................................................................................................. 5-8
Preventive Maintenance .............................................................................................................................. 5-9
Daily Checklist ............................................................................................................................................ 5-9
Note To Manager or Owner ........................................................................................................................ 5-9
Preventive Maintenance Program................................................................................................................ 5-10
6. TROUBLESHOOTING
iii
Machine Faults ............................................................................................................................................ 6-1
PLC Fault Codes, TABLE 6-1 .................................................................................................................... 6-1
Machine Fault Indicator Light, FIGURE 6-1 .............................................................................................. 6-2
Machine Fault Startup Sequence, FIGURE 6-2........................................................................................... 6-2
PLC, FIGURE 6-3....................................................................................................................................... 6-3
PLC Inputs and Outputs, TABLE 6-2 ......................................................................................................... 6-3
Machine Will Not Run ................................................................................................................................ 6-4
Checking PLC ............................................................................................................................................. 6-4
Low Ice Capacity......................................................................................................................................... 6-5
Fault # 1, High/Low Pressure during Freeze ............................................................................................... 6-6
Fault # 2, High/Low Pressure during Harvest.............................................................................................. 6-7
Fault # 3, High/Low Pressure during Partial Pumpdown............................................................................. 6-7
Fault # 4, High/Low Pressure during Total Pumpdown .............................................................................. 6-8
Fault # 5, Short Cycle Fault......................................................................................................................... 6-9
Fault # 6, Long Cycle Fault ......................................................................................................................... 6-9
Fault # 7, Pump Motor Overload Fault........................................................................................................ 6-10
Fault # 8, Cutter Motor Overload Fault....................................................................................................... 6-10
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7. SERVICE OPERATIONS
Machine Component Layout (Front View), FIGURE 7-1A ........................................................................ 7-1
Machine Component Layout (Side View), FIGURE 7-1B .......................................................................... 7-1
Machine Component Layout (Rear View - WC), FIGURE 7-1C ................................................................ 7-2
Machine Component Layout (Rear View - AC), FIGURE 7-1D................................................................. 7-2
Adjustable Blowdown (For Clearer Ice)...................................................................................................... 7-3
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TABLE OF CONTENT
Page No.
7. SERVICE OPERATIONS (Cont.)
Automatic Blowdown (Harvest Cycle), FIGURE 7-2 ................................................................................. 7-3
Float Valve (Make-Up Water), FIGURE 7-3 .............................................................................................. 7-4
Circulating Water Pump, FIGURE 7-4........................................................................................................ 7-4
Circulating Water Pump Replacement Parts, TABLE 7-1........................................................................... 7-5
Water Distributors, TABLE 7-2 .................................................................................................................. 7-5
Freezer Cover, Gasket, FIGURE 7-5........................................................................................................... 7-5
Water Tank.................................................................................................................................................. 7-6
Cutter-Water Tank Assembly, FIGURE 7-6................................................................................................ 7-6
Cutter Gear Reducer .................................................................................................................................... 7-6
Gear Reducer Replacement ......................................................................................................................... 7-7
Cutter Bearing ............................................................................................................................................. 7-7
Cutter and Gear Drive ................................................................................................................................. 7-7
Ice Discharge Arrangement, FIGURE 7-7................................................................................................... 7-8
Cutter-Water Tank Parts, FIGURE 7-8 ....................................................................................................... 7-9
Cutter Drive Parts, FIGURE 7-9 ................................................................................................................. 7-10
Cutter Parts, FIGURE 7-10 ......................................................................................................................... 7-11
Thermal Expansion Valve, FIGURE 7-11................................................................................................... 7-12
TXV Part #'s, TABLE 7-3 ........................................................................................................................... 7-12
Checking Superheat..................................................................................................................................... 7-12
Recommended Superheat Setting, TABLE 7-4 ........................................................................................... 7-13
Expansion Valve Adjustment Procedure & Installation .............................................................................. 7-13
Solenoid Valves, FIGURE 7-12 .................................................................................................................. 7-14
Solenoid Valves Parts, TABLE 7-5............................................................................................................. 7-14
Freezer Pressure Switches ........................................................................................................................... 7-15
Freezer Pressure Switch (Allen-Bradley), FIGURE 7-13............................................................................ 7-15
High/Low Pressure Switch, FIGURE 7-14.................................................................................................. 7-16
Head Pressure .............................................................................................................................................. 7-17
Air-Cooled Units ......................................................................................................................................... 7-17
Condenser Fan Switch, FIGURE 7-15 ........................................................................................................ 7-17
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Air Cooled Condenser Cleaning.................................................................................................................. 7-17
Cold Weather Kit Replacement Parts, TABLE 7-6 ..................................................................................... 7-17
Air Cooled Condenser Data, TABLE 7-7.................................................................................................... 7-18
Condenser Dimensions, FIGURE 7-16 ....................................................................................................... 7-18
Condenser Wiring, FIGURE 7-17 ............................................................................................................... 7-19
Water Cooled Units ..................................................................................................................................... 7-19
Water Regulating Valve, FIGURE 7-18...................................................................................................... 7-19
HES Series Service Manual
7. SERVICE OPERATIONS (Cont.)
Water Regulating Valve Part #'s, TABLE 7-8............................................................................................. 7-19
Water Cooled Condenser Service ................................................................................................................ 7-20
Compressor Crankcase Heater, TABLE 7-9................................................................................................ 7-20
Compressor Motor Rotation ........................................................................................................................ 7-20
Scroll Compressor, FIGURE 7-19 .............................................................................................................. 7-21
Compressor Info, TABLE 7-10 ................................................................................................................... 7-21
Compressor Suction Rota-lock Valve, FIGURE 7-20, TABLE 7-11 .......................................................... 7-22
Compressor Discharge Rota-lock Valve, FIGURE 7-21, TABLE 7-12 ...................................................... 7-23
Short Circuit Protection, FIGURE 7-22 ...................................................................................................... 7-24
Control Circuit Protection ........................................................................................................................... 7-24
Motor Short Circuit Protection .................................................................................................................... 7-25
Motor Over Current Protection ................................................................................................................... 7-25
TABLE OF CONTENTS
Page No.
v
Overload Heater Pack Settings, TABLE 7-13 ............................................................................................. 7-25
Motor Overloads, FIGURE 7-23 ................................................................................................................ 7-25
Ice Bin Control, FIGURE 7-24 ................................................................................................................... 7-26
Programming Electronic Bin Thermostat .................................................................................................... 7-26
Bin Thermostat Mounting Location, FIGURE 7-25 .................................................................................... 7-27
Electronic Bin Thermostat Error Messages................................................................................................. 7-27
Thawing Timer, FIGURE 7-26.................................................................................................................... 7-28
Thawing Timer ............................................................................................................................................ 7-28
Selector Switch, FIGURE 7-27 ................................................................................................................... 7-28
Pumping Down Freezer ............................................................................................................................... 7-29
Pumping Down Entire System..................................................................................................................... 7-29
Removal of Refrigerant From the Machine ................................................................................................. 7-29
Refrigerant Leaks ........................................................................................................................................ 7-30
Non-Condensable Gases.............................................................................................................................. 7-30
Compressor Motor Burnout......................................................................................................................... 7-30
Cylinder Ice to Crushed Ice Conversion...................................................................................................... 7-31
Cylinder to Crushed, Terminal Block jumper Locations, FIGURE 7-28 .................................................... 7-31
Recommended Freezer Pressure Setting, TABLE 7-14............................................................................... 7-31
Freezer Pressure Switch, FIGURE 7-29 ...................................................................................................... 7-31
Recommended Ice Weights/Cycle, TABLE 7-15........................................................................................ 7-31
Single to Dual Ice Conversion..................................................................................................................... 7-31
Defrost Pressure Switch (DPS), FIGURE 7-30 ........................................................................................... 7-32
Defrost Pressure Switch Wiring, FIGURE 7-31.......................................................................................... 7-32
Oil Separator, FIGURE 7-32 ....................................................................................................................... 7-33
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Page No.
8. MODEL NUMBER STRUCTURE FOR HES MACHINES................................................................. 8-1
9. TABLES AND CHARTS
Ice Capacity TABLE 9-1............................................................................................................................. 9-1
Normal Operating Vitals, TABLE 9-2 ........................................................................................................ 9-1
Temperature-Pressure Chart, TABLE 9-3 ................................................................................................... 9-2
English-Metric Conversion, TABLE 9-4..................................................................................................... 9-3
Constants, TABLE 9-5 ................................................................................................................................ 9-3
10. TECHNICAL SERVICE BULLETINS ................................................................................................ 10-1
11. INDEX .................................................................................................................................................... 11-1
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HES Series Service Manual
ELECTRICAL CONTROLS & THEIR FUNCTIONS
4. Electrical Controls & Their Functions
FIGURE 4-1A
Control Panel (Cover Removed)
Note: Machines manufactured after May 1999 will use Allen-Bradley controls
FIGURE 4-1B
Control Panel with Hoffman Enclosure (Door Open)
4-1
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HES Series Service Manual
ELECTRICAL CONTROLS & THEIR FUNCTIONS
Vogt Part #
Reference Cutler-Hammer Allen-Bradley Description
12A2117G09 SAME CRUSHED ICE BIN CONTROL (DUAL ICE ONLY)
BC1
12A2117G09 SAME CYLINDER ICE BIN CONTROL
BC2
12A7516E10 12A7516E26 COMPRESSOR CONTACTOR
C
12A7518E15 12A7518E30 COMPRESSOR AUX CONTACT
12A7515E18 SAME PUMP / CUTTER MOTOR CIRCUIT BREAKER (10 AMP)
CB1
12A7515E19 SAME * CONDENSER FAN MOTOR CIRCUIT BREAKER (15 AMP)
CB2
CB3 & CB4
CPA
FPS1
FPS2
FU1-FU3
FU10 & FU20
PLC
TEST
*Note: AIR COOLED ONLY
12A7515E20
N/A 12A7700P02 COPELAND PERFORMANCE ALERT
12A7530E11 12A7516E23 CUTTER MOTOR STARTER / CONTACTOR
CU
12A7508H2108 12A7538E01 CUTTER OVERLOAD HEATERS (3.38-5.54 A) / OL RELAY (2-7 A)
12A2117E04 SAME FREEZER PRESSURE SWITCH (DUAL ICE ONLY)
12A2117E04 SAME FREEZER PRESSURE SWITCH
N/A 12A7504E13 CONDENSER FAN MOTOR FUSES, 6A, 600V (400/460V MACH)
N/A 12A7504E14 CONTROL CIRCUIT FUSES, 7A, 600V (400/460V MACH)
12A7530E11 12A7516E23 PUMP MOTOR STARTER / CONTACTOR
P
12A7508H2109 12A7538E01 PUMP OVERLOAD HEATERS (4.96-8.16 AMPS) / OL RELAY (2-7 A)
12A7500E45 12A7500E56
PB1
N/A 12A7537S06 POWER LINE FILTER (CE MACHINES ONLY)
PLF
SAME 12A7536M01 PROGRAMMABLE CONTROLLER
12A7517E18 12A7517E27 REVERSING RELAY (DUAL ICE ONLY)
R
12A7500E43 SAME 5 POSITION SELECTOR SWITCH (DUAL ICE)
SS
12A7500E44 12A7500E61
N / A N / A TERMINAL BLOCK
TB
N / A N / A TEST BLOCK (ON CUTLER-HAMMER - FACTORY USE ONLY)
12A7500E46 12A7500E65 FAULT INDICATOR LIGHT
1LT
(QTY 2)
12A7515E21 CONTROL CIRCUIT BREAKER (3 AMP)
HARVEST / START BUTTON
12A7500E75
12A7500E73
CONTACT BLOCK (FOR ALLEN-BRADLEY ONLY)
3 POSITION SELECTOR (SINGLE ICE)
CONTACT BLOCK (FOR ALLEN-BRADLEY ONLY)
TABLE 4-1
Control Panel Parts List
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HES Series Service Manual
ELECTRICAL CONTROLS & THEIR FUNCTIONS
Description of Control Panel Parts.
*BC1 and BC2. Bin Controls. Ice bin thermostats for automatically stopping and starting the
machine based on the ice level in the storage bin. BC1 (Crushed Ice). BC2 (Cylinder Ice).
C. Compressor Motor Contactor. Provides power to the compressor motor. Energized during
freezing and thawing. Normally closed contact provides power to the compressor crankcase heater
when the machine is off.
CB1. Pump / Cutter Motor Circuit Breaker (10 amps). Two pole magnetic circuit breaker used for
short circuit protection in the cutter or pump motor circuit. If breaker trips, power is removed from
control circuit, shutting machine down.
CB2. Condenser Fan Motor Circuit Breaker (15 amps). Two-pole thermal magnetic circuit breaker
used for short circuit protection in the condenser motor circuit. If breaker trips, power is removed from
condenser only. Machine will eventually shut off on high discharge pressure.
CB3 and CB4. Control Circuit Breaker (3 Amps). Current limiting thermal magnetic circuit breaker
used as overload and short circuit protection for crankcase heater, PLC outputs and other control circuit
components.
CPA. Copeland PerformanceAlert. Device that monitors compressor current, phase and temperature
and shuts off machine if a problem is detected.
CU. Cutter Motor Starter.
Cutler-Hammer: A three phase motor starter with adjustable bimetallic heater packs, wired for use with
single-phase motor. Cutter Motor Overload (heater packs) – Class 10 overloads rated 3.38 - 5.54 Amps
set at cutter motors FLA rating. Pull "Reset" button to test overload.
Allen-Bradley: Motor starter made of 3-pole contactor and solid-state overload relay, wired for use
with single-phase motor. Overload - Class 10 rated 2 - 7 Amps set at cutter motors FLA rating. Press
"TEST" button to test overload.
Can be configured to reset automatically (“A”) or manually (“M”). PLC controlled machines will have
the overload reset in the “automatic” position. When an overload condition occurs, an auxiliary contact
signals the PLC of a problem and shuts the machine off (PLC input light # 5 will be “off” when
overload is tripped). Will automatically reset after an overloads cool.
See Section 7, Motor Over Current Protection for details.
*FPS1 and FPS2. Freezer Pressure Switches. For regulating the ice thickness by sensing the freezer
pressure and initiating the thaw period. FPS1 (Crushed Ice). FPS2 (Cylinder Ice).
FU10 & FU20. Transformer Primary Protection Fuses - 400/460V machines only. (7A, 600V,
time delay fuses). Fuses used for transformer primary protection along with control circuit upstream of
CB3/CB4.
FU1, FU2 & FU3. Condenser Fan motor Fuses - 400/460V machines only. (6A, 600V, Time delay
fuses). Fused used for short circuit protection in the condenser motor circuit. If fuse(s) blows, power is
removed from condenser only. Machine will eventually shut off on high discharge pressure.
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4-4
HES Series Service Manual
ELECTRICAL CONTROLS & THEIR FUNCTIONS
P. Pump Motor Starter.
Cutler-Hammer: A three phase motor starter with adjustable bimetallic heater packs, wired for use on
single phase. Pump Motor Overload (heater packs) – Class 10 overloads rated 4.96 – 8.16 Amps set at
pump motors FLA rating. Pull "Reset" button to test overload.
Allen-Bradley: Motor starter made of 3-pole contactor and solid-state overload relay, wired for use
with single-phase motor. Overload - Class 10 rated 2 - 7 Amps set at pump motors FLA rating. Press
"TEST" button to test overload.
Can be configured to reset automatically (“A”) or manually (“M”). PLC controlled machines will have
the overload reset in the “automatic” position. When an overload condition occurs, an auxiliary contact
signals the PLC of a problem and shuts the machine off (PLC input light # 5 will be “off” when
overload is tripped). Will automatically reset after an overloads cool.
See Section 7, Motor Over Current Protection for details.
PB1. Start/ Harvest button. For starting the machine in the ice-making mode. Momentary contact or
initiating a harvest cycle if the machine is in the freeze mode. Can be used to bypass the built in 120
minute start-up mode delays as well as terminate a harvest cycle.
PLC. Programmable Logic Controller. For monitoring, sequencing, and controlling various
functions of the Tube-Ice® operation. Also has a built in thaw timer for controlling the time of the
thawing period. Thawing time is adjustable from 1 1/2 to 5 minutes.
PLF. Power Line Filter. Used on “CE” approved machines only. Used to reduce amount of noise on
incoming power lines.
*R. Reversing Relay. Switches machine to crush ice by making or breaking various circuits
concerning crushed ice production. Energized during crushed ice production only.
SS. Selector Switch.
Dual Ice machines – Five positions switch for the purpose of selecting form five different machine
modes. Clean / crushed / cylinder / Both (cyl & crushed) / off.
Single Ice machines – Three position switch for the purpose of selecting from three different machine
modes, clean / Ice / off.
1LT. Fault indicator light (24VDC light) flashes a designated number of times. A non-auto restart fault
occurs or a auto-restart fault occurs three consecutive times.
*Note: Components used in dual ice type machines only.
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ELECTRICAL CONTROLS & THEIR FUNCTIONS
Wiring And Electrical Connection.
Refer to TABLE 4-1 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. 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”
terminal provided. On dual voltage, 50 Hz machines, the 220V single phase should be connected to
terminals L4 and L5.
Note: When initially starting the machine, the scroll compressor must be phased properly. If the
compressor is run backwards for an extended period of time, the compressor may be damaged. See
Section 7, Compressor Motor Rotation for details.
Air-cooled condenser should be wired to terminals 20,21,22 and 23 (see FIGURES 4-9, 4-10).
460V air cooled condensers should be wired to terminals B1, B2, B3, 22 & 23.
4-5
FIGURE 4-2
Terminal Block Connections
Standard Voltages: Water Cooled Air Cooled
Model Voltage F.L.A. Min. Ampacity Max. Fuse F.L.A. Min. Ampacity Max. Fuse
HES20
HES30
HES40
208/230, 3p, 60 hz 18.0 20.9 30 21.4 24.3 35
460, 3p, 60 hz 9.0 10.4 15 10.3 11.7 20
220, 3p, 50 hz 19 21.0 35 22.4 25.3 35
400, 3p, 50 hz 9.5 10.9 15 10.8 12.2 15
208/230, 3p, 60 hz 21.6 25.4 40 25.5 29.3 40
460, 3p, 60 hz 10.7 12.6 15 12.0 13.9 20
220, 3p, 50 hz 22.6 26.4 40 26.5 30.3 45
400, 3p, 50 hz 11.2 13.1 20 12.5 14.4 20
208/230, 3p, 60 hz 27.3 32.5 50 35.1 40.3 60
460, 3p, 60 hz 13.3 15.8 30 17.3 19.8 30
220, 3p, 50 hz 28.3 33.5 50 36.1 41.3 60
400, 3p, 50 hz 15.3 18.2 25 17.9 20.8 30
TABLE 4-2
Electrical Specifications
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HES Series Service Manual
ELECTRICAL CONTROLS & THEIR FUNCTIONS
Electrical Specifications “PLC” (Programmable Logic Controller)
Sequence Of Controller & Machine Operation
NOTE: Part #12A7536M01. PLC must be pre-programmed for specific model.
FIGURE 4-3
PLC Display (Fxo shown above)
PLC Inputs PLC Outputs
# Description
0 Cylinder Ice Indicator
1 Crushed Ice Indicator
2 Freezer Pressure Switch
3 Start / Manual Harvest
4 Clean Switch
5 Pump / Cutter Overload
(“off” when tripped)
6 High / Low Pressure safety
7 N/A
(“off” when tripped)
# Description
0 Machine Fault Indicator Light
1 "A" valve
2 Compressor
3 Reversing Relay (Dual Ice only)
4 Water Pump
5 Cutter / "D" valve / Suction Stop
TABLE 4-3
PLC Inputs & Outputs
Explanation. The HES-Series Tube-Ice® machine is controlled by a PLC (Programmable Logic
Controller). The PLC controls the sequence of events and monitors the ice machine functions. The
operational sequences of the HES-Series Tube-Ice® machine can be described best as a series of eight
different modes. Each mode identifies and defines a sequence of events that occur while in that mode
and thereby cause it to move to the next mode. Only one mode is active at a time.
Start-Up Mode. The start-up mode is a function, which prevents the premature automatic starting of
the machine at the time of installation, after a power interruption, or after a safety trip. Its normal time
period is two hours. The start-up mode may be bypassed at any time by pressing the “Harvest/Start”
button to immediately advance to the standby mode.
! CAUTION !
If the power has been turned off to the machine, make sure the compressor crankcase is warm
And there is no liquid refrigerant in with the oil before restarting the unit.
! CAUTION !
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ELECTRICAL CONTROLS & THEIR FUNCTIONS
Standby Mode. The standby mode is a decision-making mode. It monitors the position of all the
various switches in the control circuit and at the proper time decides which mode to advance to next.
Freeze Mode (Freeze Cycle). The freeze mode is active during the normal ice making cycle. During
this time, the circulating water pump and compressor are running and the “A” (liquid feed) solenoid
valve and “X” solenoid valve compressor discharge (AC units only) is open.
Harvest Mode (Thaw Cycle). The harvest mode is normally initiated at the termination of the freeze
mode. At this time, the circulating water pump stops and the “A” (liquid feed) solenoid valve closes.
After seven seconds, the “D” (thaw gas) solenoid valve opens, the “SS” (suction stop) solenoid valve
closes, the cutter motor starts and the thaw timer is activated.
The harvest mode is terminated by the thaw (harvest) timer at which time the machine will begin
another freeze cycle. The harvest mode can also be terminated manually by pushing in the
“Harvest/Start” button.
NOTE: If the “Selector Switch” switch is in the “Off” position or the bin control is satisfied the
machine will advance to the partial pumpdown mode before shutting off (standby mode).
Partial Pumpdown Mode. The partial pumpdown mode precedes the normal off or standby mode. Its
purpose is to transfer a portion of the liquid from the suction accumulator and freezer into the receiver
prior to shutdown of the machine (standby mode). This will discourage any migration of liquid
refrigerant to the compressor during the off or standby mode. It is also intended to prevent any liquid
refrigerant slugging to the compressor when the machine restarts in a freeze mode.
4-7
When partial pumpdown is initiated, the “A” (liquid feed) solenoid valve is closed and the water pump
and compressor run for a set time. After this set time the compressor stops and the machine is in the
standby mode.
Model HES-20 HES-30 HES-40
Time 7 minutes 5 minutes 3 minutes
TABLE 4-4
Partial Pumpdown Time
NOTE: The PLC uses the cylinder ice pressure switch (FPS2) as a partial pumpdown safety. Do not
remove this pressure switch from the machine.
Total Pumpdown Mode. The function of the total pumpdown mode is to transfer all of the liquid
refrigerant from the freezer (evaporator) into the receiver. Total pumpdown is initiated as the first
phase of and prior to entering the “Clean” mode.
Its main purpose is to clear the freezer of liquid refrigerant and prevent possible refrigerant migration to
the compressor while running the “Clean” cycle. It can also be used to check the units total refrigerant
charge, isolate the refrigerant in the receiver while making repairs, or prepare the machine for
disconnecting and moving.
To restart the machine after a total pumpdown, put the “Selector Switch” switch in the “Ice” position
and press the “Harvest/Start” button. At this time the “A” (liquid feed) solenoid valve will open for
two minutes, allowing refrigerant to feed into the freezer before the machine starts into a freeze cycle.
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ELECTRICAL CONTROLS & THEIR FUNCTIONS
Clean Mode. The “Clean” mode is considered to be maintenance or servicing function of the machine.
During this mode only the water pump will run. The first phase of the “Clean” mode is a total
pumpdown.
! CAUTION !
Do not attempt to bypass the total pumpdown phase of the “Clean” mode. If a clean cycle is
performed without first completing a total pumpdown, the warm water being circulated through
the freezer tubes can force refrigerant to migrate to the suction accumulator and compressor
which can cause compressor damage when returning to the freeze mode.
! CAUTION !
After the total pumpdown, the water pump can be stopped by simply moving the “Selector Switch”
from the “Clean” to the “Off” position. To restart the water pump, move the “Selector Switch” back to
the “Clean” position and press the “Harvest/Start” button. (Note: If the freezer and compressor suction
pressure have come up enough to open the freezer pressure switch FPS2 and close low pressure safety
switch 4PS, the compressor will come on and pump down the freezer again.) Ice machine cleaning
solution can be circulated though the tubes to accomplish the cleaning procedure. If the water pump is
left to run in the clean mode for more than two hours, the PLC will shut the machine off. The clean
mode can be resumed by pushing the “Harvest/Start” button.
NOTE: Running in Clean mode for extended period of time can cause excessive pressure to build up in
the freezer.
At the termination of the clean mode, the machine can be returned to ice making mode by putting the
“Selector Switch” in the “Ice” position and pressing the “Harvest/Start” button. . At this time the “A”
(liquid feed) solenoid valve will open for two minutes, allowing refrigerant to feed into the freezer
before the machine starts into a freeze cycle.
Fault Mode. The HES Series (“S” for Smart) is equipped with a PLC (programmable logic
controller) that controls all aspects of the operation. One of the functions of the PLC is to shut down
the machine when a problem arises and send a signal to the fault indicator light located on the far-left
side of the electrical panel. The red light is visible through the opening in the front casing and will
blink when a problem has caused the machine to shut down (See FIGURE 4-2).
NOTE: The Fault Light will flash the designated number of times ONLY if the fault is a not a autorestart fault or a auto-restart fault that has occurred three consecutive times. For your reference,
TABLE-4-3 contains a list of fault codes.
# Description Restart Off Delay
1 High / Low Press - Freeze No N/A
2 High / Low Press - Harvest No N/A
3 High / Low Press - Partial Pumpdown No N/A
4 High / Low Press - Total Pumpdown No N/A
5 Short Cycle Yes 2 hrs
6 Long Cycle No N/A
7 Pump Motor Overload Yes 30 min
8 Cutter Motor Overload Yes 30 min
N/A Power Failure Yes 2 hrs
NOTE: The machine may be off on a fault and not flashing an error code if the fault is an auto-restart
fault and it is not the third consecutive occurrence of this fault.
TABLE 4-5
PLC Fault Codes
5/24/11
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