Vogt P-24FL Service Manual

P-24FL

&

P-34FL

TUBE-ICE®

MACHINE

1/17/2006

Service Manual

$5000

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 start-up,
it should be stored in a safe place wh

ere 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 502-635­3000 or FAX at 502-635-3024 or 502-634-0479.

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.

1/17/2006

Please return to: Vogt Tube Ice LLC.
1000 W. Ormsby Ave.
Suite 19
Louisville, KY 40210

Attn. Tube-Ice Service Department

MID & LARGE MACHINE WARRANTY REGISTRATION/START-UP REPORT

Vogt® Tube-Ice® Machine

MUST COMPLETE AND RETURN TO INITIATE WARRANTY

Machine Model No. ________________________________

Serial No. ____________________________________________

Installed at: ____________________________________________________________( )_______________________________________
Company Name Phone

_______________________________________________________________________________________________________
Address City State Zip

______________________________________________________________________________________________________

Installed by: ___________________________________________________________( )________________________/____/________
Company Name Phone Date

_______________________________________________________________________________________________________
Address City State Zip

Describe any damage to machine/repairs made: _____________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

Start up by: ___________________________________________________________( )________________________/____/_________
Company Name Phone Date

_______________________________________________________________________________________________________
Address
Name of person starting up m

achine: ____________________________________________________________________________________

PRE START-UP CHECK

CHECK

Service Manual on hand
Machine room suitable 50°F minimum, 110°F maximum
Proper power supply, actual voltage _______________, _________________, _________________ (machine not running)
Compressor crankcase heater on 12 hour minimum
Necessary hand valves opened as required
Solenoid valve stems in auto position
System leak checked/tight
Auxiliary equipment overloads wired into control circuit
Compressor oil level _______ (1/4 glass min.)
All water distributors in place (visually inspected)
Water supply and drain lines installed and connected properly
Compressor, pump, cutter and other motor direction of rotation correct
Make-up water float valve adjusted properly
Hour meter in control panel connected

OPERATION CHECK

Machine charged with refrigerant lbs.______________ Actual voltage ____________ , _______________, ________________(machine running)
Ambient temp. _____ °F Fan cy

cles On _____ Off _____ Tower water in _____°F out ______ °F
Comp motor RLA _____________, _____________, _____________, Actual _____________, _____________, _____________,
Pump RLA _____________, _____________, _____________, Actual _____________, _____________, _____________
Cutter motor RLA _____________, _____________, _____________, Actual _____________, _____________, _____________
Suction pressure end of freezing _______, end of harvest _______ Discharge pressure end of freezing ___________, end of harvest __________
Evaporator/suction line frost _____________________________ Receiver liquid level operating ___________________

Test

Cycle

Water
Tem

p

FreezeTime

Min/Sec

Harvest Time

Min/Sec

First Ice Out

Min/Sec

All Ice Out

Min/Sec

Avg. Hole

Size

Ice Lb. Per

Harvest

Ice Lb. Per

Day
#1
#2
#3
#4

Note: Ice lb. per day can be found by: ice lb. per harvest
(freeze time + harvest time)

x 1440

The machine operated satisfactorily for ___ continuous hours. Date _______________________________________

Comments__________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

Installer signatur

e ____________________________________________ End user signature _________________________________

Please return to: Vogt Tube Ice LLC, 1000 W. Ormsby, Suite #19, Louisville, KY 40210

1/17/2006

The Vogt Tube Ice LLC., located in

Louisville, Kentucky since 1880.

Sales - [phone]

Service - [phone]

Parts - Your Local Distributor

Call your local distributor first for all of your parts and service needs.

Since 1880, Manufacturers of Quality

Tube-Ice® Machines

VOGT

®

TUBE-ICE® MACHINES

Installation, Service Manual, and Parts Catalog #12A-4171L13000000

Vogt Tube Ice LLC
1000 W. Ormsby Ave.
Suite 19
Louisville, Kentucky 40210
502-635-3000

FAX #[phone]

1/17/2006

P24FL & P34FL Model

P24FL & P34FL 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

Safety Symbols and What They Mean ..........................................................................................................................1-2

Special Precautions To Be Observed When Charging Refrigeration Systems..............................................................1-3

Assembly Drawing Model P24FL Tube-Ice

Assembly Drawing Model P34AFL Tube-Ice®Machine...............................................................................................1-5, 1-6, 1-7, 1-8

2. RECEIPT OF YOUR TUBE-ICE MACHINE

Inspection .....................................................................................................................................................................2-1

Description of Machine .................................................................................................................................................2-1

Safety Tags and Labels..................................................................................................................................................2-1

Model designation for P-Series Ice Machine, Figure 2-1..............................................................................................2-2

Rated Capacity ..............................................................................................................................................................2-3

Storage (prior to installation and start-up).....................................................................................................................2-4

3. INSTALLING YOUR TUBE-ICE MACHINE

Machine Room ..............................................................................................................................................................3-1

Space Requirements.......................................................................................................................................................3-1

Lifting Procedures .........................................................................................................................................................3-1

P24FLSpace Diagram, FIGURE 3-1.............................................................................................................................3-2,3-3

P24FL Foundation Layout, FIGURE 3-2 ......................................................................................................................3-4

P34FL Space Diagram, FIGURE 3-3............................................................................................................................3-5, 3-6

P34FL Foundation Layout, FIGURE 3-4 ......................................................................................................................3-7

Lifting Procedure for P24FL, FIGURE 3-5....................................................................................................................3-8

Lifting Procedure for P34FL, FIGURE 3-6....................................................................................................................3-9

Piping and Drain Connections, TABLE 3-1..................................................................................................................3-10

Make-Up Water In,........................................................................................................................................................3-10

Flushing Water In..........................................................................................................................................................3-10

Water Tank Drain..........................................................................................................................................................3-11

Water Tank Overflow...................................................................................................................................................3-11.

Safety Valves ................................................................................................................................................................3-11

Cooling Tower Piping Diagram, FIGURE 3-7..............................................................................................................3-12

Freeze Protection, FIGURES 3-8, 3-9, 3-10..................................................................................................................3-13, 3-14

Wiring and Electrical Connections.................................................................................................................................3-14

Power Supply Connections, FIGURE 3-11 ....................................................................................................................3-15

TABLE OF CONTENTS

Vogt

Model P24FL & P34FL

TABLE OF CONTENTS

®

TUBE-ICE® MACHINES

®

Machine..................................................................................................1-1, 1-2, 1-3, 1-4

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1/17/2006

ii

TABLE OF CONTENTS

3. INSTALLING YOUR MACHINE (contd)

Voltage Unbalance .........................................................................................................................................................3-15

Current Unbalance..........................................................................................................................................................3-15

Rotation Check...............................................................................................................................................................3-16

Auxiliary Controls or Equipment ...................................................................................................................................3-16

Installation Review: A Checklist....................................................................................................................................3-17

4. HOW YOUR TUBE-ICE MACHINE WORKS

Operating Features.........................................................................................................................................................4-1

Principle of Operation....................................................................................................................................................4-1

Freeze Period.................................................................................................................................................................4-1

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

Piping Nomenclature.....................................................................................................................................................4-2

Piping Schematic for P24FL, FIGURE 4-1...................................................................................................................4-3

Piping Schematic for P34FL, FIGURE 4-2...................................................................................................................4-4

5. START-UP AND OPERATION

Refrigeration System Review........................................................................................................................................5-1

Start-up Checklist..........................................................................................................................................................5-2

Refrigerant Charge ........................................................................................................................................................5-2

Start-Up .....................................................................................................................................................................5-3

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

Operating Tips...............................................................................................................................................................5-5

6. ELECTRICAL CONTROLS & THEIR FUNCTIONS

Bin Level Control..........................................................................................................................................................6-1

Safety Switches .............................................................................................................................................................6-1

Control Panel (Door Opened), FIGURE 6-1..................................................................................................................6-2

Description of Control Panel Parts (Inside), TABLE 6-1..............................................................................................6-2

Control Panel (Door Closed), FIGURE 6-2...................................................................................................................6-3

Description of Control Panel Parts (Outer Door), TABLE 6-2......................................................................................6-3

Electrical Schematic All Voltages 50-60 Hz. Across Line Start, FIGURE 6-3.............................................................6-4

Level column wiring for P24FL and P34FL,FIGURE 6-4 ............................................................................................6-5

7. MAINTENANCE

Preventive Maintenance.................................................................................................................................................7-1

Preventative Maintenance Form....................................................................................................................................7-2

Ice-Making Section........................................................................................................................................................7-3

Cleaning Procedure........................................................................................................................................................7-3

Water Distributors, TABLE 7-1 ....................................................................................................................................7-3

Average Hole Size in Tube-Ice

Water Tank....................................................................................................................................................................

Cutter Gear Reducer......................................................................................................................................................7-5

P24FL & P34FL Service Manual

®

, TABLE 7-2...............................................................................................................7-4

Page No.

7-4

P24FL & P34FL Service Manual

TABLE OF CONTENTS

Page No.

8. TROUBLESHOOTING

List Of Symptoms..........................................................................................................................................................8-1

Machine Stopped...........................................................................................................................................................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, 8-7

Poor Ice Quality.............................................................................................................................................................8-7

High Discharge Pressure................................................................................................................................................8-8

Low Discharge Pressure................................................................................................................................................8-9

High Suction Pressure....................................................................................................................................................8-9

Compressor Running Unloaded During Freeze.............................................................................................................8-9

Compressor Oil Pressure Low.......................................................................................................................................8-10

Compressor Loosing Oil Excessively............................................................................................................................8-10

Machine Short Cycles....................................................................................................................................................8-11

Shut Down By Oil Pressure Switch...............................................................................................................................8-11

High Compressor Discharge Temperature.....................................................................................................................8-11

Suction Line Frosting To Compressor........................................................................................................8-12

9. SERVICE OPERATIONS

Automatic Blow down (Harvest Cycle).........................................................................................................................9-1

Cleaning the Ice Making Section...................................................................................................................................9-1

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

Capacitive Level Control...............................................................................................................................................9-1

Troubleshooting Guide the level controller, TABLE 9-1.......................................................................... ....................9-5

Hand Expansion Valve..................................................................................................................................................9-6

Freezer Pressure Switch.................................................................................................................................................9-6

Freezer Pressure Switch, FIGURE 9-2..........................................................................................................................9-6

High/Low Pressure Switch............................................................................................................................................9-6

High/Low Pressure Switch, FIGURE 9-3......................................................................................................................9-7

Control Circuit Protection..............................................................................................................................................9-7

Thawing Timer..............................................................................................................................................................9-7

Thawing Timer, FIGURE 9-4........................................................................................................................................9-8

P24FL and P34FL Cutter Assembly, FIGURE 9-5A.....................................................................................................9-8

P24F and P34FL Water Tank Assembly, FIGURE 9-5B..............................................................................................9-9

P24FL and P34FL Cutter and Water Tank Part No., TABLE 9-2.................................................................................9-9, 9-10

Cutter Gear Reducer......................................................................................................................................................9-10

Drive Gear Replacement................................................................................................................................................9-11

Gear Reducer Replacement ...........................................................................................................................................9-12, 9-13

Water Tank and Cutter Parts Weights, TABLE 9-3 ......................................................................................................9-13

Water Tank Removal.....................................................................................................................................................9-13

Cutter Assembly Removal and Installation ...................................................................................................................9-14

Bearing Bracket and Cutter Disc Removal....................................................................................................................9-14

Cutter Shaft and Bearing Removal.............................................................................................. ..................................9-15

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TABLE OF CONTENTS

9. SERVICE OPERATIONS (contd)

Cutter Shaft and Bearing Installation.............................................................................................................................9-15, 9-16

Cutter Height Adjustment..............................................................................................................................................9-16

Water Tank Installation .................................................................................................................................................9-17

Cutter Ring Gear Replacement......................................................................................................................................9-18

Cutter Blade Replacement.............................................................................................................................................9-18

Cutter Blade and Adapter Plate Adjustment, FIGURE 9-6 ...........................................................................................9-18

Cutter Adapter Plate Installation....................................................................................................................................9-19

Pumpdown 9-19, 9-20

Removal of Refrigerant from the Machine....................................................................................................................9-20

Refrigerant Leaks ..........................................................................................................................................................9-20

Non-Condensable Gases................................................................................................................................................9-20.

Water Contamination of R-22 Refrigerant.................................................................................................................... 9-20

Circulating Water Pump Motor .....................................................................................................................................9-21

The Thaw Gas Solenoid Valve......................................................................................................................................9-21

Thaw Gas Solenoid Valve, FIGURE 9-7.......................................................................................................................9-22

The Liquid Feed A1 and A2 Solenoid Valves...............................................................................................................9-22

The Liquid Feed Solenoid Valve, FIGURE 9-8.............................................................................................................9-23

Water Flush Solenoid Valve..........................................................................................................................................9-23

10. OPTIONS AND ACCESSORIES

Crushed Ice Production .................................................................................................................................................10-2

Length of Ice .................................................................................................................................................................10-2

Power Monitor .............................................................................................................................................................. 10-3

11. TABLES AND CHARTS

P24FL Specifications, TABLE 11-1............................................................................................................................ 11-2

P34FL Specifications, TABLE 11-2............................................................................................................................ 11-3

P24FL Capacity Ratings, TABLE 11-3 A...................................................................................................................11-4

P34FL Capacity Ratings, TABLE 11-3 B...................................................................................................................11-5

P24FL Condenser Water Usage, TABLE 11-4............................................................................................................11-6

P34FL Condenser Water Usage, TABLE 11-5............................................................................................................11-6

P24FL Make-Up Water Usage, TABLE 11-6..............................................................................................................11-7

P34FL Make-Up Water Usage, TABLE 11-7..............................................................................................................11-7

P24FL Normal Operating Vitals, TABLE 11-8...........................................................................................................11-8

P24FL Normal Operating Vitals, TABLE 11-9...........................................................................................................11-8

Temperature Pressure Chart, TABLE 11-10................................................................................................................11-10

Conversion Factors: English to Metric, TABLE11-11 ................................................................................................11-11

Constants, TABLE 11-12 ............................................................................................................................................11-11

12. APPENDIX

P24FL & P34FL Service Manual

Page No.

P24FL & P34FL Service Manual

v

TABLE OF CONTENTS

1/17/2006

P24FL & P34FL Service Manual

A Brief History Of Our Company. Henry Vogt Machine Co. was founded as a small machine
shop in Louisville, Kentucky in 1880. Today, Vogt Tube Ice LLC is one of the world’s leading
producers of ice-making equipment.

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 hard labor and large
amounts of floor space for freezing, cutting, and crushing ice by hand.

Vogt Energy-Saving Tube-Ice Machines Are Cost Effective. Today, Vogt Tube-Ice
enjoy a well-earned reputation as the most energy efficient, dependable ice-making equipment in the
world.

Using as little as one-half to one-third the energy required by competitors’ ice makers, 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’ve learned in over a century of
experience is reflected in every Tube-Ice® machine. 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 operation has 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 which is a
record of the unit’s satisfactory operation at 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

®

service it properly.

Please read your manual carefully before attempting installation, operation, or servicing of this
professionally designed piece of equipment. Also, make sure the Warranty Registration/Start-up
Report is completed and returned.

If you have additional questions, please call your distributor. Also, feel free to phone the factory
direct at [phone].

INTRODUCTION

1. Introduction

Henry Vogt Machine Co.

®

machines

®

machine will give you a lifetime of service provided you install, maintain, and

1-1

9/15/09

1-2

INTRODUCTION

Important Safety Notice. This information is intended for use by individuals possessing adequate
backgrounds in electrical, refrigeration and mechanical experience. Any attempt to repair major
equipment may result in personal injury and /or 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. It is important that personnel understand the properties of this refrigerant and that they
be thoroughly trained in safe practices for its use and handling. Refer to the enclosed “Freon
Compounds and Safety” in Appendix A.

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 Tube­Ice® 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.

P24FL & P34FL Service Manual

These safety symbols will alert you

when special care is needed.

Please heed them.

! DANGER !

Indicates an immediate hazard and that special precautions

are necessary to avoid severe personal injury or death.

! DANGER !

! WARNING !

Indicates a strong possibility of a hazard and that an

unsafe practice could result in severe personal injury.

! WARNING !

! CAUTION !

Means hazards or unsafe practices could result

in personal injury or product or property damage.

! CAUTION !

9/15/09

P24FL & P34FL Service Manual

Special Precautions To Be Observed When Charging Refrigeration Systems. Only technically
qualified persons, experienced and knowledgeable in the handling of R-22 or R-404a refrigerants,
and the 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 R-22 or R-404a
refrigerants. See “Material Safety Data Sheet”, MSDS Code No. DU000025 (R-22) or MSDS Code
No. DU005612 (R-404a) in Appendix A. For further information concerning refrigerants and
handling practices see internet web site: www.dupont.com/suva/

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 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, excessive or illegal release of
refrigerant into the atmosphere.

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 brought on by an increase in temperature.

Always store cylinders containing refrigerant in a cool place. They should never be exposed to
temperatures higher than 120F (R-22) or 108F (R-404a), 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.

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 weighed continuously to
assure contents do not exceed net weight specified by cylinder manufacturer or any applicable
code requirements.

1-3

INTRODUCTION

! CAUTION !

! CAUTION !

! CAUTION !

! CAUTION !

9/15/09

1-4

INTRODUCTION

P24FL & P34FL Service Manual

9/15/09

FIGURE 1-1

P24FL Front Side (Control Panel)

P24FL & P34FL Service Manual

1-5

INTRODUCTION

9/15/09

FIGURE 1-2

1-6

INTRODUCTION

P24FL & P34FL Service Manual

9/15/09

FIGURE 1-3

P24FL Back Side

P24FL & P34FL Service Manual

1-7

INTRODUCTION

9/15/09

FIGURE 1-4

P24FL Left Side

1-8

INTRODUCTION

P24FL & P34FL Service Manual

9/15/09

FIGURE 1-5

P34FL Front Side

P24FL & P34FL Service Manual

1-9

INTRODUCTION

9/15/09

FIGURE 1-6

P34FL Right Side

1-10

INTRODUCTION

P24FL & P34FL Service Manual

9/15/09

FIGURE 1-7

P34FL Back Side

P24FL & P34FL Service Manual

1-11

INTRODUCTION

9/15/09

FIGURE 1-8

P34FL Left Side (Control Panel)

1-12

INTRODUCTION

P24FL & P34FL Service Manual

9/15/09

P24FL & P34FL Service Manual

Only service personnel experienced in refrigeration systems and
qualified to work on high amperage electrical equipment should

It is very important that you are familiar with and adhere to

all local, state, and federal, etc. ordinances and laws regarding

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. You should
also notify your Vogt distributor or the factory.

Description Of Machine. A Vogt low side Tube-Ice machine is a remote ice producing plant
requiring refrigerant suction connection, refrigerant liquid connection, thaw gas connection, make­up water supply, electrical connection, and the proper refrigerant charge.

The machine has been partially factory tested prior to shipment and will require adjustment to meet
the high side (condensing unit) operating conditions. See Start-up and Operation for the correct
setting of the controls.

After factory pressure testing of the machine, the machine is evacuated and charged with nitrogen
gas pressure for shipment. This prevents air or moisture from entering the system during transit.
There should be a positive pressure (20-25 psig) indicated on the control panel gages when the
machine is received. The machine has been cleaned with ice machine cleaner and flushed so that the
machine is ready for ice production.

Safety Tags and Labels. Be sure to read and adhere to all special tags and labels attached to valves
or applied to various areas of the machine. They provide important information necessary for safe
and efficient operation of your equipment.

The machine is available in three different tube sizes for producing ice 7/8” OD x 1” long, 1 1/8”
OD x 1” long, or 1 3/8” OD x 1” long. The ice is cut to length by a rotating breaker type cutter. Ice
can be produced up to 1 1/2” long by modifying the spacers under the adapter plates (see Chapter
10, “Ice Length” for modifying instructions). Crushed ice is also available by modifying the cutter
and making minor adjustments to the machine (see Chapter 10, “Crushed Ice”)

2-1

RECEIPT OF YOUR TUBE-ICE MACHINE

2. Receipt Of Your Tube-Ice Machine

! CAUTION !

be allowed to install or service this Tube-Ice machine.

Eye protection should be worn by all personnel

working on or around the Tube-Ice machine.

the handling, storing, and use of R-22 refrigerant.

An approved refrigerant mask should be readily available

for use in an emergency and all personnel should be aware

of its location and proper use.

! CAUTION !

9/15/09

2-2

–

RECEIPT OF YOUR TUBE-ICE MACHINE

P24FL & P34FL Service Manual

50T A L F B 5 46 NC 000

Nominal Capacity

(“T”= tons/day)
“25T” – 25 tons/day
“50T” – 50 tons/day
“80T” – 80 tons/day

Model Variation

A letter assigned to indicate
major variations within any one
family series

Basic Configuration

“P” – Package
“L” - Lowside

Refrigerant

“F” – R-22
“A” – Ammonia
“H” – R-404a

Type of Ice

“B” – Cylinder
“K” – Crushed
“L” – 1 ½” Long Ice

Product Variation Code

A number or letter designator
assigned to specific variations
within a family series
“000 or Blank” – Standard
Product

Consult factory for specific
code interpretation

Condenser Type

“WC” – Water Cooled
“NC” – No Condenser

Electrical Codes

“26” – 208/230-3-60
“46” – 460-3-60
“25” – 200-3-50
“45” – 400-3-50

Tube Size

(In ¼’s of an inch)
“4” – 1”
“5” – 1 ¼”
“6” – 1 ½”
“7” – 1 ¾”

2”

“8”

FIGURE 2-1

Model Designation for P-Series Ice Machines

Rated Capacity. The Tube-Ice machine is rated to produce a given amount of ice when operating

under the proper conditions as specified in this manual. You should be prepared to handle the ice
produced as it is discharged from the machine and move it to your storage or bagging area promptly.
The following specifications are given to help you do just that.

9/15/09

P24FL & P34FL Service Manual

Makeup Water

Temp.
85F/29C
80F/24C
75F/23C
70F/21C
65F/18C
60F/15C
55F/13C

Ice lb/harvest 750 lbs/340 Kg 600 lbs/272 Kg 450 lbs/204 Kg

(2000 lbs/24 hours)

RECEIPT OF YOUR TUBE-ICE MACHINE

Model P24FL-1.5” Model P24FL-1.25” Model P24FL-1”

Capacity Tons/day

21.4 4.46 21.5 4.48 20.8 4.33

21.9 4.57 22.6 4.71 21.7 4.53

22.5 4.69 23.2 4.83 22.3 4.64

23.1 4.81 23.8 4.95 22.8 4.76

23.7 4.94 24.4 5.09 23.4 4.88

24.3 5.07 25.1 5.23 24.0 5.00

25.0 5.70 25.8 5.37 24.7 5.14

Makeup

Water

GPM

Capacity Tons/day

(2000 lbs/24 hrs.)

Makeup

Water

GPM

Capacity Tons/day

(2000 lbs/24 hours)

Makeup

Water

GPM

2-3

9/15/09

Shipping
weight (without
charge)
Operating
weight

5,800lbs/2,630 Kg 6,200 lbs/2,810 Kg 6,000 lbs/2,720 Kg

7,150lbs/ 3,240 Kg 7,700 lbs/ 3,450 Kg 7,500 lbs/3,400 Kg

Makeup Water

Temp.

85F/29C
80F/24C
75F/23C
70F/21C
65F/18C
60F/15C
55F/13C

Ice lb/harvest 1728lbs/785 Kg 1414lbs/642 Kg

Shipping weight 9,600lbs / 4350 Kg 10,000lbs / 4,530 Kg 9,600 lbs /4,350 Kg
Operating weight 11,200 lbs/ 5,080 Kg 11,400 lbs/ 5,170 Kg 10,450lbs/4,740 Kg

Notes:

1. Makeup water is average flow and includes 25% blow down. Peak flow rate is 15 GPM. at 40 PSI minimum. When water quality is good,

machine can be operated with 5% to 10% blow down.

2. Ratings are at 90F ambient for ice machine.

3. Capacity ratings are based on 85F water entering condenser. For entering water temperatures above 85F, deduct 4% in capacity for each 5F.

4. Capacity shown is the average for model. Individual machines may vary up to 5% above or below depending on field conditions.

Model P34FL-1.5” Model P34FL-1.25” Model P34FL-1”

Capacity Tons/day

(2000 lbs/24 hours)

45.8

12.7 48.8 13.7 45.6 13.4

46.8

13.0 49.9 14.0 46.6 13.8

47.8

13.4 51 14.4 47.6 14.2

48.8

13.7 52.1 14.7 48.6 14.5

49.8

14.1 53.2 15.1 49.6 14.9

50.8

14.4 54.3 15.4 50.6 15.2

51.8

14.8 55.4 15.8 51.6 15.6

Makeup

Water

GPM

Capacity Tons/day

(2000 lbs/24 hrs.)

Makeup

Water

GPM

Capacity Tons/day

(2000 lbs/24 hours)

998lbs/453 Kg

Makeup

Water

GPM

TABLE 2-1

P24FL & P34FL Specifications

Storage (prior to installation or start-up). The machine must not be stored or installed in an area

that is subject to reach temperatures at or above 110F (43.3C). Temperatures above this may
cause the relief valves to open and result in the loss of refrigerant.

2-4

P24FL & P34FL Service Manual

RECEIPT OF YOUR TUBE-ICE MACHINE

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P24FL & P34FL Service Manual 3-1

INSTALLING YOUR TUBE ICE MACHINE

3. Installing Your Tube-Ice Machine

Your machine will be shipped to you as one package. You will need to arrange for the handling of
the package as soon as it arrives, see the machine specifications Table 2-1 for shipping and operating
weight. Before you remove the unit from the truck, be certain that any sign of damage, however
slight, is noted on the carrier’s papers.

Note: See “Lifting Procedure” drawing furnished with this manual, Fig 3-5 and 3-6.

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 radiation from other
sources (sunlight, furnaces, condenser, etc.) and unusual air current may affect the operation of the
machine and should be avoided. The electrical components of the Tube-Ice

NEMA 1. Therefore, the machine should not be located in a hazardous area or sprayed with
water. The machine should be installed in an area where water will not stand, but will readily drain

away from the machine.

Space Requirements. Refer to the space diagrams, Figures 3-1 and 3-3, for recommended
minimum clearance around the machine for ease of servicing and observation. Pay particular
attention to the additional space required. If it ever becomes necessary to mechanically clean the
condenser tubes, extra space will be required on one end (preferably on the opposite end from the
water inlet and outlet) for the cleaning tools.

Foundation. Refer to the space diagrams, Figures 3-2 and 3-5, for recommended minimum
foundation requirements. The figures show anchor bolt details and machine anchor hole details.
Contact your local distributor for seismic anchoring requirements in your area.

! WARNING !

Lifting or moving heavy equipment should only be attempted by

competent rigging and hoisting contractors. Never allow personnel

near or under heavy equipment when it is being moved or lifted.

Failure to comply could result in personal injury or loss of life.

! WARNING !

Lifting Procedures. Your Tube-Ice



machine is provided with lifting lugs for the purpose of
unloading and moving the machine to its operation location. Refer to the enclosed drawings for
instructions and illustrations of their use.

P24FL - Figure 3-5. Machine weight 6,200 lbs.
P34FL - Figure 3-6. Machine weight 10,000 lbs.

These figures are intended as a guide to unloading and lifting the P24FLand P34FL Tube-Ice
machine. The Vogt Tube Ice LLC. is not responsible for product damage or personnel injury

or loss of life during the loading or lifting procedure.

®

machine are rated

®

9/15/09

3-2 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-1A

P24FL Space Diagram (Front View)

P24FL & P34FL Service Manual 3-3

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-1B

P24FL Space Diagram (Side View)

3-4 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-2

P24FL Foundation Layout

P24FL & P34FL Service Manual 3-5

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-3A

P34FL Space Diagram (Front View)

3-6 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-3B

P34FL Space Diagram (Side View)

P24FL & P34FL Service Manual 3-7

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-4

P34FL Foundation Layout

3-8 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-5

Lifting Procedure for P24FL

P24FL & P34FL Service Manual 3-9

INSTALLING YOUR TUBE ICE MACHINE

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3-10 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

FIGURE 3-6

Lifting Procedure for P34FL

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P24FL & P34FL Service Manual 3-11

INSTALLING YOUR TUBE ICE MACHINE

Piping and Drain Connections. See Figure 1-1 to 1-8 for connection locations.

When connecting refrigeration piping, you must follow and adhere to all ANSI/ASHRAE 15 “
Safety Code for Mechanical Refrigeration” and ANSI Standard B-31.5 “ Refrigeration Piping
Code”. Also, all piping must conform to all state and local codes. Make sure all piping is kept
clean, dry and contaminate free. All piping should be supported properly.

! CAUTION !

Exterior shut-off valves must be provided in the water

inlet lines. The minimum inlet water pressure for

satisfactory operation of the machine is 40 psig.

The maximum allowable pressure is 100 psig.

! CAUTION !

Model

P24FL 3/4” FPT 3/4” FPT

P34FL 1” FPT 3/4” FPT

* Mating 4 bolt flange supplied with machine.
** Liquid connection is all purpose coupling.

Make-up
Water In

Flushing
Water In

72 gal/3 min.

104 gal/3 min.

Water
Tank
Drain

2” FPT 3” FPT 3” Flange 3/4” FPT or SW 2” Flange

2” FPT 3” FPT 4” Flange 1” FPT or SW 2” Flange

Water
Tank
Overflow

Low Side

Suction

Connection*

Low Side

Liquid

Connection**

Low Side

Thaw Gas

Connection

TABLE 3-1

Water Supply and Drain Connections

(See FIGURE 1-1 through 1-8 for locations)

Make-Up Water In. The water required for ice making must be potable water, safe for human

consumption, and should be of the highest quality available. The best way to determine water
quality is to have a complete water quality analysis by a qualified laboratory.

It is advisable to install a particle filter in the make-up and flushing water lines to trap dirt, sand,
rust, or other solid particles prior to entering the water tank and contaminating the ice. Be sure to
size the filter large enough to meet the water demands of 15 GPM (peak flow), allowing for a
restriction through the filter as it traps these particles. The inlet water pressure should be a minimum
of 40 psi. Refer to TABLE 3-1 for line size and TABLE 2-1 for average flow rate at various water
temperatures.

Flushing Water In. Flushing water (blowdown) is necessary to melt ice fines and flush dissolved
solids from the water tank during the thawing (harvest) cycle. This function is important and helps
to maintain good ice quality. If water quality is superior, this blowdown can be reduced by
installing a smaller orifice in the flushing outlet elbow. Make sure there is enough flushing water to
prevent the accumulation of excessive ice fines in the tank.

If make-up and flushing water are from the same source, they can be connected by a common line to
the machine.

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3-12 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

Water Tank Drain. This valve and connection is for the purpose of flushing and draining the water
tank of impurities, foreign material and cleaning chemicals used during servicing. It should be piped
to an open drain or sump for visible discharge. It can be tied in with the overflow line but no others.

Water Tank Overflow. A 3” FPT connection on the side of the water tank is provided to carry
away overflow water during the thawing (harvest cycle). This water contains ice fines accumulated
during harvesting and dissolved solids accumulated during the freezing cycle. Do not reduce the
size of this line. Three inches is needed to provide sufficient are a for ice fines to be flushed out,
especially if the incoming flushing water is 55F (13C) or below. This overflow line should not tie
in with any other drain line except the water tank drain.

Cooling Tower. When selecting a cooling tower, careful attention must be given to operating wet
bulb conditions. It is advisable to check with your local cooling tower distributor for their
recommendations based on actual operating conditions in your area. An average wet bulb of 78F is
typical in the U.S., but many localities have designed wet bulbs as low as 72F or as high as 82F.

The cooling tower water pump must be capable of delivering the required volume of water through
the condenser. Due to cooling tower location and pressure drop through water lines and regulating
valves, the water pump must be sized for each installation. Refer to TABLE 3-2 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. Caution must be used to prevent the condenser
water pump from losing its’ prime during off cycles.

Proper water treatment for the prevention of mineral and foreign matter accumulation in the
condenser or cooling tower is recommended. A water analysis should be obtained to determine the
proper chemicals to use. The use of a 40-mesh strainer in the condenser water supply line is also
recommended.
Condenser water flow is based on pulldown of 30F SST and 105F SDT. Condenser water pressure
drop does not include water-regulating valve. Consult factory for sizing if desired.

P24FL/P34FL Condenser Water

Entering

Water

Flow GPM Cond.

PSID

85°F 196/420 15
80°F 131/289 7

75°F 98/220 4

70°F 78/178 2
65°F 65/149 2
60°F 56/128 1
55°F 49/113 1
50°F 44/100 1

Total Heat Rejection

P24FL = 1,031,625 BTUH

P34FL = 2,033,590 BTUH

TABLE 3-2

Condenser Water Requirements

9/15/09

P24FL & P34FL Service Manual 3-13

¶

INSTALLING YOUR TUBE ICE MACHINE

The following table shows the model of Marley cooling tower required for operating at various wet
bulbs to cool 91F (33C) entering water to 85F (29.4C) exiting water.

Model GPM

Cond. PD

PSIG

75F 76F 77F 78F 79F 80F

P24 FL 187 15 4832 4841 4841 4841 4842 4851
P34 FL 371 12 4861 4861 4861 4862 4871 4871

TABLE 3-3

Marley Cooling Tower Recommendations

Tower nozzles will be selected based on GPM required for condenser.

The condenser water pump should be sized on GPM required for condenser at 80 ft. total discharge
head for a typical installation. However, due to cooling tower location and pressure drop through
water lines, the water pump should be sized for each installation.

The ice machine is supplied with a fan control switch for cycling the cooling tower fan on and off,
thereby maintaining the proper operating head pressure. If the condenser inlet water temperature is
expected to be below 75F/24C, a water-regulating valve should be installed in the condenser water
inlet line and adjusted to maintain a head pressure of not less than 190 psig.

See FIGURES 3-5 through 3-7 for possible cold climate installations with indoor sump.

Safety Valves. Two safety pressure relief valves are located in the low side of the system on the
freezer. Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with
local and national codes.

Deleted:

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3-14 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

9/15/09

FIGURE 3-7Cooling Tower Piping Diagram

Deleted: ¶
Deleted: ¶

P24FL & P34FL Service Manual 3-15

INSTALLING YOUR TUBE ICE MACHINE

COOLING TOWER

WATER
COOLED
CONDENSER

CHECK VALVE

INDOOR SUMP

FIGURE 3-8

1 PUMP/2-WAY VALVE

Poor Freeze Protection

·

Because low flow rate = high freeze chance

COOLING TOWER

WATER
COOLED
CONDENSER

Only enough water to
maintain head pressure

CHECK VALVE

Same flow rate
to cooling tower

FIGURE 3-9

1 PUMP/3-WAY VALV

* Better Freeze Protection

INDOOR SUMP

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3-16 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

COOLING TOWER

WATER
COOLED
CONDENSER

CHECK VALVE

INDOOR SUMP

Outdoor pump is off until
indoor sump needs cooling

FIGURE 3-10

2 PUMP/2-WAY VALVE

* Best Freeze Protection

Wiring and Electrical Connections.

! WARNING !

Only service personnel experienced in refrigeration and qualified
to work with high voltage electrical equipment should be allowed

to install or work with the Tube-Ice machine.

! WARNING !

A fused disconnect must be provided near the Tube-Ice
compressor motor starter are attached to the structural on the front of the Tube-Ice
FIGURE 3-11). Incoming 3-phase power will be connected at the compressor motor starter (1M).
Terminals L1, L2, L3 for operation of the Tube-Ice



machine and its controls. Rotation checking of



machine. The control panel and



machine (see

the cutter motor, and water pump is required (see rotation check). Also, if one leg of the 3-phase
power is higher or lower (“wild”), then it should be connected to terminal L3. Connect the ground
wire to the “ground” terminal provided.

Make sure wires #22 and #27 are connected to the elapse time (ET) indicator in the control panel.

9/15/09

P24FL & P34FL Service Manual 3-17

INSTALLING YOUR TUBE ICE MACHINE

FIGURE 3-11

Power Supply Connections

Voltage Unbalance Voltage unbalance can cause motors to overheat and fail. Voltage imbalance

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
(AC) 227-224 = 3 Volts

% Voltage Unbalance = 100 x (4/224) = 1.78% “Acceptable”

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

9/15/09

3-18 P24FL & P34FL Service Manual

INSTALLING YOUR TUBE ICE MACHINE

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 current 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)
(L3) 98-95 = 3 Amps

% Current Unbalance = 100 x (4/95) = 4.2% “Acceptable”

Rotation Check. The cutter, and pump motor rotation are factory synchronized, but must be
checked at installation. For cylinder ice production, the cutter disc as viewed at the ice discharge
opening should turn from left to right.

Check rotation by the following procedure:

1. Turn the power to the machine on and check voltages.

2. Make sure the water tank is full of clean water.

3. Turn the Hand-Auto switch (ISS) to HAND position. The wa ter pump wil l s tart a n d t h e free zing

(1LT) and the liquid feed (2LT) pilot lights will illuminate. Check pump rotation.

4. Push the MANUAL HARVEST button. The water pump will stop, the “Freezing and Liquid

Feed” lights will go out, and after 20-30 seconds, the cutter motor will start. The thawing gas
solenoid valve will open and the “Thawing” pilot light (3LT) will illuminate.

5. Check the cutter disc rotation. It should be turning from left to right (CCW looking from the

top).

6. Turn the HAND-AUTO switch to AUTO to stop the cutter.

To change rotation, follow this procedure:

1. Disconnect power to the machine and lock it out to make sure it can’t be turned back on.

2. Check for power at L1, L2, L3 with a volt meter to make sure it is off.

3. At the compressor motor starter (1M) or at the power disconnect, reverse wires L1 and L2.

4. Make sure these terminals are tight and restore power to the machine.

5. Perform rotation check again to confirm that it is correct.

Auxiliary Controls or Equipment. When connecting other equipment such as tower fan,
condenser pump, conveyor motors, bin level control, etc., refer to the control panel wiring drawing
for the proper connecting terminals and instructions. See Figure 6-3.

9/15/09

P24FL & P34FL Service Manual 3-19

INSTALLING YOUR TUBE ICE MACHINE

! IMPORTANT !

Be sure to follow the wiring schematic when incorporating overloads of

conveyor, fan, or pump motor starters (i.e., 5 MOL, 6 MOL, 7 MOL). Also

remove jumpers as instructed. This is necessary to provide proper

protection for the Tube-Ice machine and its component parts.

! IMPORTANT !

Installation Review: A Checklist. Make a visual check to be sure these steps have been taken

BEFORE continuing.
CHECK: _____ PRIOR TO OPENING VALVES, check all joints for leaks which may have

developed during shipment. (NOTE: the machine was shipped with a positive pressure of 20-25
PSIG, which should be indicated on the suction and discharge gages.)

CHECK: _____ All water supply and drain connections for conformity to requirements stipulated in
this manual and properly connected to inlets and outlets.

CHECK: _____ Electrical supply for proper size of fuses and for compliance to local and national
codes. See the machine nameplate for minimum circuit ampacity and maximum fuse size.

CHECK: _____ All field installed equipment (augers, conveyors, cooling towers, bin level controls,
etc.) for proper installation.

CHECK: _____ The applicable portion of the warranty registration/start-up report for proper
completion.

CHECK: _____ Cutter gear reducer oil level oil should run out of side pipe plug when removed.
CHECK: _____ The water distributors at top of freezer to make sure they are all in position (one

seated firmly in each tube with a vent tube in each distributor).

! CAUTION !

The crankcase heater should be energized for a minimum of

four hours and the oil temperature should be 100-110F

before attempting to start the compressor.

! CAUTION !

9/15/09

P24FL & P34FL Service Manual

4. How Your Tube-Ice Machine Works

HOW YOUR TUBE-ICE MACHINE WORKS

4-1

9/15/09



Operating Features. Your Tube-Ice

low side machine is an efficient ice producing plant. If
installed and maintained properly, it will give many years of operation with a minimum amount of
repairs. Refer to piping schematics, FIGURE 4-1 and 4-2 to identify component parts while
following the information and instructions in this manual.

The machine is manually started and stopped by the START and STOP push buttons. The machine
will automatically stop by safeties such as compressor, cutter and pump overloads, as well as other
auxiliary motor overloads. It will also stop automatically by high head pressure, low suction
pressure or low compressor oil pressure. The circulating water pump can be operated independently
for chemically cleaning the freezer tubes and water tank by use of the HAND/AUTO selector
switch. The machine can be manually forced into a harvest cycle with the manual harvest push
button.

Principle of Operation. The freezer (2) is a shell and tube-type vessel. During the freezing period
(cycle), water is constantly recirculated through the vertical tubes of the freezer by a centrifugal
pump (6). Make-up water is maintained by a float valve (12) in the water tank (7). The capacitive
level probe (65) opens and closes the liquid feed “A” solenoid valve (20A) and maintains the desired
refrigerant level in the freezer (2) (evaporator). The constant feed solenoid (20B) remains open
during this period. Refrigerant gas from the top of the freezer (2) passes through the suction
accumulator (88) and to the compressor (3). Here, the cool gas is compressed to a high temperature,
high pressure gas which discharges through the oil separator (14), then through the heat coil of the
condenser and then into the P24F condenser/receiver (15). P34F condenser (15C)/receiver (15R).
In the condenser, heat is removed and the gas is condensed to a high temperature, high pressure
liquid. The high pressure liquid goes out the liquid line through a strainer (43), liquid “A” solenoid
valves (20A & B) check valve (101), and hand expansion valve (17). At the hand expansion valve
(17), the refrigerant expands from a saturated high pressure liquid state to a low pressure, low
temperature liquid. This cold liquid enters the freezer (2) where it absorbs heat from the circulating
water in the freezer tubes. Cool gas is again pulled out of the freezer through the suction outlet,
thereby completing the circuit.

The freezing period is completed by action of the freezer pressure switch (2PS) in the control panel.
The water pump (6) stops and the “A” solenoid valve (20A) and constant feed solenoid valve (20 B)
closes. After a delay of 20-30 seconds, the cutter motor starts, the thawing gas “D” solenoid valve
(18) opens, and the harvest (thawing) timer (2TR) is activated. Warm gas from the receiver is
discharged through the thawing chamber (16), check valve (101), and into the freezer. There it
warms the refrigerant and the outer surface of the freezer tubes, allowing the ice to release on the
inside of the tubes and drop down onto the rotating cutter for sizing. After sizing, the ice drops on
the tines cutter disc and discharged through the ice discharge opening.

See “Freeze Period” and “Harvest Period” for more detailed description of machine.
Freeze Period. The Tube-Ice



is frozen inside the stainless steel tubes of the freezer (2) by the
direct application of refrigerant to the outside shell side of the tubes. Ice is produced from
constantly circulating water down each tube. As the ice thickness increases, the freezer suction
pressure decreases. At a set pressure, the freezer pressure switch (2PS) energizes the relay (1CR),
which stops the water pump, closes the “A” liquid feed solenoid valves (20A & B), turns out the two
pilot lights, refrigerant feed and freezing.

4-2

HOW YOUR TUBE-ICE MACHINE WORKS

Harvest Period. About 20-30 seconds after the 1CR relay is energized, the thaw gas valve (18)
opens, the “H” water flush solenoid valve (63) opens, the compressor unloads, the cutter motor
starts, the thaw timer (2TR) is energized, the red thawing gas light illuminates, and auxiliary
equipment such as conveyors etc. start. When the refrigerant in the freezer is warmed sufficiently to
allow the ice in the tubes to release and be sized, the ice is discharged into the customers ice
handling equipment. See “Ice Handling” for more information on this subject. The thaw timer
(2TR) is adjustable and should be set for the time required for all the ice to clear the freezer plus 30
seconds more.

Make sure all the ice clears the freezer with at least 30 seconds

to spare before the next freezer period begins. This is to prevent

refreezing and to allow the ice moving augers etc. to clear.

1 Control Panel 36 Oil Trap
1PG Suction Pressure Gauge 39 Water Tank Drain Valve
2PG Discharge Pressure Gauge 43 Strainer
2 Freezer 44 Receiver Drain Valve
5M Cutter Motor 46 Filter Drier
5R Gear Reducer 49 Freezer Suction Stop Valve or Regulator
6 Water Pump 50 Receiver Safety Valve
7 Water Tank (includes cutter assem bly) 51 F r eezer Safety Valve
8 Water Distributing Chamber 52 3-Way Valve
9 Water Tank Overflow (3” FPT) 56 Freezer/Pressure Switch (2PS)
10 Refrigerant Float Switch 61 Freezer Oil/Ammonia Drain Valve
12 Make-Up Water Float Valve 62 Make-up Water Inlet Valve
16 Thawing Chamber 63 Water Flush Solenoid Valve
17 Hand Expansion Valve 69 Low Suction Pressure Stop Va lve
18 Thawing Gas Regulator/Solenoid Valve “D” 75 Strainer Purge Valve
20 Liquid Feed Solenoid Valve “A1” 76 Freezer Purge Valve
28 Refrigerant Charging Valve 82 Thaw Gas Pressure Gage St op Valve
29 Liquid Line Stop Valve 88 Accumulator
29A Float Switch Stop Valve 90 Thawing Gas Stop Valve
30 Sight Glass 101 Check Valve
31 Gage Glass Stop Valve

9/15/09

P24FL & P34FL Service Manual

! CAUTION !

! CAUTION !

Piping Nomenclature

P24FL & P34FL Service Manual

4-3

HOW YOUR TUBE-ICE MACHINE WORKS

9/15/09

FIGURE 4-1

Piping Schematic for P24FL

4-4

HOW YOUR TUBE-ICE MACHINE WORKS

P24FL & P34FL Service Manual

9/15/09

FIGURE 4-2

Piping Schematic for P34FL

P24FL & P34FL Service Manual

START-UP & OPERATION

5. Start-Up & Operation

Refrigeration System Review. The refrigeration system uses R-22 refrigerant. Following the piping

schematic (Figure 4-1 or 4-2), you will see that during the machine’s freeze cycle, the compressor
discharge gas goes through the oil separator (14) to remove any oil present in the discharge gas and
return the oil to the compressor crankcase. From the oil separator, the discharge gas continues
through a heat coil in the lower part of the condenser/receiver (15). It is then discharged into the
condenser and condensed into a liquid by the removal of heat by water passing through the
condenser tubes. A reservoir of liquid refrigerant is accumulated in the receiver and is required for
thawing purposes. Liquid from the receiver flows through the filter drier (46), and the heat
exchanger (13), to the “A” solenoid valve (20A), which opens and closes by action of the capacitive
level probe (65). The liquid is then expanded through the hand expansion valve (17) and into the
evaporator (2) (freezer). The liquid is also fed through a bypass line and the constant feed solenoid
valve (20B), which is open through the freeze cycle. The cold wet refrigerant floods the evaporator
and is in contact with the outside of the ice making tubes which water is being circulated through.
The heat contained in the water passes through the wall of the tubes, lowering the temperature of the
water causing it to freeze and form a long tube of ice that adheres to the inside of freezer tubes.
Since the purest water freezes first, the circulating water continues to wash the dissolved solids
down into the sump area of the water tank. The flushing valve (63) helps to rid the water tank of
increased dissolved solids by flushing them out the overflow during the harvest (thawing) period.

The wet suction gas leaves the freezer (2) and passes through the suction accumulator (88) and heat
exchanger (13), where liquid droplets are removed, allowing the superheated dry gas to enter the
suction side of the compressor (3). The suction gas is then compressed and discharged once again,
completing the cycle. As ice continues to form in the freezer tubes, the suction pressure steadily
decreases until the freezer pressure switch is satisfied and the contact closes, initiating the thaw
(harvest) cycle.

Note: Freezing time will vary, depending on make-up water temperature and thickness of ice
produced.

During the harvest period, the “D” thawing gas valve (18) opens and the compressor unloads,
allowing the warm high pressure gas from the receiver to enter the freezer. As the tubes warm up to
slightly above freezing, the ice inside the tubes releases and falls down onto the rotating cutter for
sizing and discharging. Harvesting requires about three minutes, but can vary depending on ice
thickness, suction pressure, and discharge pressure (thawing gas temperature) and distance from the
receiver to the freezer.

! IMPORTANT !

It is a good idea and will be profitable for you to observe and

become familiar with the proper operating characteristics of your/

Tube-Ice machine. It will help you to recognize and correct minor

irregularities as they occur in order to help prevent major problems.

“An ounce of prevention is worth a pound of cure.”

! IMPORTANT !

5-1

9/15/09

5-2

START-UP & OPERATION

Start-up Checklist. Be sure to complete and return the “Warranty Registration/Start-up Report”
located in the front of the manual.

1. See that the water-inlet connections are attached properly. The water inlet shutoff valve (62) for

the water tank should be open. The water level in the water tank should be at a height where the
make-up float valve will be closed when the machine is idle and water is not running out of the
overflow (9).

2. Fill the cooling tower sump and check the tower manufacturer’s installation and operation

instructions to make sure it is ready to run.

3. Check condenser cooling water pump rotation. Check rotation of augers or ice handling

equipment to make sure they are rotating the proper direction.

4. Check all tagged valves and make sure they are in their correct operational position (opened,

closed, or automatic).

5. See that the electrical disconnect is closed and the proper power is supplied to the machine.

6. See that the compressor oil temperature is 100-110F and there is no liquid ammonia in the

crankcase. The oil level should be 1/2-3/4 of the sight glass.

7. Check the elapsed time indicator (ET) and make sure wire #22 and #27 are attached.

8. Reconfirm “Rotation Check” for compressor, cutter and water pump (See Section 3).

Refrigerant Charge. Prior to charging the machine with refrigerant (R-22) make sure the system is
leak tight and free of non-condensibles or other contaminants. All valves tagged prior to shipping
must be opened prior to starting the machine.

P24FL & P34FL Service Manual

Low Side Refrigerant Charge Tube Size

Model 1" 1 1/4" 1 1/2"
P-24FL 1,102lbs 1060lbs 1011lbs
P-34FL 2,091lbs. 1,894lbs. 1,809lbs.

Table 5-1

Total Refrigerant Charge

9/15/09

P24FL & P34FL Service Manual

Start-Up. Starting the machine in a freezing cycle can be accomplished as follows:

1. Make sure the crankcase oil temperature is approximately 100F and there is no liquid

refrigerant in the compressor crankcase.

2. Turn the Hand/Auto switch (1SS) to the “Hand” position and allow the water tank to refill.

MAKE SURE THE DRAIN VALVE IS CLOSED.

3. Push the green “Start” push button to start the compressor and immediately observe the oil

pressure, the oil level, the discharge pressure, and listen for any unusual sounds. The
compressor starts unloaded and will load automatically after several seconds by action of the
delay timer (DT).

4. Turn the Hand/Auto switch to the “Auto” position.

5. When the discharge pressure increases to about 170 psi (R-22), push the “Manual Harvest”

button to initiate the harvest cycle. See “Harvest Period”.

6. When the suction pressure raises to 65-70 psig (R-22), any ice made should release and

discharge. After all of the ice clears the cutter and auger, turn the Hand/Auto switch to “Hand”
and back to “Auto”. This will interrupt the harvest cycle and start another freeze cycle. See
“Freeze Cycle”.

As the machine continues its freezing cycle, the liquid refrigerant will feed into the freezer until the
level float switch (10) is satisfied. The float switch will open and close the liquid line solenoid valve
(20) to maintain that level of refrigerant in the freezer during the freeze cycle. When the suction
pressure pulls down to the setting of the freezer pressure switch (2PS), the switch will close and
initiate the harvest cycle. See “Harvest Period”.

Be sure to observe several complete cycles of ice production to confirm the satisfactory operation of
the machine.

5-3

START-UP & OPERATION

FIGURE 5-1.

Control Panel

9/15/09

5-4

START-UP & OPERATION

Complete the remaining part of the “Warranty/Registration Start-Up Report”

Check the refrigerant level at the receiver liquid gage glass to make sure it is near the operating level
mark.

Adding Refrigerant. Add refrigerant while the machine is running by the following procedure:

1. With a cylinder of refrigerant laying on its side, cylinder valve outlet pointing up and bottom end

raised two inches higher than the valve end, connect an “approved for R-22” charging hose
between the freezer charging valve (28) and the cylinder valve.

2. Purge all air from the charging hose and open the cylinder valve gradually to check for possible

leaks around the packing nut or hose fittings. Then open the cylinder valve fully.

3. While the “refrigerant feed light” is not illuminated, open the charging valve (28) and refrigerant

will flow from the cylinder to the freezer.

4. Close the cylinder valve immediately when the “refrigerant feed” light comes on and reopen it

when the light goes out. Repeat until properly charged.

As the machine is being charged, continually observe the following operating characteristics:

P24FL & P34FL Service Manual

! IMPORTANT !

and return it to the Henry Vogt Machine Co.

! IMPORTANT !

a) Discharge pressure - (R-22) 175 psi to 200psi maximum
b) Compressor oil pressure-11-15 psi above suction
c) Liquid level in the receiver- marked on the gage glass

d) Compressor oil level- approximately ½ glass

! 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 !

9/15/09

P24FL & P34FL Service Manual

START-UP & OPERATION

Operating Tips.

 Make sure the machine is left running in the “Auto” position. This will assure a complete

shutdown if a safety or overload is tripped.

 To initiate a harvest cycle, simply push the Manual Harvest push button (3PB).
 To interrupt the harvest cycle and revert to a freeze cycle, turn the Hand/Auto switch to “Hand”

and back to “Auto”.

 Too much refrigerant in the condenser/receiver can contribute to high discharge pressure. Do

not go above 13 1/2 inches (for the P24FL) or 15 inches (for the P34FL) from the center of the
lower gage glass cock while in normal operation. A higher level can begin to cover the
condenser tubes and reduce condenser efficiency.

 The circulating water overflow tubing will show that water is being slightly lifted up the tubing

near the end of the freezing cycle. If this action ceases and water begins overflowing from the
top water box, it is an indication that the tubes are freezing solid and the machine should begin a
harvest cycle. It is best not to freeze the ice solid with no hole.

 To cease ice production manually, allow the machine to complete the harvest period and start the

freeze period. When the “liquid feed” light comes on at the beginning of the freeze period, push
the “Stop” button to cease ice production.

Thaw Gas Regulating and Suction Regulating Valve Adjustment. The following is the
procedure for regulating valve adjustment. On dedicated compressor systems the suction regulating
valve is not required. However the compressor must unload by 50% or greater during the harvest or
a hot gas bypass must be installed.

1. Install gauge and gauge valve in gauge port of regulator.

2. Turn high pressure stem (down stream pressure) on suction regulator into the milled flats, do

not turn milled flats into packing nut.

3. Start the machine and initiate a harvest.

4. Adjust the thaw gas regulator to build pressure to 70 - 74 psig. (1 turn is approximately 13 psig)

5. Adjust (downstream) high pressure stem on suction regulator to begin regulating at 68-74 psig.

(slightly below the thaw gas regulator)

6. After the machine has completed the harvest cycle and returned to the freeze cycle, adjust the

low pressure (upstream pressure) on the suction regulator to maintain the required freezer
pressure. For clear ice a minimum of 29 psig freezer pressure is required.

5-5

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5-6

START-UP & OPERATION

P24FL & P34FL Service Manual

9/15/09

P24FL & P34FL Service Manual

6-1

ELECTRICAL CONTROLS

6. Electrical Controls



Your packaged Tube-Ice

machine is equipped with a compressor motor starter (1M) as required for
your particular voltage and a transformer (if required) for the control circuit power. The motor
starter and transformer are mounted on the machine front side (see Figures 1-1 or 1-8).

The control panel wiring schematic, FIGURE 6-3, illustrates these components as well as provisions
for auxiliary equipment which may be incorporated by the customer such as:

(FU1) Main power disconnect
(5M) Conveyor motor starter and overload (5MOL)
(6M) Tower fan starter and overload (6MOL)
(7M) Condenser pump starter and overload (7MOL)

When adding motor starters for auxiliary equipment, be sure to incorporate the overload protection
as indicated between terminals #12-#13 and remove the jumper wire. This will assure that the
machine will shutdown when any auxiliary equipment fails.

Bin Level Control. Included in the wiring schematic is provision for a bin level control (BLC).
The NC contract of your control should be wired between terminals #8-#9 and the jumper wire
removed as indicated. Installation in this manner will allow the machine to finish the harvest period
before shutdown. However, the machine will still need to be manually started to resume production.

Safety Switches. The machine is also equipped with the following safeties and control switches,
which are mounted to the frame near the compressor. Refer to the wiring schematic FIGURE 6-3 for
their circuitry.

 High/Low dual pressure switch (1PS) to stop the machine if the compressor suction pressure

goes too low (15 psi for R-22) or the compressor discharge pressure goes too high (300 psi for
R-22). See “High/Low Pressure Switch”.

9/15/09

 Oil failure pressure switch (0PS) to stop the machine if the compressor oil pressure drops to 11-

15 psi net (suction pressure minus oil pressure gage reading). See “Oil Pressure Switch”.

6-2

ELECTRICAL CONTROLS

1M

(Not shown)

2M Pump Motor Starter

3M Cutter Motor Starter

1CR Control Relay With

2CR Control Relay For making and breaking circuits during freezing and thawing. Energized during

2TR Thawing Timer Controls the time of the harvest (thawing) period.

DT Delay Timer Allows the compressor to start unloaded by delaying the energizing of the “UR-

2PS Freezer Pressure Switch Controls the desired ice thickness (hole size) by sensing the freezer suction pressure

ET Elapsed Time Indicator Indicates total hours of machine operation. Is powered when the compressor is

CB4 Circuit Breaker Overload and short circuit protection for crankcase heater and the control circuit.

TB Terminal Block Numbered for multiple wire connections and ease of troubleshooting.

DS2

(not shown)

9/15/09

P24FL & P34FL Service Manual

FIGURE 6-1

Control Panel (Door Opened)

Compressor Motor Starter Provides power to the compressor motor. Continuously energized during freezing

and thawing with auxiliary hold contact and auxiliary contact to de-energize the
compressor crankcase heater when the motor is running.

Provides power to the circulating water pump during the freezer period or when the
(Contactor & manual motor
starter)

(Contactor & manual motor
starter)

Pneumatic Timer

CE panel-Lowside Disconnect Used to disconnect power from panel when panel door opened.

Description of Control Panel Parts (Inside)

Hand/Auto switch is in the “Hand” position to circulate water or ice machine

cleaner, etc. Manual motor starter provides motor over-current and short circuit

protection.

Provides power to the cutter during the harvest period. Manual motor starter

provides motor over-current and short circuit protection.

For making and breaking various circuits during freezing and thawing period with

pneumatic timer to delay the actual thawing pr ocess. Energized during thawing.

freezing, thawing, and hand. Momentarily de-energized at the end of the harvest.

Energized during the harvest period.

SOL” (unloader solenoid) valve. This gives lower in rush amps and helps prevent

belt slippage at start-up.

and initiating the harvest period.

running.

TABLE 6-1

P24FL & P34FL Service Manual

ELECTRICAL CONTROLS

FIGURE 6-2

Control Panel (Hinged Door)

(1LT) Amber Pilot Light - Freezing Illuminated during the freeze period or whenever the

circulating water pump is running.

(2LT) Clear Pilot Light - Liquid Feed Illuminated when the circulating water pump is running and

the float switch (10) is closed. Indicates that the liquid line

solenoid valve (20) is opened.
(3LT) Red Pilot Light - Thawing Illuminated when the machine is in a harvest period.
(2PB) Green Push Button - Start For starting the compressor motor and ice production. (NO)
(1PB) Red Push Button - Stop For stopping the compressor motor and ice production. (NC)
(3PB) White Push Button - Manual

Harvest

(1SS) Selector Switch - Hand/Auto “Hand” position for running the circulating water pump

For manually initiating a harvest cycle. (NO)

independently at start-up or for cleaning the freezer tubes and

water tank.

“Auto” position for provision of automatic system shutdown

if there is a control circuit power interruption.

TABLE 6-2

Description of Control Panel Parts (Outer Door)

6-3

9/15/09

6-4

ELECTRICAL CONTROLS

Electrical Schematic for P24FL and P34FL all Voltages, 50-60 Hz.

DS2

P24FL & P34FL Service Manual

FIGURE 6-3

9/15/09

P24FL & P34FL Service Manual

Level Column Wiring for P24FL and P34FL all Voltages, 50-60 Hz.

6-5

ELECTRICAL CONTROLS

FIGURE 6-4

9/15/09

P24FL & P34FL Service Manual 7-1

MAINTENANCE

7. Maintenance

Preventative Maintenance. A careful inspection of the Tube-Ice machine for leaks and correct

operational functions at the time of installation and start-up will begin its long satisfactory life of
service. In order to insure this degree of dependability, a systematic maintenance program is
necessary. Therefore, the following schedule is suggested as a minimum.

A. Daily

1) Check operating pressures (suction, discharge, oil).

2) Check ice quality.

3) Check “ice out” time (maintain 30 seconds of continued harvest after last ice is out).

4) Check compressor oil level.

5) Check refrigerant operation level.

6) Check frost pattern on freezer shell and oil trap.

7) Check make-up water float valve adjustment.

8) Rotate the Mycom-Cuno oil filter - tee handle two complete turns.

B. Weekly (in addition to daily checks)

1) Check all belts for proper tension. Do not use belt dressings.

2) Check for leaks after 400 hours or four weeks of operation

C. Monthly (in addition to weekly checks)

1) Check calibration and operation of all controls (high and low pressure switches, oil pressure

switch, etc.)

2) Check cooling tower spray nozzles and pump suction screen for scaling and algae (consult

water treatment suppliers for corrective measures).

3) Check water distributors in freezer for scale accumulation.

4) Check water tank for solids to be removed.

5) Check all motor drive units (compressor, cutter and pump motors, cooling tower fan, and

pump, etc) for abnormal noise and/or vibrations.

6) Check oil level in gear reducer.

7) Check one complete freeze/thaw cycle, record data and compare with production check of

Registration/Start-up Report.

D. Yearly (in addition to weekly and monthly)

1) Check entire system for leaks.

2) Drain water from condenser and cooling tower and check condenser tubes. Check closely

for damage by corrosion or scale.

3) Remove all rust from all equipment, clean, and paint.

4) Check all motors for shaft wear and end play.

5) Check operation and general condition of all electrical controls, relays, motor starters, and

solenoid valves.

6) Check freezing time, ice release time, and ice out time.

7) Change oil in gear reducer box once a year.

8) Lubricate compressor motor bearings.

9) Drain compressor oil, open compressor, inspect and clean inside crankcase. Change oil

filter and add new oil. Inspect compressor suction strainer.

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7-2 P24FL & P34FL Service Manual
MAINTENANCE

PREVENTATIVE MAINTENANCE FORM

This form can be removed and duplicated for record keeping.

Date: _____________ Model #: ________________________ Serial #: _____________

The following service performed and checked:

Hour meter reading _______________ , Ambient temperature (inside)_______ F
Make-Up water float valve adjusted properly
Water distributors clean and in place
All drains freely draining
Cleaned and flushed water tank
Compressor oil changed
Cleaned and inspected inside compressor crankcase
Changed compressor oil filter
Checked/adjusted compressor belt tension
Lubricate compressor motor bearings
Check/change cutter gear reducer oil
Check/adjust cutter drive gear meshing
Leak check entire system
Check liquid refrigerant level in receiver
Drained oil from oil trap
Compressor crankcase heater working
Compressor net oil pressure (gage reading less suction)

Motor amps: Compressor ________ Cutter ________ Pump ________
Suction psig (end of freeze) __________ Discharge psig (end of freeze)_____________
Suction psig (end of thaw) __________ Discharge psig (end of thaw) _____________
Compressor water out ____F Tower fan cycles ___ On ___ Off

Production Check

Test

Cycle

Make-up

Water

Temp

Freezing

Time

Min/Sec

Harvest

Time

Min/Sec

First

Ice Out

Min/Sec

All

Ice Out

Min/Sec

Avg.

Hole

Size

Ice lb.

Per Harvest

(est)

Ice lb.

Per Day

(est)
#1
#2
#3
#4

Comments: _______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

Name: __________________________________

9/15/2009

P24FL & P34FL Service Manual 7-3

MAINTENANCE

Ice Making Section. The ice making section of the Tube-Ice machine should be cleaned at least
twice a year (more often if water conditions cause mineral build up). Use an approved food-grade
ice machine cleaner. The water pump is used to circulate the cleaner through the system. For
complete instructions, follow the “Cleaning Procedure” below.

Cleaning Procedure.

1. Stop the machine at the end of harvest.

2. Shut off make-up water supply.

3. Drain the water tank, flushing out any loose sediment.

4. Close the drain valve and fill the tank with warm water. Warm water promotes faster cleaning.

5. Cover the ice discharge opening to prevent water from splashing out and contaminating any

stored ice.

6. Add sufficient ice machine cleaner to the water tank.

P24 tank = 2.5 gallons water per inch of water height in tank, 13” = 32.5 gallons
P34 tank = 4.7 gallons water per inch of water height in tank, 13” = 60.6 gallons
Mix cleaning solution according to manufacturer’s recommendations.

7. Remove top water box cover, inspect distributors, remove any hard particles from orifices, and

make sure all distributors are in place. Replace cover.

8. Turn Hand/Auto switch to “Hand” position and circulate the cleaning solution until deposits are

dissolved or the solution is neutralized. After draining, the pump may have to be stopped and
restarted to dispel air.

9. Turn switch to “Auto” position to stop the pump. Drain and flush the water tank. Repeat

cleaning as necessary.

10. After cleaning, fill the tank with fresh water, start the pump again, and circulate for 15 minutes.

11. Stop the pump, drain and flush the tank and again refill with fresh water.

12. Remove the cover from the ice discharge opening, and clean any area that may have been

splashed with solution during cleaning.

13. Make sure the make-up water float valve is adjusted properly and the drain valve is closed.

14. Start and stop the pump again to make sure it is circulating water and it is not air bound.

You are now ready to produce ice.

Water Distributors. The water distributors are located under the top freezer cover. These
distributors are similar in design to those used in mid-size and small machines (i.e. P18F, P118, etc.)
except they have a small vent tube. It is important that this plastic vent tube remain in place in each
distributor. The distributors may require occasional or periodic cleaning to remove solids, foreign
particles, or mineral deposit accumulated from the circulating make-up (ice making) water. The
frequency of cleaning operation will depend on the characteristics of the water supply. The
distributors need inspection when the inside diameter of a large portion of the ice becomes irregular
(due to channeling of water), if some of the ice is opaque or if there is a noticeable decrease in ice
capacity and quality.

Tube Size 1 1/2” 1 1/4” 1”

Model Number of Distributors
P24FL 144 198 264
P34FL 306 420 564

TABLE 7-1

Water Distributors

9/15/2009

7-4 P24FL & P34FL Service Manual
MAINTENANCE

You may look through the plastic freezer cover to inspect the water distributors if the view is clear.
For a closer inspection you should stop the unit, remove the nuts and retaining ring sections and lift
off the top cover. Make sure the two orifices in the side of each distributor are open, the vent tubes
are in place, and a distributor and vent tube assembly is installed firmly in each tube.

To remove the water distributors for cleaning:

1. Grip the top of the distributor body (not at the vent tube) with adjustable pliers.

2. Hold and twist the distributor while pulling upward.

3. Lift the distributor out of the hole.

To install the distributors:

1. Insert one in each tube hole and seat firmly by using a short piece of pipe or conduit.

2. Slide the pipe or conduit down over the vent tube and gently tap the distributor in place.

3. Do not allow the distributor to be recessed below the top of the tube sheet.

To replace the cover:

1. Replace water distributor box cover gasket.

2. Install the cover over the bolt studs.

3. Install the four (4) cover retaining rings sections and nuts.

4. Tighten the wing nuts firmly to prevent foreign materials from entering the water box.

Note: The freezer cover and gasket are not intended to hold the pressure of the circulating water
in the event of a freeze up. Therefore every effort should be made to prevent the Tube-Ice from
freezing solid (with no hole).

Tube Size 1 1/2” 1 1/4” 1”
Hole Size 1/4”-3/8” Avg. 1/8”-3/16” Avg. 1/16”-1/8” Avg.

TABLE 7-2



Average Hole Size In Tube-Ice

Water Tank. The production of opaque ice can indicate that the water in the water tank contains a

concentrated amount of solids or salts. See Troubleshooting, “Poor Ice Quality”.

9/15/2009

P24FL & P34FL Service Manual 7-5

MAINTENANCE

To clean the water tank:

1. Stop the machine at the end of harvest.

2. Shut off the make-up water supply.

3. Open the drain valve and drain the tank.

4. Remove the water box cover and flush out any loose sediment from the tank. The wire mesh

screen can be removed if necessary.

5. If further cleaning is needed, follow “Cleaning Procedure”.

6. If further cleaning is not needed, close the drain valve and refill the tank with fresh water.

7. Make sure the float valve is adjusted properly and install the water box cover.

8. Start and stop the pump again to make sure it is circulating water and is not air bound.

Water Cooled Condenser Cleaning. As water evaporates from a cooling tower, the solid
impurities remain and must be flushed from the system to prevent a scale build-up in the condenser
and cooling tower. This can be accomplished by a continuous bleed off valve located in the pump
discharge line. The valve should be adjusted to bleed off an equal amount of water which is
evaporated. If water hardness is very high, a higher bleed off rate or chemical treatment may be
required. Consult you local water treatment company for recommendations.

If after a period of time, scale has formed inside the tubes, mechanical cleaning may be necessary.
See “Servicing Section--Condenser”.

Cooling Tower/Evap Condenser. See Figure 3-7 for parts location.

1. Bleed off valve. The bleed off valve should be checked monthly to assure that is not blocked

and that water is flowing as required. If the unit is controlled by a water treatment system, the
bleed off valve may not be required.

2. Strainer. The pan or sump strainer is located in the bottom of the sump at the suction connection

to the pump. The strainer should be inspected monthly and kept clean. Do not operate the unit
without the strainer in place.

3. Make-up water float valve. This valve should be checked monthly for proper operation and

adjustment. It should be adjusted to maintain a water level below the overflow and high enough
to prevent the pump from cavitating when the system is in operation.

4. Spray nozzles. The spray nozzles should be checked monthly to make sure none are restricted

and the spray pattern is complete and even.

5. Pump motor and fan motor. The motors should be checked and/or lubricated every six months

according to the motor manufacturer’s recommendations.

6. Fan bearings. The fan bearings should be lubricated every six months. Make sure the proper

grade of grease is used (normally conforms to NLCI-Grade 2) and it is best to use a hand grease
gun.

7. Fan belts. The fan belt tension should be checked weekly for the first two weeks of operation,

then monthly during continuous use.

The best tension for a V-belt is the lowest tension at which the belt will not slip under its full load.
Never use dressing on V-belts. Keep belts and grooves clean and free of oil, grease, and foreign
material. Clean with non-flammable, non-toxic degreasing agent or commercial detergent and
water.

! CAUTION !

9/15/2009

7-6 P24FL & P34FL Service Manual
MAINTENANCE

Follow all lock-out and tag-out procedures before servicing any electrical equipment.

! CAUTION !

Service/Frequency Start-Up Monthly Six Months Shutdown
Clean debris from unit X X X
Clean strainer and flush sump X X X
Check fan and pump rotation X
Clean spray nozzles X X
Check belt tension X X
Check for noise/vibration X X
Check/adjust make-up water valve X X
Check/adjust bleed rate X X
Check/lubricate fan bearings X X
Lubricate motor base adj. screw X X X
Drain sump and piping X

TABLE 7-3

Cooling Tower Maintenance Schedule

Compressor. In starting and charging the unit, the oil sight glass should be continually checked to

make sure an adequate oil level is maintained. The oil level should be 1/4-3/4 of the sight glass. If
the oil level drops below 1/4 of the glass, add refrigerant oil ((Texaco WF32 or equivalent for R-22)
as per the compressor manufacturer recommendations. Never allow the oil level to be out of sight,
above or below the sight glass when the compressor is operating.

! CAUTION !

The crankcase heater should be energized for a minimum of

four hours and the oil temperature should be 100-110F

before attempting to start the compressor.

! CAUTION !

9/15/2009

During operation, the specified net oil pressure should be maintained for proper lubrication and
operation of the cylinder unloader mechanism.

Net oil pressure: 45-55 psig

Note: Net oil pressure is calculated by subtracting the compressor suction pressure from the oil

pressure gage reading while the compressor is running.

Example: Oil pressure gage reading: 65 psig
Suction pressure gage reading: 40 psig
Net Oil Pressure: 25 psig

The compressor oil should be changed at close intervals during initial break-in operation and up to
the first 1000 hours (see Table 7-4 below). Your machine was test operated at the factory and

P24FL & P34FL Service Manual 7-7

MAINTENANCE

compressor oil was drained, crankcase cleaned, suction strainer sock cleaned, new oil filter installed
(if applicable), and clean oil added prior to shipping.

Note: It is the owner’s responsibility to make sure normal maintenance is initiated to insure that the

compressor is not subjected to premature wear or failure due to neglect or lack of sufficient
maintenance and care.

Frequency

1st 2nd 3rd 4th Thereafter
Change oil 200 hr. 500 hr. 1500 hr. 4000 hr. every 4000 hrs.
Clean suction strainer cloth 200 hr. 500 hr. Remove if clogging is minimal

TABLE 7-4

Compressor Maintenance

The above maintenance is only a guide. The compressor should be inspected anytime there is
unusual noise, damage is suspected or the oil becomes discolored. The oil should be changed any
time the compressor is opened. For specific recommendations and instructions, refer to the
particular compressor manufacturer’s manual. See “Compressor Oil Changing and Inspection”

Cutter Gear Reducer. The oil level of the gear reducer should be checked monthly or when there
is any evidence of leakage. The correct level is indicated by the pipe plug in the side of the gear
housing. The oil should run out of the hole when the plug is taken out. If low, add oil through one
of the top plugged holes. A high grade lubricant such as Mobil 600W or SAE 140 gear oil should be
used. The oil should be changed annually. Drain the oil and flush the gear case with mineral spirits.
Drain the mineral spirits completely and refill with the proper oil.

Note: If a USDA high food grade lubricant is desired, use Chevron FM Lubricating Oil 460X.

! CAUTION !

Follow all lock-out and tag-out procedures before servicing any electrical equipment.

! CAUTION !

V-Belt Maintenance. Belts should be kept clean, free of oil and protected from sunlight as much as

possible. To clean belts, they should be wiped with a dry cloth. The safest way to remove dirt and
grime is to wash the belt with soap and water and rinse well. BELT DRESSING SHOULD

NEVER BE USED ON A V-BELT DRIVE.

The tension on a 5 rib, banded V-belt can be checked as follows:

9/15/2009

7-8 P24FL & P34FL Service Manual
MAINTENANCE

1. Apply 50-75 pounds of deflection force uniformly across the belt, midway between the pulley

centers. Lay a straight edge across the sheaves to measure the deflection. The deflection should
be 5/8” to 3/4”.

2. When installing a new belt, move the sheaves together to allow the belt to slide across the

sheaves. Rotate the belt and sheaves to obtain proper seating. Remove the slack from the belt
and measure the outside circumference to the nearest 1/4”. Multiply this reading by .0075 and
.001, add these amounts to the circumference reading. Elongate the belt to the new length.
Example: 105 x .0075 = .7875, 105+ .7875 = 105.7875=105 3/4” min.
105 x .001 = 1.05, 105+ 1.05 = 106.05=106 1/16” max.

3. Check Compressor sheave and motor sheave with a straight edge to be sure they are parallel and

in the same plane.

4. The tension should be checked after 24 to 48 hours of operation to compensate for initial stretch

and wear-in. Periodic checks should be made and tension restored as necessary.

General Rules:
The best tension for a V-belt drive is the lowest tension at which the belt will not slip under the

highest load. Too much tension shortens belt and bearing life.

Check tension often during the first 48 hours of operation and periodically afterwards.
Keep belts and sheaves free of any foreign material which may cause slippage.
If a belt slips, tighten it.

9/15/2009

P24FL & P34FL Service Manual

Note: Your machine’s electrical system has several built-in safety and overload protection features

to stop operation when a single component fails or there is a problem from an outside source
such a power supply. Make sure all auxiliary equipment is connected to incorporate safety
and overload circuits and protect all related equipment.

When the machine stops, it must be manually restarted by pushing the “Start” button. If it stopped
while in a freeze cycle, it should be manually harvested to remove all ice from the freezer. This is
done by pushing the white “Manual Harvest” button.

Always check the machine operation thoroughly after remedying the problem. Be sure to correct the
source or cause of the problem to prevent the problem from occurring again.

Symptom Page
Machine stopped 8-2
Freeze-up due to extended freeze period 8-4
Freeze-up due to ice failing to discharge 8-5
Low ice capacity 8-6
Poor ice quality 8-7
High discharge pressure 8-8
Low discharge pressure 8-9
High suction pressure 8-9
Compressor running unloaded during freeze 8-9
Compressor oil pressure low 8-10
Compressor loosing oil excessively 8-10
Machine short cycles 8-11
Shut down by oil pressure switch 8-11
High compressor discharge temperature 8-11
Suction line frosting to compressor 8-12

Notice: Opening the compressor for observation or determination of failure does NOT void the

warranty.

Contact your distributor first for technical service assistance about operation problems not covered
in this manual.

Also feel free to contact the factory for additional service [phone].

8-1

TROUBLESHOOTING

8. Troubleshooting

9/15/09

8-2

TROUBLESHOOTING

Symptom: Machine Stopped

Power failure or interruption Check fused disconnect or circuit breaker

Circuit breaker (CB4) for control circuit
tripped

Compressor motor starter overload (1MOL)
tripped

Water pump, cutter motor, tower fan, tower
pump, conveyor motor, overload tripped

Freezer water pump motor overload (2MOL)
tripped

Cutter motor overload (3MOL) tripped Check for loose terminal connections and

Bin level control (optional) open Adjust or replace control as required. If bin

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

supplying power to the machine. If power has
been off, make sure the crankcase heater is
energized and there is no liquid refrigerant in
the compressor crankcase prior to restarting the
compressor. If ice is in the freezer, initiate a
manual harvest.
Check compressor crankcase heater, coils of
relays, contactors, starters, solenoid valves, and
thawing timer for a ground. Repair or replace
any defective part and reset circuit breaker.
Make sure there is no liquid refrigerant in the
compressor crankcase prior to restarting the
machine.
Check for a loose connection on all motor
starter and motor terminals which could cause
excessive amp draw. Reset overload and
restart the machine, check amperage, power
supply, and head pressure. (Check TR in part
wind starts only).
Check for loose connection on all terminals
which could cause excessive amp draw. Reset
the overload and manually run that particular
motor to check actual voltage and amperage
against motor rating.
Check for loose terminal connections and/or
defective breaker (CB2), reset the overload and
start the pump by turning the selector switch
(1SS) to “Hand”. Check voltage and amperage
against motor rating. Confirm proper rotation.

blown fuse, reset the overload. Clear all ice
that may have jammed cutter. Turn the
selector switch (1SS) to “Hand” and push the
“Manual Harvest” button. Check voltage and
amps against motor rating. If tripping repeats
but ice is not jammed, check the gear reducer
for resistance, cutter bearings for wear, drive
gear and ring gear for proper engagement, and
reducer motor for defect or single phasing.

level control is not used, make sure jumper
wire #8 and #9is installed at of the terminal
block.

9/15/09

P24FL & P34FL Service Manual

TROUBLESHOOTING

Symptom: Machine Stopped (con’t)

Possible Cause Possible Remedy

High/Low pressure safety switch (1PS) tripped If the machine stops by low pressure cutout,

the switch will reset automatically when the
pressure raises to the “cut-in” setting. Check
thaw gas valve (18) to make sure it opens
during harvest time.
If the machine stops by high pressure cutout,
the switch will have to be manually reset after
the pressure drops below the “cut-in” setting.
Check the head pressure during the next freeze
cycle. See FIGURE 9-3, Section 9 (High/Low
Pressure Switch).

Low oil pressure tripped (OPS) Manually reset the switch after the switch

heater cools. Check the crankcase oil level
(1/4-3/4 full). Add oil if below 1/4 glass
before attempting to restart the machine
Restart the machine and check net oil pressure
(net oil pressure = oil pump line pressure
minus crankcase suction pressure). See
FIGURE 9-5, Section 9 (Oil Pressure Switch).
See “Low Compressor Oil Pressure”

Net oil pressure range: 45-55 psig
Defective control panel component such as
1PB, 1SS, 1M contact, 2CR contact

See FIGURE 6-3, Wiring Schematic, and

check for open circuit. Refer to FIGURES 6-1

and 6-2, Control Panel to identify parts. Check

for loose wires. Replace defective part, restart

machine, check power supply, and current

draw.
Circuit breaker (CB2 or CB3) for pump or
cutter motor tripped.

Check for loose connection on all terminals,

reset breaker and check amp draw against

breaker rating. Check voltage and current

unbalance, Section 3. Replace breaker if

defective.
High refrigerant level in evaporator due to
liquid feed valve “A1” leaking through

Check the manual opening stem to make sure it

is in the automatic position (stem screwed out).

Check for leakage by sound, temperature

difference and frost during the freeze cycle.

Leakage should stop by closing the hand stop

valve downstream of thaw gas valve. Isolate

and repair or replace the valve as needed
High refrigerant level in evaporator due to
level controller failure

Check liquid level control for proper operation

and set point. Replace defective part.

8-3

9/15/09

8-4

TROUBLESHOOTING

Symptom: Freeze-up due to extended freeze period

Freezer pressure switch (2PS) set too low or
defective
Water tank drain valve, make-up water float
valve or flushing valve stuck or opened

Thaw gas solenoid valve (18) leaking through
during freeze

Level control set to high Check liquid level control for proper operation

Compressor running unloaded If the compressor is running unloaded, the

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

Adjust switch or replace if defective. See

FIGURE 9-2.

Close, repair, or replace valve as needed. The

float valve should be adjusted low enough that

water should not run out the tank overflow

during the freeze cycle.

Check the manual opening stem to make sure it

is in the automatic position (stem screwed in).

Check for leakage by sound, temperature

difference and frost during the freeze cycle.

Leakage should stop by closing the hand stop

valve downstream of thaw gas valve. Isolate

and repair or replace the valve as needed.

and set point. Replace defective part.

motor amp draw will only be 60%-70% of the

normal amp draw of a loaded compressor.

Check the delay timer (DT) electrical circuit to

make sure the “UR-SOL” coil is not energized.

Refer to the compressor manual for normal oil

pressure needed to load the compressor

cylinders and any further procedures to check

the mechanical function of the unloader

mechanism.

9/15/09

P24FL & P34FL Service Manual

TROUBLESHOOTING

Symptom: Freeze-up due to ice failing to discharge

Possible Cause Possible Remedy

Extended freeze period Check freezer pressure switch (2PS)

adjustment. See FIGURE 9-2 for adjustment

and TABLE 7-2 for average hole size. Make

sure all water distributors are in place (one in

each tube).

Thaw time too short Adjust thaw timer (2TR) to allow all ice to

clear the cutter and ice discharge opening with

at least 30 seconds to spare. Replace defective

timer.

Insufficient heat for thawing due to low
condensing pressure

The head pressure should be maintained form

175-200 psi for R-22or 210-245 psi for R-

404a, usually by a water regulating valve or

fan cycling switch. Check to make sure these

controls are working properly. Cold prevailing

wind can also be a factor.

Insufficient heat due to non-condensables
(usually air) in the system

If non-condensables are present with the

refrigerant, the saturated temperature will not

relate to the pressure reading at the receiver

and the refrigerant will be cooler, although

pressure will be high. Air can be purged from

the system by following the procedure in the

Section 9, “Purging Non-Condensables”.

Insufficient heat due to water in the refrigeration
system

If water is present in the refrigeration system,

the ice will release, but discharge very slowly.

Check the refrigerant for water content

(purchased kit or freezer pump-down).

Remove all water by following the procedure

in Section 9, “ Removing water”.

Insufficient heat due to low refrigerant charge The refrigerant level in the receiver should be

near the operating mark at the end of a freezing

cycle to provide enough volume of warm gas

for harvesting. DO NOT OVERFILL

RECEIVER.

Cutter or cutter disc does not turn Check cutter gear reducer and drive gear for

proper operation and alignment. Check for

broken gear teeth or sheared shaft key.

Replace defective parts.

Compressor not running unloaded during thaw
cycle.

Check compressor motor Amp draw. During

the thaw cycle, the compressor motor Amp

draw should be 60 - 70% of normal amp draw

during the freeze cycle. Check compressor

unloader solenoid coil (UR) to make sure it is

energized and the valve opening during the

thaw cycle.

8-5

9/15/09

8-6

TROUBLESHOOTING

Symptom: Low ice capacity.

Suspicions of low ice capacity should be confirmed by accurate calculations of actual ice product.
Much weight can be lost by melting and off fall through augers and other ice handling equipment.

1. Time the total freeze and thaw cycle for the cycle which is to be caught and weighed.

2. Catch all the ice at the ice discharge opening of the machine.

3. Weight the total amount of ice caught.

Lbs. ice per cycle
Cycle time minutes X 1440 = _____ lbs. production per 24 hours

More than one cycle should be caught and weighed to get an accurate average.

Inadequate water for ice making Water pressure of 40 psig minimum is required

Water distributors may be stopped up Check distributors and clean orifices as needed.
Freezer pressure switch or thaw timer out of
adjustment

Excessive ice chips in the water tank, causing
short cycling

Compressor running unloaded or not pumping
full volume

Restriction in the refrigerant liquid line or float
switch not operating properly

Low refrigerant charge, causing re-freeze Check the receiver gage glass mark for the

Warm make-up water for ice making Capacity of the machine is proportional to ice

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

to assure proper water supply. Check water

pressure. Check for a restriction in the incoming

line or at the make-up water float valve.

Check hole size in Tube-Ice (See TABLE 7-2).

Crushed ice should be 3/16”-1/4” thick. Check

and adjust thawing time. Thawing should be 30

seconds longer than it takes for all the ice to

clear the freezer.

Check incoming water temperature (45F

minimum). Check flushing valve to make sure

ice chips are being melted and flowing out the

tank overflow during the harvest cycle.

Check compressor motor amp draw. Check for

belt slippage and tighten as needed. Check for

leaking compressor suction or discharge valves.

Refer to your compressor manual. See other

related symptoms.

Check for a partially closed valve or an

obstruction at the strainer, solenoid valve, or

hand expansion valve. The liquid line will

normally have frost on the downstream side of a

restriction, especially as the suction pressure

decreases.

proper level. Check for and repair leaks. Add

refrigerant.

making water temperature. Warmer water will

reduce the ice making capacity. Refer to Section

11, Capacity Table. Check float adjustment and

water tank drain valve.

9/15/09

P24FL & P34FL Service Manual

Symptom: Low ice capacity (cont.)

Excessively high head pressure Check cooling tower or evap condenser to

Thawing gas solenoid valve (18) leaking
through during freeze cycle

Symptom: Poor ice quality

Excessive concentration of solids in the water
tank usually indicated by a build-up of mineral
deposit on the sides and bottom of the tank and
opaque ice production. Also, water
distributors restricted.
Insufficient water supply indicated by a low
level in the tank

Water pump rotation wrong direction Check rotation in relation with arrow on pump

Low refrigerant charge, causing an ice out
problem and re-freeze

Restriction in liquid line, causing short freeze
cycle

8-7

TROUBLESHOOTING

Possible Cause Possible Remedy

make sure sufficient water is provided for

cooling and the equipment is operational to

cool the water. Also see “Symptom High Head

Pressure”.

Check the manual opening stem to make sure it

is in the automatic position (stem screwed in).

Check for leak by sound, temperature

difference and frost during a freeze cycle.

Close the stop valve (90) to confirm suspicion

of leakage. Repair or replace the valve.

Possible Cause Possible Remedy

Perform a cleaning procedure as well as

removing the freezer cover and cleaning the

water distributors. Make sure the flushing

valve (63) is functioning and the tank overflow

piping is not restricted.

Check water pressure, 40 psig is recommended

minimum. Check for a water line restriction,

partially closed valve, or defective make-up

water float valve. Make sure the water tank

drain is closed.

housing and reverse two wires at the motor if

necessary.

Check refrigerant level mark on the receiver

and on the painted portion of the gage glass

guard. Be sure to keep the gage glass cocks

closed when finished checking the level.

Check for closed valve, defective solenoid

valve (20), float switch defective or strainer

restricted. The liquid line will normally have

frost on the down-stream side of a restriction,

especially as the suction pressure decreases.

9/15/09

8-8

TROUBLESHOOTING

Symptom: High discharge pressure (check gage accuracy)

Insufficient water flow through the cooling
tower or condenser

Fan control out of adjustment Check adjustment. Refer to FIGURE 9-4, “Fan

Non-condensable in system. If non-condensables are present with the

Cooling tower or evap condenser in need of
maintenance

Dirty condenser tubes Visually inspect the condenser tubes to see if

Too much liquid in condenser/receiver
covering tubes causing inefficiency

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

Check the condenser water pump to make sure

it is pumping enough water as specified in

TABLE 3-2. Check sump strainer screen and

clean. Check condenser pump direction of

rotation.

Control”. Replace if defective.

refrigerant, the saturated temperature will not

relate to the pressure reading at the receiver.

The refrigerant will be cooler, although the

pressure will be high. Air can be purged from

the system by following instructions in Section

9, “Purging Non-Condensables”.

Check fan motor and fan belts for proper

operation and tension. Check spray nozzles,

tubes, sump, and sump screen, for

accumulation of mineral deposit and clean as

required. Check tower blowdown and

chemical treatment if applicable.

there is any build-up of mineral deposit, which

would reduce the cooling effect of the tubes

and water. Clean chemically or mechanically

as applicable.

Remove refrigerant so all tubes will be above

liquid refrigerant level.

9/15/09

P24FL & P34FL Service Manual

TROUBLESHOOTING

Symptom: Low discharge pressure (check gage accuracy)

Possible Cause Possible Remedy

Fan cycling switch out of adjustment or
defective
Compressor running unloaded or not pumping
efficiently

Check adjustment. Refer to FIGURE 9-4, “Fan

Control”. Replace if defective.

Check compressor motor amp. If the

compressor is running unloaded, the amperage

will only be approximately 60% of normal amp

draw (FLA). Refer to the compressor manual.
Ambient temperature low and prevailing winds
blowing through tower
Too much cold water circulating through
condenser

Shield tower from prevailing winds to prevent

excessive cooling. Install an indoor sump.

Install a water-regulating valve in the water

line form the condenser and control flow by

receiver pressure.
Thaw gas valve #18 leaking through Make sure manual opening stem is in the

automatic (screwed in) position. Repair or

replace defective parts.

Symptom: High suction pressure (check gage accuracy)

Possible Cause Possible Remedy

Compressor running unloaded or not pumping
efficiently

Check compressor motor amp. If the

compressor is running unloaded, the amperage

will only be approximately 60% of normal amp

draw. Refer to the compressor manual.
Thaw gas valve #18 leaking through Make sure manual opening stem is in the

automatic (screwed in) position. Repair or

replace defective parts.
Defective gage Check pressure with accurate gage and replace

as necessary.

Symptom: Compressor running unloaded during freeze

Possible Cause Possible Remedy

Low oil pressure Check compressor net oil pressure.

Net oil pressure = oil pressure gage reading

less suction pressure: 11-15 psi

Refer to the compressor manual for “Oil

Pressure Adjustment”.
Unloader solenoid valve open Check solenoid coil to make sure it is not

energized. If valve is stuck open, replace

valve.
Unloader mechanism not working properly Refer to compressor manual for unloader

information

8-9

9/15/09

8-10

TROUBLESHOOTING

Symptom: Compressor oil pressure low (check gages)

See Section 7, for compressor oil pressure requirements.

Oil diluted with refrigerant Oil will be very foamy. Check liquid feed

Oil pressure regulating valve out of adjustment Adjust valve to increase oil pressure. Turn

Compressor rotation incorrect Check rotation direction by arrow indication.

Restriction strainer, oil filter, pick-up tube or
oil passage

Symptom: Compressor loosing oil excessively

Non-effective oil separator or float The oil separator will normally return a good

Liquid refrigerant in crankcase Check liquid feed to make sure it is not

Compressor piston rings seized or broken Check compressor efficiency. If rings are

Leaking shaft seal A few drops per minute is okay. If ammonia is

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

control for overfeed problem.

stem in to increase, out to decrease.

Reverse rotation, if necessary.

Clean strainer or restriction in passage or

replace filter.

Possible Cause Possible Remedy

portion of oil leaving the compressor, if it is

working properly. Check the oil float and

return line to see it is not restricted.

overfeeding and that the solenoid valve #20 is

not leaking through when the machine is

stopped.

seized or broken, replace defective parts.

leaking, replace the seal.

9/15/09

P24FL & P34FL Service Manual

TROUBLESHOOTING

Symptom: Machine short cycles

Possible Cause Possible Remedy

Freezer pressure switch (2PS) set too low or
defective

Adjust switch or replace if defective. See

FIGURE 9-2.
Freeze-up See “Freeze-up due to extended freezer period”

and “Freeze-up due to ice failing to discharge”.
Clogged water distributors Clean water distributors.
Lack of water for making ice Check water tank for sufficient water level.

Check for restrictions in water line, defective

float valve, open drain valve, excessive ice

chips or low water pressure and correct.
Lack of sufficient liquid refrigerant feed Check float and float switch, solenoid valve

and coil #20 in liquid line, strainer, and

refrigerant level in receiver.
Water pump rotation incorrect or pump
defective

Check pump motor rotation. Check for leaking

pump seal or defective motor and repair or

replace as needed.

Symptom: Shut down by oil pressure switch

Possible Cause Possible Remedy

Switch adjusted too high or defective Check switch adjustment and cutout pressure

activation against an accurate gage. Replace

switch if defective. See Figure 9-5.
Oil pressure low See “Compressor oil pressure low”.
Low oil level Add oil.
Defective thawing timer causing long harvest

Replace defective timer.
cycle and oil dilution

Symptom: High compressor discharge temperature

Possible Cause Possible Remedy

High head pressure Check gage accuracy and “High discharge

pressure”.
Defective suction or discharge valves Feel the compressor heads for hot spots or one

head running hot. Replace worn or leaking

valves.
Restriction in the discharge gas line Check all hand and check valves to make sure

they are fully opened and not stuck. Repair or

replace as needed.
Internal relief valve leaking Check the compressor manual to see if your

compressor is so equipped. Replace

accordingly.

8-11

9/15/09

8-12

TROUBLESHOOTING

Symptom: Suction line frosting to compressor

Liquid refrigerant overfeed Check float switch to make sure it is

Refrigerant contaminated with water Test refrigerant or oil for water contamination.

P24FL & P34FL Service Manual

Possible Cause Possible Remedy

functioning properly. Replace if defective.

Check solenoid valves #20A and#20B to make

sure it is not leaking through. Repair or

replace if defective.

Completely pump the freezer out (pumpdown)

and pull vacuum on freezer. Refer to Service,

Section 9 “Removing Water”.

9/15/09

P24FL & P34FL Service Manual

SERVICING OPERATIONS

9. Servicing Operations

Automatic Blowdown (harvest cycle). A feature of this machine is a solenoid activated flushing

valve (63) which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of
the water tank. This flushing during the harvest cycle helps to remove salts or solids accumulated in
the water as a result of the freezing action. It also helps melt ice chips which fall into the water tank
during harvest. The flushing valve is opened (energized) during each thaw cycle when the water
pump stops and the water in the freezer tubes returns to the water tank. If water quality is superior,
this blowdown can be reduced by installing a smaller reducer bushing in the outlet elbow.

The flushing action carries accumulated salts, solids, and ice chips (fines) out through the water tank
overflow pipe. This overflow should be kept open at all times to allow the water to drain freely and
keep the water level below the cutter disc and ice discharge opening. If the flushing solenoid valve
leaks through during the freeze cycle, it can be disassembled and cleaned, then reassembled.

Cleaning Ice Making Section. Refer to Section 7, Maintenance for instructions for cleaning the
circulating water tubes, water distributors, and water tank.

9-1

Float valve (make-up water). The make-up water float valve (12) maintains the proper pumping

level in the water tank for ice making. The valve should be set to maintain a water level in the water
tank during the freezing period, so that there will be a quantity of blowdown only during the thaw
mode. The water level during the freeze mode should always be below the overflow piping to
prevent excessive waste of cold water, resulting in loss of ice capacity.

If it should become necessary to clean the float valve, close the stop valve in the make-up water line
to the machine and remove the float valve. After the valve has been cleaned and reinstalled, check
to ascertain if the proper water level is being maintained. After the machine is stopped and the water
in the tank seeks its normal level, there should be no water flow through the float valve or out the
overflow.

It is advisable to install a large area strainer in the water supply line to protect the float valve from
dirt or solids in the water which would necessitate frequent cleaning. A strainer of 40 mesh screen is
usually satisfactory.

Capacitive Level Control The control unit

houses the "brains" of the Vari-Level®, its digital
readout, knobs for adjusting set points and differentials, and the relays themselves. Because the
signal from the probe is unique, it requires the control unit to interpret and convert it to an
understandable signal and display.

The control unit, which has a watertight enclosure, is mounted in an accessible area away from the
movement of material and equipment.

9/15/09

CAUTION: Do not install conduit connections into top of control unit; water can condense in
conduit and drip down on control unit electronics, causing failure.

9-2

SERVICING OPERATIONS

P24FL & P34FL Service Manual

9/15/09

Control Level 2% 20%-40%

Set Point Adjustments

Differential Set Point

High Level 2% 70%

Low Level Not Used Not Used

FIGURE 9-1

Capacitive Level Control

P24FL & P34FL Service Manual

SERVICING OPERATIONS

See Section 6 Figure 6-4 of this manual for control unit electrical wiring diagram. Before connecting electrical
power, check the voltage on the control unit nameplate and the power supply at the wire leads to be sure that
they are the same. Supply voltage must be within +10% or –15% of listed voltage. Connect power supply
leads to the quick disconnect plug (Terminals 1 & 2) and secure into the appropriate marked socket.

The probe

is the device that actually measures the liquid level. It accomplishes this by sending a
small, specialized signal out into the refrigerant liquid and vapor. This signal returns via the level
column back to electronics inside probe housing. The strength of the returning signal is measured to
determine level. This information is continuously sent to the control unit through the control cable.

When installing the probe, match its serial number with the control unit. Remove the probe from the
packing crate, being careful not to bend or whip the probe. Use nonelectrically isolating pipe thread

sealant (do not use Teflon® tape) on the ¾" MPT fitting on the probe and insert in top of the level
column. Tighten probe on hex; do not grip probe housing flats or electrical box. Pressure test for
leaks.

Probes are supplied from the factory with 50 feet of shielded control cable. If the control unit is
located less than 50 feet from probe, trim the control unit end of the cable as necessary. Securely
place the control cable quick disconnect plug into the appropriate marked socket inside the control
unit.

Setpoint and Operation. The level set point adjustment control is a slide knob with a scale in
percentage of active probe length. The percentage relates to the liquid level in the column between
the 3% level point and the 100% level point, as measured from the probe bottom end.
The level set point has a level differential adjustment control which is a rotating knob scaled in
percentage of active probe length from 2% to 20%. These percentages relate to the number of
percentage points above or below the set point at which the particular relay position will change, as
detailed in the next three paragraphs.

LOW LEVEL ADJUSTMENT. Not used on the P24FL andP34FL.
CONTROL LEVEL ADJUSTMENT. This set point is intended to maintain the level inside the

vessel via a liquid refrigerant supply solenoid valve, “A1”. The control level set point is the level at
which make-up liquid will start to feed into the vessel. The level in the P24FL and/or P34FL should
be between 20% and 40% and is dependent on make-up water and ambient temperatures. The
differential adjustment control should be set at 2%. The filling indicator light (green) will be on
when the relay is energized.

HIGH LEVEL ADJUSTMENT. This set point is intended to signal that the liquid level is
becoming too high. The high level set point is the highest level that the liquid should ever reach
before a compressor cutout occurs. The level in the P24FL and/or P34FL should be 70%. The
differential adjustment control should be set at 2%. The high level indicator light (red) will be on
when the relay is de-energized.

9-3

9/15/09

9-4

SERVICING OPERATIONS

SIMULATION. The purpose of the built-in level simulator is to enable the level set points and
differentials to be very accurately set and to be checked for proper system operation. Before
entering the simulation mode, be aware of the following:

IMPORTANT: Control devices (solenoid valves, contactors, etc.) can operate while in the
simulation mode. For calibration and electrical checkout, disconnect the main circuits of the
compressor motor, pump motor, etc., where necessary to prevent damage, or remove the relay
quick disconnect plug in control unit.

To enter simulation mode, depress and hold the simulation button; the amber simulation mode light
will be on. When in simulation mode, the digital readout displays the simulated (pretend) liquid
level. While continuing to depress the simulation button, use a small screwdriver in the other hand to
rotate the level simulation adjustment screw to change the simulated liquid level and display.
Observe the operation of the indicator lights. If necessary, make adjustments to level set point and
differential knobs.

When the relay level set points and differentials are properly set, return the simulated level to a
percentage value between the control and high level settings. This prevents the unexpected operation
of relays during the next simulation. Simply release the simulation button to return to normal
operation; the operation mode light (green) will come on. The value displayed on the readout will
now become that of the actual liquid level in the level column and the relay positions will respond to
this level.

RECALIBRATION. Control units are accurately factory calibrated to a 3" level column for the
specified refrigerant and the supplied probe. Recalibration may be necessary when a replacement
probe or control unit is installed, especially if not "factory matched" by serial number. However, the
zero point and at least one other point should be checked at the operating refrigerant temperature for
the highest level of accuracy. It is ultimately the responsibility of the installer to ensure proper
calibration for the specific application. If the control unit appears to be out of calibration, check for
possible causes in the trouble-shooting guide on before attempting to change the calibration.

If recalibration is ever required, only two points need to be checked, typically the 0% and sight glass
at 50% level point. Recalibration must be done in the order specified below.
To check the proper calibration at the 0% level, the level column should be free of liquid to below
the probe bottom end. This can be accomplished by pumping the P24FL and /or P34FL down. With
the probe end free of liquid, the control unit’s digital readout should display –00%. If not, remove
the seal on the low level calibration screw and adjust with a small screwdriver until the readout
indicates –00%; replace seal.

The level column standard sight glass location is at 50%. Raise or lower the liquid level so that it is
centered in the sight glass. The digital readout on the Vari-Level® control unit should display the

same level as the sight glass, 50 % level. If not, remove the seal on the high level calibration screw
and adjust until the digital readout displays the calculated sight glass, 50% level; replace seal. For
greatest accuracy, recheck 0% calibration and readjust if necessary.

P24FL & P34FL Service Manual

9/15/09

P24FL & P34FL Service Manual

Problem Cause Action

Digital readout and
indicator lights do not
display
Digital readout does
not indicate level
changes

1. No power to control unit or wrong voltage.

2. Moisture in control unit or probe housing.

1. Fault in control cable.

2. No continuity between probe and level

column.

3. Moisture in control unit or probe housing.

4. Probe wire loose.

Solenoid valve (#20A)
does not respond.
Digital readout
indicates too low a
level compared to
sight glass

Blown fuse in control unit. Fuses located just
above quick disconnect terminal strip.

1. Control unit and probe serial numbers do

not match.

2. Fault in control cable.

3. Moisture in control unit or probe housing.

4. Calibration not correct.

5. Calibrated for different refrigerant.

6. Insulating resistance of Teflon enclosed

probe rod is too low.
Digital readout
indicates too high a
level compared to
sight glass

1. Control unit and probe serial numbers do

not match.

2. Fault in control cable.

3. Moisture in control unit or probe housing.

4. Calibration not correct.

5. Calibrated for different refrigerant.

6. Oil rich mixture in level column.

Intermittent high level. 1. Rapid suction pressure pull down results in

excessive boiling and liquid surging.

2. High level alarm point has been positioned

too close to operating set point.

3. Moisture in control unit or probe housing.

Occasional erratic
level displayed on

1. Moisture in control unit or probe housing.

2. Radio Frequency Interference (RFI)

digital readout without
actual changes in
level.

SERVICING OPERATIONS

1. Check Voltage at terminals 1 and 2 in

the control unit.

2. See Note 1 below.

1. See Note 2 below

2. Check for Teflon tape or other non-

conductive pipe sealant at probe to
column connection; replace sealant

3. See Note 1 below.

4. Open probe housing cover and check

connection of probe wire (single wire
lead) from probe center to terminal

connection.
Find reason for electrical fault and correct.
Replace blown fuses.

1. Contact factory if mate is not available.

2. See Note 2 below.

3. See Note 1 below.

4. See re-calibration instructions.

5. Contact factory for replacement.

6. See Note 3 below.

1. Contact factory if mate is not available.

2. See Note 2 below.

3. See Note 1 below.

4. See re-calibration instructions.

5. Contact factory for replacement.

6. Check for excessive oil carry over from

compressor.

1. Check time delay timer “DT” for proper

operation.

2. Lower operating set point or raise high

level set point.

3. See Note 1 below.

1. See Note 1 below.

2. Find source of interference, such as

mobile radios or transmitters, and

disable. If unable, contact factory for

arrestor device.

9-5

9/15/09

Note 1.
MOISTURE IN CONTROL UNIT OR PROBE HOUSING. Dry out control unit or probe housing. If appearance is dry, look
for signs of moisture damage, such as white residue. Check cover gaskets, watertight cable connectors, and other water sealing
joints, replace if worn. If a conduit connection is on top of the probe, carefully seal the inside to prevent condensation migration
into the housing. Relocate any conduit connections on top of the control unit to the bottom, or seal the connections.

Note 2.
FAULT IN CONTROL CABLE. A symptom can be the digital readout display above 100% or below 0%. Check wires and
matching color dots on quick disconnect plugs at the probe and control unit for proper connection. See page 9 for probe wiring
diagram. Wires should be securely fastened and not frayed. Also check for continuity in the wiring.

Note 3.
INSULATION VALUE OF PROBE. The following procedure is only required if probe integrity is questioned. With the probe

wire removed from its socket, check the insulating resistance of the Teflon®-enclosed probe rod using a 500V “Megger”.
Connect the positive side to the probe wire, the negative side to the probe housing. The result should be over 1000 Mega Ohms;
halocarbon probes should be over 50 Mega Ohms. If not, contact the factory.

TABLE 9-1

Trouble-shooting Guide for level controller

9-6

SERVICING OPERATIONS

Hand Expansion Valve. The hand expansion valve is located directly after the “#20A” solenoid
valve. This valve should be set at a point where the float switch is open for a length of time
approximately equal to the time it is closed.

Freezer Pressure Switch. The freezing time period for producing ice of a desired thickness is
controlled by the freezer pressure switch (2PS), Figure 9-2, located inside the control panel.

The original switch was set at the factory to produce ice of recommended thickness. Look at the
“Certificate of Test” which was provided with the machine for a sample set of pressure readings
with corresponding time periods and water temperatures. Also see TABLE 11-8/ 11-9, Operating
Vitals for typical settings. When making adjustments, allow two ice discharging cycles between
adjustments. Switch adjustment is as follows: See Figure 9-1.

1. Turn the low signal adjustment nut CCW until low signal setting indicator is fully down. Turn

the high signal adjustment nut until high signal setting indicator is slightly beyond the actuation
setting of 55 psig.

2. Starting with the pressure above the actuation pressure, reduce the pressure to desired actuation

pressure of 55 psig contact opens.

3. Advance the low signal adjusting nut until the switch actuates and contact closes.

P24FL & P34FL Service Manual

9/15/09

FIGURE 9-2

ASCO Freezer Pressure Switch (2PS)

It is preferable that the freezing cycle be such that a small diameter hole remains in the center of the
ice cylinder (1/16” diameter for 7/8” diameter ice, 1/8” diameter for 1 1/8” diameter ice, 1/4”
diameter for 1 3/8” diameter ice). This insures that the freezing cycle is not extended unnecessarily
and eliminates a possible opaque core in the center of the ice, as well as a loss of production.

High-Low Pressure Switch. The high-low pressure switch (1PS), Figure 9-3, is a two pole dual
function switch mounted to the frame near the compressor. It protects the machine from possible
damage due to abnormal pressure during operation.

P24FL & P34FL Service Manual

SERVICING OPERATIONS

! CAUTION !

When this switch causes the machine to stop, the cause should be

identified and corrected before resuming normal operation.

! CAUTION !

The LOW pressure cut-in should be set at 40 psig (R-22) and the cut-out set at 20 psig (R-22). After
tripping at the cut-out setting, the switch will reset automatically when the pressure rises to the cut­in setting.

The HIGH pressure cut-out should be set at 300 psig (R-22). After tripping, reset the switch
manually.
Note: Do not rely on the switch calibration for accuracy. For accurate adjustment, check settings

with a test gage.

9-7

9/15/09

FIGURE 9-3

High-Low Pressure Switch (1PS)

Compressor Crankcase Heater

When electrical power is supplied to terminals 12 and 22 of the control panel (see Figure 6-3), the
crankcase heater is energized when the compressor is not running. It is deenergized when the
compressor is operating. The heater is designed to maintain a temperature of the oil in the crankcase
at 100-110F (38-43C) when the compressor is not running. This will prevent the migration of
refrigerant to the compressor during off periods.

9-8

SERVICING OPERATIONS

Fan Control (cooling tower)
The fan control switch is used to cycle the cooling tower fan on and off, thereby maintaining the

proper operating head pressure. This switch is mounted on the frame of your machine and should be
adjusted to maintain a head pressure between 190-210 psig (R-22) . The fan control supplies power
to the starter coil for the tower fan motor(s) (6M not furnished by Vogt). See FIGURE 9-4 for
adjustment instructions.

Oil Pressure Switch

Cut In Adjusting Screw
Set at 210 psig (R-22)

Vogt Part #: 12A2117F05

FIGURE 9-4

Fan Control Switch

P24FL & P34FL Service Manual

Cut Out Adjusting Screw
Set at 190 psig (R-22)

The compressor is protected by a manual reset type low oil pressure safety switch which is set at 15
psig. The oil pressure switch has a built-in 60-second time delay. If the net oil pressure (pump
pressure minus suction pressure) falls below the switch setting for a time period of 60 seconds and
the pressure does not increase at least 5 psi above the setting during that 60 seconds, the switch
contact will open and stop the machine. After a period of time, as the delay heater cools, the switch
can be manually reset and the machine restarted. The compressor should not be operated under low
oil pressure or low oil level conditions.

If oil is added to the compressor crankcase to resume operation after a loss of oil, be sure to observe
several cycles to make sure the oil level remains stable. See “Troubleshooting”, “Low Oil Pressure
Switch Tripped”.

CAUTION !

When this switch causes the machine to stop, the cause should be identified

and corrected before resuming operation.

! CAUTION !

9/15/09

P24FL & P34FL Service Manual

SERVICING OPERATIONS

FIGURE 9-5

Oil Pressure Switch

Control Circuit Protection. The electrical control circuit of the machine is protected by a 6 amp

circuit breaker (CB4). If this breaker should open, the machine will immediately stop. Before
resetting the circuit breaker, open the disconnect switch and lock-out all power to the control panel.
Reset CB4 and restore power. Check circuitry with a volt meter. If the machine was off for an
extended time, the crankcase heater must be energized for a minimum of four (4) hours and no liquid
refrigerant in the crankcase before restarting the machine. When ready to restart the machine,
depress the “Start” button. As usual, initiate a harvest cycle if there is ice remaining in the freezer.
Check Amp draw through the breaker for excessive load or unbalance.

Thawing Timer. The thawing timer (2TR), Figure 9-6, governs the ice thawing period. It is
located inside the control panel (FIGURE 6-1). It is started by action of the freezer pressure switch
(2PS) which energized the “1CR” relay. This timer is set prior to shipment for approximately a
three minute period. To replace the timer, simply pull the timer from its base and plug in another,
set to “0 to 12” and “Min” and set the thawing period for at least 30 seconds longer than the time
required to harvest the entire discharge of ice. If it should be necessary to change the setting of the
timer, turn the adjustment dial clockwise to increase the time or counter-clockwise to decrease the
time. Check thaw time after each adjustment.

Note: Thicker ice may require a longer thaw period, due to slower ice release time

6

Min

8

10

12

UNIT

4

0

Power Light (green)
Light blinks while
"timing"
Light solid when "timed

Units: Set to “min”

Unit adjustment

sec
min
hrs
10h

Up Light (red)
Light off while "timing"
Light solid when "timed

Range: Set to “0 to

12”

Time Range
adjustment

0 - 1.2
0 - 3
0 - 12
0 - 30

Allen Bradley Timer (White)

POWER
UP

2

RANGE

FIGURE 9-6

Thawing Timer (2TR)

9-9

9/15/09

9-10

SERVICING OPERATIONS

Condenser Cleaning
There are 124 - 1 1/4” OD x 84” long steel tubes in the P24F condenser/ receiver. These tubes are

approximately 1 1/32” inside diameter. Any brush or cleaning tool should be sized accordingly so
as not to damage the tubes during cleaning. The cleaning tools should be rotated at the specified
speed for the particular tool used. The tubes should be kept wet during cleaning. After cleaning, the
tubes should be flushed thoroughly and all foreign material removed. Contact your distributor or
Vogt’s Service Department to obtain the proper cleaning tools.

The following is the condenser cleaning procedure:

1. Refer to the space diagrams, Section 2, to make sure ample room is provided for removing the

condenser heads and using the mechanical cleaning equipment.

2. Order replacement cover gaskets for use at the time of reassembly.

3. Disconnect and lock-out power to the ice machine and auxiliary equipment.

4. Disconnect water piping and drain the condenser. Loosening the cover (heads) hex nuts and

separating the covers from the condenser end will drain additional water.

P24FL & P34FL Service Manual

5. Remove the heads, stud bolts, and gasket completely.

6. Inspect the tubes for excessive corrosion and possible refrigerant leaks. Determine whether or not

further cleaning is feasible.

7. Clean the inside of each tube as well as possible, being careful not to damage the tube. Follow

the instructions for the particular tool being used.

8. Flush each tube with water to remove all loose material and prevent contamination of the cooling

tower and sump.

9. Clean the ends of the tube sheets, so the new gasket will seal properly.

10. Insert the stud bolts to the proper depth and install the replacement gasket. Make sure the gasket
does not cover the extended tube ends.

11. Install the end covers (heads) and fasten securely in place with the hex nuts.

12. Reconnect the water piping and turn on the power. Check for leaks by turning the Hand-Auto
switch to Hand allowing the condenser pump to run.

13.Turn the switch back to Auto and wait for the crankcase heater to warm-up compressor before

starting the machine.

9/15/09

P24FL & P34FL Service Manual

Figure 9-7A

P24FL & P34FL Cutter Assembly

Figure 9-7B

P24FL & P34F Water Tank Assembly

9-11

SERVICING OPERATIONS

9/15/09

9-12

SERVICING OPERATIONS

Item # Description P24A Part Number P34A Part Number

1 Water Tank Assembly 19T4500S2400 19T4500S3400
2 Water Box Cover (Not Shown) 19T2150C0100 19T2150C0200
3 Water Pump See Pump Model # See Pump Model #
4 5/8”-11 NC x 3” Long S.S. Stud 12A 2222L11190000 12A 2222L11190000
5 5/8”-11 NC x 2” Long S.S. Stud 12A 2222L11150000 12A 2222L11150000
6 2” Red Rubber Gasket 12A 2600R07000000 12A 2600R08000000
7 2 1/2” Red Rubber Gasket 12A 2600R08000000 12A 2600R09000000
8 5/8” S.S. Hex Nut (8) 12A 2240A11300000 12A 2240A11300000
9 5/8” S. S. Lock Washer (8) 12A 2250B11300000 12A 2250B11300000
10 PVC Ell 2” MPT x Insert 12A 2450E12000000 12A 2450E16000000
11 2” PVC Round Flange 12A 2535F07060000 12A 2532F06060000
12 2” FPT Valve 12A 4200G14010000 12A 4200G14010000
13 WC 45° Ell 7/8” ODC 12A 2409W0006000 NA
14 7/8” OD Copper Tubing 12A 4180A00080000 12A 41080A0009000
15 3/4” MPT x FPT PVC 90° Ell 12A 2450E07000000 12A 2450E07000000
16 3/4” S.S. Pipe Nipple 12A 3050S04010000 12A 3050S04010000
17 3/4” FPT Solenoid 12A 4200A06020000 12A 4200A06020000
18 Thermometer 12A 4170T01000000 12A 4170T01000000
19 1/2” MPT x 1/4” Brass Bushing 12A 2451B03000000 NA
20 1/2” FPT x 7/8” ODC Adapter 12A 2401W0120000 NA
21 WC Tee 7/8” ODC 12A 2422W0009000 12A 2422W0010000
22 WC 90° Ell 7/8” ODC 12A 2417W0004000 12A 2417W0005000
23 3/4” Brass Service Valve (1” for P34A) 12A 4205G06010000 12A 4205G0602000
24 3/4” MPT x 1/2” PVC Bushing 12A 2450B04000000 12A 2450B04000000
25 1/2” MPT x 1/4” PVC Bushing 12A 2450B05000000 12A 2450B05000000
26 3/4” MPT x 7/8” ODC Adapter 12A 2400W0023000 12A 2400W0023000
27 3/4” MPT Float Valve 12A 4200H06010000 12A 4200H06010000
28 Float Valve Stem 12A 4200HP0100000 12A 4200HP0100000
29 Valve Float 12A 4200HP0200000 12A 4200HP0200000
30 WC 3/4” FPT x 7/8” ODC Adapt. 12A 2401W0007000 NA
31 Key 1/4” x 1/4” x 3 3/16” S.S. 12A 2785S04000000 12A 2785S04000000
32 Cutter Adapter Plate 19T2010A1100 19T2010A05
33 Bearing 12A 2020M0200000 12A 2020M02000000
34 Bearing Bracket 19T2025B0105 19T2025B0106
35 Cutter Blade 19T2035B0100 19T2035B0200
36 Breaker Cutter Assembly 19T2160C0401 19T2160C0501
37 Tines Disc Assembly 19T2163D0302 19T2163D0403
38 Top Excluder 12A 2210E01000000 12A 2210E01000000
39 Bottom Excluder 12A2210E04000000 12A2210E04000000
40 Cap Screw, 5/16-18 x 1” S.S. (4 ) 12A 2215G1110000 12A 2215G1110000
41 Cap Screw, 3/8-16 x 1” S.S. (8 ) 12A 2215H1110000 12A 2215H1110000
42 Cap Screw, 3/8-16 x 1” 12A 2215H6110000 12A 2215H6110000
43 Cap Screw, 5/8-11 x 1 1/2” S.S. (4) 12A 2215L11130000 12A 2215L11130000
44 Carriage Bolt, 3/8-16x1 1/4” (4 ) 12A 2218H11120000 12A 2218H11120000
45 Mach Screw 3/8”-16 x 2” Flat (8) 12A 2226H11150000 12A 2226H11150000
46 Hex Nut, 3/8-16 S.S. (12) 12A 2240A13090000 12A 2240A13090000
47 Slotted Nut, 1-14 NF S.S. 12A 2240E12160000 12A 2240E12160000
48 Lock washer 5/16” S.S. 12A 2250B10800000 12A 2250B10800000
49 Lock washer 3/8” S.S. 12A 2250B10900000 12A 2250B10900000
50 Lock washer 5/8” S.S. 12A 2250B11300000 12A 2250B11300000
51 1/4” S.S. Sq. Head Pipe Plug (2) 12A 2475T00010000 12A 2475T00010000
52 Gasket, 3/4” OD x 7/16” ID 12A 2600R02000000 12A 2600R02000000
53 Key, 3/8” x 5/16”x 3/4” S.S. 12A 2785S01000000 12A 2785S01000000
54 Gear Motor 12A 2900M07020000 12A 2900M07020000
55 Cotter Pin, 3/16” x 1 1/2” S.S. 12A 3040S06000000 12A 2900M08010000
56 Cutter Support Washer 19T4001S0224 19T4001S0224
57 Retainer 19T4065R0100 19T4065R0100
58 Seal 12A 4080S02000000 12A 4080S02000000
59 Cutter Shaft 19T4090S0300 19T4090S0300
60 Upper Bearing Spacer 19T4130C0100 19T4130C0100
61 Tines Disc Spacer 19T4130C0200 19T4130C0200
62 Seal Spacer 19T4130C0300 19T4130C0300
63 Lower Bearing Spacer 19T4130C0400 19T41030C04
64 Spacer, 5/8” OD x 7/8” Long (8) 19T4130T0400 19T4130T0400

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P24FL & P34FL Service Manual

65 Disc Spring 12A 4138S01000000 12A 4138S01000000
66 Split Taper Bushing 12B 2060B04000000 12B 2060B01000000
67 Drive Gear 12B 2615D03000000 12C 2615D05000000
68 Splash Curtain Holder 19T4001S0162 19T4001S0163
69 Splash Curtain Bottom Plate 19T4001S0415 19T4001S0411
70 Splash Curtain 12A 4078C03000000 12A 4078C02000000

Cutter Gear Reducer. The cutter motor and gear reducer (54), Figure 9-7A, drive the ring gear of
the cutter assembly. It is important that the teeth of the drive gear and the ring gear mesh properly
both vertically and horizontally. The drive gear and hub can be raised or lowered on the gear
reducer shaft to obtain maximum vertical tooth engagement and the reducer assembly can be moved
in or out horizontally to obtain the proper tooth depth for maximum gear life.

Note: The motor and gear reducer are an integral unit. Only qualified personnel should attempt to
disassemble and repair this unit.

Drive Gear Replacement.

1. Disconnect and lock-out all power to the machine.

2. Remove the top and side bolts holding the mounting plate to the support bracket. Lift the plate

and gear reducer from the bracket and rest the assembly on a stable work table sitting next to the
tank. Leave the electrical conduit connected to the gear reducer motor.

3. Inspect the drive gear teeth for proper vertical alignment and wear pattern.

4. If the wear pattern indicates less than a full width of tooth engagement, measure the difference

and make a note to correct at the time of reassembly.

5. Measure and record the dimension from the drive gear to the bottom side of the mounting plate.

6. Remove the three or four cap screws holding the drive gear to the split taper bushing.

7. Using two of the same cap screws in the threaded holes of the bushing, jack the gear off the

bushing and remove both from the gear reducer shaft.

8. Clean the split bushing and tapered hole of the new drive gear and insert the bushing into the

drive gear making sure the tapers match.

9. Slide the split hub and gear onto the keyed shaft with the key in place, positioning the hub (by

measurement previously recorded) so the full width of the gear teeth will engage when
assembled and tightened.

TABLE 9-2

P24FL - P34FL Cutter & Water Tank Part No.

9-13

SERVICING OPERATIONS

9/15/09

9-14

SERVICING OPERATIONS

10. Tighten the cap screws (three or four) progressively and uniformly around the hub and recheck

the location measurement. If it is not correct, loosen the cap screws, hub and gear assembly and
make correction. Then retighten the cap screws. Install the reducer and mounting plate assembly
on the water tank bracket and fasten in place with the side and top cap screws.

11. Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount

of backlash between the gear teeth.
NOTE: There should be only a slight amount of backlash (more specifically “tooth tip
clearance”). Too much clearance will cause premature wear and possible tooth damage. When
the cutter runs under a no load condition, it should have a smooth uniform sound. For
lubrication, see Section 7, Maintenance.

12. If the tooth tip clearance needs adjusting, loosen the four hex nuts holding the reducer to the

mounting plate and move the reducer as required for proper tooth engagement. Tighten the hex
nuts securely and recheck backlash.

Gear Reducer Replacement.

1. Disconnect and lock out all power to the machine.

2. Disconnect electrical wires and conduit from the motor.

3. Remove the top and side bolts holding the mounting plate to the support bracket and lift the plate

and gear reducer assembly from the tank bracket.

4. Inspect the drive gear teeth for proper vertical alignment and wear pattern. If the wear pattern

indicates less than a full width of tooth engagement, measure the distance so correction can be
made at the time of reassembly.

5. Measure and record either the distance of the drive gear from the mounting plate or the split hub

from the shaft end for future reference when reassembling.

6. Remove the three or four cap screws from the split taper bushing.

7. Use two of the cap screws in the threaded holes of the busing as jacking screws for pushing the

drive gear from the hub.

8. Drive a wedge in the split of the hub (bushing) and slide both the hub and gear from the shaft.

9. Remove the four hex nuts and lock washers from the carriage bolts around the reducer base and

mounting plate and separate the plate and reducer.

10. Install the replacement gear reducer and motor onto the mounting plate using the carriage bolts,

lock washers, and hex nuts. Tighten the nuts snug only for later adjustment.

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P24FL & P34FL Service Manual

11. Clean the split hub and drive gear, insert the hub into the gear, making sure the tapers of the two

match and slide the hub and gear onto the shaft.

12. Position the hub on the shaft (note measurements previously taken) so the full width of the gear

teeth will engage when assembled and tightened.

13. Tighten the cap screws (three or four) progressively and uniformly around the hub, checking the

measurements and adjusting as necessary.

14. Install the reducer and mounting plate assembly on the water tank bracket and fasten in place

with the side and top cap screws.

15. Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount

of backlash between the gear teeth.

16. If the gear tooth tip clearance needs adjusting, loosen the four hex nuts around the reducer base

and move the reducer as required for proper tooth clearance. Tighten the hex nuts securely and
recheck for backlash.

17. Reconnect the electrical wires and conduit to the motor.

18. Check cutter rotation and correct as necessary.

NOTE: When the cutter runs under a “no-load” condition, it should have a smooth uniform
sound.

The weights listed in TABLE 9-3 will give you an idea of manpower or equipment needed when
servicing and handling the various parts of the water tank and cutter. Be sure to use safe lifting and
handling practices to prevent bodily injury and/or damage to parts. If additional information is
needed, you should contact your distributor or the factory.

To inspect the cutter assembly and make repairs or replace parts, it will be necessary to lower and
remove the water tank from its mounting to the bottom of the freezer. The water tank has metal
casters allowing it to be rolled out from under the freezer for inspection and servicing.

Water tank (bare) 333 428
Bearing bracket assembly and cutter disc 106 150
Cutter assembly and ring gear 89 164
Water tank and cutter assembly 528 742
Cutter disc 57 97
Cutter drive gear 8 14
Gear reducer and motor 56 96
Water pump 85 85

SERVICING OPERATIONS

Weight (lbs.)

Description P24 P34

TABLE 9-3

Water Tank and Cutter Parts Weights

9-15

9/15/09

9-16

SERVICING OPERATIONS

Water Tank Removal

1. Disconnect and lock-out all power to the machine.

There should be ample space to roll the water tank from under the machine. It may be necessary
to provide a flat level surface such as a sheet of plywood sufficiently supported to hold the
weight of the tank and cutter assembly. See TABLE 9-3.

2. Turn off water supply, drain water, and disconnect water and drain lines from the tank.

3. Remove the overflow tubing from the water tank and remove the circulating water tubing from

the pump.

4. Disconnect the ice discharge chute or hopper from the ice discharge opening of the water tank,

making sure the tank is free to be moved.

5. Remove the mounting bolts from around the flange of the tank, allowing the tank to be lowered

to rest on its casters.

6. Roll the water tank from under the freezer, turning it as you go to clear the gear reducer and

motor. It is now accessible for inspecting and/or repair of the cutter assembly.

Cutter Assembly Removal and Installation.

1. Follow water tank removal instructions, Steps 1-6. See Figure 9-7B.

2. Remove the socket head cap screw from the center of the cutter shaft and lift out the retainer and

gasket.

3. Lift the cutter straight up and off the shaft, taking care to catch the shaft key as it is removed.

4. To install the cutter, lower it down onto the shaft, allowing the ring gear to mesh with the drive

gear.

5. Rotate the cutter, aligning the shaft and hub key way and inserting the key to its full depth.

6. Install the gasket, the retainer, and the socket head cap screw and tighten to approximately 15 ft.

lb. torque.

7. Check and adjust the cutter height per “Cutter Height Adjustment” instructions.

Bearing Bracket and Cutter Disc Removal.

1. Remove the cutter assembly per instructions.

2. Match mark the bearing bracket support arms with the water tank for reassembly reference.

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P24FL & P34FL Service Manual

SERVICING OPERATIONS

3. Remove the splash shield and ice deflector plate from the ice discharge opening.

4. Support the bearing bracket to keep it from falling in the tank. Loosen and remove the four cap

screws and lock washers from the ends of the bearing bracket support arms.

5. Lift the bracket and cutter disc from the tank. Be sure the support arms are match marked for

reassembly. You may have to gently drive the support arms up or down to release them from the
tank walls.

6. With the bracket and disc assembly turned upside down, remove the cotter pin from the shaft.

7. Loosen and remove the slotted hex nut, spring washer, and spacer.

8. Lift the cutter disc from the keyed shaft, being careful not to loose the shaft key.

The cutter shaft and bearings are sealed in the bearing bracket assembly. The cavity between the
bearings has been filled with a food-grade grease to prevent the presence of moisture and prolong
the life of the unit. If there is any vertical or side movement of the shaft or if the bearings feel rough
or tight when turning the shaft, the assembly should be dismantled and rebuilt. Refer to the cutter
tank assembly drawing, Figure 9-5B, for parts location and identification.

Cutter Shaft and Bearing Removal.
Note: Use only a soft mallet or other soft tool for fitting all parts into place.

1. With the bearing bracket assembly removed from the tank, press the shaft out of the housing

from the bottom up.

Note: The two top bearings may come out with the shaft along with the upper seal and excluder.

2. Turn the bracket over and press the bottom bearing out the bottom, along with the lower seal.

3. There are three spacers on the shaft which should be removed and labeled as to their location.

Remove them as they are made accessible.

4. Clean and inspect all parts for wear or damage. Discard all parts showing any indication of

damage.

Cutter Shaft and Bearing Installation.

1. Clean the inside of the bearing housing of grease or foreign matter. Further clean the top bearing

housing with pro-lock cleaner and primer (or a suitable substitute) and remove the pipe plugs
from the side of the housing.



2. Apply a thin coat of Loctite

RC/609 retainer (or a suitable substitute) to the inner surface and

bearing shoulder of the top of the bearing bracket.

3. Insert a bearing in the top housing and set it in place.

9-17

9/15/09