Vogt P-34AL-15 Service Manual

Download

P-34AL-15

P34ALOF-15

TUBE-ICE®

MACHINE

Service Manual

$5000

9/22/05

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 where it can be readily available when needed for future reference in maintaining troubleshooting or servicing.

Failure to comply with this notice will result in unnecessary inconvenience and possible additional expenses.

This manual is intended as an informational tool for the installation, operation, maintenance, troubleshooting, and servicing of this equipment. If an existing situation calls for additional information not found herein, we suggest that you contact your distributor first. If further assistance or information is needed, please feel free to contact the factory at 502-6353000 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.

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

Att. Tube-Ice Service Department

9/22/05

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 machine: ____________________________________________________________________________________

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 cycles 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 Temp

Freeze Time

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: (freeze time + harvest time)

ice lb. per harvest x 1440

The machine operated satisfactorily for ___ continuous hours. Date _______________________________________

Comments__________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

Installer signature ____________________________________________ End user signature _________________________________

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

9/22/05

Sales - (502) 635-3000

Service - (502) 635-3510

Parts - Your Local Distributor or the Tube-Ice parts Department

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

Since 1938, Manufacturers of Quality

Tube-Ice

Machines

VOGT

TUBE-ICE® MACHINES

Vogt Tube-Ice 1000 W. Ormsby, Suite 19 Louisville, Kentucky 40201 502-635-3000

FAX #502-634-0479

9/22/05

Installation, Service Manual, and Parts Catalog #12A4171L20

P34AL-15 & P34ALOF-15 Model

P34AL-15 & P34ALOF-15 Service Manual

Vogt

Model P34AL-15 & P34ALOF-15

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 P34AL-15 Tube-Ice

Assembly Drawing Model P34ALOF-15 Tube-Ice®Machine.......................................................................................1-7, 8, 9

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

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

3. INSTALLING YOUR TUBE-ICE MACHINE

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

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

Foundation 3-1

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

P34AL-15 Space Diagram, FIGURE 3-1......................................................................................................................3-2

P34ALOF-15 Space Diagram, FIGURE 3-2 .................................................................................................................3-3

Typical Foundation Layout, FIGURE 3-3..................................................................................................................... 3-4

Typical Lifting Procedure, FIGURE 3-4.......................................................................................................................3-5

Seismic Anchoring Detail, FIGURE 3-5.......................................................................................................................3-6

Water Supply, Drain and Refrigeration Connections, TABLE 3-1 ...............................................................................3-7

Make-Up Water In.............................................................................................................. ...........................................3-7

Flushing Water In..........................................................................................................................................................3-7

Water Tank Drain..........................................................................................................................................................3-8

Water Tank Overflow.....................................................................................................................................................3-8

Receiver .....................................................................................................................................................................3-8

Volume Requirements, TABLE 3-2..............................................................................................................................3-8

Thaw Gas Pressure Regulator........................................................................................................................................3-8

Suction Pressure Regulator............................................................................................................................................3-8

TABLE OF CONTENTS

TUBE-ICE® MACHINES

Machine............................................................................................1-4, 5, 6

TABLE OF CONTENTS

9/22/05

TABLE OF CONTENTS

Page No.

Compressor Unloading..................................................................................................................................................3-9

Cooling Tower (optional) ..............................................................................................................................................3-9

Total Heat Rejection Requirements, TABLE 3-3.................................................................................. ........................3-9

Safety Valves ................................................................................................................................................................3-10

Freeze Protection, FIGURES 3-6, 3-7, 3-8....................................................................................................................3-10, 3-11

Wiring and Electrical Connections.................................................................................................................................3-12

Power Supply Connections, FIGURE 3-9 ......................................................................................................................3-12

Voltage Unbalance .........................................................................................................................................................3-13

Current Unbalance..........................................................................................................................................................3-13

Rotation Check...............................................................................................................................................................3-13

Auxaliary Controls or Equipment...................................................................................................................................3-14

Interconnecting Piping for Vogt P34AL-15 and Dedicated High Side, FIGURE 3-11.................................................3-15

Interconnecting Piping for Vogt P34AL-15 and Central High Side, FIGURE 3-12......................................................3-16

Interconnecting Piping for Vogt P34ALOF-15 and Central High Side, FIGURE 3-13.................................................3-17

Interconnecting Piping for Vogt P34ALOF-15 and Central Screw Compressor, FIGURE 3-14...................................3-18

Interconnecting Piping for 2-Vogt P34AL-15 and Central High Side, FIGURE 3-15...................................................3-19

Interconnecting Piping for 3-Vogt P34AL-15 and Central High Side, FIGURE 3-16...................................................3-20

Interconnecting Piping for 2-Vogt P34ALOF-15 and Central High Side, FIGURE 3-17..............................................3-21

Interconnecting Piping for 3-Vogt P34ALOF-15 and Central High Side, FIGURE 3-18..............................................3-22

Installation Review: A Checklist...................................................................................................................................3-23

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 P34AL-15, FIGURE 4-1.............................................................................................................4-3

Piping Schematic for P34ALOF-15, FIGURE 4-2........................................................................................................4-4

5. START-UP AND OPERATION

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

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

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

Ammonia Specification By Grade, TABLE 5-1............................................................................................................5-2

Special Precautions to be Observed when Charging Refrigeration Systems.................................................................5-2

Charging From Tank Truck (for dedicated high side only)...........................................................................................5-3

Charging From Cylinders (for dedicated high side only) ..............................................................................................5-3

Control Panel, FIGURE 5-1...........................................................................................................................................5-5

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

Adding Refrigerant........................................................................................................................................................5-6

Operating Tips...............................................................................................................................................................5-6

Thaw Gas Regulating and Suction Regulating Valve Adjustment................................................................................5-7

P34AL-15 & P34ALOF-15 Service Manual

Page No.

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. , FIGURE 6-3...................................................................... ...................6-4

Optional PLC Electrical Schematic All Voltages 50-60 Hz., 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 .........................................................................................................................................................7-3

Water Distributors, TABLE 7-1 ....................................................................................................................................7-4

Average Hole Size in Tube-Ice

Water Tank....................................................................................................................................................................7-5

Water Cooled Condenser Cleaning (optional)...............................................................................................................7-5

Cooling Tower / Evap Condenser (optional).................................................................................................................7-5

Compressor (optional)...................................................................................................................................................7-6

Compressor Maintenance, TABLE 7-4 .........................................................................................................................7-7

Oil Trap ....................................................................................................................................................................7-7

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

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

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

Suction Line Frosting To Compressor...........................................................................................................................8-11

9/22/05

TABLE OF CONTENTS

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

iii

TABLE OF CONTENTS

Page No.

9. SERVICE OPERATIONS

Automatic Blowdown (Harvest Cycle)..........................................................................................................................9-1

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

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

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

P34AL-15 and P34ALOF-15 Float Height, FIGURE 9-1, TABLE 9-1........................................................................9-2

Hand Expansion Valve..................................................................................................................................................9-2

Freeze Timer..................................................................................................................................................................9-2

Miniature Rocker Switch Settings for Freeze Timer, TABLE 9-2................................................................................9-3

Entering and Displaying Setpoints ................................................................................................................................9-3

Freeze Timer, FIGURE 9-2...........................................................................................................................................9-4

Freezer Pressure Switch (optional)................................................................................................................................9-4

Freezer Pressure Switch, FIGURE 9-1..........................................................................................................................9-5

Control Circuit Protection..............................................................................................................................................9-5

Thawing Timer..............................................................................................................................................................9-5

Thawing Timer, FIGURE 9-4........................................................................................................................................9-6

Suggested Condenser Cleaning .....................................................................................................................................9-6

Cutter Gear Reducer......................................................................................................................................................9-7

Drive Gear Replacement................................................................................................................................................9-7

Gear Reducer Replacement ...........................................................................................................................................9-8

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

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

Cutter Assembly Removal and Installation ...................................................................................................................9-10

Bearing Bracket and Cutter Disc Removal ....................................................................................................................9-10

Cutter Shaft and Bearing Removal................................................................................................................................9-10

Cutter Shaft and Bearing Installation.............................................................................................................................9-11

Cutter Height Adjustment..............................................................................................................................................9-12

Water Tank Installation.................................................................................................................................................9-12

Typical Cutter Assembly, FIGURE 9-5A......................................................................................................................9-13

Typical Water Tank Assembly, FIGURE 9-5B.............................................................................................................9-14

Cutter and Water Tank Part No., TABLE 9-2...............................................................................................................9-15

Cutter Ring Gear Replacement......................................................................................................................................9-16

Cutter Blade Replacement.............................................................................................................................................9-16

Cutter Blade and Adapter Plate Adjustment, FIGURE 9-6...........................................................................................9-17

Cutter Adapter Plate Installation....................................................................................................................................9-17

Pumpdown 9-18

Removal of Ammonia Refrigerant from the Machine...................................................................................................9-18

Refrigerant Leaks ..........................................................................................................................................................9-19

Non-Condensable Gases................................................................................................................................................9-19

Purging Non-Condensables ...........................................................................................................................................9-19

Draining the Oil Trap ....................................................................................................................................................9-20

Removing Excess Water from Ammonia............................................................................................ ..........................9-21

P34AL-15 & P34ALOF-15 Service Manual

Page No.

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

The Thaw Gas Solenoid Valve......................................................................................................................................9-22

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

The Liquid Feed Solenoid Valve...................................................................................................................................9-23

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

The Thaw Chamber Check Valve..................................................................................................................................9-24

The Thaw Chamber Check Valve, FIGURE 9-9...........................................................................................................9-24

Water Flush Solenoid Valve..........................................................................................................................................9-24

Compressor Cooling Solenoid Valve (dedicated high side only)..................................................................................9-24

Compressor Oil Changing .............................................................................................................................................9-25

Compressor Inspection .................................................................................................................................................. 9-25

Belt Tension...................................................................................................................................................................9-25

Belt Replacement...........................................................................................................................................................9-26

Compressor Servicing....................................................................................................................................................9-26

10. OPTIONS AND ACCESSORIES

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

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

PLC (Programmable Logic Controller) ........................................................................................................................10-3

Reduced Voltage Cutter Motor Starter ......................................................................................................................... 10-13

11. TABLES AND CHARTS

P34AL-15 Specifications, TABLE 11-1........................................................................................................................11-2

P34ALOF-15 Specifications, TABLE 11-2...................................................................................................................11-3

P34AL-15 Make-up Water Usage, TABLE 11-3 ..........................................................................................................11-4

P34A Make-up Water Usage, TABLE 11-4..................................................................................................................11-4

P24A Normal Operating Vitals, TABLE 11-5...............................................................................................................11-5

P34A Normal Operating Vitals, TABLE 11-6...............................................................................................................11-5

Temperature - Pressure Chart for Common Refrigerants, TABLE 11-7.......................................................................11-7

Conversion Factors: English to Metric, TABLE 11-8...................................................................................................11-7

Constants, TABLE 11-9 ................................................................................................................................................11-7

12. APPENDIX – Anhydrous Ammonia Safety

TABLE OF CONTENTS

9/22/05

TABLE OF CONTENTS

P34AL-15 & P34ALOF-15 Service Manual

A Brief History Of Our Company. Henry Vogt Machine Co. was founded as a small machine shop in Louisville, Kentucky in 1880. In 1938, Vogt built the first Tube-Ice® machine and revolutionized the ice-making industry. Our first “sized-ice” machine quickly replaced the old canice plants, which required much hard labor and large amounts of floor space for freezing, cutting, and crushing ice by hand.

Today, TUBE ICE®, LLC carries on the tradition as one of the world’s leading producers of icemaking equipment.

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

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® machine will give you a lifetime of service provided you install, maintain, and 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 (502) 635-3000.

9/22/05

1-1

INTRODUCTION

1. Introduction

Henry Vogt Machine Co.

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 “Anhydrous Ammonia 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.

P34AL-15 & P34ALOF-15 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 !

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

Special Precautions To Be Observed When Charging Refrigeration Systems. Only technically qualified persons, experienced and knowledgeable in the handling of anhydrous ammonia refrigerant and operation of refrigeration systems, should perform the operations described in this manual. All local, federal, and EPA regulations must be strictly adhered to when handling ammonia (R-717) refrigerant. See “Material Safety Data Sheet”, MSDS Code No. 5B81-83.

If a refrigeration system is being charged from refrigerant cylinders, disconnect each cylinder when empty or when the system is fully charged. A gage should be installed in the charging line to indicate refrigerant cylinder pressure. The cylinder may be considered empty of liquid R-717 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 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 !

9/22/05

1-4

INTRODUCTION

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 1-1

P34AL-15 Front Side (Control Panel)

P34AL-15 & P34ALOF-15 Service Manual

1-5

INTRODUCTION

9/22/05

FIGURE 1-2

P34AL-15 Right Side

1-6

INTRODUCTION

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 1-3

P34AL-15 Left Side

P34AL-15 & P34ALOF-15 Service Manual

1-7

INTRODUCTION

9/22/05

FIGURE 1-4

P34ALOF-15 Front Side (Control Panel)

1-8

INTRODUCTION

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 1-5

P34ALOF-15 Right Side

P34AL-15 & P34ALOF-15 Service Manual

1-9

INTRODUCTION

9/22/05

FIGURE 1-6

P34ALOF-15 Left Side

1-10

INTRODUCTION

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

P24AL & P34AL Service Manual

Only service personnel experienced in ammonia refrigeration and

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 the 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 (condenser 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 four different tube sizes for producing ice 7/8” OD x 1” long, 1 1/8” OD x 1” long, 1 3/8” OD x 1” long, or 1 5/8” 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

2-1

RECEIPT OF YOUR TUBE-ICE MACHINE

2. Receipt Of Your Tube-Ice Machine

! CAUTION !

qualified to work on high amperage electrical equipment should

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.

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

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

the handling, storing, and use of anhydrous ammonia.

An approved ammonia mask should be readily available

for use in an emergency and all personnel should be aware

of its location and proper use.

! CAUTION !

9/22/05

2-2

–

RECEIPT OF YOUR TUBE-ICE MACHINE

available by modifying the cutter and making minor adjustments to the machine (see Chapter 10, “Crushed Ice”).

Rated Capacity. The Tube-Ice under the proper conditions as specified in this manual (see Section 11 for the operating specifications). 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.

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).

Model Designation for P-Series Ice Machines

P24AL & P34AL Service Manual

machine is rated to produce a given amount of ice when operating

Nominal Capacity "02K" - 2000 lbs/day ( "03K" - 3000 lbs/day "04K" - 4000lbs/day ( "03T" - 3 tons/day "05T" - 5 tons/day "10T" - 10 tons/day "25T" - 25 tons/day "50T" - 50 tons/day "80T" - 80 tons/day

Basic Configuration

"P" - Package "L" - Low-side "H" - High-side

Tube Size (in 1/4's of an inch) "4" - 1" "5" - 1 1/4" "6" - 1 1/2"

1 3/4”

“7”

"K" = 1000's lbs/day, "T" = tons/day)

Consult Specifications for Actual Capacity)

Model Variation

A number assigned to indicate major variations within an

Refrigerant

"F" - R-22 "A" - Ammonia "H" - R-404a

Electrical Codes

"26" - 208/230-3-60 "46" - 460-3-60 "56" - 575-3-60 "25" - 200-3-50 "45" - 400-3-50 "21" - 230-1-60

one family series.

Type of Ice

"B" - Cylinder "K" - Crushed "D" - Dual Ice (Cru & Cyl) "L" - 1 1/2" Long Cylinder "X"- 2” Long Cylinder

XXXX – XXXX – XXXX – XXX

Condenser Type

"AC" - Air Cooled "WC" - Water Cooled "HP" - High Pressure Water Cooled "SW" - Sea Water "NC" - No Condenser

Product Variation Codes (An alphanumeric designator assigned to specific variations.) "000 or Blank" – Standard Product If unsure of the product code shown on your machine please consult the factory.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

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 Section 11 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 3-4.

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® machine are rated

NEMA 1. Therefore, the machine should not be located in a hazardous area or sprayed with water. The machine should be installed 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 3-2, 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 machine, extra space will be required for the cleaning tools.

Foundation. Refer to the space diagrams, Figure 3-3, 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.

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.

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.

P34AL-15 - Figure 3-4. Machine weight 12,300 lbs (5580 Kg.). P34ALOF-15 Machine weight 11,900 lbs (5400 Kg.).

These figures are intended as a guide to unloading and lifting the P34AL-15 and P34ALOF-15 Tube-Ice

or loss of life during the loading or lifting procedure.

machine. Tube-Ice LLC. is not responsible for product damage or personnel injury

! WARNING !

INSTALLING YOUR TUBE-ICE MACHINE

3-1

9/22/05

3-2

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

ICE

DISCHARGE

FIGURE 3-1

P34AL-15 Space Diagram

P34AL-15 & P34ALOF-15 Service Manual

INSTALLING YOUR TUBE-ICE MACHINE

3-3

9/22/05

ICE

DISCHARGE

FIGURE 3-2

P34ALOF-15 Space Diagram

3-4

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-3

Typical Foundation Layout

P34AL-15 & P34ALOF-15 Service Manual

INSTALLING YOUR TUBE-ICE MACHINE

3-5

9/22/05

FIGURE 3-4

Typical Lifting Procedure for P34AL-15

3-6

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-5

Seismic Anchoring Detail for Tube-Ice Machines

P34AL-15 & P34ALOF-15 Service Manual

Piping and Drain Connections. See Figure 1-1 to 1-6 and 3-11 to 3-18 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.

Exterior shut-off valves must be provided in the water

inlet lines. The minimum inlet water pressure for

Model

P34AL-15 1 1/2” FPT 3/4” FPT

P34ALOF-15 1 1/2” FPT 3/4” FPT

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

Make-up Water In

Water Supply, Drain and Refrigeration Connections

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 80 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 Section 11 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.

9/22/05

INSTALLING YOUR TUBE-ICE MACHINE

! CAUTION !

satisfactory operation of the machine is 40 psig.

The maximum allowable pressure is 100 psig.

! CAUTION !

Flushing Water In

104 gal/3 min.

Water Tank Drain

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

2” FPT 3” FPT 6” Flange 2” SW 2 1/2” Flange

Water Tank Overflow

Low Side

Suction

Connection*

TABLE 3-1

(See FIGURE 1-1 through 1-6 for locations)

Low Side

Liquid

Connection**

Low Side

Thaw Gas

Connection

3-7

3-8

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 area 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.

Unless water quality is superior, do not discharge the overflow water to the cooling tower system. This water contains additional dissolved solids left from the ice making process and can lead to excessive condenser fouling or cooling tower chemical usage. It is recommended that a heat exchanger be used in place of direct contact with condenser water.

Receiver. The receiver used to supply hot thaw gas must be sized adequately to provide sufficient thaw gas. Table 3-2 shows the minimum volume required to hold the refrigeration charge of the freezer and the hot gas required for the thaw cycle. It is recommended that a heating coil be installed in the receiver to assure that the liquid ammonia is at saturated temperature at the start of each thaw period. The receiver 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).

Note: Additional storage volume may be required for the interconnecting piping. Add volume of interconnecting piping to the values shown in Table 3-2

MODEL

P34AL

Thaw Gas Pressure Regulator. The thaw gas pressure regulator is a 2 1/2” solenoid operated pressure combination regulator and shut-off valve (see figures 1-1 and 1-4 for locations). Do not reduce the size of this line or connect to the compressor discharge piping. This valve is

designed to carry the proper amount of thaw gas to the evaporator during the harvest cycle. See Section 5-7 for operating instructions.

Suction Pressure Regulator. When a machine is attached to a central refrigeration system a pressure regulator will be required (see Figures 3-12 through 3-16 for location and general piping arrangement). This regulator (usually furnished by the purchaser) must be a combination backpressure regulating and stop type valve. The usual minimum pressure drop across this type valve is 2 psig, therefore the valve must be set to maintain a freezer pressure at least 2 psi above the maximum general suction pressure. For improved control during pull-down it is recommended that a by-pass be installed around the suction regulator.

Compressor Unloading. When a P34AL-15 is attached to a dedicated compressor system, unloading of the compressor will be required. A minimum compressor unloading during the harvest

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

RECEIVER VOLUME (Cubic Feet)

With Heating Coil With out Heating Coil

60 80

TABLE 3-2

Receiver Volume Requirements

P34AL-15 & P34ALOF-15 Service Manual

cycle is 50% (75% is preferred). If the compressor cannot be unloaded then a hot gas bypass to the suction line must be installed. See Figures 3-11 through 3-14.

Cooling Tower (optional). 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. Table 3-3 shows the total heat rejection, in 1000 BTU’s per hour for the P34AL-15 and P34ALOF-15 at different suction temperatures. 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 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.

P34AL-15 - Cylinder P34ALOF-15 - Cylinder

Suction

Temperature °F / °C

21.4 /-6.0 1619 1326 995 1704 1395 1032

16.6 /-8.5 2067 1728 1309 2174 1818 1357

11.3 /-11.5 2677 2302 1764 2815 2422 1829

5.5 /-15.7 3142 2757 2132 3303 2900 2210

-1.0 /-18.3 3657 3280 2562 3845 3449 2655

21.4 /-6.0 1619 1841 1968 1704 1936 2039

16.6 /-8.5 2067 2325 2425 2174 2445 2511

11.3 /-11.5 2677 2972 3008 2815 3124 3115

5.5 /-15.7 3142 3455 3426 3303 3631 3548

-1.0 / -18.3 3657 3983 3871 3845 4186 4007

Total Heat Rejection is based on pulldown of 105°F SDT and are nominal values based on open drive reciprocating compressor. Consult factory for condenser sizing if desired.

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.

INSTALLING YOUR TUBE-ICE MACHINE

1”

Tube

1 1/4”

Tube

1 1/2”

Tube

1”

Tube

1 1/4”

Tube

P34AL-15 - Crushed P34ALOF-15 - Crushed

TABLE 3-3

Total Heat Rejection (MBH)

1 1/2”

Tube

3-9

9/22/05

3-10

INSTALLING YOUR TUBE-ICE MACHINE

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 175 psig.

See FIGURES 3-6 through 3-8 for possible cold climate installations with indoor sump.

Safety Valves. Two safety pressure relief valves are an integral part of the packaged Tube-Ice® machine. They are located on the suction accumulator of the freezer. Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes. Refer to the International Institute of Ammonia Refrigeration (IIAR) standard for specific requirements and instructions.

P34AL-15 & P34ALOF-15 Service Manual

COOLING TOWER

WATER COOLED CONDENSER

CHECK VALVE

FIGURE 3-6

1 PUMP/2-WAY VALVE

* Poor Freeze Protection

Because low flow rate = high freeze chance

INDOOR SUMP

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

WATER COOLED CONDENSER

Only enough water to maintain head pressure

Same flow rate to cooling tower

INSTALLING YOUR TUBE-ICE MACHINE

COOLING TOWER

3-11

CHECK VALVE

WATER COOLED CONDENSER

INDOOR SUMP

FIGURE 3-7

1 PUMP/3-WAY VALVE

* Better Freeze Protection

COOLING TOWER

9/22/05

CHECK VALVE

INDOOR SUMP

Outdoor pump is off until indoor sump needs cooling

FIGURE 3-8

2 PUMP/2-WAY VALVE

* Best Freeze Protection

3-12

INSTALLING YOUR TUBE-ICE MACHINE

Wiring and Electrical Connections.

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.

A fused disconnect must be provided near the Tube-Ice transformer (if required) are attached to the structure on the front of the Tube-Ice FIGURE 3-9). Incoming 3-phase power will be connected at terminals L1, L2, L3 at the terminal block for operation of the Tube-Ice motor, and water pump and auxiliary equipment 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.

P34AL-15 & P34ALOF-15 Service Manual

! WARNING !

machine. The control panel and

machine and its controls. Rotation checking of the, cutter

machine (see

9/22/05

FIGURE 3-9

Power Supply Connections

P34AL-15 & P34ALOF-15 Service Manual

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 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 water pump will start and the freezing

(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.

9/22/05

3-13

INSTALLING YOUR TUBE-ICE MACHINE

3-14

INSTALLING YOUR TUBE-ICE MACHINE

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 terminal block 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.

Do not attempt to start the machine until first making sure all

conditions listed in the Installation Review Checklist and all

necessary valves have been opened for operation.

Auxiliary Controls or Equipment. When connecting other equipment such as high/low pressure

switch, conveyor motors, bin level control, etc., refer to the control panel wiring drawing for the proper connecting terminals and instructions. See Figure 6-3.

P34AL-15 & P34ALOF-15 Service Manual

! CAUTION !

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

3-15

INSTALLING YOUR TUBE-ICE MACHINE

9/22/05

FIGURE 3-11

Interconnecting Piping for Vogt P34AL-15 and Dedicated High Side

3-16

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-12

Interconnecting Piping for Vogt P34AL-15 and Central High Side

P34AL-15 & P34ALOF-15 Service Manual

3-17

INSTALLING YOUR TUBE-ICE MACHINE

9/22/05

FIGURE 3-13

Interconnecting Piping for Vogt P34ALOF-15 and Central High Side

3-18

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-14

Interconnecting Piping for Vogt P34ALOF-15 and Central Screw Compressor

P34AL-15 & P34ALOF-15 Service Manual

3-19

INSTALLING YOUR TUBE-ICE MACHINE

9/22/05

FIGURE 3-15

Interconnecting Piping for 2-Vogt P34AL-15 and Central High Side

3-20

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-16

Interconnecting Piping for 3-Vogt P34AL-15 and Central High Side

P34AL-15 & P34ALOF-15 Service Manual

3-21

INSTALLING YOUR TUBE-ICE MACHINE

9/22/05

FIGURE 3-17

Interconnecting Piping for 2-Vogt P34ALOF-15 and Central High Side

3-22

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 3-18

Interconnecting Piping for 3-Vogt P34ALOF-15 and Central High Side

P34AL-15 & P34ALOF-15 Service Manual

Be sure to follow the wiring schematic when incorporating overloads of

conveyor (5 MOL). Also remove jumpers as instructed.

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

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: _____ The system is properly evacuated to 500 microns. CHECK: _____ All refrigerant piping, water supply and drain connections for conformity to

requirements stipulated in this manual and properly connected to inlets and outlets. CHECK: _____ Electrical supply for proper size of fuses and for compliance to local and national

codes. See the machine nameplate for minimum circuit ampacity and maximum fuse size. CHECK: _____ All field installed equipment (augers, conveyors, 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).

The compressor crankcase heater should be energized for a minimum of

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

INSTALLING YOUR TUBE-ICE MACHINE

! IMPORTANT !

This is necessary to provide proper

! IMPORTANT !

! CAUTION !

before attempting to start the compressor.

! CAUTION !

3-23

9/22/05

3-24

INSTALLING YOUR TUBE-ICE MACHINE

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

4. How Your Tube-Ice Machine Works

HOW YOUR TUBE-ICE MACHINE WORKS

4-1

9/22/05

Operating Features. Your Vogt low side Tube-Ice

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, cutter and pump overloads, as well as other auxiliary motor overloads. It will also stop automatically by high head pressure, low suction pressure (if field wired to the high side). 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). The make-up water level is maintained by a float valve (12) in the water tank (7). The refrigerant float switch (10) opens and closes the liquid feed “A” solenoid valve (20) and maintains the desired refrigerant level in the freezer (2) (Flooded units only). Refrigerant gas from the top of the freezer (2) passes through the suction accumulator (88) to the suction header and back to the compressor. The cool gas from the evaporator is compressed to a high temperature, high pressure gas which discharges through the oil separator (then through the heat coil of the receiver, when installed) and to the condenser. In the condenser, heat is removed and the gas is condensed to a high temperature, high-pressure liquid. The high-pressure liquid passes through the liquid line through a strainer (43), liquid “A” solenoid valve (20) 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 freeze timer (1TR) in the control panel. The water pump (6) stops and the “A” solenoid valve (20) closes. After a delay of 20-30 seconds, the cutter motor starts, the thawing gas “D” solenoid valve (18R) 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 is 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 recirculating water down each tube. As the ice thickness increases, the freezer suction pressure decreases. At a set time the freeze timer (1TR) energizes the relay (1CR), which stops the water pump, closes the “A” liquid feed solenoid valve (20), de-energizes the suction regulator (when installed), turns out the two pilot lights, ammonia 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 (when required), 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 (approximately 40°F / 5°C) to allow the ice in the tubes to release and be sized. The ice is then 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 5M Cutter Motor – Not Shown 5R Gear Reducer – Not Shown 6 Water Pump 7 Water Tank (includes cutter assembly ) 8 Water Distributing Chamber 9 Water Tank Overflow (3” FPT) 10 Refrigerant Float Switch 12 Make-Up Water Float Valve 12T Thermometer 16 Thawing Chamber 17 Hand Expansion Valve 18 Thawing Gas Regulator/Solenoid Valve “D” 20 Liquid Feed Solenoid Valve “A1” 28 Refrigerant Charging Valve 29 Liquid Line Stop Valve 29A Float Switch Stop Valve 30 Sight Glass 31 Gage Glass Stop Valve

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

! CAUTION !

Piping Nomenclature

P34AL-15 & P34ALOF-15 Service Manual

4-3

HOW YOUR TUBE-ICE MACHINE WORKS

9/22/05

FIGURE 4-1

Piping Schematic for P34AL-15

4-4

HOW YOUR TUBE-ICE MACHINE WORKS

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 4-2

Piping Schematic for P34ALOF-15

P34AL-15 & P34ALOF-15 Service Manual

START-UP & OPERATION

5. Start-Up & Operation

Refrigeration System Review. The refrigeration system uses anhydrous ammonia (R-717)

refrigerant. Following the piping schematic (Figure 3-11 to 3-17 and 4-1 or 4-2), you will see that during the machine’s freeze cycle, the compressor discharge gas goes through the oil separator to remove any oil present in the discharge gas and return the oil to the compressor crankcase. 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 R-717 (800 lbs. for P34AL-15) is accumulated in the receiver and is required for thawing purposes (see Table 3-2). Liquid from the receiver flows through the strainer to the “A” solenoid valve (20), which opens and closes by action of the low side float switch (10), flooded unit only. The liquid is then expanded through the hand expansion valve (17) and into the evaporator (2) (freezer). The cold wet R-717 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 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 and passes through the suction accumulator (88), where liquid droplets are removed, and allowing dry gas to enter the suction side of the compressor. 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, when the freeze timer (1TR) times out the contact closes, initiating the thaw (harvest) cycle.

Note: Freezing time will vary, depending on make-up water temperature, suction pressure and thickness of ice produced. The freeze timer (1TR) should be set to provide the correct time to produce ice at the required thickness under the current operating conditions.

During the harvest period, the “D” thawing gas valve (18) opens, the suction valve (field installed) and the compressor unloads (when required), allowing the warm high-pressure gas from the receiver to enter the freezer. As the tubes warm up to slightly above freezing (approximately 40°F / 5°C), 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, 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

9/22/05

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.

4. Check rotation of augers or ice handling equipment to make sure they are rotating the proper

direction.

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

closed, or automatic).

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

7. 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.

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

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

Refrigerant Charge. Prior to charging the machine with anhydrous ammonia (R-717), make sure the system is leak tight and free of non-condensables or other contaminants.

The machine will require a full charge of pure anhydrous ammonia. Make sure it is from a reputable supplier who can and will furnish quality ammonia of Refrigeration or Federal Technical grade.

Grade

Fertilizer 99.50% 5000 PPM 5 PPM N/A Refrigeration 99.98% 150 PPM 3 PPM .2 ml/g Federal Technical 99.98% 200 PPM 5 PPM None Metallurgical 99.99% 33 PPM 2 PPM 10 ml/g Research 99.999% 5 PPM 1 PPM 7 PPM

NOTE: Do not use Fertilizer grade ammonia.

Total ammonia (R717) charge required is approximately; Dedicated System - P34AL-15 = 2010 lbs. P34ALOF-15 = 2120 lbs. Evaporator only - P34AL-15 = 1239 lbs. P34ALOF-15 = 1300 lbs.

Special precautions to be observed when charging refrigeration systems. Only technically qualified persons, experienced and knowledgeable in the handling of anhydrous ammonia refrigerant and operation of refrigeration systems should perform the operations described in this manual. All local, federal, and EPA regulations must be strictly adhered to when handling ammonia (R717) refrigerants. See “Material Safety Data Sheet”, MSDS Code5B81-83, located in the Appendix A.

P34AL-15 & P34ALOF-15 Service Manual

Minimum

Ammonia Content

Maximum

Water Content

Maximum

Oil Content

Maximum Non-

condensable

TABLE 5-1

Ammonia Specification By Grade

(Reference IIAR Ammonia Data Book Chapter 1, General Information)

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

Charging From Tank Truck (dedicated high side only). The system may be charged by bulk from a tank truck and be pumped directly into the receiver through the drain valve.

Follow these instructions with caution:

1. Using a ammonia approved charging hose, connect one end to the drain/charging valve in the

bottom of the high pressure receiver.

2. Connect the other end of the charging hose to the tank truck. It is best to have a gage in this line

to indicate pressure.

3. Open the drain/charging valve and the fill valve from the tank truck.

4. While observing the sight glass on the high-pressure receiver, fill the receiver to the proper

volume.

5. Make sure the charging valve is closed and the cylinder valve is closed before attempting to

disconnect the hose. Use caution when disconnecting the charging hose, it will contain liquid ammonia and should be disposed of in accordance with local, state and federal safety and environmental rules.

Do NOT attempt to bulk charge the machine through the freezer

charging valve (28). The freezer will not hold the full charge

without exposing the compressor to serious damage.

Charging From Cylinders (dedicated high side only). The machine may also be charged from

refrigerant cylinders. To charge from cylinders, the compressor will have to operate to transfer the ammonia from the freezer to the receiver. Again, make sure all the necessary valves are opened for operation and the compressor crankcase heater has been energized for a minimum for four hours.

Follow these instructions with caution:

1. Using a approved for ammonia charging hose, connect one end to the charging valve (28) in the

liquid line near the freezer.

2. Lay a full cylinder of anhydrous ammonia horizontally with the cylinder valve outlet pointing up

to withdraw liquid and the bottom end raised about 2” higher than the top end.

3. Connect the other end of the charging hose to the cylinder valve. It is recommended that a gage

be attached to this line to indicate cylinder pressure.

4. Close the liquid line stop valve (29) or at the receiver.

5. Open charging valve (28) and carefully purge air from the charging hose.

6. Open the cylinder valve slowly, checking for leaks in the line and allow the suction pressure to

build up to approximately 40 psig and check again for leaks in the system.

7. Set the freeze timer (1TR) to maximum setting. If the machine contains a pressure switch (2PS)

in place of the freeze timer, disconnect and locked out the power, open the control panel door and disconnect wire #24 from the freezer pressure switch (2PS), then turn the power back on.

8. Check compressor rotation by starting and stopping the compressor momentarily. If the

compressor starter is wired to (3CR) then jog the compressor by using the green “Start” push button (2PB) and the red “Stop” push button (1PB). Correct compressor rotation is indicated by an arrow on the outer rim of the oil pump assembly (opposite the shaft end of the compressor.

5-3

START-UP & OPERATION

! CAUTION !

9/22/05

5-4

START-UP & OPERATION

9. Set the Hand/Auto switch (1SS) to the “Hand” position allowing the circulating water pump to

circulate water through the freezer.

10. As the pressure continues to rise in the freezer, start the compressor and pump the ammonia into

the receiver. Make sure water is circulating through the condenser and freezer tubes.

If a refrigeration system is being charged from refrigerant cylinders, disconnect each cylinder when empty or when the system is fully charged. A gage should be installed in the charging line to indicate refrigerant cylinder pressure. The cylinder may be considered empty of liquid R-717 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 hose from the cylinder. Loosen the union in the refrigerant charging line--carefully to avoid liquid ammonia release into the atmosphere.

Immediately close system charging valve at commencement of defrost or

thawing cycle if refrigerant cylinder is connected. Never leave a refrigerant

Transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended.

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

a) Discharge pressure - 175 psi to 200 psi maximum b) Compressor oil pressure - Mycom W-Series, 18-27 psi, Vilter 450-Series, 35-50 psi. c) Liquid level in receiver d) Compressor oil level

While charging the machine, the low-pressure switch will stop operation of the compressor at set point pressure. The switch will automatically reset at the differential pressure at which time you can restart the machine, (some low pressure switches may be manual reset). It is best to use warm water in the tank and open the tank drain valve somewhat to allow cold water to exit and warm water to enter continually. The idea is to prevent ice from freezing in the tubes as much as possible while charging. It may be necessary to initiate a short harvest cycle to dispel any ice made. To initiate a harvest cycle, close the charging valve and push the manual harvest push button (3PB) while the compressor is running. As soon as all the ice clears the cutter area, turn the Hand/Auto switch to “Hand” and then back to “Auto”. This will stop the harvest and start another freeze to continue the charging procedure. When the liquid level in the receiver is near the pumpdown level and the freezer is down to 15 psi suction with little of no frost on the shell, you can stop the charging procedure and disconnect the cylinder. Make sure the charging valve is closed and the cylinder valve is closed before attempting to disconnect the cylinder. Loosen the union in the charging line gradually to relieve the ammonia pressure slowly.

P34AL-15 & P34ALOF-15 Service Manual

! CAUTION !

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 !

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

START-UP & OPERATION

When charging is complete, stop the machine, disconnect and lock-out the power. If the machine contains a pressure switch (2PS), open the control panel door and reconnect wire #24 to the freezer pressure switch. Open valve #29 and/or receiver liquid feed valve and you will hear liquid refrigerant flowing through to the liquid solenoid valve #20. Turn main power disconnect to the on position and the machine is ready for start-up and ice production.

5-5

FIGURE 5-1.

Control Panel

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 ammonia

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. If the compressor motor starter is wired to the control relay (3CR) then 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 should start unloaded and will load automatically after several seconds of operation.

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

5. When the discharge pressure increases to about 170 psi, push the “Manual Harvest” button to

initiate the harvest cycle. See “Harvest Period”.

9/22/05

5-6

START-UP & OPERATION

6. Set the thaw gas pressure regulator (18R) and the suction regulator (if used). See “Thaw Gas

Regulator” and “Suction Regulator” for instructions.

7. When the suction pressure raises to 50-55 psig, 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 ammonia will feed into the freezer until the level float switch (10) is satisfied (flooded only). The float switch will open and close the liquid line solenoid valve (20) to maintain that level of ammonia in the freezer during the freeze cycle. When the freeze timer (1TR) times out the switch will close and initiate the harvest cycle. If a freezer pressure switch (2PS) has been installed, the suction pressure will decrease 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.

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 anhydrous ammonia laying on its side, cylinder valve outlet pointing up and

bottom end raised two inches higher than the valve end, connect an “approved for ammonia” 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 “ammonia feed light is not illuminated, open the charging valve (28) and ammonia

will flow from the cylinder to the freezer.

4. Close the cylinder valve immediately when the ammonia feed light comes on and reopen it when

the light goes out. Repeat until properly charged.

Disconnect it immediately when the machine is charged or the cylinder is empty.

P34AL-15 & P34ALOF-15 Service Manual

! IMPORTANT !

and return it to the Tube-Ice

! IMPORTANT !

! CAUTION !

Do not leave a refrigerant cylinder attached to the machine unattended.

! CAUTION !

9/22/05

P34AL-15 & P34ALOF-15 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 (harvest timer 2TR) and revert to a freeze cycle, turn the

Hand/Auto switch to “Hand” and back to “Auto”.

• 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 60 - 65 psig. ( 1 turn is approximately 13 psig)

5. Adjust (downstream) high pressure stem on suction regulator to begin regulating at 59-64 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 20 psig freezer pressure is required.

NOTE: In attached systems where suction pressure drops significantly during the harvest period; a bypass must be used to equalize the system pressures gradually during pull-down. Failure to equalize the pressure properly will result in carry-over of liquid refrigerant.

5-7

9/22/05

5-8

START-UP & OPERATION

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

6-1

ELECTRICAL CONTROLS

6. Electrical Controls

Your Low Side Tube-Ice

machine is equipped with a compressor motor interlock and a transformer (if required) for the control circuit power. The control panel 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) (C-SOL) Suction regulating valve

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 not equipped with the following safeties and control switches, however they can be wired into the control circuit. Refer to the wiring schematic FIGURE 6-3 for their circuitry.

• High/Low dual pressure switch (1PS & 4PS) to stop the machine if the compressor suction

pressure goes too low (15-20 psi) or the compressor discharge pressure goes too high (225-250 psi). See “High/Low Pressure Switch”.

• Bin Level Control (BLC) to stop the machine when the bin is full and prevent ice from backing

up into the cutter mechanism.

• Conveyor Motor Overload to prevent ice from backing up into the cutter mechanism.

9/22/05

6-2

ELECTRICAL CONTROLS

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

FIGURE 6-1

Control Panel (Door Opened)

(3CR) Compressor Motor

Starter contact and holding relay

(2M) Pump Motor Starter Provides power to the circulating water pump during the freezer

(3M) Cutter Motor Starter Provides power to the cutter during the harvest period. Provides

(1CR) Control Relay With

Pneumatic Timer

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

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

(1TR) Freeze Timer Controls the length of time the machine is in the freeze cycle.

(2PS) optional for dedicated high side (ET) Elapsed Time Indicator Indicates total hours of machine operation. Is powered when the

(CB4) Circuit Breaker Overload and short circuit protection for crankcase heater and the

(TB) Terminal Block Numbered for multiple wire connections and ease of

Freezer Pressure Switch Controls the desired ice thickness (hole size) by sensing the freezer

Holding relay for safety and bin level control. Auxiliary contact provides control power to the compressor motor starter. Continuously energized during freezing and thawing.

period or when the Hand/Auto switch is in the “Hand” position to circulate water or ice machine cleaner, etc. Provides overcurrent and short circuit protection in addition to a disconnect.

overcurrent and short circuit protection in addition to a disconnect. For making and breaking various circuits during freezing and thawing period with pneumatic timer to delay the actual thawing process. Energized during thawing.

Energized during freezing, thawing, and hand. Momentarily deenergized at the end of the harvest.

Energized during the harvest period.

When timed out initiates the harvest cycle.

suction pressure and initiating the harvest period .

compressor is running.

control circuit.

troubleshooting.

TABLE 6-1

Description of Control Panel Parts (Inside)

P34AL-15 & P34ALOF-15 Service Manual

6-3

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)

9/22/05

6-4

ELECTRICAL CONTROLS

P34AL-15 & P34ALOF-15 Service Manual

OPTIONAL 110 VOLT SECONDARY

9/22/05

FIGURE 6-3

Typical Electrical Schematic, all Voltages, 50-60 Hz.

P34AL-15 & P34ALOF-15 Service Manual

6-5

ELECTRICAL CONTROLS

9/22/05

FIGURE 6-4

Optional PLC Electrical Schematic, all Voltages, 50-60 Hz.

P34AL-15 & P34ALOF-15 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.

B. Weekly (in addition to daily checks)

1) 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.

9/22/2005

7-2 P34AL-15 & P34ALOF-15 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 or alignment 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: __________________________________

9/22/2005

P34AL-15 & P34ALOF-15 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. P34AL-15 tank = 6.9 gallons water per inch of water height in tank, 13” = 89.7 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.

9/22/2005

7-4 P34AL-15 & P34ALOF-15 Service Manual

MAINTENANCE

Tube Size 1 1/2” 1 1/4” 1”

Part Number 12B2185V32 12B2185V22 12B2185V12

Model Number of Distributors Required

P34A 306 420 564

TABLE 7-1

Water Distributors

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

9/22/2005

P34AL-15 & P34ALOF-15 Service Manual 7-5

MAINTENANCE

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”.

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 (optional). 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 to the evaporated. If water hardness is very high, a higher bleed off rate or chemical treatment may be required. Consult your 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 (optional).

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 cavitation 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.

9/22/2005

7-6 P34AL-15 & P34ALOF-15 Service Manual

MAINTENANCE

! CAUTION !

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 (optional). This section is only a guide; please consult the compressor manual for

manufacturers recommended maintenance.

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 refrigeration oil 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 !

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

Mycom N&W Series net oil pressure: 17-28 psig Vilter 450 Series net oil pressure: 35-50 psig

9/22/2005

P34AL-15 & P34ALOF-15 Service Manual 7-7

MAINTENANCE

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 psigThe 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).

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”

Oil Trap. Although the compressor is equipped with an oil separator, which has an automatic return, some oil will pass through the separator and eventually settle in the oil trap (36), which is offset from the base of the freezer. This oil trap will have evidence of frost on its surface during the freeze cycle and may be more pronounced at the end of a normal freeze cycle just before the harvest. Where there is oil in the trap, there will not be frost. Where there is frost, there will not be oil. When the trap is 1/2 to 3/4 full of oil, it should be drained.

The machine should be shutdown for at least 12 hours before attempting to drain oil from the trap. Follow the procedure outlined in the service section, “Draining Oil Trap”.

! CAUTION !

Only qualified refrigeration service personnel familiar and

experienced in the handling and use of anhydrous ammonia (R717) should be

authorized to perform the “Draining Oil Trap” procedure.

! CAUTION !

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.

9/22/2005

7-8 P34AL-15 & P34ALOF-15 Service Manual

MAINTENANCE

! CAUTION !

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

! CAUTION !

9/22/2005

P34AL-15 & P34ALOF-15 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 High compressor discharge temperature 8-11 Suction line frosting to compressor 8-12

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 (502) 635-3510.

8-1

TROUBLESHOOTING

8. Troubleshooting

9/22/05

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 tripped Check for a loose connection on all motor

Water pump, cutter motor, 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

P34AL-15 & P34ALOF-15 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.

starter and motor terminals which could cause excessive amp draw. Reset overload and restart the machine, check amperage, power supply, and head pressure. (Check delay timer 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.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

Symptom: Machine Stopped (con’t)

Possible Cause Possible Remedy

High/Low pressure safety switch (1PS or 4PS) tripped (optional)

Low oil pressure tripped (OPS) located on compressor

Defective control panel component such as 1PB, 1SS, 1M contact, 2CR contact, 2TR

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

8-3

TROUBLESHOOTING

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. Check Liquid feed valve (20) to make sure it is feeding during a freeze.

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. 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).

Net oil pressure range:

Mycom = 17-28 psig Vilter = 35-50 psig 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. 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.

9/22/05

8-4

TROUBLESHOOTING

Symptom: Freeze-up due to extended freeze period

Freeze timer (1TR) set to long Adjust timer or replace if defective. See

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

Thaw gas solenoid valve (18) leaking through during freeze (if 2PS is used)

Compressor running unloaded If the compressor is running unloaded, the

P34AL-15 & P34ALOF-15 Service Manual

Possible Cause Possible Remedy

FIGURE 9-1. Adjust switch or replace if defective. See FIGURE 9-1. 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.

motor amp draw will only be 60%-70% of the normal amp draw of a loaded compressor.

Check the load delay timer 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.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

TROUBLESHOOTING

Symptom: Freeze-up due to ice failing to discharge

Possible Cause Possible Remedy

Freeze timer (1TR) set to long Adjust timer or replace if defective. See

FIGURE 9-1.

Extended freeze period (if 2PS is used) Check freezer pressure switch (2PS)

adjustment. See FIGURE 9-1 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 (2TR) 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. See pressure regulating valve adj.

Thaw pressure to low The thaw gas regulator should be adjusted to

increase the pressure in the freezer to 60-65 psi during a harvest. Isolate and repair or replace

the valve as needed. Insufficient heat for thawing due to low condensing pressure

The head pressure should be maintained from

175-190 psi (maximum 200) 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 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. See Table 3-2 Cutter or cutter disc does not turn Check cutter gear reducer and drive gear for

proper operation and alignment. Check for

roken gear teeth or sheared shaft key.

Replace defective parts. Compressor not running unloaded during thaw cycle. (for dedicated high side only)

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

9/22/05

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 x1440 =__________ 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. Freeze timer, 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

P34AL-15 & P34ALOF-15 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

10, Capacity Table. Check float adjustment and

water tank drain valve.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

Symptom: Low ice capacity (cont.)

Possible Cause Possible Remedy

Excessively high head pressure Check cooling tower or evap condenser to

Suction regulator out of adjustment or defective (optional)

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

Symptom: Poor ice quality

Possible Cause Possible Remedy

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

Suction Pressure to low Adjust suction regulator valve Restriction in liquid line, causing short freeze cycle

8-7

TROUBLESHOOTING

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 freezer pressure and compare to the

main suction pressure. The suction regulator

should regulate the freezer pressure and create

a 2 psi pressure drop across the valve. Adjust

pressure regulator. Repair or replace defective

valve.

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.

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.

9/22/05

8-8

TROUBLESHOOTING

Symptom: High discharge pressure (check gage accuracy)

Possible Cause Possible Remedy

Insufficient water flow through the cooling tower or condenser

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. Fan control out of adjustment Check adjustment. Replace if defective. Non-condensable in system. If non-condensables are present with the

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”. Cooling tower or evap condenser in need of maintenance

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. Dirty condenser tubes Visually inspect the condenser tubes to see if

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. Too much liquid in condenser covering tubes causing inefficiency

Remove refrigerant so all tubes will be above

liquid refrigerant level.

P34AL-15 & P34ALOF-15 Service Manual

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

TROUBLESHOOTING

Symptom: Low discharge pressure (check gage accuracy)

Possible Cause Possible Remedy

Fan cycling switch out of adjustment or

Check adjustment. Replace if defective. defective 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 (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. Suction Pressure to low Adjust suction regulator valve Defective gage Check pressure with accurate gage and replace

as necessary.

Symptom: Compressor running unloaded during freeze (dedicated compressor only)

Possible Cause Possible Remedy

Low oil pressure Check compressor net oil pressure.

Net oil pressure = oil pressure gage reading

less suction pressure.

Mycom = 17-28 psig

Vilter = 35-50 psig.

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. Mycom

compressor can be loaded manually.

8-9

9/22/05

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 Compressor thrust bearing installed upside down

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

P34AL-15 & P34ALOF-15 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.

The Mycom compressor thrust bearing on the

shaft seal end has an oil passage hole which

has to be in the proper position when installing

the thrust bearing. Hole up for “WA” and

“WB” series Mycom compressor. Refer to

your compressor manual.

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.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

TROUBLESHOOTING

Symptom: Machine short cycles ( using freeze pressure switch (2PS) only)

Possible Cause Possible Remedy

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

Adjust switch or replace if defective. See

FIGURE 9-3. 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 restriction 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: 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

9/22/05

8-12

TROUBLESHOOTING

Symptom: Suction line frosting to compressor

Liquid refrigerant overfeed Check float switch to make sure it is

High pressure differential during harvest (suction pressure below 30 psi)

Defrost gas sourced from compressor discharge (superheated gas)

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

P34AL-15 & P34ALOF-15 Service Manual

Possible Cause Possible Remedy

functioning properly. Replace if defective.

Check solenoid valve #20 to make sure it is not

leaking through. Repair or replace if defective.

Use a by-pass to relieve the pressure in the

evaporator before opening the main suction

valve. Ensure that the compressor is unloading

properly.

Connect the defrost gas source to the receiver

as recommended.

Use a by-pass to relieve the pressure in the

evaporator before opening the main suction

valve.

Completely pump the freezer out (pumpdown)

and blow excess water out through the oil trap

drain valve #61. Refer to Service, Section 9

“Removing Excess Water”.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

8-13

TROUBLESHOOTING

9/22/05

P34AL-15 & P34ALOF-15 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.

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 that would necessitate frequent cleaning. A strainer of 40-mesh screen is usually satisfactory.

Float Switch. The float switch is installed on a header assembly that is attached to the freezer shell. Valves are provided for isolation of the float switch assembly if replacement or servicing is necessary. The float switch closes as the level of refrigerant in the freezer rises and opens as the level falls.

The float switch is connected to the “A1” solenoid valve coil. This is the solenoid valve directly before the hand expansion valve. Therefore when the refrigerant level in the freezer drops, the float switch closes, thereby energizing and opening the “A1” liquid feed solenoid until sufficient level has been reached to open the float switch. The float switch has a fixed 1/2” differential.

The float switch is installed at the correct height at the factory and should not need to be adjusted. The float switch is installed at the position, which provides highest capacity. The correct height will produce compressor superheat, which climbs throughout the freeze cycle to a minimum of 30° F.

9-1

9/22/05

9-2

SERVICING OPERATIONS

P34AL-15 & P34ALOF-15 Service Manual

Figure 9-1

P34AL-15 Float Height

Model Tube Size 1- Length of

Pipe

2- Length of

Pipe

P34AL All 24” 10”

TABLE 9-1

Length of Pipe on Float Switches

Hand Expansion Valve. The hand expansion valve is located directly after the “A1” 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.

Freeze Timer. The freezing time period for producing ice of a desired thickness is controlled by the freeze timer (1TR), Figure 9-2, located inside the control panel. This timer is a microprocessor based timer housed in a standard 15 terminal CYCL-FLEX entered into the unit using a sealed membrane keypad on the front of the unit. Each digit in the setpoint is individually increased or decreased by pressing the appropriate keypad switch. There is a mode annunciator in the display area on the front of the unit. The mode annunciator will flash when the unit is timing. Table 9-2 shows the miniature rocker switch settings for the unit. This enables the unit to pulse output, reverse start, minute/second display and battery back-up set points and timing.



plug-in case. Time set points are

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

SERVICING OPERATIONS

Switch #1 #2 #3 #4 #5 #6 #7

ON X X X X X

OFF X X

TABLE 9-2

Miniature Rocker Switch Settings for Freeze Timer

Entering and Displaying Setpoints. Whenever the freeze timer unit is powered up and the

previous setpoint has been lost, the digit display indicates four hyphens. The unit will not operate until it has been provided with a setpoint, clearing the display of hyphens.

To create or change a setpoint, press the SET key. The setpoint, if any, is displayed and the panel key pads become active. The operation of the timing or counting function and the output loads are not affected. For setpoint changes, the SET indicator appears on the graphics panel. The setpoint is changed by pressing appropriate  or  key pads. Pressing the  key increments the setpoint digit located above the key; the  key decrements the digit located above the key. If the pad is continually depressed, the digit will change every .5 second until the pad is released. The display will carry to the digit on the left on the 9 to 0 transitions when using the  pads. The display will borrow from the digits on the left on the 0 to 9 transitions when using the  pads. On ranges 6 and 7, the display will carry on the 59 to 00 transition and borrow on the 00 to 59 transition of the two least significant digits.

When the desired setpoint is displayed, touch the ENT key. The new setpoint is entered, all  and  keys become inoperable and “SET” disappears from the graphics panel. New setpoints can be entered while the unit is timing or counting, but they will not take effect until the next reset.

The setpoint may be displayed at any time without disturbing the timing or counting cycle by pressing SET. The actual value is returned by pressing ENT. If the unit is set at 0000, the load is always ON if programmed for OOX, and always OFF if programmed OXO.

A keypad “lock” is provided on the freeze timer to prevent unauthorized tampering. To initiate the keypad lock, press the word “SIGNAL” in the Eagle Signal logo for 8 seconds. To disable the lock to change setpoints, remove power from the unit and turn the battery off ( miniature rocker switch #6) and then on. The unit will lose all setpoints and they must be re-entered for further operation.

9-3

9/22/05

9-4

SERVICING OPERATIONS

Freezer Pressure Switch (optional). The freezing time period for producing ice of a desired thickness is controlled by the freezer pressure switch (2PS), Figure 9-3, 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 9-3.

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.

P34AL-15 & P34ALOF-15 Service Manual

FIGURE 9-2

Freeze Timer (1TR)

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

SERVICING OPERATIONS

FIGURE 9-3

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.

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 9-4, governs the ice thawing period. It is located inside the control panel (FIGURE 6-1). It is started by action of the freeze timer (2TR) or 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 “X1” 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 the thaw time after each adjustment.

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

9-5

9/22/05

9-6

SERVICING OPERATIONS

POWER UP

P34AL-15 & P34ALOF-15 Service Manual

Timer Settings:

Unit- Minutes Range – 0 to 12 Power – Flashing when timer operates, Lit when timer stops

Up – Lit when timer energized

UNIT

RANGE

Min

FIGURE 9-4

Thawing Timer (2TR)

Suggested Condenser Cleaning. 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 and 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. 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, compressor and auxiliary equipment.

4. Disconnect water piping and drain the condenser. Generally, additional water can be drained by

loosening the cover (heads) and separating the covers from the condenser end.

5. Remove the heads bolts and gasket completely.

6. Inspect the tubes for excessive corrosion and possible ammonia leaks to 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 to prevent contamination of the cooling

tower and sump.

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

10.Install the replacement gasket. Make sure the gasket does not cover the tube ends.

11.Install the end covers (heads) and fasten securely in place with the head bolts. It is recommended

that an anti-seize compound be applied to the bolt and nut threads to prevent rusting and ensure ease of removal at the next cleaning.

12.Reconnect the water piping and turn on the power. Check for leaks by turning the power on to

the condenser pump allowing it to run.

13.Turn the power ON to the compressor and wait for the crankcase heater to warm-up the

compressor before starting the machine.

9/22/05

P34AL-15 & P34ALOF-15 Service Manual

SERVICING OPERATIONS

Cutter Gear Reducer. The cutter motor and gear reducer (54), Figure 9-5B, 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.

9-7

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.

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.

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

with the side and top cap screws.

9/22/05

12. 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.

13. 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.

9-8

SERVICING OPERATIONS

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.

P34AL-15 & P34ALOF-15 Service Manual

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.

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.

9/22/05

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 9-1 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.

P34AL-15 & P34ALOF-15 Service Manual

SERVICING OPERATIONS

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.

Weight (lbs.)

Description P34

Water tank (bare) 428 Bearing bracket assembly and cutter disc 150 Cutter assembly and ring gear 164 Water tank and cutter assembly 742 Cutter disc 97 Cutter drive gear 14 Gear reducer and motor 96 Water pump 85

TABLE 9-3

Water Tank and Cutter Parts Weights

Water Tank Removal

9-9

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

2. 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 9-1.

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

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

the pump.

5. P34A only - the water pump is mounted to the structural frame of the machine and will have to

be disconnected from the tank at the pump inlet bolted flange before moving the water tank.

6. 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.

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

to rest on its casters.

8. P34A only - the channel support at the right side base of the machine (opposite from the pump

side) will have to be removed for the tank to be rolled out from under the freezer.

9. 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.

9/22/05

9-10

SERVICING OPERATIONS

Cutter Assembly Removal and Installation.

1. Follow water tank removal instructions, Steps 1-9. See Figure 9-5B.

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.

P34AL-15 & P34ALOF-15 Service Manual

1. Remove the cutter assembly per instructions.

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

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.

9/22/05

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.

P34AL-15 & P34ALOF-15 Service Manual

SERVICING OPERATIONS

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.

4. Clean the cutter shaft and press the top bearing onto the shaft.

5. Slide the upper bearing spacer on the shaft and begin driving the shaft down through the middle

bearing of the housing. Do not start the top shaft bearing in the housing.

6. Partially fill the housing with grease (MPG-2 or a USDA approved grease). Use enough to fill

the area between the two upper bearings, forcing some out the pipe plug hole when the shaft and top bearing are seated.

9-11

7. Finish driving the shaft and bearing into the housing until it is firmly seated.

8. Turn the bracket and shaft upside down and fill the housing around the shaft with MPG-2 (or

suitable substitute) grease.

9. Slide the lower bearing spacer over the shaft and into the housing.

10. With the top end of the shaft supported, install the lower bearing on the shaft driving it down

into the housing firmly against the housing shoulder.

11. Slide the seal spacer (ridged end in, flat end out) and seal (open face out) onto the shaft together.

12. Uniformly tap the seal into the housing against its shoulder.

NOTE: The purpose of the seals and excluders are to prevent moisture from entering the housing area not to hold the grease in.

13. Wipe off excess grease and install the two pipe plugs.

14. Install the largest excluder on the bracket as illustrated by the assembly drawing.

15. Install the tines disc, the 1/4 x 1/4 key, spacer, spring washer, castle nut, and cotter pin.

16. Turn the assembly right side up and install it in the water tank, locating the support arms as they

were match marked when removed and secure in place using the 5/8” stainless steel cap screw and lock washer maximum torque should be 90 ft. lbs.

17. Install the top seal (open side facing out*), tapping it uniformly into the housing until it seats.

9/22/05

18. Install the top water excluder.

19. Install the splash shield and ice deflector plate in the ice discharge opening.

20. Install the cutter assembly, using the 1/4” X 1/4” X 3 3/16” lg. stainless steel key to align the key

ways and lock the cutter and shaft together.

21. Install the red rubber gasket, retainer, and 3/8” stainless steel socket head cap screw. Tighten to

approximately 15 ft. lbs.

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

9-12

SERVICING OPERATIONS

Cutter Height Adjustment. The height of the cutter can be adjusted by the four bolts holding the bearing bracket assembly in place. These bolts are threaded into holes in the end of each arm through holes in the water tank. The current design has these washers welded in place after the cutter height is properly adjusted. This helps to insure proper adjustment during servicing. Using a true straight edge long enough to reach across the top flange of the water tank (30” for P24 and 40” for P34), the top of the cutter rim and blade should be 1/8”  1/16” below the top of the water tank flange.

Keep one end of the straight edge at the same point and swing the other end across the tank at various points to check the clearance.

Also, rotate the cutter to check all points. If adjustment is necessary, loosen the four side bolts and raise or lower each arm as needed. Tighten the bolts securely to approximately 90 ft. lb.

Water Tank Installation.

1. Place the 3/16” thick gum rubber gasket on the top of the tank flange. It can be held in place

with narrow strips of tape through the boltholes.

2. Push the water tank in and under the freezer aligning the boltholes and installing the mounting

bolts around the flange and tightening the nuts securely.

3. Reconnect the discharge chute or hopper to the ice discharge opening.

4. Mount the water pump (P34 only) and attach the circulating water tubing and overflow tubing.

5. Reconnect all water piping such as drain, overflow, and make-up water lines. Turn water on and

check for leaks.

6. Fill the water tank with water and make sure the drain valve is closed.

When ready, turn the power “On” to the machine, but don’t operate the compressor until the oil is

P34AL-15 & P34ALOF-15 Service Manual

warm and there is no liquid refrigerant in the crankcase.

9/22/05

Vogt P-34AL-15 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. Introduction

2. Receipt Of Your Tube-Ice Machine

3. Installing Your Tube-Ice Machine

4. How Your Tube-Ice Machine Works

5. Start-Up & Operation

6. Electrical Controls

7. Maintenance

8. Troubleshooting

9. Servicing Operations