Vogt P-42AL Service Manual
P-42AL
TUBE-ICE®
MACHINE
Service Manual
$5000
9/30/10
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: Tube Ice, LLC
1000 W. Ormsby, Suite 19
Louisville, KY 40210
Att. Tube-Ice Service Department
9/30/10
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 equipm ent 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
FreezeTime
Min/Sec
Harvest Time
Min/Sec
First Ice Out
Min/Sec
All Ice Out
Min/Sec
Avg. Hole
Size
Ice Lb. Per
Harvest
Ice Lb. Per
Day
#1
#2
#3
#4
Note: Ice lb. per day can be found by:
(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
®
VOGT
TUBE-ICE® MACHINES
P42AL Model
Tube Ice, LLC
1000 W. Ormsby Avenue, Suite 19
Louisville, Kentucky, 40210
800-853-8648 • 502-635-3000
Fax: 502-634-0479
TABLE OF CONTENTS
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 P42AL Tube-Ice
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 s tart-up).....................................................................................................................2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Machine Room ..............................................................................................................................................................3-1
Space Requirements.......................................................................................................................................................3-1
Foundation .....................................................................................................................................................................3-1
Lifting Procedures .........................................................................................................................................................3-1
P42AL Foundation Layout, FIGURE 3-1...................................................................................................................... 3-2
Lifting Procedure for P42AL, FIGURE 3-2..................................................................................................................3-3
Seismic Anchoring Detail, FIGURE 3-3 .......................................................................................................................3-4
Water Supply, Drain and Refrigeration Connections, TABLE 3-1................................................................................3-5
Make-Up Water In,........................................................................................................................................................3-5
Flushing Water In..........................................................................................................................................................3-5
Water Tank Drain..........................................................................................................................................................3-6
Water Tank Overflow.....................................................................................................................................................3-6
Receiver .....................................................................................................................................................................3-6
Receiver Volume Requirements, TABLE 3-2 ...............................................................................................................3-6
Suction Pressure Regulator............................................................................................................................................3-6
Compressor Unloading..................................................................................................................................................3-6
Wiring and Electrical Connections................................................................................................................................3-7
Power Supply Connections, FIGURE 3-4 ......................................................................................................................3-7
Voltage Unbalance..........................................................................................................................................................3-8
Current Unbalance..........................................................................................................................................................3-8
TABLE OF CONTENTS
Vogt
P42AL Service Manual
®
TUBE-ICE® MACHINES
Model P42AL
®
Machine..................................................................................................1-4, 5, 6, 7
ii
P42AL Service Manual
iii
Rotation Check...............................................................................................................................................................3-8
Auxaliary Controls or Equipment...................................................................................................................................3-9
Interconnecting Piping for 2-Vogt P42AL and Central High Side, FIGURE 3-17 ........................................................3-10
Installation Reveiw: A Checklist...................................................................................................................................3-11
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 P42AL, FIGURE 4-1...................................................................................................................4-3
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............................................................................................................5-3
Special Precautions to be Observed when Charging Refrigeration Systems..................................................................5-3
Charging From Tank Truck (for dedicated high side only)...........................................................................................5-3
Charging From Cylinders (for dedicated high side only)...............................................................................................5-4
Control Panel, FIGURE 5-1...........................................................................................................................................5-6
Start-Up .....................................................................................................................................................................5-6
Adding Refrigerant........................................................................................................................................................5-7
Operating Tips...............................................................................................................................................................5-7
Thaw Gas Regulating and Suction Regulating Valve Adjustment.................................................................................5-8
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Bin Level Control............................................................................................................. .............................................6-1
Safety Switches..............................................................................................................................................................6-1
Control Panel (Door Opened), FIGURE 6-1..................................................................................................................6-2
Description of Control Panel Parts (Inside), TABLE 6-1..............................................................................................6-2
Control Panel (Door Closed), FIGURE 6-2...................................................................................................................6-3
Description of Control Panel Parts (Outer Door), TABLE 6-2......................................................................................6-3
Electrical Schematic All Voltages 50-60 Hz. Across Line Start, FIGURE 6-3 .............................................................6-4
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....................................................................................................................................................................7-4
Water Cooled Condenser Cleaning (optional)...............................................................................................................7-5
TABLE OF CONTENTS
Page No.
®
, TABLE 7-2..............................................................................................................7-4
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TABLE OF CONTENTS
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. SERVICE OPERATIONS
Automatic Blowdown (Harvest Cycle).......................................................................................................................... 9-1
Cleaning the Ice Making Section...................................................................................................................................9-1
Float Valve (Make-Up Water)....................................................................................................................................... 9-1
Hand Expansion Valve..................................................................................................................................................9-1
Freeze Timer..................................................................................................................................................................9-1
Minature Rocker Switch Settings for Freeze Timer TABLE 9-2...................................................................................9-2
Entering and Displaying Setpoints.................................................................................................................................9-2
Freeze Timer, FIGURE 9-1...........................................................................................................................................9-3
Control Circuit Protection..............................................................................................................................................9-3
Thawing Timer..............................................................................................................................................................9-3
Thawing Timer, FIGURE 9-2........................................................................................................................................9-4
Suggested Condenser Cleaning......................................................................................................................................9-4
Cutter Gear Reducer......................................................................................................................................................9-5
Drive Gear Replacement................................................................................................................................................9-5
Gear Reducer Replacement............................................................................................................................................9-6
Water Tank Removal.....................................................................................................................................................9-7
Cutter Assembly Removal and Installation....................................................................................................................9-8
Bearing Bracket and Cutter Disc Removal....................................................................................................................9-8
Cutter Shaft and Bearing Removal................................................................................................................................9-9
Cutter Shaft and Bearing Installation.............................................................................................................................9-9
P42AL Service Manual
Page No.
iv
P42AL Service Manual
v
Cutter Height Adjustment..............................................................................................................................................9-10
Water Tank Installation.................................................................................................................................................9-11
Pumpdown .....................................................................................................................................................................9-11
Removal of Ammonia Refrigerant from the Machine ...................................................................................................9-12
Refrigerant Leaks...........................................................................................................................................................9-12
Non-Condensable Gases................................................................................................................................................9-13
Purging Non-Condensables ...........................................................................................................................................9-13
Draining the Oil Trap.....................................................................................................................................................9-14
Removing Excess Water from Ammonia ......................................................................................................................9-14
Circulating Water Pump Motor .....................................................................................................................................9-15
The Thaw Gas Solenoid Valve......................................................................................................................................9-16
Thaw Gas Solenoid Valve, FIGURE 9-3.......................................................................................................................9-16
The Liquid Feed Solenoid Valve...................................................................................................................................9-17
The Liquid Feed Solenoid Valve, FIGURE 9-4.............................................................................................................9-17
The Thaw Chamber Check Valve..................................................................................................................................9-18
The Thaw Chamber Check Valve, FIGURE 9-9 ...........................................................................................................9-18
Water Flush Solenoid Valve ..........................................................................................................................................9-18
Compressor Cooling Solenoid Valve ( dedicated high side only)..................................................................................9-18
Compressor Oil Changing .............................................................................................................................................9-19
Compressor Inspection ..................................................................................................................................................9-19
Belt Tension...................................................................................................................................................................9-20
Compressor Servicing....................................................................................................................................................9-21
10. OPTIONS AND ACCESSORIES
Length of Ice .................................................................................................................................................................10-2
PLC (Programmable Logic Controller) ........................................................................................................................10-3
11. TABLES AND CHARTS
P42AL Specifications,TABLE 11-1..............................................................................................................................11-2
11-6 Temperature - Pressure Chart for Common Refrigerants, TABLE 11-2............................................................11-7
Conversion Factors: English to Metric, TABLE 11-3 ...................................................................................................11-8
Constants, TABLE 11-4 ................................................................................................................................................11-8
TABLE OF CONTENTS
Page No.
9/30/10
TABLE OF CONTENTS
P42AL Service Manual
vi
P42AL Service Manual
INTRODUCTION
1-1
1. Introduction
Henry Vogt Machine Co.
A Brief History Of Our Company. Henry Vogt Machine Co. was founded as a small machine
shop in Louisville, Kentucky in 1880. Today, it is one of the world’s leading producers of icemaking equipment.
9/30/10
In 1938, Vogt built the first Tube-Ice
first “sized-ice” machine quickly replaced the old can-ice plants, which required hard labor and large
amounts of floor space for freezing, cutting, and crushing ice by hand.
Vogt Energy-Saving Tube-Ice Machines Are Cost Effective. Today, Vogt Tube-Ice
enjoy a well-earned reputation as the most energy efficient, dependable ice-making equipment in the
world.
Using as little as one-half to one-third the energy required by competitors’ ice makers, Tube-Ice
machines produce the same amount of ice--in restaurants, sports arenas, packing plants, and
wholesale operations around the globe--at great savings.
In addition, Tube-Ice
®
machines are renowned for their long life, giving many customers more than
35 years of dependable service. Ask someone who owns one.
Preview. All the skill in engineering and fabrication that we’ve learned in over a century of
experience is reflected in every Tube-Ice
1938, the process of making Tube-Ice
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.
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. It is evidence of our desire to deliver to you “the finest ice-making unit ever
made.”
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.
®
machine and revolutionized the ice-making industry. Our
®
machines
®
machine. Since Vogt introduced Tube-Ice® machines in
®
ice has been widely recognized as the most economical
®
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
please read this manual. Are you familiar with the installation, start-up, and operation of a Tube-
®
Ice
machine? Before you operate, adjust or service this machine, you should read this manual,
understand the operation of this machine, and be aware of possible dangers.
These safety symbols will alert you
when special care is needed.
P42AL Service Manual
®
machine,
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 !
9/30/10
P42AL Service Manual
INTRODUCTION
1-3
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.
! CAUTION !
Immediately close system charging valve at commencement of defrost or thawing cycle if
refrigerant cylinder is connected. Never leave a refrigerant cylinder connected to system
except during charging operation. Failure to observe either of these precautions can result in
transferring refrigerant from the system to the refrigerant cylinder, over-filling it, and
possibly causing the cylinder to rupture because of pressure from expansion of the liquid
refrigerant brought on by an increase in temperature.
! CAUTION !
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.
! CAUTION !
It is not recommended that refrigerant be transferred from a refrigeration system directly into
a cylinder. If such a transfer is made, the refrigerant cylinder must be an approved, CLEAN
cylinder--free of any contaminants or foreign materials--and must be weighed continuously to
assure contents do not exceed net weight specified by cylinder manufacturer or any applicable
code requirements.
! CAUTION !
9/30/10
1-4
INTRODUCTION
P42AL Service Manual
9/30/10
FIGURE 1-1
P42AL Front Side (Control Panel)
P42AL Service Manual
INTRODUCTION
1-5
9/30/10
FIGURE 1-2
P42AL Right Side
1-6
INTRODUCTION
P42AL Service Manual
9/30/10
FIGURE 1-3
P42AL Left Side
P42AL Service Manual
INTRODUCTION
1-7
9/30/10
FIGURE 1-4
P42AL Top
1-8
INTRODUCTION
P42AL Service Manual
9/30/10
P42AL Service Manual
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 ma ke 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 Henry Vogt Machine Co. 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
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 three different tube sizes for producing ice 7/8” OD x 1” long, 1 1/8”
OD x 1” long, or 1 3/8” OD x 1” long. The ice is cut to length by a rotating breaker type cutter. Ice
can be produced up to 1 1/2” long by modifying the spacers under the adapter plates (see Chapter 10,
“Ice Length” for modifying instructions). Crushed ice is also available by modifying the cutter and
making minor adjustments to the machine (see Chapter 10, “Crushed Ice”).
RECEIPT OF YOUR TUBE-ICE MACHINE
2. Receipt Of Your Tube-Ice Machine
! CAUTION !
Only service personnel experienced in ammonia refrigeration and
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 !
®
machine is a remote ice producing plant
2-1
9/30/10
2-2
RECEIPT OF YOUR TUBE-ICE MACHINE
P42AL Service Manual
9/30/10
FIGURE 2-1
Model Designation for P-Series Ice Machines
Rated Capacity. The Tube-Ice
®
machine is rated to produce a given amount of ice when operating
under the proper conditions as specified in this manual (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).
P42AL Service Manual
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 3-5 and 3-6.
Machine Room. The machine must be located inside a suitable building and must not be subjected
to ambient temperatures below 50°F (10°C) or above 110°F (43.3°C). Heat radiation from other
sources (sunlight, furnaces, condenser, etc.) and unusual air current may affect the operation of the
machine and should be avoided. The electrical components of the Tube-Ice
NEMA 1. Therefore, the machine should not be located in a hazardous area or sprayed with
water. The machine should be installed in an area where water will not stand, but will readily drain
away from the machine.
Space Requirements. Refer to the space diagrams, Figures 1-2 and 1-4, 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
freezer tubes, extra space will be required.
Foundation. Refer to the space diagrams, Figures 1-2,1-3 and 1-4, 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 Procedures. Your Tube-Ice
unloading and moving the machine to its operation location. Refer to the enclosed drawings for
instructions and illustrations of their use.
P42AL - Machine weight 13,200 lbs.
These figures are intended as a guide to unloading and lifting the P42AL Tube-Ice
Vogt Tube-Ice LLC is not responsible for product damage or personnel injury or loss of life
during the loading or lifting procedure.
INSTALLING YOUR TUBE-ICE MACHINE
3. Installing Your Tube-Ice Machine
®
machine are rated
! WARNING !
Lifting or moving heavy equipment should only be attempted by
competent rigging and hoisting contractors. Never allow personnel
near or under heavy equipment when it is being moved or lifted.
Failure to comply could result in personal injury or loss of life.
! WARNING !
®
machine is provided with lifting lugs for the purpose of
®
machine. The
3-1
9/30/10
3-2
INSTALLING YOUR TUBE-ICE MACHINE
Reference Only
P42AL Service Manual
9/30/10
FIGURE 3-1
P42AL Foundation Layout
P42AL Service Manual
INSTALLING YOUR TUBE-ICE MACHINE
3-3
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FIGURE 3-2
Lifting Procedure for P42AL
3-4
INSTALLING YOUR TUBE-ICE MACHINE
P42AL Service Manual
9/30/10
FIGURE 3-3
Seismic Anchoring Detail for P42AL Tube-Ice Machine
P42AL Service Manual
Piping and Drain Connections. See Figure 1-1 to 1-8 and 3-11 to 3-17 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.
Model
P42AL 11/2” FPT 3/4” FPT
* Mating 4 bolt flange supplied with machine.
** Liquid connection is all purpose coupling.
Make-Up Water In. The water required for ice making must be potable water, safe for human
consumption, and should be of the highest quality available. The best way to determine water
quality is to have a complete water quality analysis by a qualified laboratory.
It is advisable to install a particle filter in the make-up and flushing water lines to trap dirt, sand,
rust, or other solid particles prior to entering the water tank and contaminating the ice. Be sure to
size the filter large enough to meet the water demands of 15 GPM (peak flow), allowing for a
restriction through the filter as it traps these particles. The inlet water pressure should be a minimum
of 40 psi. Refer to TABLE 3-1 for line size and 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, installing a smaller orifice in the flushing
outlet elbow can reduce this blowdown. 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, a common line to the machine can connect
them.
9/30/10
Make-up
Water In
INSTALLING YOUR TUBE-ICE MACHINE
! CAUTION !
Exterior shut-off valves must be provided in the water
inlet lines. The minimum inlet water pressure for
satisfactory operation of the machine is 40 psig.
The maximum allowable pressure is 100 psig.
! CAUTION !
Flushing
Water In
Water
Tank
Drain
Water
Tank
Overflo
w
Low Side
Suction
Connectio
n*
2” FPT 3” FPT 6” SW
104gal/3 min.
Flange
TABLE 3-1
Water Supply, Drain and Refrigeration Connections
(See FIGURE 1-1 through 1-4 for locations)
Low Side
Liquid
Connection*
*
2 1/2” FPT
or SW
Low Side
Thaw Gas
Connectio
n
3” SW
Flange
3-5
3-6
INSTALLING YOUR TUBE-ICE MACHINE
P42AL Service Manual
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 suffecient
thaw gas. Table 3-2 shows the 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.
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
P42AL
RECEIVER VOLUME (Cubic Feet)
With Heating Coil With out Heating Coil
70 100
TABLE 3-2
Receiver Volume Requirements
Thaw Gas Pressure Regulator. The thaw gas pressure regulator is a 2” solenoid operated pressure
combination regulator and shut-off valve (see figures 1-2 and 1-5 for locations). Do not reduce the
size of this line. This valve is deigned 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 P42AL is attached to a central system a n evaporator
pressure regulator will be required (see Figures 3-15 through 3-16 for location). This regulator
(usually furnished by the purchaser) must be a combination back-pressure regulating and open 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. A
throttling by-pass line with a solenoid shut-off and hand valve for regulating flow should accompany
this valve.
Compressor Unloading. When multiple P42AL are attached to a dedicated compressor system
unloading of the compressor may be required. A minimum compressor unloading during the harvest
cycle is 50%. If the compressor can’t be unloaded then a hot gas bypass to the suction line must be
installed.
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P42AL Service Manual
Wiring and Electrical Connections.
A fused disconnect must be provided near the Tube-Ice
transformer (if required) are attached to the structurals on the front of the Tube-Ice
FIGURE 3-11). Incoming 3-phase power will be connected at the cutter motor circuit breaker
(CB3). Terminals L1, L2, L3 for operation of the Tube-Ice® machine and its controls. Rotation
checking of the, cutter 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.
INSTALLING YOUR TUBE-ICE MACHINE
! WARNING !
Only service personnel experienced in refrigeration and qualified
to work with high voltage electrical equipment should be allowed
to install or work with the Tube-Ice® machine.
! WARNING !
®
machine. The control panel and
®
machine (see
3-7
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FIGURE 3-4
Power Supply Connections
3-8
INSTALLING YOUR TUBE-ICE MACHINE
P42AL 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 compressor, 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.
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P42AL Service Manual
4. Push the MANUAL HARVEST button. The water pump will stop, the “Freezing and Liquid
Feed” lights will go out, and after 20-30 seconds, the cutter motor will start. The thawing gas
solenoid valve will open and the “Thawing” pilot light (3LT) will illuminate.
5. Check the cutter disc rotation. It should be turning from left to right (CCW looking from the
top).
6. Turn the HAND-AUTO switch to AUTO to stop the cutter.
To change rotation, follow this procedure:
1. Disconnect power to the machine and lock it out to make sure it can’t be turned back on.
2. Check for power at L1, L2, L3 with a volt meter to make sure it is off.
3. At the cutter motor circuit breaker (CB3) or at the power disconnect, reverse wires L1 and L2.
4. Make sure these terminals are tight and restore power to the machine.
5. Perform rotation check again to confirm that it is correct.
Auxiliary Controls or Equipment. When connecting other equipment such as high/low pressure
swith, conveyor motors, bin level control, etc., refer to the control panel wiring drawing for the
proper connecting terminals and instructions. See Figure 6-3.
INSTALLING YOUR TUBE-ICE MACHINE
! CAUTION !
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.
! CAUTION !
3-9
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3-10
INSTALLING YOUR TUBE-ICE MACHINE
P42AL Service Manual
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FIGURE 3-5
Interconnecting Piping for 2-Vogt P42AL and Central High Side
P42AL Service Manual
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).
INSTALLING YOUR TUBE-ICE MACHINE
! IMPORTANT !
Be sure to follow the wiring schematic when incorporating overloads of
conveyor (5 MOL). Also remove jumpers as instructed.
This is necessary to provide proper
protection for the Tube-Ice® machine and its component parts.
! IMPORTANT !
! CAUTION !
The compressor 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 !
3-11
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