Page 1
03TA
TUBE-ICE®
MACHINE
(Includes models HE60 & P112F)
Part Number 12A4171M07
Revision 3
4/11/14
Service Manual
$5000
Page 2
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.
IMPORTANT: To activate the machine warranty, the Product Registration
Form MUST be completed and returned to the factory promptly after the
official start-up. Product Registration Form is located in the Owners Packet
or can be found online at www.vogtice.com/registration.htm.
Please return to: VOGT ICE, LLC
Suite #19
1000 W. Ormsby Ave.
Louisville, KY 40210
Page 3
VOGT ICE
, LLC, located in
Louisville, Kentucky since 1880.
Sales - (800) 959-8648
Service - (502) 635-3000
Parts - Your Local Distributor
Call your local distributor first for all of your parts and service needs.
4/11/14
Since 1880, Manufacturers of Quality
Tube-Ice® Machines
Page 4
Vogt
Tube-Ice Machines
Installation, Service Manual and Parts Catalog #12A4171M07
03TA Model
Revision 3.0
Page 5
03TA Service Manual
Page No.
1. INTRODUCTION
A Brief History of Our Company .................................................................................................................................. 1-1
Vogt Energy-Savings Tube-Ice® Machines .................................................................................................................. 1-1
Preview ..................................................................................................................................................................... 1-1
Important Safety Notice ................................................................................................................................................. 1-2
Special Precautions To Be Observed When Charging Refrigeration Systems ............................................................... 1-2
Safety Symbols and What They Mean ........................................................................................................................... 1-3
Assembly Drawing Model 03TB Air-Cooled, FIGURES 1-1, 1-2, & 1-3 ..................................................................... 1-4, 1-5, 1-6
Assembly Drawing Model 03TB Water-Cooled, FIGURES 1-4, 1-5, & 1-6 ................................................................ 1-7, 1-8, 1-9
2. RECEIPT OF YOUR TUBE-ICE MACHINE
Inspection ..................................................................................................................................................................... 2-1
Safety Valves ................................................................................................................................................................. 2-1
Machine Room .............................................................................................................................................................. 2-1
Storage (prior to installation and start-up) ..................................................................................................................... 2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Bin Installation .............................................................................................................................................................. 3-1
Setting the Ice Machine on the Bin ................................................................................................................................ 3-1
Ice Chute Location/Machine Footprint, FIGURE 3-1 .................................................................................................... 3-1
Forklift and Blocks Method, FIGURE 3-2 .................................................................................................................... 3-2
Forklift and Ropes or Lifting Strap Method, FIGURE 3-3 ............................................................................................ 3-3
Connections and Space Diagram (Air-Cooled Machine), FIGURE 3-4 ........................................................................ 3-4
Connections and Space Diagram (Water-Cooled Machine), FIGURE 3-5 .................................................................... 3-5
Piping and Drain Connections ....................................................................................................................................... 3-6
Water Supply and Drain Sizes, TABLE 3-1 .................................................................................................................. 3-6
Cooling Tower ............................................................................................................................................................... 3-7
Wiring and Electrical Connection .................................................................................................................................. 3-8
Control Panel Power Connections, FIGURE 3-6 ........................................................................................................... 3-8
Electrical Specifications, TABLE 3-2 ........................................................................................................................... 3-8
Phase Check ................................................................................................................................................................... 3-9
Voltage Unbalance......................................................................................................................................................... 3-9
Current Unbalance ......................................................................................................................................................... 3-9
Air-Cooled Condenser Installation Instructions ............................................................................................................. 3-10
Pounds of Refrigerant To Add Vs. Liquid Line Length, TABLE 3-3 ............................................................................ 3-11
Air-Cooled Condenser Data ........................................................................................................................................... 3-12
Condenser Dimensions, FIGURE 3-7 ............................................................................................................................ 3-13
Condenser Field Piping (Cold Weather Valve Kit), FIGURE 3-8 ................................................................................. 3-14
TABLE OF CONTENTS
Vogt
i
TABLE OF CONTENTS
®
TUBE-ICE® MACHINES
Model 03TA
4/11/14
Page 6
ii
TABLE OF CONTENTS
Page No.
3. INSTALLING YOUR TUBE-ICE MACHINE (Cont.)
Condenser Equivalent Line Size Worksheet .................................................................................................................. 3-15
Equivalent Feet Due To Friction, TABLE 3-5 ............................................................................................................... 3-15
Minimum Traps For Discharge Lines, FIGURE 3-9 ..................................................................................................... 3-15
Air-Cooled Condenser Wiring ....................................................................................................................................... 3-16
Wiring for 2 Fan Condenser, FIGURE 3-10 .................................................................................................................. 3-16
Air-Cooled Connections ................................................................................................................................................ 3-17
Rota-lock Connector Torque Ratings, TABLE 3-6........................................................................................................ 3-17
Pressure Relief Valves ................................................................................................................................................... 3-17
Ice Bin Thermostat Sensor Installation .......................................................................................................................... 3-18
Ice Bin Thermostat Location, FIGURE 3-11 ................................................................................................................. 3-18
Programming the Electronic Ice Bin Thermostat ........................................................................................................... 3-
Storing Ice .................................................................................................................................................................... 3-20
Saigle Ice / Dual Ice ...................................................................................................................................................... 3-20
Installation Review : A Checklist .................................................................................................................................. 3-21
03TA Service Manual
19
4. HOW YOUR TUBE-ICE MACHINE WORKS
Principle of Operation .................................................................................................................................................... 4-1
Freeze Period ................................................................................................................................................................. 4-2
Harvest Period ............................................................................................................................................................... 4-2
Piping Nomenclature, TABLE 4-1 ................................................................................................................................ 4-2
Water-Cooled Piping Schematic, FIGURE 4-1 ............................................................................................................. 4-3
Air-Cooled Piping Schematic, FIGURE 4-2 .................................................................................................................. 4-4
5. START-UP AND OPERATION
Refrigeration System Review ........................................................................................................................................ 5-1
Refrigerant Charge......................................................................................................................................................... 5-1
Start-Up Checklist ......................................................................................................................................................... 5-2
Start-Up ..................................................................................................................................................................... 5-3
Control Panel Switch Layout, FIGURE 5-1 ................................................................................................................. 5-3
Adding Refrigerant ........................................................................................................................................................ 5-4
Operating Tips ............................................................................................................................................................... 5-5
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Control Panel FIGURE 6-1............................................................................................................................................ 6-1
Control Panel (Standard), FIGURE 6-2 ......................................................................................................................... 6-2
Control Panel Door, FIGURE 6-2A ............................................................................................................................... 6-3
Control Panel (Australian & CE approved), FIGURE 6-2B .......................................................................................... 6-4
Description of Control Panel Parts, TABLE 6-1 ............................................................................................................ 6-5
Description of Control Panel Component Function, TABLE 6-2 .................................................................................. 6-6
Electrical Schematic All Voltages 50-60 Hz. (Standard/Australian/CE), FIGURE 6-3 ................................................. 6-7
Compressor Wiring Detail
, FIGURE 6-4 .................................................................................................................. 6-8
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03TA Service Manual
6
7. MAINTENANCE
Ice-Making Section ........................................................................................................................................................ 7-1
Cleaning Procedure ........................................................................................................................................................ 7-1
Sanitizing Procedure ..................................................................................................................................................... 7-2
Water Distributors ......................................................................................................................................................... 7-3
Water Tank .................................................................................................................................................................... 7-3
Water-Cooled Condensers, Checking Operation ........................................................................................................... 7-3
Water-Cooled Condensers, Draining ............................................................................................................................. 7-4
Water-Cooled Condenser Cleaning ............................................................................................................................... 7-4
Lubrication .................................................................................................................................................................... 7-
Compressor .................................................................................................................................................................... 7-6
Cutter Gear Reducer ...................................................................................................................................................... 7-7
Preventive Maintenance ................................................................................................................................................. 7-8
Daily /Weekly / Monthly / Yearly Check List ......................................................................................................... 7-8
Pressure Relief Valve Replacement Note ................................................................................................................ 7-8
Note To Manager or Owner ..................................................................................................................................... 7-9
Preventive Maintenance Program ............................................................................................................................ 7-10
8. TROUBLESHOOTING
List Of Symptoms .......................................................................................................................................................... 8-1
Machine Won’t Run ...................................................................................................................................................... 8-2, 8-3
Freeze-Up Due To Extended Freezing Period ............................................................................................................... 8-4
Freeze-Up Due To Ice Failing To Discharge ................................................................................................................. 8-5
Low Ice Capacity ........................................................................................................................................................... 8-6
Low Compressor Oil Level ............................................................................................................................................ 8-7
Poor Ice Quality ............................................................................................................................................................. 8-8
High Head Pressure (Water-Cooled) ............................................................................................................................. 8-9
High Head Pressure (Air-Cooled) .................................................................................................................................. 8-10
9. SERVICE OPERATIONS
Adjustable Blowdown (For Clearer Ice) ........................................................................................................................ 9-1
Water Pump/ Blowdown Assembly, FIGURE 9-1 ........................................................................................................ 9-1
Automatic Blowdown (Harvest Cycle) .......................................................................................................................... 9-1
Float Valve (Make-Up Water) ....................................................................................................................................... 9-1
Thermal Expansion Valve, FIGURE 9-2 ....................................................................................................................... 9-2
Superheat / Checking Superheat ................................................................................................................................. 9-2
Freezer Pressure Switch ................................................................................................................................................. 9-3
Freezer Pressure Switch (Allen-Bradley), FIGURE 9-3 ................................................................................................ 9-3
High-Low Pressure Switch ............................................................................................................................................ 9-4
High-Low Pressure Switch, FIGURE 9-4 ...................................................................................................................... 9-4
Head Pressure ................................................................................................................................................................ 9-4
Water-Cooled Units ....................................................................................................................................................... 9-4
Air-Cooled Units ........................................................................................................................................................... 9-5
Water Regulating Valve, FIGURE 9-5A ....................................................................................................................... 9-5
Condenser Fan Switch, FIGURE 9-5B .......................................................................................................................... 9-5
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TABLE OF CONTENTS
9. SERVICE OPERATIONS (Cont.)
Oil Separator, FIGURE 9-6 ........................................................................................................................................... 9-6
Solenoid Valve .............................................................................................................................................................. 9-5
Solenoid Valve (“D” & "X" Valve Before Aug 2006), FIGURE 9-7A ......................................................................... 9-6
Solenoid Valve (“D” & "X" Valve After Aug 2006), FIGURE 9-7B ............................................................................ 9-6
Solenoid Valve (“A” Valve), FIGURE 9-7C ................................................................................................................. 9-6
Compressor Crankcase Heater ....................................................................................................................................... 9-7
Compressor Connections, FIGURE 9-8 ......................................................................................................................... 9-7
Sentronic Oil Pressure Safety Control, FIGURE 9-9A .................................................................................................. 9-8
Oil Pressure Sensor .................................................................................................................................................. 9-9
Sentronic Oil Pressure Safety Control ..................................................................................................................... 9-8
CoreSense Protection ..................................................................................................................................................... 9-9
CoreSense Protection Faults / Connection, Figure 9-9B ............................................................................................... 9-10
Control Circuit Protection .......................................................................................................................................... 9-10
Circulating Water Pump Motor, FIGURE 9-10 ............................................................................................................. 9-11
Cutter Gear Reducer, FIGURE 9-11 ........................................................................................................... 9-11
03TA Service Manual
Page No.
Thawing Timer, FIGURE 9-12A ................................................................................................................ 9-12
Thawing Timer Pin Connections, FIGURE 9-12B...................................................................................... 9-12
Condenser Cleaning ....................................................................................................................................................... 9-13
Pump Down ................................................................................................................................................................... 9-13
Removal Of Refrigerant From Machine ........................................................................................................................ 9-13
Refrigerant Leaks........................................................................................................................................................... 9-14
Non-Condensable Gases ................................................................................................................................................ 9-14
Compressor Motor Burnout ........................................................................................................................................... 9-15
Capacity Control Valve (Internal Construction) ............................................................................................................ 9-16
Copeland Compressor Unloader Valve, FIGURE 9-13 ................................................................................................. 9-16
Loaded Operation (Freeze Period), Unloaded Operation (During Thaw Only) ....................................................... 9-16
Component Removal and Replacement Operations ....................................................................................................... 9-17
Cutter Motor ............................................................................................................................................................ 9-17
Water Tank .............................................................................................................................................................. 9-18
Cutter & Bearing ..................................................................................................................................................... 9-18
Cutter/Tank Assembly Nomenclature, TABLE 9-1 ....................................................................................................... 9-19
Cutter, Water Tank & Drive Gear Assembly, FIGURE 9-14 ........................................................................................ 9-20
Water Tank & Pump Assembly, FIGURE 9-15 ............................................................................................................. 9-21
Crushed Ice Production .................................................................................................................................................. 9-22
10. OPTIONS AND ACCESSORIES
Power Monitor, FIGURE 10-1 ..................................................................................................................................... 10-1
Power Monitor Parameters, TABLE 10-1 .................................................................................................................... 10-1
PLC (Programmable Logic Controller) ........................................................................................................................ 10-4
Mitsubishi HMI (E1012), FIGURE 10-2 ...................................................................................................................... 10-5
PLC, FIGURE 10-3 ...................................................................................................................................................... 10-6
PLC, Input / Output Table, TABLE 10-2 ..................................................................................................................... 10-6
Wiring Schematic
, FIGURE 10-24 ............................................................................................................................. 10-6
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03TA Service Manual
11. TABLES AND CHARTS
03TA Ratings (60 Hz., 7.5 HP), TABLE 11-1 ............................................................................................................... 11-1
03TA Ratings (50 Hz., 10 HP), TABLE 11-1 ................................................................................................................ 11-1
03TA Capacity Ratings, TABLE 11-2 ........................................................................................................................... 11-2
03TA Condenser Water Usage, TABLE 11-3 ............................................................................................................... 11-3
03TA Make-up Water Usage, TABLE 11-4 .................................................................................................................. 11-3
03TA Normal Operating Vitals, TABLE 11-5............................................................................................................... 11-3
Recommended Spare Parts List ..................................................................................................................................... 11-4
Temperature - Pressure Chart for Common Refrigerants, TABLE 11-6 ........................................................................ 11-5
Conversion Factors: English to Metric, TABLE 11-7 ................................................................................................... 11-6
Constants, TABLE 11-8 ................................................................................................................................................ 11-6
12. INDEX
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03TA Service Manual
INTRODUCTION
1. Introduction
VOGT ICE
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 , VOGT 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’ icemakers, Tube-Ice®
machines produce the same amount of ice--in restaurants, sports arenas, packing plants, and
wholesale operations around the globe--at great savings.
In addition, Tube-Ice® machines are renowned for their long life, giving many customers more than
35 years of dependable service. Ask someone who owns one.
Preview. All the skill in engineering and fabrication that we have learned in over a century of
experience, is reflected in the 03TA model Tube-Ice® machines. Since Vogt introduced Tube-Ice®
machines in 1938, the process of making Tube-Ice® ice has been widely recognized as the most
economical means of production. The machine’s economic and reliable operations have been proven
over and over again, in a network of varied types of installations throughout the world.
Furnished with your machine is the “Certificate Of Test”--the report of operating data that is a record
of the unit’s satisfactory operation on our factory test floor. It is evidence of our desire to deliver to
you “the finest ice-making unit ever made.”
This manual is designed to assist you in the installation, start-up, and maintenance of your unit.
Your Tube-Ice® machine will give you a lifetime of service when you install it, maintain it, and
service it properly.
Please read your manual carefully before attempting installation, operation, or servicing of this
professionally designed piece of equipment.
If you have additional questions, please call your distributor. Also, feel free to phone the factory
direct at (502) 635-3000 OR 1-800-853-8648.
, LLC
1-1
4/21/14
Page 12
1-2
INTRODUCTION
Important Safety Notice. This information is intended for use by individuals possessing adequate
backgrounds of electrical, refrigeration and mechanical experience. Any attempt to repair major
equipment may result in personal injury and property damage. The manufacturer or seller cannot be
responsible for the interpretation of this information, nor can it assume any liability in connection
with its use.
Special Precautions To Be Observed When Charging Refrigeration Systems. Only technically
qualified persons, experienced and knowledgeable in the handling of refrigerant and operation of
refrigeration systems, should perform the operations described in this manual. All local, federal, and
EPA regulations must be strictly adhered to when handling refrigerants.
If a refrigeration system is being charged from refrigerant cylinders, disconnect each cylinder when
empty or when the system is fully charged. A gage should be installed in the charging line to
indicate refrigerant cylinder pressure. The cylinder may be considered empty of liquid R-22/404A
refrigerant when the gauge pressure is 25 pounds or less, and there is no frost on the cylinder. Close
the refrigerant charging valve and cylinder valve before disconnecting the cylinder. Loosen the
union in the refrigerant charging line--carefully to avoid unnecessary and illegal release of refrigerant
into the atmosphere.
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.
Always store cylinders containing refrigerant in a cool place. They should never be exposed to
temperatures higher than 125°F and should be stored in a manner to prevent abnormal mechanical
shocks.
Also, transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is
not recommended.
It is not recommended that refrigerant be transferred from a refrigeration system directly into
a cylinder. If such a transfer is made, the refrigerant cylinder must be an approved, CLEAN
cylinder--free of any contaminants or foreign materials--and must be connected to an
approved recovery mechanism with a safety shutoff sensor to assure contents do not exceed net
weight specified by cylinder manufacturer or any applicable code requirements.
03TA Service Manual
! CAUTION !
! CAUTION !
! CAUTION !
! CAUTION !
3/31/14
Page 13
03TA Service Manual
Safety Symbols & What They Mean. Prior to installation or operation of the Tube-Ice® machine,
please read this manual. Are you familiar with the installation, start-up, and operation of a Tube-Ice®
machine? Before you operate, adjust or service this machine, you should read this manual,
understand the operation of this machine, and be aware of possible dangers.
These Safety Symbols will alert you
when special care is needed.
Please heed.
! DANGER !
Indicates an immediate hazard and that special precautions
are necessary to avoid severe personal injury or death.
! DANGER !
! 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 and/or product and/or property damage.
! CAUTION !
INTRODUCTION
1-3
3/31/14
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1-4
INTRODUCTION
03TA Service Manual
`
FIGURE 1-1
Assembly (Air-Cooled)
Front View
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03TA Service Manual
1-5
INTRODUCTION
4/21/14
FIGURE 1-2
Assembly (Air-Cooled)
Rear View
Page 16
1-6
INTRODUCTION
03TA Service Manual
4/21/14
FIGURE 1-3
Assembly (Air-Cooled)
Right
Side View
Page 17
03TA Service Manual
1-7
INTRODUCTION
4/21/14
FIGURE 1-4
Assembly (Water Cooled)
Front View
Page 18
1-8
INTRODUCTION
03TA Service Manual
4/21/14
FIGURE 1-5
Assembly (Water Cooled)
Rear View
Page 19
03TA Service Manual
1-9
INTRODUCTION
4/21/14
FIGURE 1-6
Assembly (Water Cooled)
Right Side View
Page 20
1-10
INTRODUCTION
03TA Service Manual
BLANK
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03TA Service Manual
RECEIPT OF YOUR TUBE-ICE MACHINE
2. Receipt Of Your Tube-Ice Machine
! WARNING !
Only service personnel experienced in refrigeration and qualified
to work with high voltage electrical equipment should be allowed
to install or work on this Tube-Ice® machine.
! WARNING !
Inspection As soon as you receive your machine, inspect it for any damage. If damage is suspected,
note it on the shipper’s papers (i.e., the trucker’s Bill of Lading). Immediately make a separate
written request for inspection by the freight line’s agent. Any repair work or alteration to the
machine without the permission of Vogt Ice, LLC can void the machine’s warranty.
The machine was shipped with a full charge of refrigerant stored in the receiver. Visually check all
lines for mechanical damage. If a leak is suspected, check all joints with a Halogen Leak Detector.
All leaks should be reported to Vogt Ice, LLC to obtain authorization for repair.
! CAUTION !
The approximate weight of the machine is 2000 pounds. Always use
equipment with adequate load carrying capacity.
! CAUTION !
The machine frame has lifting lugs at each corner in the top for eyebolts and hooks to be used for
lifting purposes if desired. Lifting lugs should be used whenever possible.
! CAUTION !
The Tube-Ice® machine is top heavy.
Secure to avoid tipping.
! CAUTION !
If a forklift is used, make sure its capacity is sufficient. The forks must be wide enough apart to
prevent tipping sideways and must extend beyond the extremities of the frame base structure. The
machine needs to be bound in place to prevent tipping.
Safety Valves Safety pressure relief valves are an integral part of the packaged Tube-Ice® machine.
One is located in the low-side of the system on the freezer, one is in the high side of the system on
the receiver, and one is on the condenser. Vent each of the pressure relief valves to the atmosphere
in such a manner as to comply with local and national codes.
Machine Room The machine must be located inside a suitable building and must not be subjected to
ambient temperatures below 50°F (10°C) or above 110°F (43.3°C). Heat from other sources
(sunlight, furnaces, condenser, etc.) and unusual air currents may affect the operation of the machine
and should be avoided. The electrical components of the Tube-Ice® machine are rated NEMA 1.
Therefore, the machine should not be located in a hazardous area or sprayed with water. The
machine should be installed on a drainable condensate drip pan or in an area where water will not
stand but will readily drain away from the machine. See Space Diagram for clearances and utility
connections, FIGURES 3-4A,3-4B and 3-5.
2-1
3/31/14
Page 22
2-2
"8" - 2"
Product Variation Codes
(
RECEIPT OF YOUR TUBE-ICE MACHINE
Storage (prior to installation or start-up) The machine must not be stored or installed in an area
that may reach temperatures 115°F (46.1°C) or above.
This equipment contains HCFC-22 or HFC-404a refrigerant under pressure.
Do not store in an area exposed to temperatures above 115°°°°F (46°°°°C)
or in direct sun at temperatures above 105°°°°F (40°°°°C).
The machine nameplate is located on the front of the control panel. The model number and machine
description are located in the top left hand corner. The following figure can be used to verify that
the correct model has been received.
03TA Service Manual
! CAUTION !
! CAUTION !
Nominal Capacity
"02K" - 2000 lbs/day ("K" = 1000's lbs/day, "T" = tons/day)
"03K" - 3000 lbs/day
"04K" - 4000lbs/day (Consult Specifications for Actual Capacity)
"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"
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.
Model Variation
A number assigned to indicate major
variations within any one family series.
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
Type of Ice
"B" - Cylinder
"K" - Crushed
"D" - Dual Ice (Cru & Cyl)
"L" - 1 1/2" Long Cylinder
"X"- 2” Long Cylinder
Figure 2-1
Vogt Model Nomenclature
XXXX – XXXX – XXXX – XXX
Condenser Type
"AC" - Air Cooled
"WC" - Water Cooled
"HP" - High Pressure Water Cooled
"SW" - Sea Water
"NC" - No Condenser
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03TA Service Manual
PLAN
MINIMUM BIN OPENING - 6 1/2" x 6 1/2"
MAXIMUM BIN OPENING - 7" x 7"
FRONT OF MACHINE
INSTALLING YOUR TUBE-ICE ®MACHINE
3-1
3. Installing Your Tube-Ice
! WARNING !
Only service personnel experienced and certified in refrigeration and qualified to work
with high voltage electrical equipment should be allowed to install or work
on this Tube-Ice® machine.
! WARNING !
Important Notice.
®
Machine
To activate the machine warranty, the Product Registration Form MUST be
completed and returned to the factory promptly after the official start-up.
Product Registration Form is located in the Owners Packet or can be found
online at www.vogtice.com/registration.htm.
Bin Installation
Screw these legs to the bottom of the bin. You can make MINOR leveling adjustments by using
these legs as leveling screws, as outlined in the manufacturer’s instructions.
Set the bin on solid, level footing. Inside the bin you will find the four legs.
Setting the ice machine on the ice bin
machine can be elevated and placed on the bin top. Using the dimensions in FIGURE 3-1 below,
mark the machine footprint on the bin top by measuring over from the ice chute opening.
Once the ice storage bin is level, the Tube-Ice®
ICE BIN
CHUTE SIZE - 5 5/8" X 5 5/8"
4'-2"
6 1/2"
6 1/2"
2'-3 1/16"
2'-5"
1'-2 1/4"
Ice Chute Location/Machine Footprint
FIGURE 3-1
Page 24
3-2
CONTROL PANEL
& SWITCH BOX
INSTALLING YOUR TUBE-ICE® MACHINE
03TA Service Manual
FIGURES 3-2 & 3-3 illustrate two methods of lifting & setting Tube-Ice machine on an ice storage
bin.
! CAUTION !
The approximate weight of the machine is 2000 pounds.
Always use equipment with adequate load-carrying capacity.
! CAUTION !
REMOVE CASINGS FROM MODEL HE60
BEFORE PLACING MACHINE ON BIN
TUBE-ICE MACHINE
WOOD BLOCKS
TWO (2) EACH CORNER
ICE STORAGE BIN
FIGURE 3-2
You need:
Forklift-&-Blocks Method
forklift truck with adequate load and height capacities
(8) 2X4 wood blocks 8 in. long
(2) wooden 2X4’s measuring 3-ft. long
pry bar
Step 1. Position Tube-Ice machine on forks.
Step 2. Stack wood blocks in each corner of the drip pan on top of the ice storage bin.
Step 3. Lift and set Tube-Ice machine on wood blocks.
Step 4. Remove forklift.
Step 5. Stack 3-ft. long 2X4’s beside drip pan, overlapping front and back of bin.
Step 6. Using a pry bar with fulcrum on 2X4’s, raise side of machine enough to remove TOP wood
blocks.
! CAUTION !
Do not remove top AND bottom blocks at the same time.
! CAUTION !
Step 7. Repeat steps 5 and 6 on other side.
Step 8. With machine sitting on one (1) block under each corner, repeat steps 5, 6, and 7 remove
Step 9. Straighten bent drip pan flanges.
Step 10. Check alignment of ice chute to bin opening.
4/2/14
remaining blocks. Drip pan flanges may bend slightly.
Page 25
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
REMOVE CASINGS FROM MODEL HE60
BEFORE PLACING MACHINE ON BIN
ROPE OR STRAPS
TUBE-ICE MACHINE
ICE STORAGE BIN
3-3
FIGURE 3-3
Forklift-&-Rope or Lifting Straps Method
You need:
extra head room
forklift with adequate load and height capacities
1/2” rope or four lifting straps to bind forks to top angles
Step 1. Remove front, rear, and top access panels.
Step 2. Position fork truck so that forks are resting flat on top angles of Tube-Ice®
machine.
Step 3. Use the rope or straps to securely bind forks to the top angles.
! CAUTION !
Be sure the bin is level and is set in its proper location.
See the space diagram, FIGURE 6.
! CAUTION !
Step 4. Lift Tube-Ice® machine and set into drip pan of bin.
Step 5. Remove rope or straps and fork truck.
Step 6. Check alignment of ice chute to bin opening.
Page 26
3-4
INSTALLING YOUR TUBE-ICE® MACHINE
9 11/16"
ROTA-LOCK TEFLON SEAL
PART # 12A2600T03
ROTA-LOCK FIELD CONNECTOR
PART # 12A2396A0601
1 3/4"-12 THREADS(F) X 1 3/8" IDS
FIELD ATTACHMENT FOR AIR
COOLED CONDENSER TUBING
ROTA-LOCK FIELD CONNECTOR
(FITINGS SUPPLIED WITH MACHINE)
Connections and Space Diagram (Air Cooled Machine)
03TA Service Manual
LINE
DISCHARGE
5'-4 11/16"
LINE
LIQUID
RETURN
5'-1 9/16"
TOP VIEW
AIR COOLED CONDENSER
LINE SHOWN
ALLOW 12" MINIMUM CLEARANCE ABOVE
UNIT FOR INSTALLATION AND ACCESS
6'
1"
PART # 12A2396A0501
ROTA-LOCK TEFLON SEAL
PART # 12A2600T01
1 1/4"-12 THREADS(F) X 1 1/8" IDS
ALLOW 40" MINIMUM CLEARANCE
FOR COMPRESSOR ACCES
1'-11"
ALLOW 40" MINIMUM CLEARANCE
FOR WATER TANK ACCES
WATER CONNECTION
1/2" MPT MAKE-UP
DRAIN CONNECTION
3/4" FPT WATER TANK
(LOCATED ON THE BACK OF UNIT)
ALLOW 24" MINIMUM
FOR CONDENSER LINE ACCES
CLEARANCE BEHIND UNIT
LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW
FIGURE 3-4A
4/2/14
Page 27
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
ALLOW 12" MINIMUM CLEARANCE ABOVE
UNIT FOR INSTALLATION AND ACCESS
6'-1 3/8"
1"
ALLOW 40" MINIMUM CLEARANCE
FOR COMPRESSOR ACCES
1'-11"
11 1/4"
ALLOW 40" MINIMUM CLEARANCE
WATER IN CONNECTION
1 1/4" FPT CONDENSER
WATER OUT CONNECTION
1 1/4" FPT CONDENSER
FOR WATER TANK ACCES
6 5/16"
4 1/16"
8 1/16"
DRAIN CONNECTION
3/4" FPT WATER TANK
(LOCATED ON THE BACK OF UNIT)
WATER CONNECTION
1/2" MPT MAKE-UP
5 1/8"
ALLOW 24" MINIMUM
FOR CONDENSER LINE ACCES
CLEARANCE BEHIND UNIT
TOP VIEW
CONDENSER CONNECTION SHOWN
2'-5"
LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW
FIGURE 3-4B
Connections and Space Diagram (Water Cooled Machine)
3-5
Page 28
3-6
Condenser
INSTALLING YOUR TUBE-ICE® MACHINE
Piping and Drain Connections
Figure 3-4A (Air Cooled) and 3-4B (Water Cooled) show locations and sizes for all connections.
• The condenser water outlet and water tank drain connections must be extended separately to an
4/2/14
03TA Service Manual
! CAUTION !
External shut-off valves must be provided in the water inlet lines.
The minimum inlet water pressure for satisfactory operation of the machine is 30 psig.
The maximum allowable pressure is 100 psig.
! CAUTION !
Make-up
Water In
1/2” MPT 3/4” FPT 1 1/4” FPT 1 1/4” FPT
open drain or sump, arranged for visible discharge. Do not trap the water tank drain line, as
this will interfere with the operation of the automatic blowdown system. A 20 mesh strainer,
supplied with the machine, should be installed in the supply line to the condenser.
These lines must NOT be connected into a pressure tight common header
due to the possibility that warm condenser water may back up into the water tank.
The condenser water outlet MUST be piped separately to the drain.
Water Tank
Drain*
TABLE 3-1
Water Supply and Drain Sizes
! CAUTION !
! CAUTION !
Condenser Water
In
Water Out*
Page 29
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
Water-Cooled Connections
Connect water supply to the water regulator valve on condenser water inlet connection (bottom
connection on condenser). Connect the condenser water out line to the top connection on the
condenser.
1 1/4” FPT
Condenser
Water Outlet
1 1/4” FPT
Condenser
Water Inlet
FIGURE 3-5
Water Cooled Condenser Connections
Cooling Tower.
For water cooled machines only. When selecting a cooling tower, careful attention must be given
to operating wet bulb conditions. It is advisable to check with your local cooling tower distributor
for their recommendations based on actual operating conditions in your area. An average wet-bulb
of 78°F is typical in the U.S. but many localities have design wet-bulbs as low as 72°F or as high as
82°F.
The cooling tower water pump must be capable of delivering the required volume of water through
the condenser. Due to cooling tower location and pressure drop through water lines and water
regulating valves, the pump must be sized for each installation. Refer to TABLE 11-1 for condenser
water requirements. The water piping for the cooling tower and the installation of the pump must be
in accordance with the manufacturer’s instructions.
Proper water treatment for the prevention of mineral and foreign matter accumulation in the
condenser or cooling tower is recommended. A water analysis should be obtained to determine the
proper chemicals to use.
3-7
Page 30
3-8
Power for Condenser control circuit (11 & 22)
INSTALLING YOUR TUBE-ICE® MACHINE
Wiring and Electrical Connection
Only service personnel experienced in refrigeration and qualified to work with high voltage
electrical equipment should be allowed to install or work on the Tube-Ice® machine.
Refer to TABLE 3-2 below to properly size wiring connections. A fused disconnect must be
provided near the Tube-Ice® machine. Connect 3 phase power, L1, L2, L3 to the power distribution
block (PDB) for operation of the Tube-Ice® machine and its controls. Rotation checking of cutter
motor and water pump is required (see following section). Also, if one leg of the 3 phase power is
higher or lower (“Wild”), then it should be connected to terminal #L2. Connect the “Ground” wire
to the “Ground” lug provided.
MAIN MACHINE POWER
Incoming power to be connected to
Power Distribution Block (PDB)
AIR COOLED CONDENSER CONNTECTIONS
Standard Voltages
208/230, 3ph, 60 Hz 48.3 58.6 100 54.3 64.6 110
460, 3ph, 60 Hz 23.7 28.7 50 26.4 31.4 55
200, 3ph, 50 Hz 50.9 61.8 110 57.5 68.4 115
400, 3ph, 50 Hz 24.2 30.4 55 27.2 32.2 55
4/2/14
! WARNING !
! WARNING !
FIGURE 3-6
Control Panel Power Connections
Water Cooled Air Cooled
F.L.A. Min.
Ampacity
Max. Fuse F.L.A. Min.
TABLE 3-2
Electrical Specifications
03TA Service Manual
AUX CONNECTIONS
Cutter Motor, Pump Motor &
Compressor Interlocks
AIR COOLED CONDENSER
CONNTECTIONS
Power for Fan Motors (B7, B8 & B9)
Max. Fuse
Ampacity
Page 31
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
Phase Check
! CAUTION !
DO NOT attempt to start machine without priming pump
and insuring proper rotation of both cutter and pump.
Refer to FIGURE 3-4A & 3-4B (space diagram) for connection locations.
! CAUTION !
Cutter and pump motor rotation are factory synchronized but must be checked at installation. For
ice production, the cutter disc, as viewed at the ice discharge opening should turn from left to right
(crushed rotation should be from right to left). The pump rotation should match the marking on the
pump housing. The pump will need to be primed by starting the machine in the clean mode and
allowing it to run for several minutes. To change direction of rotation for both, cutter and pump,
disconnect power and reverse L1 and L3 (incoming power wires) at the compressor motor contactor.
Voltage Unbalance
Voltage unbalance can cause motors to overheat and fail.
The maximum voltage unbalance between any two legs should be no greater than 2%.
Example: Supply Voltage = 230-3-60
Voltage Readings: AB = 220 Volts
BC = 225 Volts Average = (220 + 225 + 227)/3 = 224 Volts
AC = 227 Volts
(AB) 224-220 = 4 Volts (Highest Deviation)
(BC) 225-224 = 1 Volts % Voltage Unbalance = 100 x (4/224) = 1.78% “Acceptable”
(AC) 227-224 = 3 Volts
Important: If the supply voltage phase unbalance is more the 2%, contact your local electric
utility company.
Current Unbalance
Voltage unbalance will cause a current unbalance, but a current unbalance
does not necessarily mean that a voltage unbalance exists. A loose terminal connection or a buildup
of dirt or carbon on one set of contacts would cause a higher resistance on that leg than on the other
two legs. Current follows the path of least resistance, therefore if terminal connection L1 is loose or
dirty, L2 and/or L3 will have higher current. Higher 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) % Current Unbalance = 100 x (4/95) = 4.2% “Acceptable”
(L3) 98-95 = 3 Amps
3-9
Page 32
3-10
INSTALLING YOUR TUBE-ICE® MACHINE
Air-Cooled Condenser Installation Instructions
These installation guidelines must be followed to obtain
reliable operation from air cooled ice machines.
IF THESE GUIDELINES ARE NOT FOLLOWED THE
COMPRESSOR WARRANTY WILL NOT BE HONORED.
1. Use only Vogt approved condensers. Any exceptions to this policy must be obtained in writing
from Vogt prior to installation and operation of the ice machine.
2. Outdoor condensers must be installed with vertical air flow. Indoor condensers used for heat
recovery may be installed with either horizontal or vertical air flow.
NOTE: Condenser must be ordered for horizontal air flow.
3. The condenser must be mounted above the ice machine.
4. Horizontal runs in the liquid return line should slope 1/4” per foot with liquid refrigerant
draining freely in the direction of normal operating flow (back to the ice machine) with no traps
in the liquid line.
03TA Service Manual
! WARNING !
! WARNING !
5. Horizontal runs in the discharge line should slope 1/4” per foot in the normal direction of flow
(away from the ice machine).
6. Traps must be installed in discharge lines at the base of all vertical risers. There should be no
intentional traps in liquid lines. Trap volume should be kept to a minimum. Long vertical rises
should have traps every 20 feet. Typical details are shown in FIGURE 3-9.
7. Flooding head pressure controls such as Alco Headmaster are not to be used since they cause
excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest.
8. The discharge and liquid lines must be insulated with 1/2” thick Armaflex insulation or equal.
9. Use only ACR grade copper pipe, Type L. Recommended line sizes are shown in TABLE 3-3.
10. For field attachment instructions, see FIGURE 3-4 A.
11. Distance between ice machine and condenser must not exceed 150 equivalent feet. Refer to
Condenser Equivalent Line Size worksheet (see TABLE 3-4 ).
12. Condensers must be provided with a cold weather valve kit per FIGURE 3-8. These valves
allow one-half of the condenser to be disabled in cold weather. Running the ice machine with
one-half of the condenser in cold weather makes it easier to maintain minimum necessary
condensing pressure particularly in windy conditions.
4/2/14
13. Condensers with multiple fans must be provided with a thermostat (see FIGURE 3-10) to turn
off unneeded fans in cold weather. Turning off unneeded fans reduces on-off cycling of the
fan(s) and allows for a steadier condensing pressure and more consistent warm gas for ice
harvesting.
14. When extreme cold conditions are expected or encountered (temperatures below 0°F and wind
greater than 15 MPH), it may be necessary to install a protective enclosure around the condenser.
Apparatuses such as louvers may also be used for varying conditions. Contact the factory for
suggestions.
Page 33
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
3-11
15. After installation, the field installed lines are to be evacuated to a vacuum of 500 microns or less
and held for at least one hour. After the vacuum pump is removed, vacuum should hold at 500
microns or less for at least 5 minutes.
16. The machine is shipped with a full operating charge of refrigerant sufficient to fill the condenser
and connecting lines. If the condenser piping is longer than 50 feet (one way), additional R-22
or R-404a may need to be added to retain enough refrigerant in the receiver for thawing purposes
(see table. Refer to the operating level mark on the receiver and charge accordingly. Each 1” of
liquid level in the receiver equals approximately 5.5 pounds of R-22 or R-404a.
Liquid Line Size 75 ft. 100 ft. 125 ft. 150 ft.
1/2” none None None 2
5/8” none 2 4 6
7/8” none 4 8 12
1-1/8” none 6 12 18
TABLE 3-3
Pounds of R-22 / 404A to Add vs. Liquid Line Length
17. All piping must be done in accordance with applicable local and national codes. Such codes may
include “The Safety Code For Mechanical Refrigeration” (ANSI B9.1) and “The Code For
Refrigerant Piping” (ANSI B31.5).
18. The following installation guidelines are strongly suggested. While they do not affect the
machine warranty, they may be required for safe operation and to comply with all applicable
electrical and mechanical codes:
a. Local electrical code must be checked for wiring method.
b. The installer must provide a disconnect switch(s) adjacent to the condenser.
c. Electrical connections between the condenser and the Tube-Ice® machine require
minimum 12 ga. wire.
d. All electrical fittings and components exposed to the weather must be suitable for
outdoor installation.
The design total heat rejection for each Tube-Ice® machine, the recommended air-cooled condenser,
and condenser physical and electrical data are shown on the next page. Specified energy efficiency
ratings of the ice machines are based on use of the recommended condenser and approved piping
practices.
Recommended condensers provide the indicated total heat rejection at 90°F ambient, 100°F
condensing. Vogt Ice, LLC is not responsible for head pressure problems if other than the
recommended condensers are used. For continuous operation at ambient temperature above 105°F,
consult the factory about using a larger condenser.
Page 34
3-12
INSTALLING YOUR TUBE-ICE® MACHINE
Ice Machine Model 03TA (Standard) 03TA (High Ambient)
Electrical Frequency, Hz. 60/50 60/50
Recommended Condenser
Total Heat Rejection (BTU/hr) 157,500 / 144,900 172,500 / 159,700
Fans:
Number
HP, Each
Total CFM
Full Load Amps (FLA):
3 ph., 208/230V, 60 hz.
3 ph., 460V, 60 hz.
3 ph., 200V, 50 hz.
3 ph., 380V, 50 hz.
Weight, lbs.:
Net
Shipping
Operating (Maximum flooded) R-404a
Condenser Dimensions, inches
A (Width)
B (Length)
C (Height)
D (Leg centerline)
E (Leg centerline)
F (Clearance below)
Recommended Line Sizes, OD
Liquid
All lengths and orientations
Discharge Gas
Vertical Up, all lengths
Horiz. or Down, < 75 ft.
Horiz. or Down > 75 ft.
Connections at Condenser:
Liquid (ODV)
Discharge Gas (ODV)
Connections at Ice Machine:
Liquid (ODV)
Discharge Gas (ODV)
BNHS02A011 BNHS02A011(12)
580
760
610
(See Fig. 3-7)
TABLE 3-4
Air-Cooled Condenser Data
03TA Service Manual
2
1 1/2
20,500
14.0
7.0
14.0
7.0
585
765
615
45.46”
127”
49.15”
38”
106.15”
20.5”
7/8”
1 1/8”
1 1/8”
1 3/8”
1 1/8”
1 3/8”
1 1/8"
1 1/8"
4/2/14
Page 35
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
3-13
FIGURE 3-7
Condenser Dimensions
Machine Bohn Part # Vogt Part # Coil Split
P112 (Standard) BNHS02A011 12A2115B07 50/50
P112 (High Ambient) BNHS02A011(12) 12A2115B08 50/50
Note: Condensers listed above are 200/208/230V, 50/60hz. 400/460V, 50/60hz available
Page 36
3-14
INSTALLING YOUR TUBE-ICE® MACHINE
Note: Liquid return lines are customer supplied. The Check Valve in the return line (labeled “Output
Liquid Return Line”) is supplied with the condenser.
03TA Service Manual
FIGURE 3-8
Condenser Field Piping / 50-50 Coil Split
4/21/14
Page 37
03TA Service Manual
Fitting Type
Number Used
Factor
Total
90°
Elbow
45°
Elbow
Tee (90
° turn through)
Tee (90
° straight through)
INSTALLING YOUR TUBE-ICE ®MACHINE
3-15
CONDENSER EQUIVALENT LINE SIZE WORKSHEET
Discharge Gas Line O.D. ___________________
Globe Valve (open)
Angle Valve (open)
Feet of Straight Copper Used
Tee
Total Fitting Factor
Total Equivalent Feet
Copper Tube O.D. Type “L” 5/8" 7/8" 1 1/8” 1 3/8” 1 5/8” 2 1/8"
Globe valve (open)
Angle valve (open)
90o Elbow
45o Elbow
16 22 28 36 42 57
9 12 15 18 21 28
2 2 3 4 4 5
1 1 1.5 2 2 2.5
4 5 6 8 9 12
1 1.5 2
TABLE 3-5
Equivalent Feet Due To Friction
2.5
2.8
3.5
*Note: Each recommended line size is based on use of Type “L” copper tubing at a maximum
equivalent distance of 150 feet. See TABLE 3-5 for equivalent feet of valves and fittings.
FIGURE 3-9
Minimum Traps For Discharge Lines
Page 38
3-16
INSTALLING YOUR TUBE-ICE® MACHINE
Air-Cooled Condenser Wiring
Wiring For BOHN BNHS02A011/BNHS02A011(12) with Cold Weather Valve and
03TA Service Manual
FIGURE 3-10
Two Fan, 50/50 Condenser Split
4/21/14
Page 39
03TA Service Manual
Spud Size
Amount of Torque
7/8”
50-
60 FT LBS
1 1/8”
80-
100 FT LBS
1 3/8”
100-110 FT LBS
INSTALLING YOUR TUBE-ICE ®MACHINE
Air-Cooled Connections
(See FIGURE 3-4 A for connection sizes)
3-17
Follow these procedures to make a tight joint:
1. Silver solder or braze condenser tubing ends to the female Rota-lock connectors.
2. Remove dust caps if used, making sure that component plastic seals are intact.
3. Wipe off connector and spud threaded surfaces with a clean cloth to prevent the inclusion
of dirt or any foreign material in the system.
4. Connector coupling nut should be screwed onto Rota-lock spud using the proper amount
of torque.
TABLE 3-6
Rota-lock Connector Torque Ratings
Pressure Relief Valves
Pressure relief valves are installed on the freezer, receiver and the
water cooled condenser. These valves are designed to vent in emergency conditions. This ensures
vessel internal pressure does not exceed maximum allowable pressures.
Vent the relief valve outlet to a safe outdoor location in the approved manner away from people and
building openings. Vent line piping must have drain line at low point to drain condensate from line
per ASME Boiler and Pressure Code, Section VIII, Division 1.
PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE.
BEFORE REPLACING RELIEF VALVE, REVIEW REQUIREMENTS PER CURRENT
LOCAL AND NATIONAL CODE.
VALVE REPLACEMENT SHOULD BE MADE BY PROPERLY TRAINED PERSONNEL ONLY.
NOTE: IF RELIEF VALVE DISCHARGES, VALVE MUST BE REPLACED AFTER DISCHARGING
BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED.
CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES.
PHONE: 502-635-3000
Page 40
3-18
INSTALLING YOUR TUBE-ICE® MACHINE
Ice Bin Thermostat Sensor Installation Each machine is equipped with an electronic ice bin
thermostat. To assure proper protection for the machine, the sensor of the ice bin thermostat must be
located so that ice will contact it when the bin is full (See FIGURE 3-11). The distance between the
ice chute and the sensor allows space for the machine to make an additional discharge of ice AFTER
the ice contacts the probe WITHOUT the ice building up into the discharge opening of the chute
Note: The probe should also be mounted on the back side of the bracket, opposite of the front of the
bin to reduce the possibility of damage from ice removal equipment.
The control panel is electrically connected so that the bin thermostat will stop the machine only upon
the completion of a harvest period.
When both cylinder and crushed ice are produced and separately stored in a divided bin, the control
sensor of thermostat BT2 is placed in the crushed ice section of the storage bin (left side) and the
control sensor of thermostat BT1 is placed in the cylinder ice section (right side of bin).
Note:
Drip loop not necessary for Electronic Thermostat
03TA Service Manual
.
4/2/14
FIGURE 3-11
Ice Bin Thermostat Location
Page 41
03TA Service Manual
READING
CONNECTION
CONNECTION
INSTALLING YOUR TUBE-ICE ®MACHINE
3-19
Programming the Electronic Bin Thermostat
The electronic bin thermostat has an LCD readout that displays the temperature in the bin at the sensor.
The control has been preset and locked out at the factory to shut the machine down at 38°°°°F and
to re-start at 40°°°°F. The control retains the program even if power is cut to the machine. Under special
conditions, the settings may need to be changed. The lockout switch is located on the inside of the
control. Removal of the four screws on the face of the control will reveal the lock-switch.
Follow the instructions below to reset the switch.
1. Press the “SET” button to enter the sensors setup mode
2. Select between “C”- Celsius and “F” - Fahrenheit
Use the up ↑ or down ↓ key to select “F”
3. Press the “SET” button to set the Set point (S1 will be blinking)
Use the up ↑ or down ↓ key to set the temperature at 38°F
4. Press the “SET” button to set the Differential (DIF 1 will be blinking)
Use the up ↑ or down ↓ key to set the differential at 2°F
5. Select between “C1”- Cooling mode and “H1” - Heating mode
Use the up ↑ or down ↓ key to select “C1”
Machine will shut off when temperature drops to 38
°
F and come on when temperature reaches 40°F.
Note: The sensor will automatically exit the programming mode if no keys are depressed for a period
of thirty seconds. Any settings that have been input to the control will be accepted at that point.
DIGITAL TEMPERATURE
SENSOR
SENSOR POWER
CONTROL CIRCUIT
FIGURE 3-12
Electronic Thermostat
Note: If damaged, the sensor can be replaced without replacing entire unit.
Replacement sensor part #12A2117G0901. Electronic temperature control part #12A2117G09.
Sensor cable can be extended up to 400 feet. For more information, consult Tube-Ice
Service Department.
®
Technical
Page 42
3-20
INSTALLING YOUR TUBE-ICE® MACHINE
Storing Ice. When storing ice in a bin, make sure the bin control sensors are mounted in the bin
properly. Dual ice machines require a storage bin with a divider and must have two bin controls.
A machine making one type of ice will not have a bin divider and will require only one bin control. If
the machine is making cylinder ice, the sensor should be mounted on the right side of the bin. If
making crushed ice, the sensor should be mounted on the left side of the bin.
Ice Bin Capacity. Crushed or cylinder ice weighs approximately 35 pounds per cubic ft. (35 lb/ft3 ).
As ice drops into a bin, it will pile up and slope naturally at about a 45° angle. This natural slope
should be taken into account when locating the bin thermostat bulb (or other bin level control) and
when calculating the normal bin capacity. If the ice is spread out by hand in the bin for maximum
storage capacity, make sure a hazard is not created by allowing ice to back up into the chute and
jamming the cutter. Always allow enough room below the chute for at least one harvest (cylinder
ice = 62 lbs. / cycle , crushed ice = 48 lbs. / cycle).
If a two-way defector is installed below the ice chute, care should be taken to make sure it is located
directly in the center of the stream of ice as it falls to give even distribution of the ice.
When ice bin thermostats are NOT used. With the selector switch set on either “Auto” or “Cyl” ice,
the machine will produce cylinder ice only. If the switch is changed to “Cru” while the unit is
producing cylinder ice, after the first 5 minutes of a cycle, it will complete the freeze and harvest of
cylinder ice before changing to the production of crushed ice. The next cycle will produce crushed ice.
03TA Service Manual
With the switch set on “Cru” the machine will produce crushed ice. If the switch is changed to “Both
Auto” or “Cyl” within the first 5 minutes of a cycle, the unit will revert immediately to the production
of cylinder ice.
If an alternate bin level control is used, it must be located in a position to stop the machine prior to ice
backing up into the ice chute and jamming cutter.
Single Ice Type.
No Divider in bin (cylinder or crushed ice). With the selector switch on “Ice”, the machine will
produce either cylinder or crushed ice. The machine will contain only one freezer pressure switch (FPS)
and one bin Control (BC), and two selector switches (SS1 (Ice/Clean) & SS2 (On/Off), the reversing
relay (R) is not included. The machine will also be supplied with an ice chute without an ice deflector
door assembly.
Dual Ice Type (crushed and cylinder).
Divider in bin (cylinder and crushed ice separately stored). With the selector switch on “Auto”, the
machine will automatically produce cylinder ice until the cylinder-ice bin is filled. This action will
open the cylinder ice thermostat switch in the cylinder ice bin and will automatically change the
machine over to crushed ice production--provided the crushed bin is not full. When the crushed ice bin
is filled, its thermostat switch opens and stops the machine upon completion of the harvest cycle.
With the selector switch set on “Cru”, the machine will produce crushed ice until the bin is filled and
the thermostat switch opens. It will then shut down at the completion of the thawing period. If the
switch is changed to “Auto” or “Cyl” within five minutes of the machine starting crushed ice freeze, it
will not switch immediately to the production of cylinder ice.
4/2/14
The machine will never stop by action of the bin thermostat during any freezing operation. It will
always complete the evacuation and discharge of all the ice and completion of a cycle regardless of the
causes which open either thermostat switch.
Page 43
03TA Service Manual
INSTALLING YOUR TUBE-ICE ®MACHINE
3-21
! IMPORTANT !
Be sure to follow the wiring schematic and electrical
specification table when incorporating overloads.
This is necessary to provide proper protection
for the Tube-Ice
machine and its component parts.
! IMPORTANT !
Installation Review: A Checklist. Make a visual check to be sure these steps have been taken
BEFORE continuing.
CHECK: ____ PRIOR TO OPENING VALVES, check all joints for leaks which may have
developed during shipment.
(NOTE: the machine was shipped with a positive pressure of 20-25 PSIG, verify on
the freezer pressure gage.)
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
! CAUTION !
The compressor crankcase heater should be energized for a minimum of
Two (2) hours before attempting to start the compressor.
! CAUTION !
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03TA Service Manual
Principle of Operation For a detailed description of the functions of each control panel component,
see Section 6. “Clean/Off/Ice”, “Start” and “Stop” switches located in the control panel of the
freezing unit control operation of the machine. Automatic operation can be controlled by an optional
ice bin thermostat, which will automatically stop and start the ice maker by the level of the ice in the
storage bin (NOTE: See FIGURE 3-11, “Ice Bin Thermostat Location” for instructions on
installation of the control sensor of the ice bin thermostat(s)). The type ice produced (cylinder or
crushed) is determined by how the machine cutter is set-up (cylinder is standard, crushed or
automatic is optional). The control wiring is arranged so that the unit will stop only upon the
completion of a thawing period whether by action of the “Clean/Off/Ice” switch in the “Off”
position or the ice bin thermostat.
The “Clean/Off/Ice” switch must always be set in the “Ice” position during normal ice-making
operation. It is set in the “Clean” position only when the equipment is to be cleaned as outlined in
the “Cleaning Procedure” (Section 7) and instructions shown on the water tank cover.
If it should become necessary to instantly stop the machine, push the “Stop” button. To restart the
machine, push the “Start” button. The machine will restart in a harvest, to clear out any ice
remaining in the freezer, if stopped during a freeze period.
FIGURES 4-1 & 4-2 illustrate the piping diagram of the refrigerant and water circuits of the TubeIce® machine with numbers for easy reference. Throughout this manual, the numbers you see in
parentheses refer to the numbers in this piping schematic.
The freezer (2) is a shell and tube-type vessel. During the freezing period, water is constantly
recirculated through the vertical tubes of the freezer by a centrifugal pump (6). Make-up water is
maintained by a float valve (12) in the water tank (7). The liquid feed solenoid valve (20),
sometimes referred to as the “A” valve, is open and the thawing gas solenoid valve (18), sometimes
referred to as the “D” valve, is closed.
Refrigerant gas from the top of the freezer (2) passes through the suction accumulator (88), the heat
exchanger (13), and to the compressor (3). Here the cool gas is compressed to a high temperature,
high pressure gas which discharges through the oil separator (14) and into the condenser (15). In the
condenser, heat is removed and the gas is condensed to a high temperature, high-pressure liquid.
The high-pressure liquid goes through the accumulator boil out coil (88) and suction line heat
exchanger (13) where it gives up heat to the suction gas for compressor protection. In addition, this
liquid is subcooled and carried to the receiver (15R). Liquid refrigerant from the receiver flows
through the filter/drier (46), thawing chamber (16), liquid feed solenoid valve (“A” valve) (20) and
thermal expansion valve (17) into the freezer. The “A” solenoid is energized when the machine is in
freeze cycle. The cold liquid refrigerant enters the freezer where it absorbs heat from the circulating
water. Cool gas is pulled out of the freezer at the suction outlet thereby completing the cycle.
The freezing period is completed by action of the freezer pressure switch in the control panel. The
water pump (6) is stopped and solenoid valve “A” (20) is closed. The thawing period then begins.
Solenoid valve “D” (18) is opened, the cutter motor (5M) is started and the harvest (thaw) timer is
activated. Warm gas from the receiver is discharged into the freezer through valve (18), thereby
slightly thawing the outer edge of the ice, which drops on the rotating cutter for sizing. Air-cooled
machines have a solenoid valve (53), sometimes referred to as the “X” valve, in the compressor
4-1
HOW YOUR TUBE-ICE MACHINE WORKS
4. How Your Tube-Ice® Machine Works
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Page 46
4-2
HOW YOUR TUBE-ICE MACHINE WORKS
discharge line, and a check valve (101) in the liquid return line to the receiver. These valves prevent
the migration of refrigerant to the condenser when the machine is not operating.
Freeze Period The Tube-Ice® is frozen inside the stainless steel tubes in the freezer (2) by the direct
application of refrigerant to the shell side (outside) of the tubes. The ice is produced from constantly
recirculating water during the freeze period. As the ice thickness increases, the freezer suction
pressure decreases. At a set pressure, the freezer pressure switch initiates the harvest period.
Harvest Period When the freezer pressure switch (56, FPS) contact closes, a control relay (CR) is
energized. The “CR” relay stops the water pump and starts the cutter motor. The “A” (liquid line)
solenoid valve closes, the “D” (thaw gas) solenoid valve opens and the thaw timer (T) is energized.
As the ice releases and drops through the rotating cutter and onto the cutter disc, it is discharged
through the side opening of the water tank. The harvest timer (T) is to be set for the time required to
discharge all the ice plus 30 seconds longer (usually 2 1/2 minutes).
Make sure all the ice clears the freezer with at least 30 seconds to spare
before the next freeze period begins. This is to prevent refreezing.
Item No. Description Item No. Description
1 Control Panel 32 A/C Condenser Service Connection
2 Freezer 34 Compressor Suction Service Valve
3 Compressor 35 Compressor Discharge Service Valve
4PS Dual High/Low Pressure Switch 37 Oil Charging/Drain Valve
5M Cutter Motor 39 Water Tank Drain Valve
5R Gear Reducer 40 Automatic Water Tank Blowdown
6 Water Pump 41 Condenser Water Regulator (W/C Machines Only)
6A Water Pump Check Valve 41A Condenser Pressure Control (A/C Machines Only)
7 Water Tank (includes cutter assembly) 43 Liquid Feed Solenoid Valve Strainer
8 Water Distributing Chamber 46 Filter Drier
12 Make-up Water Float Valve 48 Muffler
13 Heat Exchanger 50 Receiver Safety Valve
14 Oil Separator 51 Freezer Safety Valve
15 Condenser 52 Condenser Safety Valve (W/C Machines Only)
15R Receiver 53 Cold Weather Solenoid Valve “X” (A/C Machines Only)
16 Thawing Chamber 55 Discharge Line Stop Valve
17 Thermal Expansion Valve 56 Freezer Pressure Switch (Inside Control Panel)
18 Thawing Gas Solenoid Valve (“D” Valve) 58 Liquid Outlet Valve (King Valve)
20 Liquid Feed Solenoid Valve (“A” Valve) 69 Freezer Pressure Stop Valve
23 Condenser Water Inlet (W/C Machines Only) 88 Accumulator/Heat Exchanger
24 Condenser Water Outlet (W/C Machines Only) 90 Thawing Gas Stop Valve
25 Water Tank Drain Connection (3/4” FPT) 91 Receiver Liquid Return Stop Valve
28 Refrigerant Charging Valve 94 Compressor Oil Pressure Safety Control
30 Receiver Gage Glass 101 Check Valve
31 Gage Glass Stop Valve
03TA Service Manual
! CAUTION !
! CAUTION !
TABLE 4-1
Piping Nomenclature
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03TA Service Manual
4-3
HOW YOUR TUBE-ICE MACHINE WORKS
4/11/2014
FIGURE 4-1
Water-Cooled Piping Schematic
Page 48
4-4
HOW YOUR TUBE-ICE MACHINE WORKS
03TA Service Manual
3/31/2014
FIGURE 4-2
Air-Cooled Piping Schematic
Page 49
03TA Service Manual
START-UP AND OPERATION
5-1
5. Start-Up and Operation
Refrigeration System Review. The refrigeration system uses R-22 or R-404a refrigerant, a
compressor, a refrigerant float switch, a flooded evaporator (freezer), and warm gas defrost.
Following the schematic, notice that during the freeze period of the machine’s cycle, the compressor
discharge gas leaves the compressor and goes to the condenser where it is condensed into liquid by
the removal of heat by either air or water passing through the condenser. A reservoir of liquid is
accumulated in the receiver and flows as required, passing through the filter/drier, the thawing
chamber (a lower separate section of the freezer) and the liquid feed solenoid valve (the “A” valve).
The opening of the “A” valve by the float switch during the freeze cycle allows the liquid to be
metered by the (17) hand expansion valve. The “A” valve opens and closes in response to the
refrigerant level in the freezer. Wet refrigerant floods the evaporator and is in contact with the
outside of the ice-making tubes in which water is being circulated. The heat contained in this 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 each of the freezer tubes. The flowing water
keeps the accumulated ice clear by washing separated solids down into the sump area of the water
tank.
The wet suction gas leaves the freezer and any remaining liquid droplets are removed by the
accumulator and suction line heat exchanger. The dry gas enters the compressor and is compressed
then discharged to the condenser completing the cycle.
As the ice is formed in the freezer, the suction pressure steadily reduces until it causes the freezer
pressure switch contacts to close, initiating the harvest period.
During the harvest period, the liquid feed solenoid valve (“A” valve) closes and the thawing gas
solenoid valve (the “D” valve) is open allowing the warm high pressure gas to enter the freezer.
This heat melts a thin film from the outside of the ice, reducing the diameter and letting it fall free
from the freezer tubes. This period lasts approximately 2 1/2 minutes.
Refrigerant Charge. Included with the machine is the required charge (approximately 135 lbs.) of
Refrigerant 22 or 404a, depending on the model, which has been isolated in the receiver (15R).
Before shipment of the machine, the compressor service valves (34), (35), and the stop valves in the
various lines to the condenser and receiver have been closed. These valves are tagged with
instructions that the valves are to be opened prior to start-up of the machine. Before opening these
valves, it is advisable to check all joints for leaks that may have developed during shipment. If no
leaks are present, a positive pressure should show on the suction and discharge pressure gages.
If it should ever become necessary to add refrigerant to the system, charging valve (28) is provided
for this purpose. Through this valve, refrigerant can be added in liquid form. See “Adding
Refrigerant." The compressor crankcase heater must be energized for a minimum of two hours prior
to starting and running the compressor.
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5-2
03TA Service Manual
5-2
START-UP AND OPERATION
Start-up Checklist. Be sure to complete and return the “Warranty Registration/Start-Up Report”
located at the front of the manual.
_____ 1. See that water-inlet and outlet connections are attached properly. The water inlet
shutoff valves for the water tank and condenser should be open. The water level in
the water pan should be at a height where the make-up water float valve will be
closed when the machine is idle.
_____ 2. See that the cutter motor gear reducer is lubricated (see Section 7 “lubrication of
the cutter gearbox (5R)” for instructions).
_____ 3. See that compressor crankcase oil level is at proper height of 1/4 to 1/2 of
the sight glass.
NOTE
All valves are tagged with instructions.
NOTE
_____ 4. Open compressor service valves (34 and 35), the hand-stop valve (90) in the
thawing gas line, the receiver liquid return stop valve (91) in the condenser return
line, hand-stop valve (58) in the liquid line, hand-stop valve (69) to the freezer
pressure switch and the stop valve (70) in the oil return line. These valves are tagged
to indicate that they were closed for shipping purposes. Gage glass valves (31) on the
receiver can be opened for liquid level observation but should remain closed for
unattended operation.
_____ 5. IMPORTANT! CHECKS TO SEE that all stop valves in the various refrigerant
lines are open according to the attached tags.
_____ 6. Immediately after opening all valves, entire machine should be checked for
refrigerant leaks with electronic leak detector.
_____ 7. See that “Ice/Off/Clean” Switch (SS) is in the “Ice” position.
_____ 8. Close exterior disconnect switch to energize crankcase heater and check for
compliance to nameplate.
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Off
03TA Service Manual
START-UP AND OPERATION
5-3
! CAUTION !
The crankcase heater should be energized for a MINIMUM of
2 hours and the crankcase must be free of liquid before
attempting to operate the compressor.
! CAUTION !
Clean Ice
Stop
Start/
Manual
Harvest
CONTROL PANEL DOOR)
FIGURE 5-1
Bottom Portion of Control Panel
Start-Up Procedure
Starting the machine in freeze mode:
(NOTE: to start in harvest mode, turn “Clean/Off /Ice selector switch to “Ice” and press “Start”)
1. Set the “Clean/Off/Ice” selector switch to the “Clean” position.
2. Push the “Start” button to start the water pump.
3. The pump can be stopped and started by the “Stop” and “Start” push buttons to purge the
tubing of air.
4. When there is good water flow, turn the “Clean/Off/Ice” switch to “Ice”. The machine will
then start in a harvest (thaw) period with the compressor running.
5. At the termination of the harvest period, the machine will begin the freeze period.
NOTE: Be sure to observe several cycles of ice production to confirm the satisfactory
operation of the machine.
6. Complete the remaining part of the “Warranty Registration/Start-Up Report” and return it to
the Vogt Ice LLC.
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5-4
03TA Service Manual
5-4
START-UP AND OPERATION
! CAUTION !
If it should become necessary to add refrigerant to the system,
charging valve (28) is provided for this purpose. Be sure to follow
all local and federal regulations regarding the handling of
refrigerants and their illegal emission into the atmosphere.
! CAUTION !
Check the refrigerant level after the machine has operated for a few cycles. It should be slightly
above the minimum operating level, as indicated on the receiver, a few minutes prior to start of a
thawing period. If this level is low at this time, sufficient refrigerant should be added to the system
to raise the level above this point. Add only a small quantity (10 lbs. or less) at a time and operate
the machine several cycles to check the level before adding additional refrigerant. Refrigerant may
be added as a liquid through the charging valve (28) only while the machine is operating. It is
important that no air or other non-condensable gas enter the system when charging refrigerant into
the unit. It is also possible to check the refrigerant level by pumping machine down (See page 9-15).
When the machine is pumped down, a liquid level should be observed in the gage glass on the
receiver.
Adding Refrigerant. When adding refrigerant, use the following procedure:
1. Make connection between charging valve and refrigerant cylinder using hose or pipe
suitable for R-22 or R-404a service. See instruction card attached to refrigerant cylinder.
2. Open valve on R-22 or R-404a cylinder and purge air out of charging line at the charging
valve connections.
3. Open charging valve.
4. Refrigerant can be added only during the freeze cycle. The charging valve must be
closed when the freezer is in a harvest.
In order to check the total charge in the system, it is necessary to transfer all refrigerant to the
receiver. A total pumpdown procedure should be performed.
See the nameplate for the approximate refrigerant charge for the machine. Remember that the total
charge will vary for air-cooled machines with remote air-cooled condensers.
! DANGER !
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,
overfilling it, and possibly causing the cylinder to rupture because
of pressure from expansion of the liquid refrigerant.
! DANGER !
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03TA Service Manual
START-UP AND OPERATION
5-5
OPERATING TIPS
• If the operation of your machine is not controlled by a timer, bin level control or some other
mechanism to automatically start and stop ice production, you should use ONLY the
“Clean/Off/Ice” selector switch to start and stop machine.
By turning the “Clean/Off/Ice” switch “Off”, the machine will stop after the next harvest cycle.
• Do not use the “Stop” pushbutton or the machine disconnect for normal shutdown of the
machine.
• Throw the “Disconnect” only in an emergency or for safety when performing certain service or
repairs to the machine. The compressor crankcase heater is de-energized when the disconnect is
thrown.
• The “Start” push button can be used to initiate a harvest cycle. When it is pushed during a freeze
cycle, it will immediately initiate a harvest cycle.
• When the machine is stopped with no power to the control circuit and the “Start” button is
pushed, the machine will begin in a harvest cycle when operation is resumed.
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5/24/11
Page 55
03TA Service Manual
SS
PB1
PB2
6-1
ELECTRICAL CONTROLS
6. Electrical Controls
3/31/14
FIGURE 6-1
Control Panel (Standard)
Page 56
6-2
ELECTRICAL CONTROLS
03TA Service Manual
4/17/14
FIGURE 6-2
Control Panel Components (Standard)
Page 57
03TA Service Manual
6-3
ELECTRICAL CONTROLS
OPTIONAL POWER MONITOR
LOCATED ON BACK OF
ENCLOSURE DOOR.
3/31/14
SWITCHES LOCATED ON
OUTSIDE OF CONTROL
PANEL DOOR
FIGURE 6-2A
Control Panel Door (Standard) and Optional Power Monitor
Page 58
6-4
ELECTRICAL CONTROLS
03TA Service Manual
FIGURE 6-2B
Control Panel Components (CE & Australian Approved)
3/31/14
Page 59
03TA Service Manual
Item No. Vogt Part No. Description
AX 12A7518E33UL
BT 12A2117G09 Bin Thermostat
CB2 12A7515E22
CC
200V,
208/230V
CC
400V/ 460V
CR 12A7517E27 Control Relay (10 Amp, 2 N.O./2 N.C., 208/240V Coil)
CU
ET
FC
Air Cooled Only
FPS 12A2117E04 Freezer Pressure Switch
FU1 & FU2 12A7504E18 Fuses, 5A, 600V, Class CC, Time Delay
FU10-FU60 12A7504E29 Fuses, 1A, 600V, Class CC, Fast Acting (For use w/optional
P
PB1
PB2
PF 12A7516E23 Power Failure Contactor (9 Amp, 3 Pole, 1 N.O. Aux. Contact,
PM 12A7700P01 Power Monitor, Universal Phase Protector (Optional)
SS
T
TB1 & TB N/A Main Terminal Block Assembly
TB2 N/A Terminal Block Assembly Connections for Customer
ELECTRICAL CONTROLS
Aux Trip Indicator, 6A, 1NO / 1NC
Control Circuit Breaker, 6 Amp, 2 Pole (400V & 460V
machines only)
12A7516E33 Compressor Motor Contactor (85 Amp, 3 Pole)
12A7518E30 Aux. Contact (10 Amp, 1 N.O./1 N.C., Side Mount)
12A7518E32 Aux. Contactor (5 Amp, 2 N.O., Top Mount)
12A7516E28 Compressor Motor Contactor (37 Amp, 3 Pole, w/N.O. Aux)
12A7518E30 Aux. Contact (10 Amp, 1 NO/1NC, Side Mount)
12A7518E44 Aux. Contact (2 Amp, 2 N.O., Side Mount)
12A7516E23 Contactor (9Amp, 3 Pole, with 1 N.O. Aux, 208/240V Coil)
12A7530E54UL Cutter Manual Motor Starter, 1.6-2.5A (200/208/230V)
12A7530E52UL Cutter Manual Motor Starter, 0.63-1.0A (460V)
12A7530E53UL Cutter Manual Motor Starter, 1.0-1.6A (400V)
12B7503E17 Timer, Elapsed, Panel Mount, 220V (50Hz only)
12B7503E18 Timer, Elapsed, Panel Mount, 220V (60Hz only)
12A7516E25
Condenser Fan Contactor (16 Amp, 3 Pole, 1 N.O. Aux. Contact,
208/240V Coil)
12A7530E57UL Fan Manual Motor Starter, 6.3-10.0A (400/460V)
12A7530E58UL Fan Manual Motor Starter, 10.0-16.0A (200/230V)
Power Monitor)
12A7516E23 Contactor (9Amp, 3 Pole, with 1 N.O. Aux, 208/240V Coil)
12A7530E54UL Pump Manual Motor Starter, 1.6-2.5A (460V, 60hz)
12A7530E55UL Pump Manual Motor Starter, 2.5-4.0A (400V, 50hz)
12A7530E56UL Pump Manual Motor Starter, 4.0-6.3A (200/208/230V, 50/60hz)
12A7500E57 Stop Push Button (Red)
12A7500E76 Contact Block/Mounting Latch (1 N.C.)
12A7500E56 Start Push Button (Green)
12A7500E73 Contact Block/Mounting Latch (2 N.O.)
208/240V Coil)
12A7500E61 Selector Switch, 3 Position (Clean/Off/Ice)
12A7500E77 Contact Block/Mounting Latch (2 N.O./1 N.C.)
12A7503E22 Thawing Timer (Delay On Make) 100-240V
12A7503E39 Timer Base (8 Pin, Guarded Terminal)
6-5
TABLE 6-1
Control Panel Components and Part Numbers (See FIGURE 6-1, 6-2, 6-2A & 6-2B)
3/31/14
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6-6
ELECTRICAL CONTROLS
03TA Service Manual
Description of Component Function
AX –
CB2 –
CC –
CR –
CU –
CS –
DS –
ET –
FC –
FPS –
FU1 & FU2 –
FU10-FU60 –
PB1 –
PB2 –
PDB –
PF –
PM
SS –
TB –
TB1 –
TB2 –
Auxiliary trip indicator for manual motor starters. Switches when cutter or pump motor starter
trips.
Overload and short circuit protection for control circuit and crankcase heater. (400/460V machines
only)
Provides power to the compressor motor. Continuously energized during freezing and thawing.
Auxiliary contacts control main power for control circuit components, crankcase heater, control
relay and harvest timer.
Controls sequencing of Freezing and Thawing circuits. Energized during thawing period.
Cutter Motor Starter (Manual motor starter and contactor). Starts and stops cutter motor. Provides
short circuit and over current protection. Stops cutter motor and ice machine in the event of a
mechanical or electrical malfunction that results in excessive motor amperes.
CoreSense replaces Copeland Sentronic Oil Pressure Safety module on all Discus compressors and
the Electronic Motor Protector module in 4D & 6D compressors. Note: 2D & 3D compressor will
still have Internal Line Break overload protection.
Disconnect switch (CE and Australian Approved machines only)
Indicates hours of machine operation. Energized when compressor is operating.
Cutter Motor Starter (Manual motor starter and contactor). Cycles the fan motor(s) of air-cooled
condenser on and off. Activated by the condenser pressure switch (Air-cooled Machines ONLY).
Provides short circuit and over current protection. Stops fan motors in the event of a mechanical or
electrical malfunction that results in excessive motor amperes.
Regulates the ice thickness by reading freezer pressure and initiating the thaw period at the set
point.
Short circuit protection for control circuit and crankcase heater on 200/230V machines.
Protection for primary side of transformer on 400/460V machines
Short circuit protection for power monitor (Optional)
Pump Motor Starter (Manual motor starter and contactor). Starts and stops pump motor. Provides
P –
short circuit and over current protection. Stops water pump motor in the event of a mechanical or
electrical malfunction that results in excessive motor amperes.
Used to stop machine immediately (Should be used for emergency stopping only).
Used for starting machine or manually harvesting. Will initiate a harvest cycle whenever pushed
with the “Clean/Off/Ice” selector switch in the “Ice” position and machine operating in a freeze
cycle.
Power distribution block.
Stops the machine when there is a power failure or interruption. Also, stops the machine when the
high/low pressure switch, oil pressure safety control, pump overload, cutter overload, compressor
overload or the control circuit breaker is tripped. If the “Stop” button was pushed, any of the
safeties tripped, or there was a power outage, the machine must be manually restarted by pushing
the “Start” button.
(Optional) Phase monitor for compressor motor. Monitors voltage in / out of compressor motor
–
contactor. Will shut machine off in voltage is outside of set parameters.
Used to select operating mode of machine. When in clean position, only the water pump will run.
This allows cleaner to be circulated through the freezer without making ice. In the off position, the
machine will shut down after the completion of a freeze and harvest period. In the ice position,
machine will cycle on and off based on a control signal (i.e. bin thermostat or timer) or run
continuously until manually stopped by setting the switch to the “Off” position.
Controls the time of the thawing period.
T –
Numbered for multiple wire connections and ease of troubleshooting.
Customer connections for remote Air Cooled condenser.
Customer connections for auxiliary contacts on cutter, pump and compressor contactors.
TABLE 6-2
Description of Control Panel Component Function
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Page 61
03TA Service Manual
6-7
ELECTRICAL CONTROLS
FIGURE 6-3
Electrical Schematic All Voltages, 50-60 Hz.
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6-8
ELECTRICAL CONTROLS
03TA Service Manual
FIGURE 6-4
Compressor Schematic Detail All Voltages, 50-60 Hz.
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03TA Service Manual
7. 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 by setting
the “Clean/Off/Ice” selector switch to “Clean" and starting and stopping the pump by the
“Start/Manual Harvest” and “Stop” switch. For complete instructions, refer to the “Cleaning
Procedure” attached to the equipment and duplicated here.
NOTE: Before cleaning or sanitizing any Tube-Ice machine, pump the machine down and make sure
the crankcase heater is working properly. This will eliminate the possibility of refrigerant migrating to
the compressor while circulating warm water through the evaporator.
Cleaning Procedure
1. Before cleaning any Tube-Ice machine make sure the crankcase heater is working properly. When the
crankcase heater is not working there is a possibility for refrigerant evaporated by warm circulating water
to migrate to the compressor during the cleaning operation.
MAINTENANCE
7-1
2. Set “Clean/Off/Ice” selector switch (SS) to the “Off” position. If the machine is running, it will shut
down on completion of the next ice harvest period.
3. Remove ice from storage area or cover opening into it.
4. Shut off water supply and drain water tank (7) by opening drain valve (39). Remove any loose sediment
from tank.
5. Close drain valve (39) and fill water tank (approximately 6 gallons) with warm water. Close the petcock
on the water pump during the cleaning period.
6. Add 16 ounces (8 ounces per 3 gallons) of Nu-Calgon ice machine cleaner or equivalent (a food grade
liquid phosphoric acid) to water tank during the refill period. Note: Tank capacity = 6 gallons
7. Inspect the water distributors by looking through clear freeze cover. If required, remove the cover. Clean
and remove any solid particles from the distributor orifices (two orifices in each distributor). Clean the
rubber cover gasket and reinstall the cover.
8. To run the pump only, set the selector switch (SS) to the “Clean” position and press “Start”.
9. Circulate cleaning solution until deposits are dissolved or solution is neutralized. Repeat cleaning if
necessary.
10. Press “Stop” button to stop pump, then drain and flush water tank with fresh water. Open water supply to
machine.
11. Drain and flush tank and then refill with fresh water.
12. Clean inside of ice storage area and remove any solution that entered during the cleaning process.
Remove cover if one was installed over opening into storage area.
3/31/14
13. Start ice-making cycle by setting the “Clean/Off/Ice” selector switch (SS) to “Ice”. Check for water leaks
around the freezer cover and tighten nuts if needed
14. Adjust setting of pump petcock per instructions under “Adjustable Blow down” in Section 9.
Page 64
7-2
MAINTENANCE
Sanitizing Procedure
1. After pumping machine down, set “Clean/Off/Ice” selector switch (SS) to the “Off” position.
2. Remove ice from storage area.
3. Shut off water supply and drain water tank (7) by opening drain valve (39). Remove any loose sediment
4. In a clean container, mix 6 gallons of warm water (90°F–115°F / 32°C-46°C) and 9.6 ounces of Nu-
5. Close drain valve (39) and fill water tank with sanitizing solution. Close the petcock (adjustable blow
6. To run the pump only, set the selector switch (SS) to the “Clean” position and press “Start” button to
7. Mix an additional 2 gallons of warm water (90°F–115°F / 32°C-46°C) and 3.2 ounces of Nu-Calgon®
03TA Service Manual
from tank.
Calgon® IMS-II Sanitizing Concentrate or equivalent. Note: Concentration should be 200-ppm active
sanitizing solution. (Nu-Calgon® IMS-II: 1.6 ounces of sanitizer per 1 gallon of water = 200 ppm).
Note: Tank capacity = 6 gallons
down) on the water pump.
circulate the sanitizing solution.
IMS-II Sanitizing Concentrate or equivalent in the clean container. Note: Concentration should be 200
ppm active sanitizing solution. (Nu-Calgon® IMS-II: 1.6 ounces of sanitizer per 1 gallon of water = 200
ppm).
8. Submerge a clean sponge in the sanitizing solution and wipe all inside surfaces of water box and water
box cover, including the makeup water float valve.
9. With the water pump running, add the additional 2 gallons of sanitizing solution to the water tank. Install
water box cover on water tank and allow sanitizing solution to circulate for at least 20 minutes.
10. While circulating sanitizing solution, open petcock valve (adjustable blow down) and allow solution to
flow down the drain. With petcock valve open, allow water to circulate for a minimum of 3 minutes.
11. Press “Stop” button to stop pump, then drain and flush water tank with fresh water. Open water supply to
machine.
12. To sanitize inside the ice storage area, flood the area with sanitizing solution, making sure to wet all
surfaces completely for at least 60 seconds. Note: Concentration should be 200-ppm active sanitizing
solution. (Nu-Calgon® IMS-II: 1.6 ounces of sanitizer per 1 gallon of water = 200 ppm).
13. Drain, flush tank and refill with fresh water.
Return machine to ice making operation
1. Make sure the water tank drain valve is closed, and the “Selector” switch is in the “Off” position. Turn
on the water supply and refill tank with clean water.
2. Manually open the thaw gas solenoid valve “D-valve” (18), by running the stem in. This will allow the
pressure to rise in the evaporator and allow the machine to operate. After approximately 1 minute, put
“D-valve” back into the automatic position.
3. When tank is full, turn the selector button to the “Ice” position and push the “Start” button for immediate
start-up in the ice production mode.
3/31/14
4.
Make use the adjustable blow down petcock is adjusted properly.
NOTE: The petcock should be adjusted to the minimum rate required to maintain production of clear
ice. (Should be no more than 1 gallon/5 minutes)
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03TA Service Manual
Water Distributors. The water distributors are located under the freezer cover (8) at the top of the
freezer. These distributors may require occasional or periodic cleaning to remove solids and foreign
particles accumulated from the make-up water. The frequency of this cleaning operation will
depend on the characteristics of the water supply. The cleaning operation is needed when the inside
diameter of a large proportion of the ice becomes irregular (due to channeling of water), or if some
of the ice is opaque, or if there is a noticeable decrease in ice capacity.
To clean distributors, stop the unit and remove the freezer cover (8) on top of the freezer. The water
distributors (one in each tube) may then be removed with pliers for cleaning. Use pliers on the
distributor’s top part with a twisting upward motion.
Note: When re-installing distributors on the outside row, make sure holes are away from the gasket
Vogt Part #
Size Ice Number of Tubes Water Distributor Freezer Cover Freezer Cover Gasket
1” 78 12B2185N11 12A2145C06 12A2600G01
1 1/4” 48 12B2185N21
Table 7-1
Number of Water Distributors Per Tube Size
Water Tank. The production of opaque ice can indicate that the water in the water tank contains a
concentrated amount of solids or salts.
Remove cover plate. Open drain valve (39). Clean tank thoroughly by flushing out with a hose and
scrubbing with a stiff brush. Fill the water tank with fresh water.
When restarting the machine, be sure that the water pump is circulating water. It is possible that air
may have collected in the pump impeller housing and the pump may have to be stopped and started
several times to expel the air.
Water Cooled Condenser
Checking Operation. Scheduled maintenance for water-cooled condensers is based primarily on
the operating conditions found at the machine. The condenser should be inspected at least annually
and cleaned as required. For extreme operating conditions where water quality is poor the condenser
may need to be cleaned several times a year.
Proper operation of cooling towers will increase the interval between cleaning considerably. The
tower overflow rate should be checked frequently. If a tower is operated with insufficient overflow,
nominal 1-1/2 to 3 gallons per hour bleed depending on water quality, the resulting mineral
concentration in the water can cause rapid and heavy fouling inside the condenser tubes, requiring
excessively frequent cleaning. Also, these conditions often lead to severe corrosion.
Chemical additives, including those to stop algae and related growths, should be obtained only from
a reputable, established supplier, and used specifically according to directions. Excessive treatment
of the water can cause more harm than good and the condensers, pumps, piping, and the towers
themselves may be damaged.
MAINTENANCE
7-3
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7-4
MAINTENANCE
It is advisable to double-check the system to make sure that fouling is actually causing the trouble.
High head pressure alone does not mean a fouled condenser.
The following possibilities should always be checked before cleaning is undertaken:
After the above possibilities have been eliminated, determine the temperature difference between the
water leaving the condenser and the refrigerant condensing temperature (saturation temperature,
from pressure-temperature chart, corresponding to head pressure). If this difference is more than
10°F, cleaning is indicated because this difference indicates a good heat exchange is not being made.
If this difference is less than 8°F, something other than a fouled condenser may be causing the high
head pressure. In normal operation, this difference will stay between 5°F and 10°F regardless of
water inlet temperature when the water flow is regulated by a pressure operated water valve. If this
difference is less than 5°F, restricted water flow or a low supply pressure is indicated. A restriction
can occur with foreign matter in the condenser, but it is also likely to be somewhere else in the
system.
Draining Condenser. Draining of water cooled condensers is recommended in preparation for the
winter cold where units may be left exposed to ambient temperatures below 32°F. Theoretically, it
is easy to drain a condenser. In practice, the problem can be complex.
Despite the fact that a condenser my have vent and drain fittings, the opening of these fittings is not
sufficient for a natural gravity flow. Water will be retained in a tube due to (1) surface tension and
(2) the normal curvature between tube supports. Our experience shows that as much as 20% of the
water in the condenser can be retained. To break the surface tension on the tubes and to drain all
tubes completely, it is necessary to remove the back plate and actually tilt the condenser a minimum
of 5 degrees. Whether water left in the tubes will cause damage during a freeze-up will be
dependent upon how quickly the freeze occurs and the location of the water inside the condenser.
In the field it is recommended that the tubes be blown out individually with air. Alternatively, a
minimum of 25% ethylene glycol in the system will also prevent a freeze, which can rupture the
tubes.
Water Cooled Condenser Cleaning.
3/31/14
1. Non-condensables in system or faulty head pressure gauge? Check standby pressures
against refrigerant tables.
2. Incorrectly set or defective water regulator valve? Check its setting and operation.
3. Partly closed compressor discharge service valve? Check its setting. Stem should be
backseated.
4. High water temperatures entering condenser? Check tower fan and system.
! CAUTION !
The following directions and precautions should be observed
when cleaning is undertaken. The warranty on condensers is void if
they are damaged by improper cleaning tools or methods. If
harsh chemicals are used, be sure to follow the manufacturer’s
recommendations regarding safety in handling those solutions.
! CAUTION !
03TA Service Manual
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03TA Service Manual
Chemical Cleaning. Vogt Tube-Ice makes no recommendation for any particular chemical
preparation. The same chemical may not be effective for all situations.
a) Use only preparations from an established, reliable source.
b) Follow directions exactly, particularly regarding amounts to use, and flushing or neutralizing
procedure after cleaning.
c) Close the water supply stop valve. Remove the condenser water-regulating valve (41).
d) Circulate the solution through the condenser until it is considered clean.
e) Flush the condenser according to directions.
f) Install the water regulating valve and connecting piping.
g) Open the water supply stop valve and check for leaks.
Mechanical Cleaning.
MAINTENANCE
7-5
Part I.
a) Close the stop valve in the water supply line.
b) Drain the water from the condenser.
c) Remove water regulating valve (41) and attached piping to the condenser.
d) Remove the cover plate on the side of the frame to expose the condenser end plate.
e) Remove the nuts, water plates, and gaskets from both ends of the condenser. If the gasket does
not lift off with the end plate, do not try to pry it off. The seal surface may be damaged, which
would cause a water leak. To free a sticking gasket, replace the water plate and tap it on the
outside face with a mallet or a block of wood. After a few taps, the gasket will spring free and
will then slip off with the water end plate.
f) Gaskets need only be rinsed in running water: rust, scale or dirt will not stick to gasket material.
A rag or soft brush is all that is required to remove any foreign matter.
Part II.
The inside of the water end plates and the outer tube sheet surfaces should be cleaned only with clear
water and a rag or a soft bristle brush. A worn paintbrush is excellent.
These surfaces have been coated with a special material that will give years of protection against
corrosion unless damaged. Never use a wire brush or a strong caustic on these surfaces.
Flush condenser tubes clear with air, water, or a piece of rag on a stick or wire. In many cases this is
all that is required. If the inside surfaces are smooth, even though discolored, further cleaning is not
necessary. It is not necessary to get a bright copper surface on the inside of the tubes. They will
discolor almost immediately in service and the condenser has been designed with an adequate
reserve for moderate fouling on these surfaces.
If, however, a rough coating remains inside the tubes after flushing and wiping, further cleaning is
desirable. The color of this coating varies with water conditions, but roughness indicates cleaning
tools should be used.
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7-6
MAINTENANCE
Any type tool to be considered should be tried first on a piece of copper tubing held in a vise or flare
block. Nylon, brass, or copper brushes are recommended. If any flakes of copper appear or if score
marks are made inside the tube, the tool should not be used. Never use anything with sharp or rigid
edges which could cut into the copper tubing.
Lubrication
Compressor. When starting and charging the unit, the oil sight glass (33) in the crankcase of the
compressor should be watched carefully for the first hour to make certain the proper lubrication is
being maintained. The oil may become low in the crankcase on an initial start-up if electrical current
has been interrupted to the machine, thus de-energizing the compressor crankcase heater.
Before starting the machine again, the heater should be energized for a time period of at least two
hours to evaporate refrigerant that may have condensed in the crankcase during the shutdown period.
If the level is low after start-up, it should begin to return after a short period of operation.
The oil level should be checked frequently, particularly during the start-up operation, to see that a
sufficient amount of oil remains in the crankcase. While it is important to observe the oil splash
during operation, the true level can be obtained only when the compressor is stopped. With the
compressor idle, the oil level should be at a height of 1/4 to 1/2 of the sight glass but never above the
top of the sight glass.
Although the machine was shipped with the oil charge, which was originally added for the test
operation, it may be necessary to add some oil when or if new refrigerant is added to the system.
Refrigerant Recommended Lubricants Type of Lubricant
R-22 Suniso 3GS, Texaco WF32, Calumet RO15 (Witco) Mineral Oil
R-404A Mobil EAL ARCTIC 22 CC, ICI (Virginia KMP) Emkarate RL 32S Polyol Ester Oil
3/31/14
Oil Return shut-off valve
(from oil separator)
Suction
Service
Valve
Oil Charging Connection
(1/4” access fitting with shrader)
To Oil Separator
FIGURE 7-1
Copeland Discus Compressor (3D)
TABLE 7-2
Recommended Lubricants
03TA Service Manual
Oil Sightglass
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03TA Service Manual
Oil Charge
Compressor HP
3DE3R & 3DEHR 6.5 125
3DP3R & 3DPHR 7.5 125
(oz)
TABLE 7-3
Compressor Oil Capacity
An oil pump should be used to force any oil that may be required into the system. Oil may be added
to the compressor through the low pressure test connection adjacent to the high/low pressure switch
or through the compressor suction service valve. The compressor suction service valve should be
“backseated” to shut off pressure to the gauge port when connecting the oil pump. Air should be
purged from the oil pump discharge line by forcing some oil through the line before tightening the
charging connection.
Cutter Gear Reducer. The oil level for the gear reducer should be checked if there is evidence of a
leak. It should be level with the plugged opening in the side of the gear housing. Use Mobile 600W
cylinder oil or equal. Change oil once a year.
Gear Reducer (10:1)
Part #: 12A4030R12
Vent Plug
Vent Plug
Replacement food grade oil:
Part #: 19T3020C01
Texaco Cygnus 220
Oil Capacity: 8 ounces
Oil Level Plug
Drain Plug
Note: Ventless gear reducer used after August 2010
FIGURE 7-2
Gear Reducer
MAINTENANCE
7-7
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Page 70
7-8
MAINTENANCE
Preventive Maintenance. A careful inspection of the Tube-Ice® machines refrigeration system for
leaks and correct operational functions at time of installation will start its long satisfactory life of
service. In order to insure this degree of dependability, a systematic maintenance program is
recommended. Therefore, the following schedule is suggested as a minimum.
(A) Daily
1. Check “ice-out” time (maintain 30 second free running after last ice is out).
2. Check clarity of ice produced and hole size.
3. Check compressor oil level.
4. Check refrigerant charge by observing operation level in receiver gage glass (30).
(B) Weekly
1. Check system for leaks with suitable leak detector for the first four weeks of operation.
2. Check oil level and condition.
(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 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.
(D) Yearly (in addition to weekly and monthly)
1. Check entire system for leaks (see “B”).
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.
03TA Service Manual
PRESSURE RELIEF VALVES MUST BE REPLACED AFTER 5 YEARS OF SERVICE.
BEFORE REPLACING RELIEF VALVE, REVIEW REQUIREMENTS PER CURRENT
LOCAL AND NATIONAL CODE.
NOTE: IF RELIEF VALVE DISCHARGES, VALVE MUST BE REPLACED BECAUSE SETTING OR SEAT
TIGHTNESS MAY BE ALTERED.
CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES.
PHONE: 502-635-3000
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03TA Service Manual
For The Manager Who Depends Upon This Machine For Efficient Operation.
“Preventive Maintenance” simply means that you or a delegated employee makes a daily visual
check of your Tube-Ice® machine. Here is what to look for and why:
Daily checklist:
1. Is the machine running or is the bin full
2. Bin doors kept closed
3. Thermostat bulb in bracket
4. Ice quality (clarity and uniformity)
5. Does all ice discharge during harvest
6. Cleanliness
7. Unusual noises
Why? When you make these simple observations on a daily basis, you insure the smooth
production of ice for your facility. When you are aware of the proper operating conditions and
observe them on a daily basis, changes in these conditions can alert you to changes in the operation
of the machine which may require maintenance--long before a service situation arises.
“An ounce of prevention is worth a pound of cure!”
Note To Manager or Owner:
The following page is a complete Preventive Maintenance Schedule that should be performed each
90 days. The Preventive Maintenance page may be copied and given to your service person. It
should be signed, dated, and returned to you for permanent record.
MAINTENANCE
7-9
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Page 72
7-10
MAINTENANCE
Note To Manager or Owner:
This page is a complete Preventive Maintenance Schedule that should be performed each 90 days.
The Preventive Maintenance page may be copied and given to your service person. It should be
signed, dated, and returned to you for permanent record.
This form can be removed and duplicated for keeping accurate records.
Model # ___________________ Serial # ____________________ Date _____________
Customer/Address ___________________________________________________________
____________________________________________________________
Mgr. Name ______________________ Service Tech Name __________________________
The following service performed and checked:
_____ Last maintenance performed (approx. date)
_____ Scale condition of water tank & tubes (good - fair - poor)
_____ All drains freely draining (water tank, drip pan, ice bin)
_____ Water distributors cleaned
_____ Ice machine cleaner circulated through system
_____ Condenser clean (if applicable)
_____ Voltage at machine (actual reading) ________, ________, ________
_____ Compressor amps (halfway through the freeze cycle) ________, ________, ________
_____ Cutter motor amps (cutting ice) ________, ________, ________
_____ Water pump amps ________, ________, ________
_____ AC condenser motor amps (if applicable) ________, ________, ________
_____ Crankcase heater heating
_____ Refrigerant leak (okay - high - low)
_____ Leak checked system ______ leaks found & repaired
_____ Compressor oil level (i.e., 1/4 - 1/2 - 3/4 - low - high)
_____ Gear reducer oil (okay - low)
_____ PSIG, low pressure switch set @
_____ PSIG, high pressure switch set @
_____ Bin stat(s) installed and operating properly
_____ Make-up water float valve adjusted okay
_____ Adjustable blowdown adjusted for clear ice
CYL__________ CRU________ Suction PSIG at end of freeze
CYL_____/____ CRU____/____ Suction PSIG during harvest (high/low)
CYL__________ CRU________ Discharge PSIG at end of freeze
______°F/°C at machine ______ °F/°C outside ambient (at condenser if applicable)
______ °F/°C make-up water temperature
_____ Freeze cycle time (minutes)
_____ Harvest cycle time (minutes)
_____ First ice out (seconds)
_____ All ice out (seconds)
_____ Pounds of ice per cycle
Capacity check: ice weight per cycle X 1440 = _________ lbs. (24 hr. capacity)
total cycle time (min) _____
Remarks:_________________________________________________________________________
03TA Service Manual
Preventive Maintenance Program
3/31/14
_________________________________________________________________________________
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03TA Service Manual
NOTE: With the exception of bin control, anytime the machine stops, it must be manually re-started
by pushing the "Start" push-button. If it stopped while in a freeze cycle, it will then start in a
thawing cycle.
Always check the machine thoroughly after remedying the problem to prevent the same cause from
reoccurring.
8-1
TROUBLESHOOTING
8. Troubleshooting
Symptom Page
Machine Won’t Run 8-2 & 8-3
Freeze-up Due To Extended Freeze Period 8-4
Freeze-up Due To Ice Failing To Discharge 8-5
Low Ice Capacity 8-6
Low Compressor Oil Level 8-7
Poor Ice Quality 8-8
High Head Pressure (Water-Cooled Machines) 8-9
High Head Pressure (Air-Cooled Machines) 8-10
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Page 74
8-2
TROUBLESHOOTING
SYMPTOM: Machine won't run.
Power failure ++ Intermittent power
interruption
One of the 3amp circuit breaker (CB) in the
control panel tripped.
High/Low safety pressure switch tripped. If the machine stops by low-pressure cutout,
03TA Service Manual
POSSIBLE CAUSE POSSIBLE REMEDY
Check electrical fused disconnect or circuit
breaker supplying power to the machine. If
power has been off, make sure the
compressor crankcase heater is energized, the
crankcase is warm, and there is no liquid
refrigerant in the crankcase prior to running
the machine. Push the "Start" button to
initiate startup in a thawing cycle.
Check compressor crankcase heater, coils of
relays, contactors, starters, solenoid valves,
and thawing timer for a ground. Repair or
replace any defective part, and replace fuse.
Make sure there is no liquid refrigerant in the
compressor crankcase prior to re-starting the
machine.
the switch will reset automatically when the
pressure rises to the " cut in " setting. If it
stops by high-pressure cutout, the switch will
have to be manually reset after the pressure
drops below the " cut-in " setting. Check
switch settings and push the "Start" push
button to start the machine in a thawing cycle.
Check the head pressure during the next freeze
cycle. See FIGURE 9-4, Section 9,
(High/Low Pressure Switch).
2/14/07
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03TA Service Manual
SYMPTOM: Machine won't run (CONT.)
Low oil pressure switch tripped. If the machine stops by low oil pressure
Cutter motor overload tripped. Check and clear the cutter area and ice
Pump motor overload tripped. Check voltage and overload range adjustment
Bin thermostat or bin level control stops
machine.
Defective control panel component such as,
PF, CMS, PB1, CB, T, Etc.
8-3
TROUBLESHOOTING
POSSIBLE CAUSE POSSIBLE REMEDY
cutout, the switch will have to be manually
reset. Check the crankcase oil level. Restart
the machine by pushing the "Start" push
button. Check the oil level and net oil pressure
(net oil pressure = pressure reading at the oil
pump end bearing housing minus suction
pressure). The oil level should be 1/4 - 3/4
level in the glass. If above 3/4, drain some oil
out. See page 9-8, (Oil Pressure Sensor ).
discharge path of all ice. Check voltage and
overload range adjustment against motor
rating. Reset the switch and restart the
machine by the "START" push button. Check
the cutter operation and motor amp draw. If
tripping repeats, but ice is not jammed, check
the cutter bearing for wear, the gear reducer
for resistance, and the motor for defect or
single phasing.
against motor rating. Reset the switch, set the
"Ice/Clean" switch to the "Clean" position and
restart the machine by the "Start" push button.
Check the pump operation and motor amps. If
tripping repeats, check for a defective
overload, defective motor, or single phasing.
Adjust or replace the bin stat or level control.
Make sure bin stat bulb or level control is
located properly in the bin. See FIGURE 311, Section 3 (Bin Thermostat).
See FIGURE 6-3, Section 6 (Wiring
Schematic). Check for open circuit. Refer to
FIGURE 6-2, Section 6 (Control Panel) to
identify parts. Replace defective part, restart
machine and check power supply and current
draw.
2/14/07
Page 76
8-4
TROUBLESHOOTING
SYMPTOM: Freeze-up due to extended freeze period.
Freezer pressure switch setting too low. Adjust freezer pressure switch, or replace if
Water tank drain valve (39) open or leaking, or
make-up water float valve (12) stuck open.
Thawing gas solenoid valve (18) leaking
through during the freeze cycle.
Float switch stuck or failed in the closed
position.
“A” valve (20) stuck open Check to make sure the “A” Valve is not in
03TA Service Manual
POSSIBLE CAUSE POSSIBLE REMEDY
defective. See FIGURE 9-3, Section 9.
Close valve, repair, or replace as necessary.
Check the manual opening stem to make sure
it is in the automatic position (stem screwed
out). Check for leakage through the valve by
sound and temperature difference. Close the
stop valve (90) at the receiver to confirm
suspicion of leakage. Repair or replace the
valve as needed.
Check to make sure the float switch is opening
and closing.
the manual open position. Disassemble valve
and inspect for debris that could hold the
valve open.
2/14/07
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03TA Service Manual
SYMPTOM: Freeze-up due to ice failing to discharge.
Insufficient heat for thawing because of low
condensing pressure, non-condensables
(usually air) in system, low refrigerant charge,
or thaw gas solenoid valve stuck closed.
Thawing time too short. Check the thaw timer (T), which should be
Cutter or cutter disc does not turn. Check cutter reducer and drive gear for proper
Ice backs up into cutter or discharge opening,
jamming cutter
Extended freeze period. Check freezer pressure switch adjustment; see
Compressor not unloading. Check compressor amps during harvest. A
8-5
TROUBLESHOOTING
POSSIBLE CAUSE POSSIBLE REMEDY
The head pressure should be maintained at
approximately 210 PSIG for R-22 or 250
PSIG for R-404a, which relates to 105 oF
(37.8 C). This is done by a water-regulating
valve (water-cooled units) FIGURE 9-5A,
Section 9, or a Fan cycling switch (air-cooled
units) FIGURE 9-5B, Section 9. If noncondensables are present with the refrigerant,
the saturated temperature will not relate to the
pressure reading at the receiver. The
refrigerant level in the receiver should be near
the operating mark at the end of a freezing
cycle to provide enough volume for
harvesting. (1" = approx. 5.5 lbs. of R-22 or
R-404a).
adjusted to allow all the ice to clear the cutter
and ice discharge opening with at least 30
seconds to spare.
operation and alignment. Check for broken
cutter disc or drive pin and replace as
necessary.
Ice mushy due to concentration of solids in the
water tank. Perform "Cleaning Procedure" and
check automatic and adjustable blowdown. If
the machine discharges ice into a chute, it
should slope at an angle of 30 degrees for
cylinder ice and 45 degrees for crushed ice.
Check bin stat or level control to make sure it
will stop the machine before ice backs-up into
the cutter.
FIGURE 9-3, Section 9, (Freezer Pressure
Switch) and TABLE 11-6, Section 11
(Operating Vitals).
noticeable drop in amperage should occur.
Check unloader solenoid coil. If coil is okay,
replace unloader head assembly.
2/14/07
Page 78
8-6
TROUBLESHOOTING
SYMPTOM: Low ice capacity.
Low refrigerant charge. Check for and repair leaks, and add
Restriction in liquid line. Check for a partially closed valve or an
TXV overfeeding. Check freezer superheat. Average superheat
Thawing gas solenoid valve (18) leaking
through during the freeze cycle.
Water distributors at top of freezer may be
stopped up.
Inadequate water for ice making. Check water pressure (30 PSIG minimum
Make-up water float valve (12) stuck open,
adjusted too high, or water tank drain valve
(39) open or leaking
Controls for regulating freezing and thawing
cycles not adjusted properly.
Excessively high head pressure. Check water regulating valve or fan control
Warm make-up water for ice making. Capacity of the machine is proportional to ice
Drain valve (39) open. Close drain valve (39).
4/21/14
03TA Service Manual
POSSIBLE CAUSE POSSIBLE REMEDY
refrigerant.
obstruction at the drier, strainer, solenoid
valve, or expansion valve. The liquid line will
normally have frost on the downstream side of
a restriction, especially as the suction pressure
decreases.
should be between 8 - 10 deg F. Before
adjusting TXV, make sure all other potential
liquid overfeed causes have been checked.
Check TXV bulb for proper insulation and
contact on suction line. Make sure machine is
clean and there is proper water flow.
Check the manual opening stem to make sure
it is in the automatic position (stem screwed
out). Check for leakage through the valve by
sound and temperature difference. Close the
stop valve (90) at the receiver to confirm
suspicion of leakage. Repair or replace the
valve as needed.
Remove freezer cover and clean the
distributors. See Water Distributors, Section 7.
recommended). Check for a restriction in the
water supply line or at the make-up water float
valve.
Repair, replace or adjust float valve, or close,
repair, or replace water tank drain valve.
For highest capacity, cylinder ice should have
a small hole and crushed ice should be about
3/16" thick. Check the freezer pressure switch
and thaw timer for proper adjustment, Section
9.
adjustment. Check to make sure the WC or
AC condenser is clean. Check refrigerant
tables for pressure/temperature relation.
making water temperature. Warmer water
will reduce the ice making capacity. See
Section 10, Capacity Table.
Page 79
03TA Service Manual
SYMPTOM: Low compressor oil level.
Oil separator not returning oil. Check oil separator float and oil return stop
Repeated short cycling (refrigerant carrying oil
out of compressor).
Worn piston rings. This condition is hard to detect without
8-7
TROUBLESHOOTING
POSSIBLE CAUSE POSSIBLE REMEDY
valve (70) and line for a restriction. The oil
return line should be above ambient
temperature most of the time as it returns oil.
It may be cooler at the start of a freeze cycle.
Repair or replace defective parts.
Usually caused by freeze-up, low refrigerant
charge, low head pressure, faulty timer, faulty
pressure switch or expansion valve clogged.
Use process of elimination.
dismantling the compressor and checking
piston ring tolerances. Normally there will be
a little puddle of oil lying on top of the piston
when the head and valve plate are removed. It
is best to replace the compressor.
2/14/07
Page 80
8-8
TROUBLESHOOTING
SYMPTOM: Poor ice quality.
Excessive concentration of solids in the water
tank usually indicated by a build-up of mineral
deposits on the sides and bottom of the tank.
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. Check refrigerant level mark on the receiver,
Insufficient blowdown during harvest Check for proper operation of the blowdown
03TA Service Manual
POSSIBLE CAUSE POSSIBLE REMEDY
Perform a cleaning procedure as well as
removing the freezer cover and cleaning the
water distributors. Adjust continuous
blowdown.
Check water pressure (30 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 valve is closed.
housing, and reverse two wires at the motor if
necessary.
and on the painted portion of the gage glass
guard. Perform a pumpdown if necessary. Be
sure to close the gage glass cocks after
checking the level.
siphon and restrictions or traps in the water
tank drain assembly.
2/14/07
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03TA Service Manual
SYMPTOM: High head pressure. (Water-cooled machine)
Misadjusted or defective water regulating
valve
Insufficient water supply. Check size of water line and pump output at
Cooling tower needs maintenance. Check cooling tower fan belt and tighten or
Non-condensables (usually air) in system. Check refrigerant tables for correct
Fouled (dirty) condenser. Follow the diagnostic procedure outlined on
8-9
TROUBLESHOOTING
POSSIBLE CAUSE POSSIBLE REMEDY
Adjust or replace the valve. Never adjust the
valve stem as far open as it will turn, because
it will not close when the head pressure drops.
the condenser. Refer to the specification sheet
for water requirements. Check cooling tower
sump level and make-up water supply.
replace as needed. Check spray nozzles and
sump screen and clean as needed.
pressure/temperature relation. If noncondensables are present, Perform a total
pumpdown, let stand for at least 6 hours,
allowing non-condensables to gather in the
upper part of the receiver. Evacuate the
freezer and attach a recovery unit to the top
receiver purge valve (59). Open the valve and
recover the vapor for about five minutes.
When the freezer is evacuated, open the thaw
gas solenoid valve manually for about 15
seconds letting the top vapor in the receiver
blow into the freezer. Close the solenoid
valve and evacuate the freezer again.
Evacuate to 500 microns and restart the
machine.
page 7-3, Section 7, and clean the condenser
per instructions under Condenser Cleaning,
2/14/07
Page 82
8-10
TROUBLESHOOTING
SYMPTOM: High head pressure (Air-cooled machine).
Condenser fan(s) not running. Defective motor, fan control switch, fan
Dirty condenser causing restricted airflow. Visually inspect condenser and clean as
Non-condensables (usually air) in the system. Follow same procedure as specified for
03TA Service Manual
POSSIBLE CAUSE POSSIBLE REMEDY
contactor. Replace defective part. Check
condenser fan disconnect for thrown switch,
or blown fuse. Replace fuse and reset switch.
If the condenser is split, check the normally
open solenoid valve to make sure it is open;
also check the fan sequencing thermostats and
fan motor contactors to make sure they are
functioning properly. Replace any defective
parts.
necessary.
removing non-condensables from Water
Cooled machine, except evacuate the aircooled condenser also.
2/14/07
Page 83
03TA Service Manual
Part #: 12A4200H0401
Adjustable Blowdown (for clearer ice) A petcock is installed on the overflow of the water pump to
provide means for obtaining blowdown from the water tank during the freezing period. The petcock
was set at the factory to discharge enough water during the freeze cycle to produce clear ice. After
installation it should be adjusted to the minimum rate required to maintain clear ice and checked
after a few days of ice making.
Automatic Blowdown (Harvest Cycle). A feature of this machine is the automatic blowdown (40)
which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water
tank (7) and to remove accumulated salts or solids in the water as a result of the freezing action.
During the harvest water returning from the freezer raises the tank level and causes an overflow of
water which creates a siphon to remove a fixed amount of water from the tank.
Float Valve (make-up water). The make-up 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 by-pass or
blowdown only during the thaw mode. The water level during the freeze mode should always be
below the by-pass 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 drain bypass.
It is advisable to install a large area strainer in the water supply line to protect the float valve from
dirt or solids in the water, which would necessitate frequent cleaning.
4/11/14
9-1
SERVICE OPERATIONS
9. Service Operations
Adjustable Blowdown
(petcock valve)
Automatic
Blowdown
Water Pump
FIGURE 9-1
Water Pump / Blowdown Assembly
Page 84
9-2
SERVICE OPERATIONS
Expansion Valve. The expansion valve was adjusted before shipment and it is rarely necessary to
change this setting.
If considerably less ice than shown in TABLE 11-5 is being produced per discharge, check the water
supply, circulating water pump, water distributors, liquid line valve, refrigerant level, freezer
pressure switch and all other avenues BEFORE changing the factory setting of the expansion valve.
Vogt Part #: 12A4200C0503
Superheat. Superheat is the difference between the refrigerant vapor temperature and its saturation
temperature. (Translate the pressure to saturated temperature and subtract from the actual temperature.)
Checking Superheat. Follow this procedure:
1. Attach an accurate pressure gage to the freezer-charging valve (#28).
03TA Service Manual
FIGURE 9-2
Thermal Expansion Valve
2. Using a digital thermometer, attach the thermocouple to the suction line directly below and in-
line with the existing TXV sensing bulb.
3. Hold the thermocouple in place with tape and insulation to assure good contact and a true reading.
4. Operate the machine and monitor the superheat during the freeze cycle after the first four
minutes and at two minute intervals for at least two cycles.
5. Adjust the valve only 1/4 turn at a time. Close (turn stem in) to raise superheat. Open (turn stem
out) to lower superheat. Monitor at least two cycles after each adjustment before adjust further.
If the valve cannot be adjusted satisfactorily, check the bulb insulation as follows:
1. Remove the insulation from the sensing bulb.
2. Loosen the bulb clamps and remove the bulb.
3. Clean and polish the sensing bulb and suction line to assure maximum contact between them.
4. Install the bulb in the same place tightening the clamps securely.
5. Replace the insulation around the bulb making sure it is well sealed. Repeat the adjustment
procedure and if you are still unable to accomplish the proper superheat setting, replace valve.
When installing a new valve, be sure to use the proper soldering techniques to prevent overheating
the valve body, which could damage the superheat spring and result in flood back problems.
4/2/14
When soldering:
1. Wrap a wet cloth around the valve body and element.
2. Direct the flame away from the valve body.
3. Apply only enough heat to flow the alloy material into all the joint areas. Do not overheat.
4. After the brazing alloy has set, quench or apply a wet brush or swab to remove the flux residue.
Use Emery cloth or a wire brush if necessary.
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03TA Service Manual
Freezer Pressure Switch. The freezer pressure switch (FPS), located inside the control panel,
controls the freezing time period for the production of cylinder or crushed ice.
This 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 10-6, Operating Vitals for
typical settings. Do not make adjustments until several ice discharging cycles have been completed.
Turn top screw to adjust the pressure setting
(also referred to as the Range)
Clockwise = increase pressure setting (thinner ice)
Counterclockwise = decrease pressure setting (thicker ice)
The following procedure is recommended for initially setting an AB pressure switch that has not
been previously adjusted:
1. Turn the bottom screw (differential) approximately 1/2 turn to the Left (counter clockwise).
The pointer arrow, which is at the top middle of the switch, will be at the “F” setting.
2. Turn the top screw (range adjustment) approximately 4 1/2 turns to the Left (counter
clockwise). The pointer on the range setting will be between 40 psi and 50 psi.
3. After the machine is running, the range adjustment (top screw) will have to be fine-tuned to get
the proper ice thickness. (Clockwise = Thinner Ice) (Counter Clockwise = Thicker Ice)
The freezing time can be such that a small percentage of the ice is frozen solid. If so, some ice from
the top and bottom of the freezer should have a small hole in the center to insure that the freezing
time has not been extended to where a loss in capacity would result.
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.
When crushed ice is produced, the freezer pressure switch (FPS) (FIGURE 9-3) should be set to
produce ice having a wall thickness of approximately 3/16”.
Vogt Part #: 12A2117E04
FIGURE 9-3
Allen Bradley Pressure Switch
9-3
SERVICE OPERATIONS
4/2/14
Page 86
9-4
SERVICE OPERATIONS
High-Low Pressure Safety Switch. The high-low pressure switch (HPS) (FIGURE 9-4) is a two
pole dual function switch. Located in the machine mounted to the frame near the compressor. It
protects the machine from possible damage due to abnormal pressure during operation.
The LOW pressure cut-in should be set at 40 psig and the cutout set at 20 psig for R-22
The LOW pressure cut-in should be set at 52 psig and the cutout set at 28 psig for R-404a.
After tripping at the cutout setting, the switch will reset automatically when the pressure rises to the
cut-in setting.
The HIGH pressure cutout should be set at 300 psig for R-22 and 350 psig for R-404a. After
tripping, reset the switch manually.
Differential Adjusting Screw
Vogt Part #: 12A2117D02
If it becomes necessary to install a new high/low pressure switch, the following procedure is
recommended for its adjustment:
Turn the adjusting screws clockwise to raise the pressure setting. Turn counter-clockwise to lower
the setting. Adjust the switch to the indicated pressure settings and test with an accurate gage to be
sure the switch functions properly before installation.
Head Pressure. The head pressure should be maintained at 190-210 psig for R-22 and 230-250 psig
for R-404a during the freeze cycle. This pressure can be checked at the test connection in the high
pressure line near the high-low pressure switch.
Water-Cooled Units. A water regulating valve (FIGURE 9-5A) located in the condenser water
inlet line is used to control the water flow through the condenser. This valve should be adjusted to
maintain a head pressure of 195 psig for R-22 and 235 psig for R-404a. Increasing the water flow
lowers the head pressure and decreasing the water flow raises the head pressure. The valve is
adjusted during the factory test. The valve stem should not be opened as far as it will go or the valve
will not close fully when the head pressure drops below its setting.
! CAUTION !
When this switch causes the machine to stop, the cause should be
identified and corrected before resuming normal operation.
! CAUTION !
Range Adjusting Screw
Set at 40 PSIG (R-22)
Set at 20 PSIG
(CW Raises Setting)
Set at 52 PSIG (R-404A)
(CW Raises Setting)
Reset Button
Low Pressure
Test Connection
High Pressure
Test Connection
FIGURE 9-4
High-Low Pressure Switch
03TA Service Manual
High Pressure Adjustment
Set at 300 PSIG (R-22)
Set at 350 PSIG (R-404A)
(CW Raises Setting)
Differential Factory Set
4/2/14
Page 87
03TA Service Manual
Line to condenser
Line to condenser
Air-Cooled Units. The condenser fan switch mounted to the frame (lower right side) (FIGURE 95B) (CPS) is used to regulate the head pressure. This is an adjustable pressure switch located on the
right-hand front of machine. It controls the operation of the condenser fan motor(s) through a
contactor (FC) (FIGURE 6-2) located in the control panel. The switch is set to cycle the fan
motor(s) “On” at 210 psig and “Off” at 190 psig for R-22 and “On” at 250 psig and “Off” at 230
psig for R-404a. Higher settings may be necessary for 0°F and below ambient conditions to assure
there is enough warm gas for ice harvesting.
Adjusting Stem
Set at 200 PSI (R-22)
Set at 235 PSI (R-404A)
(CW Lowers Setting)
Cut In Adjusting Screw
Set at 210 PSIG (R-22)
Set at 250 PSIG (R-404A)
(CW Lowers Setting)
Vogt Part #: 12A4200E1001
1 1/4” FPT Connection
(water connections)
Connected to High Side of
Water Cooled Condenser
FIGURE 9-5A.
Water Regulating Valve
Cut Out Adjusting Screw
Set at 190 PSIG (R-22)
Set at 230 PSIG (R-404A)
(CW Raises Setting)
Vogt Part #: 12A2117F05
Connected to
Compressor Discharge
FIGURE 9-5B.
Condenser Fan Switch
Oil Separator. A coalescent oil separator is used to separate the oil from the discharge gas and return
it to the compressor
Oil return line to
compressor
Replacement filter
Vogt Part #: 12A3025F03
Gasket – supplied with filter
Discharge line from
compressor
Temprite Oil Separator
Vogt Part #: 12A3025S14
(Add 16 ounces of oil when installing
new or after changing filter)
Oil return line
to compressor
Discharge line from
compressor
AC&R Oil Separator
Vogt Part #: 12A3025S12
(Add 12 ounces of oil when
installing new separator)
FIGURE 9-6
Oil Separator
9-5
SERVICE OPERATIONS
4/11/14
Page 88
9-6
SERVICE OPERATIONS
Solenoid Valves. All solenoid valves are pilot operated with “floating” type diaphragms. For
satisfactory operation be sure that the manual opening stem is in the closed or automatic position.
This means the stem is backed all the way out. Correct direction of stem rotation should be labeled on
the stem seal nut.
Sporlan 1 1/8” Solenoid Valve
Vogt Part #: 12A4200A0904
Sporlan #: ME34S290
Replacement Coil – MKC-2
Vogt Part #: 12A2105C16
Rebuild Kit – KS-E34
Vogt Part #: 12A4199V46
MANUAL STEM (UNDER CAP)
IN - TO OPEN
OUT - TO CLOSE (AUTOMATIC)
Note: Manual stem not shown
FIGURE 9-7A
“D”& “X” Solenoid Valve (Sporlan) Before August 2006
Sporlan 1 1/8” Solenoid Valve
Vogt Part #: 12A4200A09041
Sporlan #: ME35S190
Replacement Coil – MKC-1
Vogt Part #: 12A2105C26
Rebuild Kit – KS-E35
Vogt Part #: 12A4199V56
Sporlan Rebuild Kit – KS-E35
Vogt Part #: 12A4199V56
FIGURE 9-7B
“D”& “X” Solenoid Valve (Sporlan) After August 2006
Sporlan 5/8" Solenoid Valve
Vogt Part #: 12A4200A0505
Sporlan #: ME19S290
Replacement Coil – MKC-2
Vogt Part #: 12A2105C16
Rebuild Kit – KS-B19/E19
Vogt Part #: 12A4199V43
MANUAL STEM (UNDER CAP)
IN - TO OPEN
OUT - TO CLOSE (AUTOMATIC)
FIGURE 9-7C
“A” Solenoid Valve (Sporlan)
03TA Service Manual
4/11/14
Page 89
03TA Service Manual
Compressor Crankcase Heater. When electrical power is supplied to
terminals L1, L2 & L3 of the control panel, the crankcase heater is energized when the machine is
not operating. It is de-energized when the compressor is operating.
Oil Return shut-off valve
(from oil separator)
Suction
Service
Valve
Suction Screen
(Behind suction valve)
Oil Charging Connection
(1/4” access fitting with shrader)
Oil Pump Screen
Vogt Part #: 12A7509E12
To Oil Separator
Oil Sightglass
Oil Pump
FIGURE 9-8
Copeland Discus Compressor (3D shown)
9-7
SERVICE OPERATIONS
Compressor
Unloader
Discharge
Service
Valve
Sentronic Oil
Pressure Safety
Switch
Crankcase Heater
4/2/14
Page 90
9-8
machines
SERVICE OPERATIONS
Sentronic Oil Pressure Safety Control. All Sentronics utilize a pressure sensor and an electronic
control module to precisely measure oil pump differential pressure. The main advantage of
Sentronic is the elimination of the traditional capillary tubes, bellows, and pressure connections that
mechanical pressure switches require to measure differential oil pressure. These require careful
handling and are known to be a source of leaks in refrigeration systems.
A second advantage of Sentronic is in the use of a precise electronic clock for the two minute time
out circuit. Traditional mechanical controls use resistance heaters to provide the time to trip in the
event of low oil pressure. 208 volt systems, low ambient temperatures or brown-out type conditions
cause the heater output to be reduced, thus increasing the time out period from two minutes to three
or four minutes when low oil pressure conditions exist. With the electronic clock, the time out will
always be the same.
As a result of the elimination of the capillary tube measuring system and a more precise timing
circuit, Sentronic will improve the overall reliability of the refrigeration system. As in the past, all
new and replacement Copelametic compressors equipped with oil pumps require the use of a
Copeland approved oil pressure safety switch. Failure to use an approved oil pressure safety switch
will be considered as misuse of the compressor, and can adversely affect warranty replacement of
the compressor should a lubrication connected failure occur.
Oil Pump
Copper
Washer
Sensor
03TA Service Manual
Oil Sightglass (50hz machine)
Note: Sightglass on other side
of compressor for 60hz
Reset Button
Module
4/11/14
Sentronic/CoreSense Oil Safety (Sensor Only)
Part #: 12A2117A0501
Sentronic Oil Safety Control (Entire Unit)
Part #: 12A2117A05
FIGURE 9-9A
Sentronic Oil Pressure Safety Control
Page 91
03TA Service Manual
Sentronic Sensor (2D, 3D, 4D & 6D compressors before March 2011). The same oil pressure
sensor is used for all Sentronics. It mounts directly into the oil pump. The Sentronic sensor
measures oil pump differential pressure. It has an internal contact that opens on low oil pressure
and signals the Sentronic electronic control module to begin time out. The same contact closes
when proper oil pressure is present and stops the module time out. Should oil pressure fall below
7-9 PSID for a period of two minutes, the Sentronic module will open the control circuit, using
its Normally-Closed (N) contact, and shut the compressor off.
Approximate oil pressure can be measured in the field. Oil pumps are furnished with a Schrader
valve mounted on the oil pump discharge port. To measure oil pressure, subtract crankcase
pressure from discharge oil pressure. Tripping of the oil pressure safety switch is a warning that
the system has been without proper lubrication for too long a time. Repeated trips of the oil
pressure safety control are a clear indication that something in the system requires immediate
remedial action.
Sentronic Module (2D, 3D, 4D & 6D compressors before March 2011). The Sentronic has in
addition to the (N) contact, used for compressor shutdown, a Normally Open (N.O.) contact that
can be used in an alarm circuit. The Single Pole Double Throw (S.P.D.T.) contact of Sentronic
can be electrically isolated from the control circuit power supply, and used to control a circuit
with a different voltage. Sentronic has a timing circuit that actually compares the amount of time
with good oil pressure to that with insufficient oil pressure and has a memory that will shut the
compressor down after a period of more than two minutes if the compressor has a "history" of oil
pressure fluctuations with more unacceptable than acceptable pressures.
Sentronic also has a memory that retains the compressor oil pressure "history" for up to one
minute in the event of a power loss. Sentronic uses a permanent magnet integral with the reset
button to reset its output control relay in the event of a trip. When the reset button is depressed,
it magnetically pulls the Sentronic relay's armature to its original, reset position. Sentronic needs
no voltage present to reset.
Coresense Protection
Discus compressors manufactured after March 2011 will be supplied with CoreSense Protection.
CoreSense replaces the Sentronic Oil Pressure Safety Module on all Discus compressors and the
Electronic Motor Protector Module on 4D & 6D compressors. Note: 2D & 3D compressors will
continue to have Internal Line Break overload protection.
The oil pressure monitoring portion of the CoreSense will act very similar to the Sentronic Oil
Pressure Safety switch. A current transformer (CT) in the compressor junction box determines
when the compressor is running and starts monitoring oil pressure. Note: Wire “T1” passes
through CT before connecting to compressor terminal.
SERVICE OPERATIONS
9-9
4/2/14
Page 92
9-10
Description
Vogt #
Copeland #
SERVICE OPERATIONS
The CoreSense module has power applied at all times to allow for more detailed fault
notification. An LED will flash when a fault occurs. The number of flashes will identify the
fault condition.
# of Flashes Condition
1 Oil Pressure
2 Motor Protection Trip
3 Discharge Temperature (optional add-on)
4 Current Sensor Fault
5 Communication Error
3
22
22
6
FIGURE 9-9B
CoreSense Protection
03TA Service Manual
4/11/14
Crankcase Heater 100 W (insert type) 12A7509E12 518-0028-01
Oil Pressure safety switch
CoreSense Protection Module and Sensor 12A2117A07 943-0109-00
Oil safety – sensor only
Sentronic3
Module and Sensor
For Sentronic, Sentronic 3
or CoreSense
12A2117A05 585-1076-02
12A2117A0501 998-0162-00
Control Circuit Protection. The electrical control circuit of the machine is protected by a 2 pole 3
amp circuit breaker. If breaker trips, the machine will immediately stop. Before resetting the
breaker, open the disconnect switch to machine and set the “Ice/Off/Clean” switch to the “Off”
position. If the machine was off for an extended time the crankcase heater must be energized for a
minimum of two hours before restarting the machine. When ready to restart the machine, depress
the “Start” button. The machine will automatically return to a freeze cycle upon completion of the
harvest cycle.
Page 93
03TA Service Manual
Suction (2” FPT)
Pump Discharge (1 1/2” FPT)
Circulating Water Pump Motor. The motor bearings are prelubricated and sealed. They require
no further lubrication. The pump should operate with the water level above the impeller housing.
The pump is equipped with a mechanical seal that is self-adjusting and requires no lubrication.
However, the pump should not be operated unless circulating water. The pump manufacturer
recommends that a mechanical seal be kept as a spare. When ordering a seal, specify pump size,
type, serial number, and manufacturer’s name as indicated on the nameplate.
9-11
SERVICE OPERATIONS
Pump
Seal Kit Part #: 12A4080S12
Pump Part #: 12A4020G01
FIGURE 9-10
Water Pump
Cutter Gear Reducer. The oil level for the gear reducer should be checked if there is evidence of a
leak. It should be level with the plugged opening in the side of the gear housing. Use Mobile 600W
cylinder oil or equal. Change oil once a year.
The motor bearings are prelubricated and require no further lubrication. For additional information,
refer to manufacturer’s instructions.
Vent Plug
Vent Plug
Gear Reducer (10:1)
Replacement food grade oil:
Part #: 12A4030R12
Part #: 19T3020C01
Texaco Cygnus 220
Oil Capacity: 8 ounces
Oil Level Plug
Drain Plug
Gear Reducer (5:1)
Crushed Ice Only
Part #: 12A4030R14
Note: Ventless gear reducer used after August 2010
FIGURE 9-11
Gear Reducer
4/2/14
Page 94
9-12
Light solid when "timed
out"
Light solid when "timed
SERVICE OPERATIONS
Thawing Timer. The thawing timer governs the ice thawing period. It is located inside the control
panel (FIGURE 6-2). It is started by action of the freezer pressure switch (FPS) which energizes the
“CR” relay. This timer is set prior to shipment for approximately a two minute period.
Light
indicates
timer has
timed out
Light
indicates
timer is timing
Up Light (red)
Light off while "timing"
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
screw clockwise to increase the time or counter-clockwise to decrease the time. Check thaw time
after each adjustment.
Syrelec Timer (Orange)
Scale: Set to
“X1”
Range: Set to
“0 to 12”
Time Range
adjustment
0 - 1.2
0 - 3
0 - 12
0 - 30
Timer Part #: 12A7503E22
Time Base:
Set to “min”
Allen Bradley Timer (White)
POWER
UP
6
4
8
2
0
RANGE UNIT
Min
10
12
FIGURE 9-12A
Thawing Timer
FIGURE 9-12B
Thawing Timer Wiring
03TA Service Manual
Crouzet Timer (White)
Range: Set
to “1-10
min”
Voltage rating: 24-240V
Light flashing when timing
Light Solid when timed out
Power Light (green)
Light blinks while "timing"
Units: Set to “min”
Unit adjustment
sec
min
hrs
10h
4/2/14
Page 95
03TA Service Manual
Condenser Cleaning. See “Water Cooled Condensers”, “Maintenance”, Section 7.
Air-Cooled Condenser. Visual inspection will indicate if dirt is accumulating and clogging the fin
face of the condenser. A vacuum cleaner, compressor air or a brush may be used to remove any
accumulation of dirt from the fin section of the condenser.
Pumpdown. The function of the pumpdown is to transfer all of the liquid refrigerant from the
freezer (evaporator) into the receiver. Pump-down should only be performed when the freezer is
clear of ice. Its main purposes are:
3. To perform service or repair work on the machine.
4. To winterize the machine.
5. To prepare the machine for disconnecting and moving.
To perform a pumpdown, follow this procedure:
1. Before Cleaning machine
2. To check the total refrigerant charge.
9-13
SERVICE OPERATIONS
1. Push manual harvest button to clear the freezer of all ice and stop operation.
2. Close the liquid stop valve (58) at the receiver.
3. Open the water tank drain valve (39) partially to allow a continuous flow
of warm make-up water into the water tank, and still maintain a good level
in the tank. An auxiliary supply of warm water (not to exceed 100°F) may
be used if available. Warmer water affords a more complete pumpdown.
4. Start the machine and allow it to operate and complete one harvest
5. During the thaw cycle, close the 1/4" valve going to the freezer pressure switch
to prevent another thaw cycle.
6. Allow the machine to operate until the low pressure switch stops the machine
@ 20 PSIG. If a lower pressure is desired, it can be accomplished by lowering the
low pressure switch and starting and stopping the machine by the "Start" and "Stop"
push buttons. Continually observe the oil level to make sure the oil is not carried
from the compressor while operating at a low pressure.
7. Close the thawing gas stop valve (90), the receiver liquid return stop valve (91),
the compressor suction valve (34), the compressor discharge valve and the oil
return stop valve (70).
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9-14
SERVICE OPERATIONS
Removal Of Refrigerant From The Machine. To transfer the refrigerant charge from the machine
into a separate container, proceed as instructed above under “Pumpdown”. This will isolate most of
the refrigerant in the receiver and the recovery unit can be connected to the access port (44) of the
hand stop valve (58) at the bottom of the receiver. Open the valve access port by turning the valve
stem in (front seat) and operate the recovery unit until the system is considered empty.
Approved recovery equipment, hoses, gages, and refrigerant containers must be
It is not recommended that refrigerant be transferred from a refrigeration system
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
Refrigerant Leaks. In addition to testing the machine for leaks as instructed under “Refrigerant
Charge”, it is advisable to again make a leak test after the unit has been in operation approximately
one week. Any noticeable change in operating conditions, other than shown on the “Certificate of
Test” may indicate a loss of refrigerant due to a leak. Always remove the refrigerant pressure from
the vessel or tubing before repairs are attempted.
Non-condensable Gases. Satisfactory operation of the machine is not possible if non-condensable
gases (usually air) are present in the system. Excessive condensing pressure is an indication of such
gases. Excessive condensing pressure in water cooled condensers may also be due to the
accumulation of scale in the cooling coil or due to insufficient cooling water or excessive water
temperature. See “Water Cooled Condensers”, Section 7.
03TA Service Manual
! WARNING !
used to comply with all local and federal EPA regulations.
! WARNING !
! WARNING !
Follow these instructions carefully.
Severe personal injury can result from improper
discharge of refrigerant.
! WARNING !
! WARNING !
by cylinder manufacturer or any applicable code requirements.
! WARNING !
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Compressor Motor Burnout. There are several causes of compressor motor burnout. Some of
these are described below.
1. Low line voltage. A compressor motor is designed to operate within the range of plus or minus
10% of its nameplate voltage. Low voltage requires the motor windings to carry more current at
the same compressor load. When this current gets too high or is applied for an extended period,
the motor windings overheat, resulting in a failure or burnout.
2. Loss of refrigerant. The hermetic compressor motor is maintained at proper operating
temperature by passing cool suction gas over the motor windings. A loss of refrigerant can cause
the winding to overheat resulting in a failure or burnout.
3. High head pressure. The system is designed to operate at 200 psig. Excessive head pressure
adds refrigerating load on the compressor, which can cause the windings to overheat and result in
a failure or burnout.
4. Moisture. Moisture in contact with refrigerant oil and the presence of heat will form
hydrochloric or hydrofluoric acid. The acid will destroy the insulation on the motor winding
causing a short circuit, which can increase motor temperature in excess of 3000°F. This extreme
temperature will also create a sludge or black residue in the system.
5. Mechanical failure. Mechanical failure has been determined as a major cause of motor burnout.
Bearing wear or wipe-out may allow rotor to drag--overheating the windings and burnout.
Whenever there is a compressor failure due to a motor burnout, it is important that the system be
thoroughly cleaned before replacing the damaged compressor or otherwise the new compressor may
also be damaged.
SERVICE OPERATIONS
9-15
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9-16
SERVICE OPERATIONS
Capacity Control (Internal) Valve Construction. A schematic illustration of the internal valve
operation is shown in FIGURE 9-13.
In the normal (full capacity) operating position with the solenoid valve de-energized, the needle
valve is seated on the lower port, and the unloading plunger chamber is exposed to suction pressure
through the suction port. Since the face of the plunger is open to the suction chamber, the gas
pressures across the plunger are equalized, and the plunger is held in the open position by the spring.
When the solenoid valve is energized, the needle valve is seated on the upper port, and the unloading
plunger chamber is exposed to discharge pressure through the discharge pressure port. The
differential between discharge and suction pressure forces the plunger down, sealing the suction port
in the valve plate, thus preventing the entrance of suction vapor into the unloaded cylinders.
The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may
be used with the valve either energized or de-energized without excessive compressor cycling.
Loaded Operation (during freeze). This capacity control valve is controlled by an electric
solenoid. When the solenoid is de-energized, the valve loads the cylinder bank (2 cylinders) as
shown in the above figure.
Unloaded Operation (during thaw only). During the thaw cycle, the solenoid coil is energized.
The needle valve is seated on the upper port, and the unloading plunger chamber is exposed to
discharge pressure through the discharge pressure port. The differential between discharge and
suction pressure forces the plunger down, sealing the suction port in the valve plate, thus preventing
the entrance of suction vapor into the unloaded cylinders.
03TA Service Manual
FIGURE 9-13
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03TA Service Manual
Component Removal and Replacement Operations
Cutter Motor The cutter motor’s bearings are prelubricated and sealed and require no further
lubrication. If the motor needs replacing, proceed as follows:
1. Turn power off and lockout disconnect.
2. Check terminals with voltmeter to confirm power is off.
3. Remove motor terminal cover and disconnect wires. Mark wires for ease of replacement.
4. Remove four cap screws around the motor flange and separate the motor from the reducer.
Watch for shaft key that must be reinstalled later.
5. Check the motor electrically to confirm it is defective.
6. Apply Anti-Seize lubricant to the shaft of the replacement motor.
7. Position the shaft key in the motor keyway, align it with the reducer keyway and install the
motor. Make sure the key stays in position as shaft is.
8. Install the four cap screws to hold the motor in place on the reducer.
9. Connect the wires and install the terminal cover.
10. Check motor rotation to make sure the cutter turns in the proper direction. Reverse two wires at
the motor if necessary to change rotation direction.
Cutter Gear Reducer To remove the gear reducer, proceed as follows: (See FIGURE 9-11)
1. Turn power off and lockout disconnect.
2. Remove motor from reducer.
3. Loosen (slightly) the four bolts and nuts holding the gear reducer in place.
4. Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove
the reducer and mounting plate from the tank.
5. Measure the distance between the top of drive gear and the mounting plate for future reference.
6. Remove the three cap screws from the gear and hub and install two 1/4”-20 x 2” long all thread
set or cap screws in the threaded holes of the drive gear. These two screws can be used as
jacking bolts to remove the gear from the tapered split hub.
7. In necessary, driving a screwdriver in the split and sliding the hub off the shaft can remove the
split hub.
8. The new gear reducer can then be installed by reversing the removal procedure.
9. Be sure the gear and hub is properly positioned on the shaft so it will have a full vertical mesh
with the cutter ring gear.
10. Final gear meshing should be adjusted so there is only a slight amount of play between the ring
gear and drive.
11. Make sure all bolts are tightened securely and there is no excessive gear noise when the cutter
motor is running.
SERVICE OPERATIONS
9-17
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9-18
SERVICE OPERATIONS
Water Tank Removal
1. Turn off and lock out power to the machine.
2. Turn off water supply and disconnect lines from the tank.
3. Drain the tank and disconnect pump suction tube and drain line tubing and water lines.
4. Disconnect the ice discharge chute.
5. Loosen bolts holding the tank to the cutter assembly until the tank rests on the bars.
6. Loosen bolts holding the tank supports.
7. The tank can then be removed to the side of the machine.
8. Make sure the rubber gasket is in place and aligned properly when the tank is installed and
bolted to the freezer.
Cutter and Bearing Removal/Installation
Refer to FIGURES 9-14 for parts identification and location.
1. Turn off and lock out power to the machine.
2. Remove the cutter motor from the reducer.
3. Remove the water tank assembly and then the cutter assembly.
4. With a 1/4” or slightly smaller punch, reach in through the ice discharge opening, drive the spiral
pin out of the disc hub and cutter shaft, and push or drive the disc off the shaft.
5. Lift the cutter assembly out of the bearing surface of the cutter. The surface should be smooth
and free from nicks or burrs.
6. Inspect the bearing for wear. There should be no side movement between the shaft and bearing
and the bearing thrust flange should be no thinner than 3/16” (it is 1/4” thickness new).
7. Before removing the bearing, reference mark the location of the bearing support on the side of
the tank.
8. Loosen and remove the three cap screws from the bearing support ends and lift the support out of
the water tank.
9. Drive the 3/16” x 1/2” pin located in the side of the support hub in and through the bearing wall.
10. Now the bearing can be pressed or driven out of the support hub.
11. Try the new bearing on the cutter shaft to make sure it turns easily.
12. Press or drive the new bearing into the hub. Be careful not damage the bearing surfaces (the old
bearing may be used as a driver).
13. Drill a 3/16” hole through the bearing wall, using the original hub hole as a pilot. Insert and
drive the 3/16” pin flush with the outside of the hub, making sure the pin doesn’t extend beyond
the inner surface of the bearing.
14. Slide the new bearing and support onto the cutter shaft to make sure it spins freely. If it is tight,
ream the bearing inner surface slightly until it turns free.
15. Install the bearing support in the tank, using the reference marks as a guide.
16. Slide the cutter and shaft into the bearing and check the cutter alignment. By laying a straight
edge across the tank top flange, there should be 0” to 1/16” clearance between the rim of the
cutter and the top of the tank flange. Loosen the bearing support cap screws and drive the
support arms up or down for the proper alignment.
17. Tighten the support screws securely and finish assembly of the cutter and cutter disc.
18. Install the tank and other parts, reversing the procedure of removal.
03TA Service Manual
4/2/14
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