Page 1
10TA
®
TUBE-ICE
MACHINE
(Includes model P18FXT)
Manual Part Number 12A4171M08
Revision 3
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.
Since 1880, Manufacturers of Quality
Tube-Ice® Machines
Page 4
Vogt
Tube-Ice Machines
Installation, Service Manual and Parts Catalog #12A4171M08
10TA Model
Page 5
10TA Service Manual
i
TABLE OF CONTENTS
TABLE OF CONTENTS
®
Vogt
TUBE-ICE® MACHINES
Model 10TA (Includes P18FXT)
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 10TA (P18FXT) Air-Cooled, FIGURES 1-1, 1-2, & 1-3 ................................................... 1-4, 1-5, 1-6
Assembly Drawing Model 10TA (P18FXT) 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
Vogt Model Nomenclature, FIGURE 2-1 ...................................................................................................................... 2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Piping and Drain Connections, TABLE 3-1 ................................................................................................................. 3-1
Water Cooled Condenser Connections, FIGURE 3-1 .................................................................................................... 3-2
Cooling Tower ............................................................................................................................................................... 3-2
Space Diagram (Air-Cooled Machine), FIGURE 3-2A ................................................................................................. 3-3
Space Diagram (Water Cooled Machine), FIGURE 3-2B ............................................................................................. 3-4
Wiring and Electrical Connection FIGURE 3-3 ............................................................................................................ 3-5
Electrical Specifications, TABLE 3-2 ........................................................................................................................... 3-5
Phase Check, Voltage and Current unbalance ............................................................................................................... 3-6
Rotation Check .............................................................................................................................................................. 3-6
Air-Cooled Condenser Installation Instructions ............................................................................................................. 3-7,3-8
Pounds of R-22 to Add Vs. Liquid Line Length, TABLE 3-3 ....................................................................................... 3-8
Air-Cooled Condenser Data, TABLE 3-4 ...................................................................................................................... 3-9
Condenser Dimensions, FIGURE 3-4 ............................................................................................................................ 3-10
Condenser Field Piping (Cold Weather Valve Kit), FIGURE 3-5 ................................................................................. 3-11
Equivalent Feet Due To Friction, TABLE 3-5 ............................................................................................................... 3-12
Minimum Traps For Discharge Lines, FIGURE 3-6 ..................................................................................................... 3-12
Wiring For Bohn BNHS04A029 Condenser (3 phase motors), FIGURE 3-7 ................................................................ 3-13
Ice Bin Thermostat Sensor ............................................................................................................................................. 3-15
Typical Bin Sensor Mounting, FIGURE 3-9 ................................................................................................................. 3-15
Programming Electronic Bin Thermostat ...................................................................................................................... 3-16
Installation Review: A Checklist .................................................................................................................................. 3-17
Page 6
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TABLE OF CONTENTS
Page No.
4. HOW YOUR TUBE-ICE MACHINE WORKS
Principle of Operation .................................................................................................................................................... 4-1
Freeze Period ................................................................................................................................................................. 4-2
Harvest Period ............................................................................................................................................................... 4-2
Piping Nomenclature ..................................................................................................................................................... 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 Procedure ......................................................................................................................................................... 5-3
Control Panel Switch Layout, FIGURE 5-1 .................................................................................................................. 5-3
Shut-down Procedure ..................................................................................................................................................... 5-4
Operating Tips ............................................................................................................................................................... 5-4
Adding Refrigerant ........................................................................................................................................................ 5-5
10TA Service Manual
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Control Panel (Cover On), FIGURE 6-1 ....................................................................................................................... 6-1
Control Panel (Cover Removed), FIGURE 6-2 ............................................................................................................. 6-2
Control Panel (Cover Removed), and Optional Power Monitor, FIGURE 6-2A ........................................................... 6-3
Control Panel Components (CE & Australian Approved), FIGURE 6-2B .................................................................... 6-4
Control Panel Components and Part Numbers, TABLE 6-1 .......................................................................................... 6-5
Control Panel Part Descriptions, TABLE 6-2 ................................................................................................................ 6-6
Electrical Schematic All Voltages, 50-60 Hz. Across Line Start, FIGURE 6-3 ............................................................ 6-7
3-Phase Power - Electrical Schematic All Voltages, 50-60 Hz, FIGURE 6-3A ............................................................ 6-8
Compressor Schematic Detail All Voltages, 50-60 Hz., FIGURE 6-4 .......................................................................... 6-9
7. MAINTENANCE
Ice-Making Section ........................................................................................................................................................ 7-1
Cleaning Procedure ........................................................................................................................................................ 7-1
Sanitizing Procedure ..................................................................................................................................................... 7-2
Water Distributors ......................................................................................................................................................... 7-3
Number of Water Distributors Per Tube Size, TABLE 7-1 ........................................................................................... 7-3
Average Hole Size In Tube-Ice, TABLE 7-2 ............................................................................................................... 7-3
Water Tank .................................................................................................................................................................... 7-3
Freezer Cover ................................................................................................................................................................ 7-3
Water Cooled Condensers ............................................................................................................................................. 7-4
Checking Operation ...................................................................................................................................................... 7-4
Draining ..................................................................................................................................................................... 7-4
Chemical Cleaning......................................................................................................................................................... 7-5
Mechanical Cleaning .................................................................................................................................................... 7-5
Lubrication .................................................................................................................................................................... 7-6
Lubrication, Compressor ............................................................................................................................................... 7-6
Compressor Recommended Lubricants, TABLE 7-3 .................................................................................................... 7-6
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10TA Service Manual
TABLE OF CONTENTS
Page No.
7. MAINTENANCE (cont)
Cutter Gear Reducer Lubrication ................................................................................................................................... 7-7
Preventive Maintenance ................................................................................................................................................. 7-8
For The Manager ........................................................................................................................................................... 7-9
Preventive Maintenance Form ....................................................................................................................................... 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
Poor Ice Quality ............................................................................................................................................................. 8-6
Low Ice Capacity ........................................................................................................................................................... 8-7
Low Compressor Oil Level ............................................................................................................................................ 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
Float Switch ................................................................................................................................................................... 9-2
Hansen Float, FIGURE 9-2 ........................................................................................................................................... 9-2
Hand Expansion Valve .................................................................................................................................................. 9-3
Freezer Pressure Switch ................................................................................................................................................. 9-3
Freezer Pressure Switch (Allen-Bradley), FIGURE 9-3 ................................................................................................ 9-3
Capillary Bypass ............................................................................................................................................................ 9-4
High/Low Pressure Switch ............................................................................................................................................ 9-4
High/Low Pressure Switch, FIGURE 9-4 ...................................................................................................................... 9-4
Head Pressure ................................................................................................................................................................ 9-5
Water Cooled Units ....................................................................................................................................................... 9-5
Air-Cooled Units ........................................................................................................................................................... 9-5
Water Regulating Valve, FIGURE 9-5A ....................................................................................................................... 9-5
Condenser Fan Switch, FIGURE 9-5B .......................................................................................................................... 9-5
Condenser Cleaning ....................................................................................................................................................... 9-5
Air-Cooled Condenser ................................................................................................................................................... 9-5
Compressor Motor Protection, Electronic...................................................................................................................... 9-6
High Potential Testing .................................................................................................................................................. 9-7
Field Troubleshooting ................................................................................................................................................... 9-7
Electronic Module and Compressor Terminal Board Connections, FIGURE 9-6 ........................................................ 9-8
Oil Pressure Safety Control / Sentronic Oil Safety, FIGURE 9-7 .................................................................................. 9-9
Oil Pressure Sensor ........................................................................................................................................................ 9-9
Oil Pressure Module ...................................................................................................................................................... 9-10
iii
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iv
TABLE OF CONTENTS
9. SERVICE OPERATIONS (cont.)
Coresense Protection ..................................................................................................................................................... 9-10
Oil Separator, FIGURE 9-8 ........................................................................................................................................... 9-11
Compressor Crankcase Heater ...................................................................................................................................... 9-11
Control Circuit Protection .............................................................................................................................................. 9-11
Thawing Timer, FIGURE 9-9A ..................................................................................................................................... 9-12
Thawing Timer .............................................................................................................................................................. 9-12
Pump Down ................................................................................................................................................................... 9-13
Removal Of Refrigerant From Machine ........................................................................................................................ 9-13
Refrigerant Leaks........................................................................................................................................................... 9-14
Non-Condensable Gases ................................................................................................................................................ 9-14
Compressor Motor Burnout ........................................................................................................................................... 9-14
Solenoid Valves ............................................................................................................................................................. 9-15
Thawing Gas Solenoid Valve ( “D” Valve), FIGURE 9-10A ........................................................................................ 9-15
Liquid Feed Solenoid Valve ( “A1” & “A2” Valve), FIGURE 9-10B .......................................................................... 9-15
Capacity Control Valve (Compressor Unloader) ........................................................................................................... 9-16
Copeland Compressor Unloader Valve, FIGURE 9-11 ................................................................................................. 9-16
Loaded Operation (Freeze Period) ................................................................................................................................. 9-16
Unloaded Operation (During Thaw Only) ..................................................................................................................... 9-16
Circulating Water Pump Motor, FIGURE 9-12 ............................................................................................................. 9-17
Cutter Gear Reducer, FIGURE 9-13 .............................................................................................................................. 9-17
Component Removal and Replacement Operations ....................................................................................................... 9-18
Cutter Gear Reducer ...................................................................................................................................................... 9-18
Water Tank Removal ..................................................................................................................................................... 9-19
Cutter & Bearing Removal/Installation ......................................................................................................................... 9-19
Cutter Assembly, FIGURE 9-14 .................................................................................................................................... 9-20
Cutter Parts (Cylinder Ice), FIGURE 9-15 .................................................................................................................... 9-20
Cutter Drive Parts, FIGURE 9-16 .................................................................................................................................. 9-21
Crushed Ice Production, FIGURE 9-17 ......................................................................................................................... 9-22
Defrost Pressure Switch - DPS (R404A Machines only) ............................................................................................... 9-23
Pressure Relief Valve ................................................................................................................................................... 9-23
Technical Service Bulletin (Water quality) ................................................................................................................... 9-24
10TA Service Manual
Page No.
10. OPTIONS AND ACCESSORIES
Power Monitor, FIGURE 10-1 ..................................................................................................................................... 10-1
Power Monitor, Parameters, TABLE 10-1 ................................................................................................................... 10-2
PLC, Programmable Logic Controller .......................................................................................................................... 10-4
11. TABLES AND CHARTS
P18FXT Ratings (60 Hz.), TABLE 11-1 ....................................................................................................................... 11-1
P18FXT Ratings (50 Hz.), TABLE 11-2 ....................................................................................................................... 11-2
P18FXT Capacity Ratings, TABLE 11-3 ...................................................................................................................... 11-3
Condenser Water Usage, TABLE 11-4 .......................................................................................................................... 11-4
Make-up Water Usage (gpm), TABLE 11-5 .................................................................................................................. 11-4
Page 9
10TA Service Manual
11. TABLES AND CHARTS (cont.)
Normal Operating Vitals, TABLE 11-6 ......................................................................................................................... 11-4
Recommended Spare Parts List ..................................................................................................................................... 11-5
Temperature - Pressure Chart for Common Refrigerants, TABLE 11-7 ........................................................................ 11-6
Conversion Factors: English to Metric, TABLE 11-8 ................................................................................................... 11-7
Constants, TABLE 11-9 ................................................................................................................................................ 11-7
12. INDEX
TABLE OF CONTENTS
Page No.
v
Page 10
vi
TABLE OF CONTENTS
BLANK
10TA Service Manual
Page 11
10TA Service Manual
INTRODUCTION
1. Introduction
VOGT ICE®, LLC
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 10TA 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.
1-1
4/14/14
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/R404A
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.
10TA Service Manual
! CAUTION !
! CAUTION !
! CAUTION !
! CAUTION !
4/14/14
Page 13
10TA 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 TubeIce® machine? Before you operate, adjust or service this machine, you should read this manual,
understand the operation of this machine, and be aware of possible dangers.
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 or product or property damage.
! CAUTION !
INTRODUCTION
1-3
4/14/14
Page 14
1-4
INTRODUCTION
THAWING GAS
STOP VALVE
(90)
CONTROL PANEL
(1)
FAN CONTROL
SWITCH
(41A)
COMPRESSOR
(3)
LIQUID OUTLET
STOP VALVE
(KING VALVE)
(58)
WATER TANK
(7)
FIGURE 1-1
Assembly (Air-Cooled)
Front View
10TA Service Manual
HEAT
EXCHANGER
(13)
LOW PRESSURE
GAGE
(1PG)
HIGH PRESSURE
GAGE
(2PG)
OIL PRESSURE
SWITCH
(94)
HIGH-LOW
PRESSURE SWITCH
(4PS)
HIGH PRESSURE
TEST CONNECTION
LOW PRESSURE
TEST CONNECTION
CIRCULATING
WATER PUMP
(6)
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Page 15
10TA Service Manual
SAFETY RELIEF
VALVE
(51)
CHECK VALVE
(101)
CONDENSER
SERVICE
CONNECTION
(32)
LIQUID RETURN
STOP VALVE
(91)
OIL RETURN
STOP VALVE
(70)
1" FPT WATER
TANK DRAIN
FIGURE 1-2
Assembly (Air-Cooled)
Right Side View
INTRODUCTION
FREEZER
(2)
FREEZER
PRESSURE
STOP VALVE
(69)
SUCTION
ACCUMULATOR
(88)
FLOAT SWITCH
(22)
LIQUID FEED
SOLENOID VALVE
("A1" VALVE)
(20)
HAND
EXPANSION
VALVE
(17)
FREEZER
REFRIGERANT
CHARGING VALVE
(28)
LIQUID FEED
SOLENOID VALVE
("A2" VALVE)
(21)
FILTER DRIER
(46)
1-5
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1-6
INTRODUCTION
SAFETY RELIEF
VALVE (50)
RECEIVER (15R)
RECEIVER
SIGHT GLASS
(30)
THAWING GAS
SOLENOID VALVE
("D" VALVE)
(18)
RECEIVER DRAIN
VALVE (44)
GEAR REDUCER
(5R)
MAKE-UP
WATER FLOAT
VALVE
(12)
FIGURE 1-3
Assembly (Air-Cooled)
Left Side View
10TA Service Manual
COLD WEATHER
SOLENOID VALVE
("X" VALVE)
(53)
OIL
SEPARATOR
(14)
CUTTER MOTOR
(5M)
1/2" MPT
MAKE-UP WATER
CONNECTION
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Page 17
10TA Service Manual
CONDENSER
(15)
THAWING GAS
STOP VALVE
(90)
CONTROL PANEL
(1)
COMPRESSOR
(3)
LIQUID OUTLET
STOP VALVE
(KING VALVE)
(58)
WATER TANK
(7)
L
FIGURE 1-4
Assembly (Water Cooled)
Front View
1-7
INTRODUCTION
HEAT
EXCHANGER
(13)
LOW PRESSURE
GAGE
(1PG)
HIGH PRESSURE
GAGE
(2PG)
OIL PRESSURE
SWITCH (94)
HIGH-LOW
H
PRESSURE SWITCH
(4PS)
HIGH PRESSURE
TEST CONNECTION
LOW PRESSURE
TEST CONNECTION
CIRCULATING
WATER PUMP
(6)
4/14/14
Page 18
1-8
INTRODUCTION
SAFETY RELIEF
VALVE
(51)
LIQUID RETURN
STOP VALVE
(91)
OIL RETURN
STOP VALVE
(70)
1" FPT WATER
TANK DRAIN
FIGURE 1-5
Assembly (Water Cooled)
Right Side View
10TA Service Manual
FREEZER
(2)
FREEZER
PRESSURE
STOP VALVE
(69)
SUCTION
ACCUMULATOR
(88)
FLOAT SWITCH
(22)
LIQUID FEED
SOLENOID VALVE
("A1" VALVE)
(20)
HAND
EXPANSION
VALVE (17)
FREEZER
REFRIGERANT
CHARGING VALVE
(28)
LIQUID FEED
SOLENOID VALVE
("A2" VALVE)
(21)
FILTER DRIER
(46)
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10TA Service Manual
CONDENSER
WATER
REGULATING
VALVE
(41)
SAFETY RELIEF
VALVE
(50)
RECEIVER
(15R)
RECEIVER
SIGHT GLASS
(30)
THAWING GAS
SOLENOID VALVE
("D" VALVE)
(18)
RECEIVER DRAIN
VALVE
(44)
GEAR REDUCER
(5R)
MAKE-UP
WATER FLOAT
VALVE
(12)
FIGURE 1-6
Assembly (Water Cooled)
Left Side View
INTRODUCTION
OIL
SEPARATOR
(14)
CUTTER MOTOR
(5M)
1/2" MPT
MAKE-UP WATER
CONNECTION
1-9
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1-10
INTRODUCTION
10TA Service Manual
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10TA 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 the Vogt Ice, LLC to obtain authorization for repair.
! CAUTION !
The approximate weight of the machine is 4900 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 Two 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, and one is in the high side of
the system on the receiver. 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 current may affect the operation of the machine
and should be avoided. The electrical components of the Tube-Ice® machine are rated NEMA 1.
Therefore, the machine should not be located in a hazardous area or sprayed with water. The
machine should be installed 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 3-2A and 3-2B.
2-1
4/14/14
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.
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
Vogt Model Nomenclature
! CAUTION !
! CAUTION !
XXXX – XXXX – XXXX – XXX
Type of Ice
"B" - Cylinder
"K" - Crushed
"D" - Dual Ice (Cru & Cyl)
"L" - 1 1/2" Long Cylinder
"X"- 2” Long Cylinder
Condenser Type
"AC" - Air Cooled
"WC" - Water Cooled
"HP" - High Pressure Water Cooled
"SW" - Sea Water
"NC" - No Condenser
Figure 2-1
10TA Service Manual
4/14/14
Page 23
10TA Service Manual
Condenser
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.
Piping and Drain Connections
Figure 3-2A (Air Cooled) and 3-2B (Water Cooled) show locations and sizes for all connections.
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.
Make-up
Water In
1/2” MPT 1” FPT 2” FPT 2 1/2” FPT
∗∗∗∗ The condenser water outlet and water tank drain connections must be extended to an 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.
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.
Note: Due to variations in water quality by geographic location, water filtering or treatment may be
required to reduce maintenance and inhibit hardness buildup on machine components (tubes, valves).
! CAUTION !
! CAUTION !
Water Tank
Drain*
TABLE 3-1
Water Supply and Drain Sizes
! CAUTION !
! CAUTION !
Condenser
Water In
Water Out*
4/14/14
Page 24
3-2
INSTALLING YOUR TUBE-ICE® MACHINE
Water-Cooled Connections
Note: Water regulator valve is not installed on condenser when shipped from the factory.
Installed 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.
2 1/2” Condenser
Water Outlet
2” Condenser
Water Inlet
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 11-4 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.
FIGURE 3-1
Water Cooled Condenser Connections
10TA Service Manual
4/14/14
Page 25
10TA Service Manual
ROTA-LOCK TEFLON SEAL
FIELD ATTACHMENT AIR
COOLED CONDENSER TUBING
ROTA-LOCK TEFLON SEAL
10'-4"
LIQUID
FIELD
CONNECTIONS
6"
1'-0 1/2"
7'-9 7/8"
INSTALLATION AND ACCESS
12" MINIMUM CLEARANCE FOR
40" MINIMUM CLEARANCE
FOR COMPRESSOR ACCESS
PART# 12A2600T01
ROTALOCK FIELD CONNECTOR
PART# 12A2396A0501
1 1/4"-12 THREADS (F) X 1 1/8" IDS
5'
TOP VIEW
DRAIN LOCATED
ON RIGHT SIDE
1" WATER TANK
4'
PART# 12A2600T03
ROTALOCK FIELD CONNECTOR
PART# 12A2396A0601
1 3/4"-12 THREADS (F) X 1 3/8" IDS
FIGURE 3-2A
Connections and Space Diagram (Air Cooled Machine)
INSTALLING YOUR TUBE-ICE® MACHINE
LINE
RETURN
LINE
7'-9 1/2"
DISCHARGE
FRONT
1'-5 7/16"
CONNECTION
1/2" MPT MAKE-UP WATER
1'-3 3/16"
LEFT SIDE
2'-4 3/4"
PROVIDE
SUFFICIENT
SPACE
ICE DISCHARGE
40" MINIMUM CLEARANCE
FOR WATER TANK ACCESS
1'-1 1/2"
REAR
10 1/16"
6 5/16"
11 5/8"
3-3
4/14/14
Page 26
3-4
INSTALLING YOUR TUBE-ICE® MACHINE
INSTALLATION AND ACCESS
12" MINIMUM CLEARANCE FOR
5'
40" MINIMUM CLEARANCE
FOR CONDENSER CLEANING
11 7/8"
4'
Connections and Space Diagram (Water Cooled Machine)
10TA Service Manual
10'-4"
1'-5 3/8"
CONNECTION
1/2" MPT MAKE-UP WATER
40" MINIMUM CLEARANCE FOR
COMPRESSOR ACCESS
1'-3 1/8"
2'-4 3/4"
7"
PROVIDE
SUFFICIENT
SPACE
DRAIN LOCATED
ON RIGHT SIDE
WATER INLET
2" CONDENSER
WATER OUTLET
2 1/2" CONDENSER
11 1/4"
1" WATER TANK
ICE DISCHARGE
40" MINIMUM CLEARANCE
FOR WATER TANK ACCESS
1'-1 1/2"
REAR LEFT SIDE FRONT
10"
6 3/8"
11 5/8"
FIGURE 3-2B
4/14/14
Page 27
10TA Service Manual
Power for Condenser control circuit (11 & 22)
INSTALLING YOUR TUBE-ICE® MACHINE
Wiring and Electrical Connection
! WARNING !
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.
! WARNING !
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 to terminals L1, L2, L3 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.
AIR COOLED CONDENSER CONNTECTIONS
AUX CONNECTIONS
Cutter Motor, Pump Motor &
Compressor Interlocks
Standard Voltages
208/230, 3ph, 60 Hz 112.3 138.6 245 140.3 166.6 275
460, 3ph, 60 Hz 56.2 69.3 125 70.2 83.3 140
220, 3ph, 50 Hz 134.1 165.4 295 162.1 193.4 320
400, 3ph, 50 Hz 67.3 82.9 150 81.3 96.9 160
F.L.A. Min. Ampacity Max. Fuse F.L.A. Min. Ampacity Max. Fuse
FIGURE 3-3
Control Panel Power Connections
Water Cooled Air Cooled
MAIN MACHINE POWER
Incoming power to be connected to
Power Distribution Block (PDB)
AIR COOLED CONDENSER
CONNTECTIONS
Power for Fan Motors (B7, B8 & B9)
3-5
4/14/14
TABLE 3-2
Electrical Specifications
Page 28
3-6
INSTALLING YOUR TUBE-ICE® MACHINE
Phase Check
DO NOT attempt to start machine without priming pump
and insuring proper rotation of both cutter and pump.
Refer to FIGURE 3-1 & 3-2 (space diagram) for connection locations.
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
4/14/14
10TA Service Manual
! CAUTION !
! CAUTION !
Page 29
10TA Service Manual
Air-Cooled Condenser Installation Instructions
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.
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 3-6.
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.
11.
Distance between ice machine and condenser must not exceed 150 equivalent feet. Refer to
Condenser Equivalent Line Size worksheet (see TABLE 3-5 ).
12.
Condensers must be provided with a cold weather valve kit per FIGURE 3-5. 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.
13. Condensers with multiple fans must be provided with a thermostat 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.
4/14/14
INSTALLING YOUR TUBE-ICE® MACHINE
! WARNING !
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.
! WARNING !
3-7
Page 30
3-8
INSTALLING YOUR TUBE-ICE® MACHINE
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.
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
Pounds of R-22 /R404A 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 10 ga. wire for 200/230V motors / 14 ga. wire for 400/460V motors. For control
wiring, a minimum of 14 ga. wire should be used.
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.
10TA Service Manual
TABLE 3-3
4/14/14
Page 31
10TA Service Manual
Ice Machine Model 10TA
Electrical Frequency, Hz. 60 50
Recommended Condenser BNHS04A029
Total Heat Rejection (BTU/hr) 427,500 393,300
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 (See Fig. 3-7)
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 (Condenser):
Liquid (ODF)
Discharge Gas (ODF)
Connections (Ice Machine):
Liquid (ODF)
Discharge Gas (ODF)
1 1/2
38,600
28.0
14.0
TABLE 3-4
Air-Cooled Condenser Data
INSTALLING YOUR TUBE-ICE® MACHINE
4
4
1 1/2
38,600
--
--
--
--
28.0
14.0
1210
1520
1265
45.46”
233.16”
49.15”
38”
106.15(3)”
20.5”
1 3/8”
1 5/8”
1 5/8”
2 1/8”
1 3/8”
2 1/8”
1 1/8”
1 3/8”
3-9
4/14/14
Page 32
3-10
INSTALLING YOUR TUBE-ICE® MACHINE
10TA Service Manual
Machine
P18XT BNHS04A029 12A2115B11 50/50
Note: Condensers listed above are 200/208/230V, 50/60hz. 400/460V, 50/60hz available
FIGURE 3-4
Condenser Dimensions
Bohn Part # Vogt Part # Coil Split
4/14/14
Page 33
10TA Service Manual
Note: Condenser return lines supplied by customer. (check valve supplied by Vogt)
INSTALLING YOUR TUBE-ICE® MACHINE
FIGURE 3-5
Condenser Field Piping (Cold Weather Valve Kit)
3-11
4/14/14
Page 34
3-12
Fitting Type
Number Used
Factor
Total
90°
Elbow
45°
Elbow
Tee (90
° turn through)
INSTALLING YOUR TUBE-ICE® MACHINE
CONDENSER EQUIVALENT LINE SIZE WORKSHEET
Discharge Gas Line O.D. ___________________
Globe Valve (open)
Angle Valve (open)
Copper Tubing Type “L” 1 1/8” O.D. 1 3/8” O.D. 1 5/8” O.D. 2 1/8” O.D.
Globe valve (open)
Angle valve (open)
Tee (straight through)
Feet of Straight Copper Used
Total Equivalent Feet
90o Elbow
45o Elbow
Tee
Total Fitting Factor
28 36 42 57
15 18 21 28
3 4 4 5
1.5 2 2 2.5
6 8 9 12
2
TABLE 3-5
Equivalent Feet Due To Friction
2.5
10TA Service Manual
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.
4/14/14
FIGURE 3-6
Minimum Traps For Discharge Lines
Page 35
10TA Service Manual
Air-Cooled Condenser Wiring
Wiring For BOHN BNHS04A029 with Cold Weather Valve and
INSTALLING YOUR TUBE-ICE® MACHINE
FIGURE 3-7
Four Fans, 50/50 Condenser Split
3-13
4/14/14
Page 36
3-14
Spud Size
Amo
unt 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
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.
Pressure Relief Valves
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.
CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES.
PHONE: 502-635-3000
BEFORE REPLACING RELIEF VALVE, REVIEW REQUIREMENTS PER CURRENT
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.
10TA Service Manual
(See FIGURE 3-2A for connection sizes)
TABLE 3-6
Rota-lock Connector Torque Ratings
Pressure relief valves are installed on the freezer, receiver and the
LOCAL AND NATIONAL CODE.
4/14/14
Page 37
10TA Service Manual
Ice Bin Thermostat Sensor (Optional)
automatically cycle machine operation. To assure proper protection for the machine or auxiliary
equipment, the sensor of the ice bin thermostat must be located so that ice will contact it when the
bin is full (See FIGURE 3-8 for typical mounting bracket). The distance between the top of the ice
bin and the sensor allows space for the machine to make an additional discharge of ice AFTER the
ice contacts the probe. This will vary based on the size of the bin and the ice distribution system
employed.
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.
Note: Actual location of sensor will vary based on bin layout and ice distribution system.
NOTE: Use front of angle to
protect probe
Typical Bin Sensor Mounting
INSTALLING YOUR TUBE-ICE® MACHINE
An electronic ice bin thermostat may be added to
Bin Opening
STAINLESS STEEL
ANGLE
FIGURE 3-8
3-15
4/14/14
Page 38
3-16
READING
CONNECTION
CONNECTION
INSTALLING YOUR TUBE-ICE® MACHINE
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.
10TA Service Manual
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 3-9
Electronic Thermostat
Note: If damaged, the sensor can be replaced without replacing entire unit.
Replacement sensor part #12A 2117G0901. Electronic temperature control part #12A 2117G09.
Sensor cable can be extended up to 400 feet. For more information, consult Tube-Ice®
Technical Service Department.
4/14/14
Page 39
10TA Service Manual
INSTALLING YOUR TUBE-ICE® MACHINE
! 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 !
3-17
4/14/14
Page 40
3-18
INSTALLING YOUR TUBE-ICE® MACHINE
10TA Service Manual
BLANK PAGE
4/14/14
Page 41
10TA Service Manual
Principle Of Operation. For a detailed description of the functions of each control panel
components, see Section 6. Operation of the machine is controlled by “Clean/Off/Ice”, “Start” and
“Stop” switches located in the control panel of the freezing unit. Automatic operation can be
controlled by optional ice bin thermostats which will automatically stop and start the ice maker by
the level of the ice in the storage bin (NOTE: See “Ice Bin Thermostat Typical Installation” for
instructions on installation of the control bulb of the ice bin thermostat, FIGURE 3-8). The type ice
produced (cylinder or crushed) is determined by how the machine cutter is set-up (cylinder is
standard, crushed 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 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 attached to the machine.
If it should become necessary to instantly stop the machine, push the “Stop” button. To restart the
machine, push the “Start” button.
FIGURES 4-1 & 4-2 illustrate the piping diagram of the refrigerant and water circuits of the TubeIce® machines 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). Solenoid valve (20), sometimes referred to as
the “A” valve, is open and 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 is gives up heat to the suction gas for compressor protection. In addition,
this liquid is subcooled and carried to the receiver (15R). Condensed liquid refrigerant from the
receiver flows through the thawing chamber (16) of the freezer, the filter/drier (46), the “A1” and
“A2” liquid feed valves (20) & (21) and then the expansion valve (17) and capillary. At the
expansion valve(17) and capillary feed, the refrigerant is taken from a saturated liquid state of
relatively high pressure and expanded to a very low pressure, low temperature liquid. The "A2"(21)
solenoid and capillary feeds liquid to the freezer (2) during the entire freeze cycle. The float switch
(22) is wired to the “A1” solenoid valve (20). The float switch energizes and de-energizes the “A1”
solenoid in response to the level of refrigerant in the freezer. The cold liquid refrigerant enters the
freezer where it absorbs heat from the circulating water. This cool gas is pulled out of the freezer at
the suction outlet thereby completing the circuit.
The freezing period is completed by action of the freezer pressure switch in the control panel. The
water pump (6) is stopped and solenoid valves “A1” & “A2” (20) & (21) are 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. See “Freezer Period and Harvest Period” for more detailed description of operation.
7/1/2014
4-1
HOW YOUR TUBE-ICE MACHINE WORKS
4. How Your Tube-Ice® Machine Works
Page 42
4-2
HOW YOUR TUBE-ICE MACHINE WORKS
Air-cooled machines have a solenoid valve (53), sometimes referred to as the “X” valve, in the
compressor discharge line, and a check valve (101) in the liquid return line to the receiver. These
valves prevent the migration of refrigerant when the machine is not operating. The "X" valve is open
any time the compressor is running.
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 “A1” & "A2"
liquid line solenoid valves close , the “D” (thaw gas) solenoid valve opens and the thaw timer (T) is
energized.
The defrost pressure switch (dps) will open and close the "D" valve to maintain the proper pressure
to get the ice to release but not add unnecessary heat. 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.
1
1PG Suction Pressure Gauge 31 Gage Glass Stop Valve
2PG Discharge Pressure Gauge 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)
7 Water Tank (includes cutter assembly) 41A Condenser Pressure Control (A/C Machines)
8 Water Distributing Chamber 43 Strainer
12 Make-Up Water Float Valve 44 Receiver Drain Valve
13 Heat Exchanger 46 Filter Drier
14 Oil Separator 48 Muffler
15 Condenser 50 Receiver Safety Valve
15R Receiver 51 Freezer Safety Valve
16 Thawing Chamber 53 Cold Weather Solenoid Valve “X” (A/C Machines)
17 Expansion Valve 55 Discharge Line Stop Valve For A/C Machines
18 Thawing Gas Solenoid Valve “D” 56 Freezer/Pressure Switch
18S Thawing Gas Pressure Switch 58 Liquid Outlet Valve (King Valve)
20 Liquid Feed Solenoid Valve “A1” 59 Receiver Purge Valve
21 Liquid Feed Solenoid Valve “A2” 69 Freezer Pressure Stop Valve
22 Float Switch 70 Oil Return Stop Valve
23 Condenser Water Inlet W/C Machines 88 Accumulator/Heat Exchanger
23A Make-Up Water Inlet 3/4 FPT 90 Thawing Gas Stop Valve
24 Condenser Water Outlet (W/C Machines) 91 Receiver Liquid Return Stop Valve
25 Water Tank Drain Connection (1” FPT) 94 Compressor Oil Pressure Safety Control
28 Refrigerant Charging Valve
7/1/2014
Control Panel
! CAUTION !
! CAUTION !
30
101 Check Valve
Receiver Sight Glass
TABLE 4-1
Piping Nomenclature
10TA Service Manual
Page 43
10TA Service Manual
4-3
HOW YOUR TUBE-ICE MACHINE WORKS
FIGURE 4-1
Water Cooled Piping Schematic
4/14/2014
Page 44
4-4
HOW YOUR TUBE-ICE MACHINE WORKS
10TA Service Manual
FIGURE 4-2
Air-Cooled Piping Schematic
4/14/2014
Page 45
10TA Service Manual
START-UP AND OPERATION
Start-Up and Operation
Refrigeration System Review The refrigeration system uses R-22 or R-404a refrigerant, a
compressor, a refrigerant float switch, expansion valve, a flooded evaporator (freezer), and warm gas
defrost. Following the schematic, you see that during the freeze period of the machine’s cycle, the
condenser 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 thawing chamber (a
lower separate section of the freezer) then the filter/drier. The liquid feed solenoid valves (“A1” and
“A2”) being open during the freeze cycle allows the liquid to be metered by the float switch as the
“A1” 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 to close, initiating the harvest period.
During the harvest period, 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 500 lbs.) of
Refrigerant (R-22 or R-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.
They should indicate a pressure approximately equal to the ambient temperature. This pressure can
be found using the pressure temperature chart for the applicable refrigerant, TABLE 11-7.
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.
5-1
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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”
Cutter gear reducer (5R) for instructions).
_____ 3. See that compressor crankcase oil level is at proper height of 1/4 to 1/2 of
the sight glass.
_____ 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, handstop valve (58) in the liquid line, hand-stop valve (69) to the freezer pressure switch,
top and bottom float switch hand stop valves (22A) and 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! CHECK TO SEE that all stop valves in the various refrigerant lines
are open except charging valves (28 & 44), 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.
NOTE
All valves are tagged with instructions.
NOTE
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10TA Service Manual
Off
Start-Up
Starting Procedure (Initial Start-Up):
(NOTE: The machine will start in the harvest mode when set to “Ice” )
1. Set the “Clean/Off/Ice” selector switch to the “Clean” position.
2. Push the “Start” button (PB2) to start the water pump.
3. The pump can be stopped and started by the “Stop” and “Start” push buttons. Water should be
circulated for a minimum of five (5) minutes to prime the pump, purge the tubing of air and
lubricate the cutter bearing.
Note: If pump is already primed skip steps 1-3
4. When there is good water flow, turn the “Clean/Off/Ice” selector switch to “Ice”. The machine
will then start in a harvest (thaw) period with the compressor running.
5. At the termination of the harvest (thaw) period, the machine will begin the freeze period.
6. Be sure to observe a minimum of four (4) cycles of ice production to confirm the satisfactory
operation of the machine (approximate time for four cycles is 60-80 minutes).
Complete the remaining part of the “Warranty Registration/Start-Up Report” upon initial machine
start-up and return it to Vogt Ice, LLC.
4/14/14
START-UP AND OPERATION
! 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 !
Start/
Manual
Harvest
Clean Ice
Stop
CONTROL PANEL DOOR)
FIGURE 5-1
Control Panel Switch Layout
5-3
Page 48
5-4
START-UP AND OPERATION
Shut-down
The red “Stop” button should only be used for emergency shutdown.
1. Set the “Clean/Off/Ice” switch to the “Off” position. Do not use the machine disconnect to
stop the machine. If the disconnect is used the crankcase heater will be de-energized and liquid
refrigerant will migrate to the compressor.
2. If in a freeze mode, the machine will continue to run.
3. At the completion of the freeze cycle the machine will harvest and stop. The completion of a
cycle ensures that all ice is removed from the freezer to prevent refreeze when the machine is
restarted.
4. If in a harvest, the machine will complete the harvest and stop.
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” toggle switch to start and stop machine.
• By turning the “Clean/Off/Ice” selector switch to “Off”, the machine will stop after the next
harvest cycle.
• Do not use the “Stop” push button 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.
10TA Service Manual
! CAUTION !
For normal shutdown use the “Clean/Off/Ice” button.
! CAUTION !
4/14/14
Page 49
10TA Service Manual
START-UP AND OPERATION
Adding Refrigerant
! 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 9-12).
When the machine is pumped down, a liquid level should be observed in the gage glass on the
receiver.
Refrigerant Charging 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 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 of the refrigerant to the
receiver. A total pump down procedure should be performed. See the name plate for the
approximate refrigerant charge for the machine. Remember, 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 !
5-5
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5-6
START-UP AND OPERATION
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BLANK
4/14/14
Page 51
10TA Service Manual
SS
PB1
PB2
6-1
ELECTRICAL CONTROLS
6. Electrical Controls
FIGURE 6-1
Control Panel
4/14/14
Page 52
6-2
ELECTRICAL CONTROLS
10TA Service Manual
4/14/14
FIGURE 6-2
Control Panel Components (Standard)
Page 53
10TA Service Manual
6-3
ELECTRICAL CONTROLS
OPTIONAL POWER MONITOR
LOCATED ON BACK OF
ENCLOSURE DOOR.
4/14/14
SWITCHES LOCATED ON
OUTSIDE OF CONTROL
PANEL DOOR
FIGURE 6-2A
Control Panel Door (Standard) and Optional Power Monitor
Page 54
6-4
ELECTRICAL CONTROLS
10TA Service Manual
4/14/14
FIGURE 6-2B
Control Panel Components (CE & Australian Approved)
Page 55
10TA Service Manual
Item No. Vogt Part No. Description
AX 12A7518E33UL
BT 12A2117G09 Bin Thermostat (Optional )
CB2 12A7515E22
CC
400/460V
CC
200V, 208/230V
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
P
PB1
PB2
PM 12A7700P01 Power Monitor, Universal Phase Protector (Optional)
PF
SS
T
12A7516E30 Compressor Motor Contactor (72 Amp, 3 Pole)
12A7518E30 Aux. Contact (10 Amp, 1 N.O./1 N.C., Side Mount)
12A7518E31 Aux. Contact (10 Amp, 2 N.O., Side Mount)
12A7518E32 Aux. Contact (5 Amp, 2 N.O., Top Mount)
12A7516E48 Compressor Motor Contactor (140 Amp, 3 Pole)
12A7518E43 Aux. Outside Contact (2 Amp, 2 N.O., Side Mount)
12A7518E44 Aux. Inside Contact (2 Amp, 2 N.O., Side Mount)
12A7516E23 Contactor (9Amp, 3 Pole, with 1 N.O. Aux, 208/240V Coil)
12A7530E52UL Cutter Manual Motor Starter, 0.63-1.0A (460V, 60hz)
12A7530E53UL Cutter Manual Motor Starter, 1.0-1.6A (400V, 50hz)
12A7530E54UL Cutter Manual Motor Starter, 1.6-2.5A (200/208/230V, 50/60hz)
12B7503E17 Timer, Elapsed, Panel Mount, 220V (50Hz)
12B7503E18 Timer, Elapsed, Panel Mount, 220V (60Hz)
12A7516E27
12A7530E58UL Fan Manual Motor Starter, 10.0-16.0A (400/460V, 50/60hz)
12A7530E63UL Fan Manual Motor Starter, 23.0-32.0A (200/208/230V, 50/60hz)
12A7504E29
12A7516E23 Contactor (9Amp, 3 Pole, with 1 N.O. Aux, 208/240V Coil)
12A7530E55UL Pump Manual Motor Starter, 2.5-4.0A (400V/460V, 50/60hz)
12A7530E56UL Pump Manual Motor Starter, 4.0-6.3A (208/230V, 60hz)
12A7530E57UL Pump Manual Motor Starter, 6.5-10.0A (200V only)
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.)
12A7516E23
12A7500E61 Selector Switch, 3 Position
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)
Aux Trip Indicator, 6A, 1NO / 1NC
Control Circuit Breaker, 6 Amp, 2 Pole (400V & 460V machines
only)
Condenser Fan Contactor (30 Amp, 3 Pole, 1 N.O. Aux. Contact,
208/240V Coil)
Fuses, 1A, 600V, Class CC, Fast Acting (For use w/optional
Power Monitor)
Power Failure Contactor (9 Amp, 3 Pole, 1 N.O. Aux. Contact,
208/240V Coil)
TB1 & TB N/A Main Terminal Block Assembly
TB2 N/A
Terminal Block Connections for Customer (CE & Australian
Approval)
6-5
ELECTRICAL CONTROLS
TABLE 6-1
Control Panel Components and Part Numbers (See FIGURE 6-1, 6-2, 6-2A & 6-2B)
4/14/14
Page 56
6-6
ELECTRICAL CONTROLS
AX –
CB2 –
CC –
CR –
CU –
DS –
ET –
FC –
FPS –
FU1&2 –
FU10-60 –
PB1 –
PB2 –
PF –
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.
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.
Overload and short circuit protection for control circuit and crankcase heater.
Short circuit protection for optional Power Monitor.
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.
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.
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 –
Main terminal block numbered for multiple wire connections and ease of troubleshooting.
Customer connections for auxiliary contacts on cutter, pump and compressor contactors. (CE & AUS
approval)
10TA Service Manual
Description of Component Function
TABLE 6-2
Description of Control Panel Component Function
4/14/14
Page 57
10TA Service Manual
6-7
ELECTRICAL CONTROLS
Control Circuit - Electrical Schematic All Voltages, 50-60 Hz.
4/14/14
FIGURE 6-3
Page 58
6-8
ELECTRICAL CONTROLS
10TA Service Manual
4/14/14
FIGURE 6-3A
3-Phase Power - Electrical Schematic All Voltages, 50-60 Hz.
Page 59
10TA Service Manual
6-9
ELECTRICAL CONTROLS
FIGURE 6-4
Compressor Schematic Detail All Voltages, 50-60 Hz.
4/14/14
Page 60
6-10
ELECTRICAL CONTROLS
10TA Service Manual
BLANK
4/14/14
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10TA 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
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
5. Close drain valve (39) and fill water tank (approximately 15 gallons) with warm water. Close the petcock
6. Add 40 ounces (8 ounces per 3 gallons) of Nu-Calgon ice machine cleaner or equivalent (food grade liquid
7. Inspect the water distributors by looking through clean freeze cover. If required, remove the cover. Clean
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
10. Press “Stop” button to stop pump, then drain and flush water tank with fresh water. Open water supply to
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
“Clean/Off/Ice” selector
down on completion of the next ice harvest period.
from tank.
on the water pump during the cleaning period.
phosphoric acid) to water tank during the refill period. Note: Tank capacity = 14.5 gallons
and remove any solid particles from the distributor orifices (two orifices in each distributor). Clean the
rubber cover gasket and reinstall the cover.
necessary.
machine.
cover if one was installed over opening into storage area.
switch (SS) to the “Off” position. If the machine is running, it will shut
4/15/14
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 Blowdown” in Section 9.
Page 62
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
from tank.
4. In a clean container, mix 15 gallons of warm water (90°F–115°F / 32°C-46°C) and 24 ounces of
Nu-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 = 14.5 gallons
5. Close drain valve (39) and fill water tank with sanitizing solution. Close the petcock (adjustable blow
down) on the water pump.
6. To run the pump only, set the selector switch (SS) to the “Clean” position and press “Start” button to
circulate the sanitizing solution.
7. Mix an additional 5 gallons of warm water (90°F–115°F / 32°C-46°C) and 8 ounces of Nu-Calgon
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.)
10TA Service Manual
®
IMS-II
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 5 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.
2. Turn on the water supply and refill tank with clean water.
3. 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.
4/15/14
4. 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.
5.
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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10TA Service Manual
Water Distributors. The water distributors are located under the freezer cover 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.
Size Ice Number of Tubes Water Distributor Freezer Cover Freezer Cover Gasket
1 1/4” 102 12B2185N21
1 1/2” 72 12B2185N31
To clean distributors, stop the unit and remove the freezer cover 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. Use care when removing distributors to avoid
distorting orifice holes or the body of the distributor. The distributors can be soaked in ice machine
cleaner to remove mineral buildup. Rinse distributors thoroughly before reinstalling and tap lightly
with a rubber mallet to seat them in the freezer tubes.
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 (28). Clean tank
thoroughly by flushing out with a hose and scrubbing with a stiff brush. It may be necessary to
completely remove the water tank in order clean all surfaces. After cleaning, close drain (reinstall tank
if necessary) and 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.
Freezer Cover. A clear polycarbonate freezer cover is provided for visual inspection of the water box
and water distributors located at the top of the freezer. The cover should be removed and cleaned if it
becomes coated with deposits. Generally, if the freezer cover is coated with solids this is a prime
indicator that the other areas (i.e. water tank and distributors) also require cleaning.
MAINTENANCE
Vogt Part #
1” 156 12B2185N11 1BA2145C03 12A2600G15
TABLE 7-1
Number of Water Distributors Per Tube Size
Tube Size
Hole Size
1/16”-1/8” Avg. 1/8”-3/16” Avg. 1/4”-3/8” Avg.
1” 1 1/4” 1 1/2”
TABLE 7-2
Average Hole Size In Tube-Ice
7-3
4/15/14
Page 64
7-4
MAINTENANCE
Water Cooled Condensers
Checking Operation. How often condensers need cleaning depends on so many variables that it is
impossible to recommend a schedule. Some will seldom need cleaning, others perhaps need cleaning
once a year. In rare cases, cleaning is required 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 GPH 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.
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:
1. Non-condensables in system or faulty head pressure gauge? Check standby pressures against
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.
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 likely to be somewhere else in the system.
Draining. 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. Despite the fact that a
condenser may have a 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. Experience has shown 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 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.
7/1/14
10TA Service Manual
refrigerant tables.
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10TA Service Manual
Chemical Cleaning. Vogt Ice, LLC makes no recommendation for any particular chemical
reparation. The same chemical may not be effective for all situations.
! 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 !
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.
MAINTENANCE
7-5
e) Flush the condenser according to directions.
f) Install the water regulating valve and connecting piping.
Open the water supply stop valve and check for leaks.
Mechanical cleaning.
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 paint brush is excellent.
These surfaces have been coated with a special material which will give years of protection against
corrosion unless damaged. Never use a wire brush or a strong caustic on these surfaces.
4/23/14
Page 66
7-6
Oil Charge
MAINTENANCE
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 useless to try and 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.
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 out of sight above it.
The machine is properly charged with oil for the test operation, but it may be necessary to add some oil
when or if new refrigerant is added to the system. Generally, air-cooled machines will require
additional refrigerant and oil to compensate for long piping runs to the condenser.
Refrigerant Recommended Lubricants Type of Lubricant
HCFC-22 (R-22) Suniso 3GS, Texaco WF32, Calumet RO15 (Witco) Mineral Oil
R-404A Mobil EAL ARCTIC 22 CC, ICI (Virginia KMP) Emkarate
RL 32S
TABLE 7-3
Recommended Lubricants
Compressor HP
6DYN & 6DY3 21 140
6DNN & 6DN3 24 140
10TA Service Manual
Polyol Ester Oil
(oz)
4/15/14
TABLE 7-4
Compressor Oil Capacity
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10TA Service Manual
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 oil separator oil return line fitting on the compressor or the compressor
suction service valve. The compressor suction service valve should be “back seated” 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
Note: Ventless gear reducer used after August 2010
Drain Plug
FIGURE 7-2
Gear Reducer
MAINTENANCE
7-7
4/15/14
Page 68
7-8
MAINTENANCE
Preventive Maintenance
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
B. Weekly (in addition to daily checks)
C. Monthly (in addition to weekly checks)
D. Yearly (in addition to weekly and monthly)
10TA Service Manual
A careful inspection of the Tube-Ice® machines refrigeration system
1. Check operating pressures (suction, discharge, oil).
2. Check ice quality.
3. Check “ice out” time (maintain 30 seconds of continued harvest after last ice is out).
4. Check compressor oil level.
5. Check refrigerant operation level.
6. Check frost pattern on freezer shell and oil trap.
7. Check make-up water float valve adjustment.
1. Check for leaks after 400 hours or four weeks of operation
1. Check calibration and operation of all controls (high & low press switches, oil press switch, etc.)
2. Check cooling tower spray nozzles and pump suction screen for scaling and algae (consult
water treatment suppliers for corrective measures).
3. Check water distributors in freezer for scale accumulation.
4. Check water tank for solids to be removed.
5. Check all motor drive units (compressor, cutter and pump motors, cooling tower fan, and
pump, etc) for abnormal noise and/or vibrations.
6. Check oil level in gear reducer.
7. Check one complete freeze/thaw cycle, record data and compare with production check of
Registration/Start-up Report.
1. Check entire system for leaks.
2. Drain water from condenser and cooling tower and check condenser tubes. Check closely for
damage by corrosion or scale.
3. Remove all rust from all equipment, clean, and paint.
4. Check all motors for shaft wear and end play.
5. Check operation and general condition of all electrical controls, relays, motor starters, and
solenoid valves.
6. Check freezing time, ice release time, and ice out time.
7. Change oil in gear reducer box once a year.
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
4/15/14
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10TA 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!”
MAINTENANCE
7-9
4/15/14
Page 70
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:_________________________________________________________________________
_________________________________________________________________________________
10TA Service Manual
Preventive Maintenance Program
4/15/14
Page 71
10TA 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.
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
Poor Ice Quality 8-6
Low Ice Capacity 8-7
Low Compressor Oil Level 8-8
High Head Pressure (Water Cooled Machines) 8-9
High Head Pressure (Air-Cooled Machines) 8-10
5/29/14
8-1
TROUBLESHOOTING
8. Troubleshooting
Page 72
8-2
TROUBLESHOOTING
SYMPTOM:
Power failure ++ Intermittent power
interruption
Compressor motor overload (CMS-OL) trips.
Note: Used on 4D & 6D compressors without
Compressor cylinder head temperature switch
trips.
3.0 amp circuit breaker (CB) in the control
panel tripped.
High/Low safety pressure switch tripped. If the machine stops by low pressure cut-out, the
Machine won't run.
POSSIBLE CAUSE POSSIBLE REMEDY
Coresense. All 3D compressor have
Internal Line Break for overcurrent
protection.
Coresense on 4D & 6D compressors
combines overcurrent & oil pressure
protection. (after March 2011)
10TA Service Manual
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 which will initiate startup in a
thawing cycle.
Check for a loose connection on all motor
contactor and compressor terminals, which could
have caused excessive amp draw. Check
amperage, power supply, and head pressure.
Excessive temperature may be caused by gas
leakage between suction and discharge port of
the compressor. Check for broken cylinder head
gasket or valve assemblies. Replace broken or
defective parts. Restart the machine and check
motor amps and temperature of compressor body.
Note: Switch on 4D & 6D compressors without
Coresense and 3D compressors (with line break
protection) will reset automatically after the
motor has cooled sufficiently.
The thermal switch will reset automatically after
the motor has cooled sufficiently. Excessive
temperature may be caused by gas leakage
between suction and discharge port of the
compressor. Check for broken cylinder head
gasket or valve assemblies. Replace broken or
defective parts. Restart the machine and check
motor amps and temperature of compressor body.
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.
switch will reset automatically when the pressure
raises to the " cut-in " setting. If it stops by high
pressure cut-out, 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).
4/23/14
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10TA Service Manual
SYMPTOM:
Low oil pressure switch tripped. If the machine stops by low oil pressure cut-out,
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, BC, CMS PB1, CB, T, Etc.
4/23/14
8-3
TROUBLESHOOTING
Machine won't run (CONT.)
POSSIBLE CAUSE POSSIBLE REMEDY
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 99, Section 9 (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 3-9,
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.
Page 74
8-4
TROUBLESHOOTING
SYMPTOM:
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.
Liquid feed, “A1” valve stuck open Check to make sure the “A1” Valve is not in the
10TA Service Manual
Freeze-up due to extended freeze period.
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.
manual open position. Disassemble valve and
inspect for debris which could hold the valve
open.
4/23/14
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10TA Service Manual
SYMPTOM:
Insufficient heat for thawing because of low
condensing pressure, non-condensables
(usually air) in system, low refrigerant
charge, or thaw gas pressure switch adjusted
too low.
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
Freeze-up due to ice failing to discharge.
POSSIBLE CAUSE POSSIBLE REMEDY
The head pressure should be maintained at
approximately 210 PSIG for R-22 or 250 PSIG
for R404a, which relates to 105F (37.8C). This
is done by a water regulating valve (watercooled units) FIGURE 9-5A, Section 9, or a
Fan cycling switch (air-cooled units) FIGURE
9-5B, Section 9. If non-condensables 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. 11 lbs. of
R22 or R404a).
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.
4/23/14
Page 76
8-6
TROUBLESHOOTING
SYMPTOM:
Excessive concentration of solids in the
water tank, usually indicated by a build-up of
mineral deposit on the sides and bottom of
the tank.
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 siphon
10TA Service Manual
Poor ice quality.
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 keep the gage glass cocks closed when
finished checking the level.
vacuum break valve and restrictions or traps in
the water tank drain assembly.
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10TA Service Manual
SYMPTOM:
Low refrigerant charge. Check for and repair leaks, and add refrigerant.
Restriction in liquid line. Check for a partially closed valve, or an
Float switch stuck or failed in open position Make sure the float switch is opening and
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
(15) 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 (12) open. Close drain valve (12).
4/23/14
Low ice capacity.
POSSIBLE CAUSE
TROUBLESHOOTING
POSSIBLE REMEDY
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.
closing. Make sure the “A1” valve is getting
power.
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 water restriction in
the 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 11,
Capacity Table.
8-7
Page 78
8-8
TROUBLESHOOTING
SYMPTOM:
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
10TA Service Manual
Low compressor oil level.
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 laying on top of the piston when
the head and valve plate are removed. It is best
to replace the compressor.
4/23/14
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10TA Service Manual
SYMPTOM:
Misadjusted or defective water regulating
valve
Insufficient water supply. Check size of water line and pump output at the
Cooling tower needing maintenance. Check cooling tower fan belt and tighten or
Non-condensables (usually air) in system. Check refrigerant tables for
Fouled (dirty) condenser. Follow the diagnostic procedure outlined in,
4/23/14
High head pressure. (Water cooled machine)
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.
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.
Section 7, and clean the condenser per
instructions under Condenser Cleaning,
8-9
TROUBLESHOOTING
Page 80
8-10
TROUBLESHOOTING
SYMPTOM:
Condenser fan(s) not running. Defective motor, fan control switch, fan
Dirty condenser causing restricted air flow. Visually inspect condenser and clean as
Non-condensables (usually air) in the
system.
High head pressure (Air-cooled machine).
POSSIBLE CAUSE POSSIBLE REMEDY
contactor, or tripped fan motor overload.
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.
Follow same procedure as specified for
removing non-condensables from Water
Cooled machine, except evacuate the air-cooled
condenser also.
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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.
Make-up Water Float Valve (Part No. 12A4200H0402P) 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. A strainer of 40 mesh screen
is usually satisfactory.
4/28/14
9-1
SERVICE OPERATIONS
9. Service Operations
Adjustable Blowdown
(petcock valve)
Automatic
Blowdown
Water Pump
FIGURE 9-1
Water Pump / Blowdown Assembly
Page 82
9-2
SERVICE OPERATIONS
Float Switch (Part No. 12A7500E22) The float switch is installed on a header assembly that is
attached to the freezer shell. Valves are provided for isolation of the float switch assembly if
replacement or servicing is necessary. The float switch closes as the level of refrigerant in the
freezer rises and opens as the level falls.
The float switch is connected to the liquid feed solenoid valve (“A” valve) coil. This is the solenoid
valve directly before the hand expansion valve. Therefore when the refrigerant level in the freezer
drops, the float switch opens, thereby de-energizing the normally open liquid feed solenoid until
sufficient level has been reached to close the float switch. The float switch has a fixed 1/2”
differential.
The float switch is installed at the correct height at the factory and should not need to be adjusted.
The float switch is installed at the position that provides highest capacity. The correct height will
produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30° F.
Switch assembly only
Part No. 12A7500E24
Float switch assembly
Part No. 12A7500E22
Float calling for refrigerant
FIGURE 9-2
Hansen Refrigerant Float Switch
Magnet
Lever Arm
Attractor
Springs
Float satisfied – Not
calling for refrigerant
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Hand Expansion Valve (Part No. 12A4200C0605) The hand expansion valve is located after the
liquid feed solenoid valve (“A1” Valve). This valve should be set at a point where the float switch is
open for a length of time approximately equal to the time it is closed. The factory setting is about 2
turns from full open.
Freezer Pressure Switch (Part No. 12A2117E04) 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 11-6, 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 a freezer pressure switch that has not
been previously adjusted (See FIGURE 9-2):
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) This
insures that the freezing cycle is not extended unnecessarily and eliminates a possible opaque core in
the center of the ice.
Part No. 12A2117E04
FIGURE 9-3
Freezer Pressure Switch
9-3
SERVICE OPERATIONS
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9-4
SERVICE OPERATIONS
Capillary Bypass The capillary bypass is located directly following the “A2” solenoid. The “A2”
solenoid should be energized (Open) during the entire freeze cycle. The function of the capillary
bypass is to meter a set minimum amount of refrigerant to the freezer during the freeze cycle,
thereby reducing cycling of the float switch.
High-Low Pressure 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.
NOTE: 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
SET AT 20 PSIG
(CW RAISES SETTING)
RESET BUTTON
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.
! 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 52 PSIG (R-404A)
(CW RAISES SETTING)
LOW PRESSURE
TEST CONNECTION
HIGH PRESSURE
TEST CONNECTION
FIGURE 9-4
High-Low Pressure Switch
10TA Service Manual
HIGH PRESSURE ADJUSTMENT
SET AT 300 PSIG (R-22)
SET AT 350 PSIG (R-404A)
(CW RAISES SETTING)
DIFFERENTIAL FACTORY SET
CE Approved machine
Vogt Part #: 12A2117D01CE
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10TA Service Manual
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 200 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.
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)
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, compressed air or a brush may be used to remove an
accumulation of dirt from the fin section of the condenser.
CONNECTED TO
CONDENSER
Vogt Part #: 12A4200E1401
FIGURE 9-5A FIGURE 9-5B
Water Regulating Valve Condenser Fan Switch
CUT IN ADJUSTING SCREW
SET AT 210 PSIG (R-22)
SET AT 250 PSIG (R-404A)
(CW LOWERS SETTING)
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
CE Approved machine
Vogt Part #: 12A2117F05CE
9-5
SERVICE OPERATIONS
7/1/14
Page 86
9-6
SERVICE OPERATIONS
Compressor Motor Protector, Electronic Copeland compressors using solid state protection have
PTC (Positive Temperature Coefficient) internal sensors with an avalanching resistance in the event
of high temperatures. The sensors are calibrated for proper motor protection.
The solid state sensor protectors provide excellent protection against high motor temperatures
resulting from locked rotor, loss of charge, or motor overload. The combination of low voltage
sensing and time delay provide positive protection against low voltage conditions which can occur in
the pilot circuit in the event of a single phase condition on a three phase circuit.
The low voltage protection feature removes the compressor from the line in the event of low voltage
("brown-out") conditions. The module locks the compressor off the line until the voltage rises to the
cut-in setting. The time delay provides a two-minute delay before restarting each time the power
circuit is opened. Pressing the start button before the two-minute delay will have no effect. Service
and test personnel must be alert to this feature since it is possible in checking the compressor or
system, power may be applied, disconnected, and reapplied in less than two minutes. In such case
the time delay feature will prevent operation until the time delay has expired and this may be
misinterpreted by service personnel as a module malfunction.
The time delay would be energized in the event of a discharge pressure or short circuit protector trip,
low voltage, or a break in the power supply to the module. The time delay is not energized on
opening of the high or low pressure switches.
There are two major components in the protection system.
1. The protector sensors are mounted internally in the motor windings. The characteristics of the
sensor are such that a change in temperature causes a change in the sensor's electrical resistance.
2. The control module is a sealed enclosure containing a relay or triac, transformer, and several
electronic components. Leads from the internal motor sensors are connected to the module as
shown on the wiring diagrams. While the exact internal circuitry is quite complicated, basically
the module senses the change in resistance of the sensors. As the motor temperature rises or falls,
the resistance also rises or falls, triggering the action of the control circuit at predetermined
opening and closing settings.
Protector modules have two terminals on the module marked "T1-T2" or "L1-L2". These are to be
connected to a power source of the proper voltage, normally the line terminals on the compressor
motor contactor or the control circuit transformer as required.
The control circuit is to be connected to the two terminals marked "control circuit". When the
proper voltage is present and the motor temperature is within limits, the "M1-M2" circuit is closed
and the pilot circuit is energized after the two-minute off-cycle time delay. If the motor temperature
rises beyond safe limits, the resistance of the motor sensors rises, causing the control circuit to open.
The solid state module cannot be repaired in the field, and if the cover is opened or the module
physically damaged, the warranty on the module is voided. No attempt should be made to adjust or
repair this module, and if it becomes defective, it must be returned intact for replacement.
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Electronic Motor Protector / CoreSense Protection High-Potential Testing. The solid state
sensors and the electronic components in the solid state module are delicate and can be damaged by
exposure to high voltage. Under no circumstances should a high potential test be made at the sensor
terminals with the sensor leads connected to the solid state module. Even though the power and pilot
circuit leads are not connected, the module can be damaged.
Note: 4D & 6D Compressors manufactured before March 2011 have Electronic Motor Protector.
SERVICE OPERATIONS
Compressor with Electronic
Motor Protection
Compressor with CoreSense
Motor Protection
9-7
FIGURE 9-6
Compressor Protection Wiring
4/28/14
Page 88
9-8
SERVICE OPERATIONS
Electronic Motor Protector Field Trouble Shooting (4D & 6D compressors before March 2011).
In the event the motor compressor is inoperable or is not operating properly, the solid state control
circuit may be checked as follows:
1. If the compressor has been operating and tripped on the protector, allow the compressor to cool
for at least one hour before checking. This allows time for the motor to cool and the control
circuit to reset.
2. Disconnect control circuit power to deenergize the module. Connect a jumper wire across the
"control circuit" ("M1-M2") terminals on the module control circuit terminal board. This will
bypass the "control contact" of the module.
3. Reconnect control circuit power. If the compressor will not operate with the jumper wire
installed, then the problem is external to the solid state protection system. If the compressor
operates with the module bypassed, but will not operate when the jumper wire is removed, then
the control circuit relay or triac in the module is open.
4. If after allowing time for motor cooling, the protector still remains open, the motor sensors may
be checked as follows.
a) Disconnect control circuit power to deenergize the module. Remove the jumper of Step 2.
Remove wiring connections from the sensor and common terminals on the module control
circuit terminal board.
b) CAUTION: Use Ohmmeter with a maximum of 9 VAC for checking. The sensors are
sensitive, easily damaged, and no attempt should be made to check continuity through them
with other than an ohmmeter. Any external voltage or current applied to the sensors may
cause damage requiring compressor replacement.
c) Measure the resistance from each sensor terminal to the common terminal. The resistance
should be in the following range:
500 ohms (cold) to 20,000+ ohms (hot. compressor tripped)
Resistance readings in this range indicate the sensors are good. A resistance approaching
zero indicates a short; a resistance approaching infinity indicates an open connection. Proper
operation of the control system is dependent on a continuous parallel circuit through all three
sensors with no individual resistance reading higher than 10,000 ohms. On initial start-up,
and after any module trip due to high temperatures, the resistance of the sensors must be
below the module reset point before the module circuit will close. Reset values are 27004500 ohms.
5. If the sensors have the proper resistance, and are below 2700 ohms resistance, the compressor
will run with the control circuit bypassed, but will not run when connected properly, the solid
state module is defective, and must be replaced. The replacement module must be the same
voltage and be compatible with the original module on the compressor.
4/28/14
10TA Service Manual
! WARNING !
Before checking the TI31AA model for its attached wiring sensor, be aware
that the sensor terminal “C” has the same voltage as terminal L1.
! WARNING !
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10TA Service Manual
Sentronic Oil Pressure Safety Control (4D & 6D compressors before March 2011).
The Sentronic utilizes 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.
Sentronic Oil Safety (Sensor Only)
Part #: 12A2117A0501
Sentronic Sensor (2D, 3D, 4D & 6D compressors before March 2011). The same oil pressure
sensor is used for all Sentronic Oil Pressure Controls. It mounts directly into the oil pump. The
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.
4/28/14
9-9
SERVICE OPERATIONS
Sentronic Oil Safety Control
(Entire Unit)
Part #: 12A2117A05
FIGURE 9-7A
Sentronic Oil Pressure Safety Control
Page 90
9-10
SERVICE OPERATIONS
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 (See Figure 6-3). The Sentronic has a timing circuit that actually compares the
amount of time with good oil pressure to that with insufficient oil pressure. The module memory
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.
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
FIGURE 9-7B
CoreSense Protection
22
22
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6
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10TA Service Manual
Description
Vogt #
Copeland #
Line to condenser
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
Oil Separator. A helical oil separator is used to separate the oil from the discharge gas and return it
to the compressor. Oil may be drained from the separator through the angle valve located on the
bottom of the oil separator. If necessary, the oil return float mechanism may accessed for cleaning
or replacement by removing the bottom flange. Note: Make sure oil is drained and the pressure
removed from oil separator before disassembling.
Compressor Crankcase Heater-100Watt (Part No. 12A7509E12) 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 contactor is energized.
Control Circuit Protection (Part No. 12A7504E1) The electrical control circuit of the machine is
protected by a 2 Pole, 3A circuit breaker. If the breaker should open, the machine will immediately
stop. Before resetting the breaker, open the disconnect switch to machine and set the
“Clean/Off/Ice” selector 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, set the “Clean/Off/Ice” selector switch to “Ice” and depress the
“Start” button. The machine will start in a harvest, and begin a new freeze cycle upon completion.
Sentronic3
Module and Sensor
For Sentronic, Sentronic 3
or CoreSense
Discharge line
from compressor
Oil Separator
Vogt Part #: 12A3025S08
(Add 25 ounces of oil when installing new)
Oil return shutoff valve
Note: Valve may be located at compressor
FIGURE 9-8
Oil Separator
9-11
SERVICE OPERATIONS
12A2117A05 585-1076-02
12A2117A0501 998-0162-00
Angle valve with
1/4” access fitting
Oil return line to
compressor
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9-12
Light solid when "timed
out"
Light solid when "timed
SERVICE OPERATIONS
Light
indicates
timer has
timed out
Light
indicates
timer is timing
Thawing Timer (Part No. 12A7503E22) 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.
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. Verify time after
each adjustment.
4/28/14
Syrelec Timer (Orange)
Scale: Set to
“X1”
Up Light (red)
Light off while "timing"
Range: Set to
“0 to 12”
Time Range
adjustment
0 - 1.2
0 - 3
0 - 12
0 - 30
Range: Set
Time Base:
Set to “min”
Allen Bradley Timer (White)
POWER
UP
6
4
8
2
RANGE UNIT
0
Min
10
12
FIGURE 9-9A
Thawing Timer
FIGURE 9-9B
Thawing Timer Wiring
10TA Service Manual
Crouzet Timer (White)
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
Page 93
10TA Service Manual
Pumpdown The function of the pumpdown is to transfer all the liquid refrigerant from the freezer
(evaporator) into the receiver. Pumpdown should only be performed when the freezer is clear of ice.
Its main purposes are:
1. To check the total refrigerant charge.
2. To perform service or repair work on the machine.
3. To winterize the machine.
4. To prepare the machine for disconnecting and moving.
5. Before cleaning
To perform a pumpdown, follow this procedure:
1. Push manual harvest button to clear the freezer of all ice and stop operation.
2. Close the liquid stop valve (king valve) (58) at the receiver.
3. Open the water tank drain valve 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 (69) at the top of the freezer to
isolate the freezer pressure switch and 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 jumping
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).
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.
SERVICE OPERATIONS
! WARNING !
Approved recovery equipment, hoses, gages, and refrigerant containers must be
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 !
9-13
4/28/14
Page 94
9-14
SERVICE OPERATIONS
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.
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 that 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.
10TA Service Manual
! WARNING !
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 by cylinder manufacturer or any applicable
code requirements.
! WARNING !
4/28/14
Page 95
10TA Service Manual
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.
208/230V coil
Part No.126229
208/230V coil
Part No.126229
Hansen 1 1/4” Solenoid Valve
Part No. 12A4200A1001
Hansen Rebuild Kit – HS7
Part No. 12A4199V52
Thawing Gas Solenoid Valve (“D” Valve)
Hansen 1/2” Solenoid Valve
Part No. 12A4200A0604
Hansen Rebuild kit – HS8
Part No. 12A4199V51
Liquid Feed Solenoid Valve (“A1” & “A2” Valve)
9-15
SERVICE OPERATIONS
FIGURE 9-10A
FIGURE 9-10B
4/28/14
Page 96
9-16
SERVICE OPERATIONS
Capacity Control Valve (Internal Construction) A schematic illustration of the internal valve
operation is shown in FIGURE 9-11. (Part No. 12A2110P0907)
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.
10TA Service Manual
Part No. 12A2110P0907
(Unloader Valve & 240V Coil)
4/28/14
FIGURE 9-11
Copeland Compressor Unloader Valve
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.
Page 97
10TA Service Manual
Pump Suction (2” FPT)
Pump Discharge (1 1/2” FPT)
Circulating Water Pump Motor (Part No. 12A4020G01- 60hz, 12A4020G08 – 50hz)
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.
Cutter Gear Reducer (Part No. 12A4030R12) 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.
Seal Kit Part #: 12A4080S12
Gear Reducer (10:1)
Part #: 12A4030R12
Replacement food grade oil:
Part #: 19T3020C01
Texaco Cygnus 220
Oil Capacity: 8 ounces
Note: Ventless gear reducer used after August 2010
Pump Part #: 12A4020G01 (60hz)
12A4020G08 (50hz)
FIGURE 9-12
Circulating Water Pump
Vent Plug
Oil Level Plug
Drain Plug
9-17
SERVICE OPERATIONS
Vent Plug
4/28/14
FIGURE 9-13
Gear Reducer
Page 98
9-18
SERVICE OPERATIONS
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 inserted.
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 9-16)
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. The split hub can be removed by driving a screwdriver in the split and sliding the hub off the shaft.
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.
10TA Service Manual
4/28/14
Page 99
10TA Service Manual
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 & 9-15 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 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.
4/28/14
SERVICE OPERATIONS
9-19
Page 100
9-20
SERVICE OPERATIONS
BEARING
SUPPORT
BRACKET
PIN FOR CUTTER BEARING
PART NO. 12A3040S02
SPIRAL PIN HOLDS DISC
ASSEMBLY TO CUTTER SHAFT
PART NO. 12A3040S01
DEFLECTOR PLATE
PART NO. 19T4001S023
19T4500S01805
CUTTER HOUSING
ASSEMBLY
4/28/14
UHMW CUTTER BEARING
PART NO. 19T2160C0201
PART NO. 19T2160C0202
FREEZER
ICE DEFLECTOR
PLATE
CUTTER HOUSING
CUTTER BEARING (47)
DRIVE PIN
FOR BEARING
FIGURE 9-14
Cutter Assembly
FIGURE 9-15
Cutter Parts (cylinder ice)
10TA Service Manual
GASKET
3/8” BOLTS FASTEN BEARING
SUPPORT TO CUTTER HOUSING
CUTTER DISC
DRIVE PIN FOR CUTTER DISC
ADAPTOR PLATE
FOR CAST CUTTER
PART NO. 19T2010A12
CUTTER ASSEMBLY
FOR CYLINDER ICE
PART NO. 19T2160C0202
CUTTER SUPPORT
PART NO. 12A2025B0102
CUTTER DISC ASSEMBLY
PART NO. 19T2163D0202
GUM RUBBER GASKET
PART NO. 12A2600G05
GEAR REDUCER
PART NO. 12A4030R12
CUTTER MOTOR
208/230/460V-3Ph-50/60Hz
PART NO. 12A2900M0508
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