P-24A
&
P-34A
TUBE-ICE®
MACHINE
Service Manual
$5000
12/20/12
NOTICE
This manual is the property of the owner of this particular Tube-Ice®
machine.
Model #____________________ Serial #____________________.
It is to be left on the premises with this machine at all times. After start-up,
it should be stored in a safe place where it can be readily available when
needed for future reference in maintaining troubleshooting or servicing.
Failure to comply with this notice will result in unnecessary inconvenience
and possible additional expenses.
This manual is intended as an informational tool for the installation,
operation, maintenance, troubleshooting, and servicing of this equipment.
If an existing situation calls for additional information not found herein, we
suggest that you contact your distributor first. If further assistance or
information is needed, please feel free to contact the factory at 502-6353000 or FAX at 502-635-3024 or 502-634-0479.
IMPORTANT: The Warranty Registration/Start-Up Report found in the
front of this manual is to be completed and returned to the factory promptly
after the official start-up.
Please return to: Vogt Ice, LLC
12/20/12
1000 W. Ormsby, Suite 19
Louisville, KY 40210
Att. Service Department
12/20/12
Vogt Tube-Ice Machine
MID & LARGE MACHINE WARRANTY REGISTRATION/START-UP REPORT
MUST COMPLETE AND RETURN TO INITIATE WARRANTY
Machine Model No. ________________________________ Serial No. ____________________________________________
Installed at: ____________________________________________________________( )_______________________________________
Company Name Phone
_______________________________________________________________________________________________________
Address City State Zip
______________________________________________________________________________________________________
Installed by: ___________________________________________________________( )________________________/____/________
Company Name Phone Date
_______________________________________________________________________________________________________
Address City State Zip
Describe any damage to machine/repairs made: _____________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
Start up by: ___________________________________________________________( )________________________/____/_________
Company Name Phone Date
_______________________________________________________________________________________________________
Address
Name of person starting up machine: ____________________________________________________________________________________
PRE START-UP CHECK
CHECK
Service Manual on hand
Machine room suitable 50°F minimum, 110°F maximum
Proper power supply, actual voltage _______________, _________________, _________________ (machine not running)
Compressor crankcase heater on 12 hour minimum
Necessary hand valves opened as required
Solenoid valve stems in auto position
System leak checked/tight
Auxiliary equipment overloads wired into control circuit
Compressor oil level _______ (1/4 glass min.)
All water distributors in place (visually inspected)
Water supply and drain lines installed and connected properly
Compressor, pump, cutter and other motor direction of rotation correct
Make-up water float valve adjusted properly
Hour meter in control panel connected
OPERATION CHECK
Machine charged with refrigerant lbs.______________ Actual voltage ____________ , _______________, ________________(machine running)
Ambient temp. _____ °F Fan cycles On _____ Off _____ Tower water in _____°F out ______ °F
Comp motor RLA _____________, _____________, _____________, Actual _____________, _____________, _____________,
Pump RLA _____________, _____________, _____________, Actual _____________, _____________, _____________
Cutter motor RLA _____________, _____________, _____________, Actual _____________, _____________, _____________
Suction pressure end of freezing _______, end of harvest _______ Discharge pressure end of freezing ___________, end of harvest __________
Evaporator/suction line frost _____________________________ Receiver liquid level operating ___________________
Test
Cycle
Water
Temp
FreezeTime
Min/Sec
Harvest Time
Min/Sec
First Ice Out
Min/Sec
All Ice Out
Min/Sec
Avg. Hole
Size
Ice Lb. Per
Harvest
Ice Lb. Per
Day
#1
#2
#3
#4
Note: Ice lb. per day can be found by: ice lb. per harvest x 1440
(freeze time + harvest time)
The machine operated satisfactorily for ___ continuous hours. Date _______________________________________
Comments__________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
Installer signature ____________________________________________ End user signature _________________________________
Please return to: Vogt Ice LLC, 1000 W. Ormsby, Suite #19, Louisville, KY 40210
12/20/12
VOGT
TUBE-ICE® MACHINES
P24A & P34A Model
nstallation, Service Manual, and Parts Catalog #12A4171L13
I
Vogt Ice, LLC
1000 W. Ormsby Avenue, Suite 19
Louisville, Kentucky, 40210
800-853-8648 • 502-635-3000
Fax: 502-634-0479
12/26/12
12/20/12
P24A & P34A Service Manual
Page No.
1. INTRODUCTION
A Brief History Of Our Company .................................................................................................................................1-1
Vogt Energy-Savings Tube-Ice® Machines ..................................................................................................................1-1
Preview .....................................................................................................................................................................1-1
Important Safety Notice.................................................................................................................................................1-2
Safety Symbols and What They Mean...........................................................................................................................1-2
Special Precautions To Be Observed When Charging Refrigeration Systems ...............................................................1-3
Assembly Drawing Model P24A Tube-IceMachine....................................................................................................1-4,1-5,1-6,1-7
Assembly Drawing Model P34A Tube-IceMachine....................................................................................................1-8,1-9,1-10, 1-11
P24A Compressor Diagram ...........................................................................................................................................1-12
2. RECEIPT OF YOUR TUBE-ICE MACHINE
Inspection .....................................................................................................................................................................2-1
Description of Machine .................................................................................................................................................2-1
Safety Tags and Labels..................................................................................................................................................2-1
Model designation for P-Series Ice Machine, Figure 2-1...............................................................................................2-2
Rated Capacity...............................................................................................................................................................2-3
Storage (prior to installation and start-up) .....................................................................................................................2-3
3. INSTALLING YOUR TUBE-ICE MACHINE
Machine Room ..............................................................................................................................................................3-1
Space Requirements.......................................................................................................................................................3-1
Foundation ....................................................................................................................................................................3-1
Lifting Procedures .........................................................................................................................................................3-1
P24A Space Diagram, FIGURE 3-1A & 3-1B ..............................................................................................................3-2,3-3
P24A Foundation Layout, FIGURE 3-2 ........................................................................................................................3-4
P34A Space Diagram, FIGURE 3-3A & 3-3B ..............................................................................................................3-5, 3-6
P34A Foundation Layout, FIGURE 3-4 ........................................................................................................................3-7
Lifting Procedure for P24A, FIGURE 3-5 ......................................................................................................................3-8
Lifting Procedure for P34A, FIGURE 3-6 ......................................................................................................................3-9
Piping and Drain Connections, Table 3-1 ......................................................................................................................3-10
Make-Up Water In,.......................................................................................................................................................3-10
Flushing Water In .......................................................................................................................................................... 3-10
Compressor Cooling Water In and Out..........................................................................................................................3-10
Water Tank Drain ..........................................................................................................................................................3-11
Water Tank Overflow .....................................................................................................................................................3-11
Condenser water In and Out ..........................................................................................................................................3-11
TABLE OF CONTENTS
Vogt
iii
TABLE OF CONTENTS
®
TUBE-ICE® MACHINES
Model P24A & P34A
12/20/12
P24A & P34A Service Manual
Page No.
3. INSTALLING YOUR TUBE-ICE MACHINE (Cont.)
Cooling Tower...............................................................................................................................................................3-11
Condenser Water Requirements TABLE 3-2 ................................................................................................................3-12
Marley Cooling Tower Recommendations TABLE 3-3 ................................................................................................3-12
Safety Valves ................................................................................................................................................................3-12
Cooling Tower Piping Diagram, FIGURE 3-7 ..............................................................................................................3-14
Freeze Protection, FIGURES 3-8, 3-9, 3-10 ..................................................................................................................3-14,3-15
Wiring and Electrical Connections .................................................................................................................................3-15
Power Supply Connections, FIGURE 3-11 ....................................................................................................................3-16
Voltage Unbalance..........................................................................................................................................................3-16
Current Unbalance ..........................................................................................................................................................3-16
Rotation Check ...............................................................................................................................................................3-17
Auxiliary Controls or Equipment....................................................................................................................................3-18
Installation Review: A Checklist ...................................................................................................................................3-18
4. HOW YOUR TUBE-ICE MACHINE WORKS
Operating Features.........................................................................................................................................................4-1
Principle of Operation....................................................................................................................................................4-1
Freeze Period .................................................................................................................................................................4-1
Harvest Period ...............................................................................................................................................................4-2
Piping Nomenclature .....................................................................................................................................................4-2
Piping Schematic for P24A, FIGURE 4-1 .....................................................................................................................4-3
Piping Schematic for P34A, FIGURE 4-2 .....................................................................................................................4-4
5. START-UP AND OPERATION
Refrigeration System Review ........................................................................................................................................5-1
Start-up Checklist ..........................................................................................................................................................5-2
Refrigerant Charge.........................................................................................................................................................5-2
Ammonia Specification By Grade, TABLE 5-1 ............................................................................................................ 5-2
Special Precautions to be Observed when Charging Refrigeration Systems..................................................................5-2
Charging From Tank Truck ..........................................................................................................................................5-3
Charging From Cylinders .............................................................................................................................................5-3
Start-Up .....................................................................................................................................................................5-5
Adding Refrigerant ........................................................................................................................................................5-6
Operating Tips ...............................................................................................................................................................5-6
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Bin Level Control .......................................................................................................................................................... 6-1
Safety Switches..............................................................................................................................................................6-1
Control Panel (Door Opened), FIGURE 6-1..................................................................................................................6-2
Description of Control Panel Parts (Inside), TABLE 6-1 ..............................................................................................6-2
Control Panel (Door Closed), FIGURE 6-2 ...................................................................................................................6-3
Description of Control Panel Parts (Outer Door), TABLE 6-2 ......................................................................................6-3
Electrical Schematic All Voltages 50-60 Hz. Across Line Start, FIGURE 6-3 .............................................................6-4
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P24A & P34A Service Manual
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS (Cont.)
Electrical Schematic All Voltages 50-60 Hz. Part Wind Start Comp Motor Starter, FIGURE 6-4...............................6-5
Description of Control Panel Parts, Part Wind Start, TABLE 6-3 .................................................................................6-5
Electrical Schematic All Voltages 50-60 Hz. Across the Line Start Comp Motor Starter, FIGURE 6-5.......................6-6
Description of Control Panel Parts, Across the Line Start, TABLE 6-4 ........................................................................6-6
Electrical Schematic All Voltages 50-60 Hz. Soft Start Comp Motor Starter, FIGURE 6-6 .........................................6-7
Description of Control Panel Parts, Soft Start, TABLE 6-5...........................................................................................6-7
Allen Bradley Soft Start Wiring, FIGURE 6-7 ..............................................................................................................6-8
Allen Bradley Soft Start Settings and Faults, TABLE 6-6.............................................................................................6-9
Allen Bradley Soft Start Dip Switch Settings, TABLE 6-7 ...........................................................................................6-10
7. MAINTENANCE
Preventive Maintenance.................................................................................................................................................7-1
Preventative Maintenance Form ....................................................................................................................................7-2
Ice-Making Section........................................................................................................................................................7-3
Cleaning Procedure........................................................................................................................................................7-3
Water Distributors, TABLE 7-1 ....................................................................................................................................7-4
Average Hole Size in Tube-Ice, TABLE 7-2...............................................................................................................7-4
Water Tank ....................................................................................................................................................................7-4
Water Cooled Condenser Cleaning ...............................................................................................................................7-5
Cooling Tower / Evap Condenser .................................................................................................................................7-5
Cooling Tower Maintenance Schedule, TABLE 7-3 .....................................................................................................7-6
Compressor ...................................................................................................................................................................7-6
Compressor Maintenance, TABLE 7-4 .........................................................................................................................7-7
Cutter Gear Reducer ......................................................................................................................................................7-7
V-Belt Maintenance.......................................................................................................................................................7-8
8. TROUBLESHOOTING
List Of Symptoms..........................................................................................................................................................8-1
Machine Stopped ........................................................................................................................................................... 8-2, 8-3
Freeze-Up Due To Extended Freezing Period ...............................................................................................................8-4
Freeze-Up Due To Ice Failing To Discharge .................................................................................................................8-5
Low Ice Capacity...........................................................................................................................................................8-6, 8-7
Poor Ice Quality.............................................................................................................................................................8-7
High Discharge Pressure................................................................................................................................................8-8
Low Discharge Pressure ................................................................................................................................................8-9
High Suction Pressure....................................................................................................................................................8-9
Compressor Running Unloaded During Freeze .............................................................................................................8-9
Compressor Oil Pressure Low .......................................................................................................................................8-10
Compressor Loosing Oil Excessively ............................................................................................................................8-10
Machine Short Cycles....................................................................................................................................................8-11
Shut Down By Oil Pressure Switch ...............................................................................................................................8-11
High Compressor Discharge Temperature.....................................................................................................................8-11
Suction Line Frosting To Compressor ...........................................................................................................................8-12
12/20/12
iii
TABLE OF CONTENTS
Page No.
iv
TABLE OF CONTENTS
P24A & P34A Service Manual
Page No.
9. SERVICE OPERATIONS
Automatic Blowdown (Harvest Cycle)..........................................................................................................................9-1
Cleaning the Ice Making Section ...................................................................................................................................9-1
Float Valve (Make-Up Water) ....................................................................................................................................... 9-1
Float Switch...................................................................................................................................................................9-1
Hand Expansion Valve ..................................................................................................................................................9-2
Freeze Timer..................................................................................................................................................................9-2
Freezer Pressure Switch, FIGURE 9-1 ..........................................................................................................................9-2
High/Low Pressure Switch ............................................................................................................................................9-2
High/Low Pressure Switch, FIGURE 9-2......................................................................................................................9-3
Fan Control (Cooling Tower) ........................................................................................................................................9-3
Fan Control Switch, FIGURE 9-3 .................................................................................................................................9-3
Compressor Crankcase Heater .......................................................................................................................................9-4
Oil Pressure Switch........................................................................................................................................................9-4
Oil Pressure Switch, FIGURE 9-4 .................................................................................................................................9-4
Control Circuit Protection..............................................................................................................................................9-4
Thawing Timer ..............................................................................................................................................................9-5
Thawing Timer, FIGURE 9-5........................................................................................................................................9-5
Condenser Cleaning......................................................................................................................................................9-6
Cutter Gear Reducer ......................................................................................................................................................9-6
Drive Gear Replacement................................................................................................................................................9-7
Gear Reducer Replacement ...........................................................................................................................................9-8
Water Tank and Cutter Parts Weights, TABLE 9-1.......................................................................................................9-9
Water Tank Removal.....................................................................................................................................................9-9
Cutter Assembly Removal and Installation....................................................................................................................9-10
Bearing Bracket and Cutter Disc Removal ....................................................................................................................9-10
Cutter Shaft and Bearing Removal ................................................................................................................................9-10
Cutter Shaft and Bearing Installation.............................................................................................................................9-11
Cutter Height Adjustment..............................................................................................................................................9-12
Water Tank Installation .................................................................................................................................................9-12
P24A Cutter Assembly, FIGURE 9-5A .........................................................................................................................9-12
P24A Water Tank Assembly, FIGURE 9-5B ................................................................................................................9-13
P24A and P34A Cutter and Water Tank Part No., TABLE 9-2 .....................................................................................9-14
Cutter Ring Gear Replacement ...................................................................................................................................... 9-15
Cutter Blade Replacement .............................................................................................................................................9-15
Cutter Blade and Adapter Plate Adjustment, FIGURE 9-6............................................................................................9-16
Cutter Adapter Plate Installation....................................................................................................................................9-16
Pumpdown .....................................................................................................................................................................9-17
Removal of Ammonia Refrigerant from the Machine ...................................................................................................9-17
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P24A & P34A Service Manual
20
Page No.
9. SERVICE OPERATIONS
Refrigerant Leaks...........................................................................................................................................................9-18
Non-Condensable Gases ................................................................................................................................................9-18
Purging Non-Condensables ...........................................................................................................................................9-18
Draining the Oil Trap.....................................................................................................................................................9-19
Removing Excess Water from Ammonia ......................................................................................................................9-
Circulating Water Pump Motor .....................................................................................................................................9-21
The Thaw Gas Solenoid Valve ......................................................................................................................................9-21
Thaw Gas Solenoid Valve, FIGURE 9-7.......................................................................................................................9-21
The Liquid Feed Solenoid Valve ................................................................................................................................... 9-22
The Liquid Feed Solenoid Valve, FIGURE 9-8.............................................................................................................9-22
Water Flush Solenoid Valve ..........................................................................................................................................9-22
Compressor Cooling Solenoid Valve ( dedicated high side only)..................................................................................9-23
Compressor Oil Changing .............................................................................................................................................9-23
Compressor Inspection ..................................................................................................................................................9-23
Belt Tension...................................................................................................................................................................9-24
Compressor Servicing....................................................................................................................................................9-24
v
TABLE OF CONTENTS
10. OPTIONS AND ACCESSORIES
Crushed Ice Production .................................................................................................................................................10-1
Length of Ice .................................................................................................................................................................10-1
Power Monitor...............................................................................................................................................................10-2
11. TABLES AND CHARTS
P24A Specifications, TABLE 11-1................................................................................................................................11-2
P34A Specifications, TABLE 11-2................................................................................................................................11-3
P24A Capacity Ratings, TABLE 11-3 ...........................................................................................................................11-4
P24A Condenser Water Usage, TABLE 11-4................................................................................................................11-5
P34A Condenser Water Usage, TABLE 11-5................................................................................................................11-5
P24A Make-up Water Usage, TABLE 11-6 ..................................................................................................................11-6
P34A Make-up Water Usage, TABLE 11-7 ..................................................................................................................11-6
P24A Normal Operating Vitals, TABLE 11-8...............................................................................................................11-7
P34A Normal Operating Vitals, TABLE 11-9...............................................................................................................11-7
Recommended Spare Parts List .....................................................................................................................................11-8
Temperature - Pressure Chart for Common Refrigerants, TABLE 11-10......................................................................11-9
Conversion Factors: English to Metric, TABLE 11-11 .................................................................................................11-10
Constants, TABLE 11-12 ..............................................................................................................................................11-10
APPENDIX
12. TABLES AND CHARTS
12/26/12
12/20/12
P24A & P34A Service Manual
A Brief History Of Our Company. Vogt Ice, L.L.C. (formerly Henry Vogt Machine Co.) was
founded as a small machine shop in Louisville, Kentucky in 1880. Today, it is one of the world’s
leading producers of ice-making equipment.
In 1938, Vogt built the first Tube-Ice® machine and revolutionized the ice-making industry. Our first
“sized-ice” machine quickly replaced the old can-ice plants, which required hard labor and large
amounts of floor space for freezing, cutting, and crushing ice by hand.
Vogt Energy-Saving Tube-Ice Machines Are Cost Effective. Today, Vogt Tube-Ice® machines
enjoy a well-earned reputation as the most energy efficient, dependable ice-making equipment in the
world.
Using as little as one-half to one-third the energy required by competitors’ ice makers, Tube-Ice®
machines produce the same amount of ice--in restaurants, sports arenas, packing plants, and
wholesale operations around the globe--at great savings.
In addition, Tube-Ice® machines are renowned for their long life, giving many customers more than
35 years of dependable service. Ask someone who owns one.
Preview. All the skill in engineering and fabrication that we’ve learned in over a century of
experience is reflected in every Tube-Ice® machine. Since Vogt introduced Tube-Ice® machines in
1938, the process of making Tube-Ice® ice has been widely recognized as the most economical
means of production. The machine’s economic and reliable operation has been proven over and over
again, in a network of varied types of installations throughout the world.
Furnished with your machine is the Certificate Of Test--the report of operating data that is a record
of the unit’s satisfactory operation at our factory test floor. It is evidence of our desire to deliver to
you “the finest ice-making unit ever made.”
This manual is designed to assist you in the installation, start-up, and maintenance of your unit.
Your Tube-Ice® machine will give you a lifetime of service provided you install, maintain, and
service it properly.
Please read your manual carefully before attempting installation, operation, or servicing of this
professionally designed piece of equipment. Also, make sure the Warranty Registration/Start-up
Report is completed and returned.
If you have additional questions, please call your distributor. Also, feel free to phone the factory
direct at (502) 635-3000.
1-1
INTRODUCTION
1. Introduction
Vogt Ice, L.L.C.
12/18/12
1-2
INTRODUCTION
Important Safety Notice. This information is intended for use by individuals possessing adequate
backgrounds in electrical, refrigeration and mechanical experience. Any attempt to repair major
equipment may result in personal injury and/or property damage. The manufacturer or seller cannot
be responsible for the interpretation of this information, nor can it assume any liability in connection
with its use. It is important that personnel understand the properties of this refrigerant and that they
be thoroughly trained in safe practices for its use and handling. Refer to the enclosed “Anhydrous
Ammonia Safety” in Appendix A.
Safety Symbols & What They Mean. Prior to installation or operation of the Tube-Ice® machine,
please read this manual. Are you familiar with the installation, start-up, and operation of a Tube-Ice®
machine? Before you operate, adjust or service this machine, you should read this manual,
understand the operation of this machine, and be aware of possible dangers.
P24A & P34A Service Manual
These safety symbols will alert you
when special care is needed.
Please heed them.
! DANGER !
Indicates an immediate hazard and that special precautions
are necessary to avoid severe personal injury or death.
! DANGER !
! WARNING !
Indicates a strong possibility of a hazard and that an
unsafe practice could result in severe personal injury.
! WARNING !
! CAUTION !
Means hazards or unsafe practices could result
in personal injury or product or property damage.
! CAUTION !
12/18/12
P24A & P34A Service Manual
Special Precautions To Be Observed When Charging Refrigeration Systems. Only technicallyqualified persons, experienced and knowledgeable in the handling of anhydrous ammonia refrigerant
and operation of refrigeration systems, should perform the operations described in this manual. All
local, federal, and EPA regulations must be strictly adhered to when handling ammonia (R-717)
refrigerant. See “Material Safety Data Sheet”, MSDS Code No. 5B81-83.
If a refrigeration system is being charged from refrigerant cylinders, disconnect each cylinder when
empty or when the system is fully charged. A gage should be installed in the charging line to
indicate refrigerant cylinder pressure. The cylinder may be considered empty of liquid R-717
refrigerant when the gauge pressure is 25 pounds or less, and there is no frost on the cylinder. Close
the refrigerant charging valve and cylinder valve before disconnecting the cylinder. Loosen the
union in the refrigerant charging line--carefully to avoid unnecessary, excessive or illegal release of
refrigerant into the atmosphere.
Immediately close system charging valve at commencement of defrost or thawing cycle if
refrigerant cylinder is connected. Never leave a refrigerant cylinder connected to system
except during charging operation. Failure to observe either of these precautions can result in
transferring refrigerant from the system to the refrigerant cylinder, over-filling it, and
possibly causing the cylinder to rupture because of pressure from expansion of the liquid
refrigerant brought on by an increase in temperature.
Always store cylinders containing refrigerant in a cool place. They should never be exposed to
temperatures higher than 120°F and should be stored in a manner to prevent abnormal mechanical
shocks.
Also, transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is
not recommended.
It is not recommended that refrigerant be transferred from a refrigeration system directly into
a cylinder. If such a transfer is made, the refrigerant cylinder must be an approved, CLEAN
cylinder--free of any contaminants or foreign materials--and must be weighed continuously to
assure contents do not exceed net weight specified by cylinder manufacturer or any applicable
code requirements.
1-3
INTRODUCTION
! CAUTION !
! CAUTION !
! CAUTION !
! CAUTION !
12/18/12
1-4
INTRODUCTION
P24A & P34A Service Manual
12/18/12
FIGURE 1-1
P24A Front Side (Control Panel)
P24A & P34A Service Manual
1-5
INTRODUCTION
12/18/12
FIGURE 1-2
P24A Right Side
1-6
INTRODUCTION
P24A & P34A Service Manual
12/18/12
FIGURE 1-3
P24A Back Side
P24A & P34A Service Manual
1-7
INTRODUCTION
12/18/12
FIGURE 1-4
P24A Left Side
1-8
INTRODUCTION
P24A & P34A Service Manual
12/18/12
FIGURE 1-5
P34A Front Side
P24A & P34A Service Manual
1-9
INTRODUCTION
12/18/12
FIGURE 1-6
P34A Right Side
1-10
INTRODUCTION
P24A & P34A Service Manual
12/18/12
FIGURE 1-7
P34A Back Side
P24A & P34A Service Manual
1-11
INTRODUCTION
12/18/12
FIGURE 1-8
P34A Left Side (Control Panel)
1-12
INTRODUCTION
P24A & P34A Service Manual
12/18/12
FIGURE 1-9
P24A Compressor Diagram
P24A & P34A Service Manual
Inspection. As soon as you receive your machine, inspect it for any damage. If damage is
suspected, note it on the shipper’s papers (i.e., the trucker’s Bill of Lading). Immediately 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 L.L.C. can void the machine’s warranty. You
should also notify your Vogt distributor or the factory.
Description Of Machine. A Vogt package Tube-Ice machine is a complete ice producing plant
requiring only make-up water supply, condenser water supply, electrical connection, and the proper
refrigerant charge.
The machine has been fully factory tested prior to shipment and should require minimum adjustment.
After factory testing of the machine, the liquid ammonia is removed and only ammonia gas pressure
is allowed to remain. This prevents air or moisture from entering the system during transit. There
should be a positive pressure (20-25 psig) indicated on the control panel gages when the machine is
received.
The compressor oil is drained and the compressor suction strainer and cloth filter are cleaned and
reinstalled. The crankcase is inspected and cleaned by removing the side handhold cover, swabbing
out the remaining oil and wiping the interior sides and bottom with a clean dry cloth. Do not use
woolen fabrics or material which may leave loose fibers. New oil is added and the compressor is
evacuated then pressurized with ammonia vapor to 20-25 psig.
Refer to your compressor manual for additional operation, service, maintenance instructions, and
information.
Safety Tags and Labels. Be sure to read and adhere to all special tags and labels attached to valves
or applied to various areas of the machine. They provide important information necessary for safe
and efficient operation of your equipment.
12/18/12
RECEIPT OF YOUR TUBE-ICE MACHINE
2. Receipt Of Your Tube-Ice Machine
! CAUTION !
Only service personnel experienced in ammonia refrigeration and
qualified to work on high amperage electrical equipment should
be allowed to install or service this Tube-Ice
Eye protection should be worn by all personnel
working on or around the Tube-Ice
It is very important that you are familiar with and adhere to
all local, state, and federal, etc. ordinances and laws regarding
the handling, storing, and use of anhydrous ammonia.
An approved ammonia mask should be readily available
for use in an emergency and all personnel should be aware
of its location and proper use.
! CAUTION !
machine.
machine.
2-1
2-2
"J" - R-
507
“SCT”
–
Stainless Steel Cas
ings and Bin Thermostat
- P F B 4 26 C
variations within any one family series.
RECEIPT OF YOUR TUBE-ICE MACHINE
The machine is available in three different tube sizes for producing ice 7/8” OD x 1” long, 1 1/8” OD
x 1” long, or 1 3/8” OD x 1” long. The ice is cut to length by a rotating breaker type cutter. Ice can
be produced up to 1 1/2” long by modifying the spacers under the adapter plates (see Chapter 10,
“Ice Length” for modifying instructions). Crushed ice is also available by modifying the cutter and
making minor adjustments to the machine (see Chapter 10, “Crushed Ice”).
Nominal Capacity
"02K" - 2000 lbs/day
"03K" - 3000 lbs/day
"04K" - 4000lbs/day
"03T" - 3 tons/day
"05T" - 5 tons/day
"10T" - 10 tons/day
"25T" - 25 tons/day
"50T" - 50 tons/day
"80T" - 80 tons/day
("K" = 1000's lbs/day, "T" = tons/day)
(Consult Specifications for Actual Capacity)
Model Variation
A number assigned to indicate major
02K A -
Basic Configuration
"P" - Package
"L" - Low-side
"H" - High-side
Tube Size
"4" - 1"
"5" - 1 1/4"
"6" - 1 1/2"
"7" - 1 3/4"
"8" – 1 7/8"
Refrigerant
"F" - R-22
"A" - Ammonia
"H" - R-404a
Electrical Codes
"26" - 208/230-3-60
"46" - 460-3-60
"56" - 575-3-60
"25" - 200-3-50
"45" - 400-3-50
"21" - 230-1-60
Type of Ice
"B" - Cylinder
"K" - Crushed
"D" - Dual Ice (Cru & Cyl)
"L" - 1 1/2" Long Cylinder
Condenser Type
"AC" - Air Cooled
"WC" - Water Cooled
"HP" - High Pressure Water Cooled
"SW" - Sea Water
"NC" - No Condenser
Product Variation Codes (A number or letter designator assigned to specific variations within a family.)
"000 or Blank" – Standard Product
"001" – Pillsbury Job
"002" – Liquid Overfeed, Less Control Panels
“003” – Liquid Overfeed, Panel shipped separate, No Wiring
"RCP" – Remote Control Panel
"PWS" – Part-Wind Starter
"LOF" – Liquid Overfeed
"120" – 120 Volt Controls
"FPS" – Freezer Pressure Switch (Instead of timer)
"HKA" – Insulated Casings & Part-Wind Start (Hong Kong Airport)
"LCP" – Less Control Panel
"45T" – Transformer added for 400-3-50, 0_K Models
“SSC” – Stainless Steel Casing
“VTC” – Von’s Type Cutter
“ISC” – Insulated Stainless Steel Casings
FIGURE 2-1
Model Designation for P-Series Ice Machines
P24A & P34A Service Manual
A
-
RC
12/18/12
P24A & P34A Service Manual
Rated Capacity. The Tube-Ice machine is rated to produce a given amount of ice when operating
under the proper conditions as specified in this manual. You should be prepared to handle the ice
produced as it is discharged from the machine and move it to your storage or bagging area promptly.
The following specifications are given to help you do just that.
Makeup Water
Temp.
85°F/29°C
80°F/24°C
75°F/23°C
70°F/21°C
65°F/18°C
60°F/15°C
55°F/13°C
Ice lb/harvest 750 lbs/340 Kg 600 lbs/272 Kg 450 lbs/204 Kg
RECEIPT OF YOUR TUBE-ICE MACHINE
Model P24A-1.5” Model P24A-1.25” Model P24A-1”
Capacity Tons/day
(2000 lbs/24 hours)
19.5 4.06 21.0 4.37 20.0 4.18
20.0 4.16 21.5 4.48 20.5 4.27
20.5 4.27 22.0 4.60 21.0 4.37
21.0 4.38 22.6 4.71 21.5 4.48
21.6 4.49 23.2 4.84 22.0 4.59
22.2 4.62 23.9 4.97 22.6 4.71
22.8 4.75 24.5 5.11 23.2 4.83
Makeup
Water
GPM
Capacity Tons/day
(2000 lbs/24 hrs.)
Makeup
Water
GPM
Capacity Tons/day
(2000 lbs/24 hours)
2-3
Makeup
Water
GPM
12/18/12
Shipping weight 12,200 lbs/5533 Kg 12200 lbs/5533 Kg 11,800 lbs/5352 Kg
Operating weight 14,000 lbs/ 6350 Kg 14000 lbs/6350 Kg 13,450 lbs/6100 Kg
Makeup Water
Temp.
85°F/29°C
80°F/24°C
75°F/23°C
70°F/21°C
65°F/18°C
60°F/15°C
55°F/13°C
Ice lb/harvest 1350 lbs/612 Kg
Shipping weight 21500 lbs/9750 Kg
Operating weight 23000 lbs/10500 Kg
Notes:
1. Makeup water is average flow and includes 25% blowdown. Peak flow rate is 15 GPM. at 40 PSI minimum. When water quality is good,
machine can be operated with 5% to 10% blowdown.
2. Ratings are at 90°F ambient for ice machine.
3. Capacity ratings are based on 85°F water entering condenser. For entering water temperatures above 85°F, deduct 4% in capacity for each 5°F.
4. Capacity shown is the average for model. Individual machines may vary up to 5% above or below depending on field conditions.
Model P34A-1.5” Model P34A-1.25” Model P34A-1”
Capacity Tons/day
(2000 lbs/24 hours)
36.0 7.50 39.5 8.24 35.9 7.48
36.9 7.69 40.5 8.45 36.7 7.66
37.8 7.89 41.6 8.67 37.6 7.84
38.8 8.10 42.7 8.90 38.6 8.04
39.9 8.32 43.8 9.14 39.6 8.25
41.0 8.55 45.1 9.39 40.6 8.47
42.2 8.79 46.4 9.66 41.7 8.70
Makeup
Water
GPM
Capacity Tons/day
(2000 lbs/24 hrs.)
1300 lbs/589 Kg
21500 lbs/9750 Kg
23000 lbs/10500 Kg
Makeup
Water
GPM
Capacity Tons/day
(2000 lbs/24 hours)
850 lbs/385 Kg
20900 lbs/9480 Kg
22400 lbs/10200 Kg
Makeup
Water
GPM
TABLE 2-1
P24A and P34A Specifications
Storage (prior to installation or start-up). The machine must not be stored or installed in an area
that is subject to reach temperatures at or above 110°F (43.3°C).
2-4
RECEIPT OF YOUR TUBE-ICE MACHINE
P24A & P34A Service Manual
12/26/12
P24A & P34A Service Manual
Your machine will be shipped to you as one package. You will need to arrange for the handling of
the package as soon as it arrives, see the machine specifications Table 2-1 for shipping and operating
weight. Before you remove the unit from the truck, be certain that any sign of damage, however
slight, is noted on the carrier’s papers.
Note: See “Lifting Procedure” drawing furnished with this manual, Fig 3-5 and 3-6.
Machine Room. The machine must be located inside a suitable building and must not be subjected
to ambient temperatures below 50°F (10°C) or above 110°F (43.3°C). Heat radiation from other
sources (sunlight, furnaces, condenser, etc.) and unusual air current may affect the operation of the
machine and should be avoided. The electrical components of the Tube-Ice® machine are rated
NEMA 1. Therefore, the machine should not be located in a hazardous area or sprayed with
water. The machine should be installed in an area where water will not stand, but will readily drain
away from the machine.
Space Requirements. Refer to the space diagrams, Figures 3-1 and 3-3, for recommended
minimum clearance around the machine for ease of servicing and observation. Pay particular
attention to the additional space required. If it ever becomes necessary to mechanically clean the
condenser tubes, extra space will be required on one end (preferably on the opposite end from the
water inlet and outlet) for the cleaning tools.
Foundation. Refer to the space diagrams, Figures 3-2 and 3-4, for recommended minimum
foundation requirements. The figures show anchor bolt details and machine anchor hole details.
Contact your local distributor for seismic anchoring requirements in your area.
Lifting Procedures. Your Tube-Ice machine is provided with lifting lugs for the purpose of
unloading and moving the machine to its operation location. Refer to the enclosed drawings for
instructions and illustrations of their use.
P24A - Figure 3-5. Machine weight 13,000 lbs.
P34A - Figure 3-6. Machine weight 22,000 lbs.
These figures are intended as a guide to unloading and lifting the P24A and P34A Tube-Ice®
machine. Vogt Ice, L.L.C. is not responsible for product damage or personnel injury or loss of
life during the loading or lifting procedure.
INSTALLING YOUR TUBE-ICE MACHINE
3. Installing Your Tube-Ice Machine
! WARNING !
Lifting or moving heavy equipment should only be attempted by
competent rigging and hoisting contractors. Never allow personnel
near or under heavy equipment when it is being moved or lifted.
Failure to comply could result in personal injury or loss of life.
! WARNING !
3-1
12/20/12
3-2
INSTALLING YOUR TUBE-ICE MACHINE
P24A & P34A Service Manual
12/20/12
FIGURE 3-1A
P24A Space Diagram (Front View)
P24A & P34A Service Manual
INSTALLING YOUR TUBE-ICE MACHINE
3-3
12/20/12
FIGURE 3-1B
P24A Space Diagram (Side View)
3-4
INSTALLING YOUR TUBE-ICE MACHINE
P24A & P34A Service Manual
12/20/12
FIGURE 3-2
P24A Foundation Layout
P24A & P34A Service Manual
INSTALLING YOUR TUBE-ICE MACHINE
3-5
12/20/12
FIGURE 3-3A
P34A Space Diagram (Front View)
3-6
INSTALLING YOUR TUBE-ICE MACHINE
P24A & P34A Service Manual
12/20/12
FIGURE 3-3B
P34A Space Diagram (Side View)
P24A & P34A Service Manual
INSTALLING YOUR TUBE-ICE MACHINE
3-7
12/20/12
FIGURE 3-4
P34A Foundation Layout
3-8
INSTALLING YOUR TUBE-ICE MACHINE
P24A & P34A Service Manual
12/20/12
FIGURE 3-5
Lifting Procedure for P24A
P24A & P34A Service Manual
INSTALLING YOUR TUBE-ICE MACHINE
3-9
12/20/12
FIGURE 3-6
Lifting Procedure for P34A
3-10
INSTALLING YOUR TUBE-ICE MACHINE
Piping and Drain Connections. See Figure 1-1 to 1-8 for connection locations.
Exterior shut-off valves must be provided in the water
inlet lines. The minimum inlet water pressure for
satisfactory operation of the machine is 40 psig.
The maximum allowable pressure is 100 psig.
Model
P24A 3/4” FPT 3/4” FPT
P34A 1” FPT 3/4” FPT
Make-up
Water In
Flushing
Water In
72 gal/3 min.
104 gal/3 min.
Make-Up Water In. The water required for ice making must be potable water, safe for human
consumption, and should be of the highest quality available. The best way to determine water
quality is to have a complete water quality analysis by a qualified laboratory.
It is advisable to install a particle filter in the make-up and flushing water lines to trap dirt, sand, rust,
or other solid particles prior to entering the water tank and contaminating the ice. Be sure to size the
filter large enough to meet the water demands of 15 GPM (peak flow), allowing for a restriction
through the filter as it traps these particles. The inlet water pressure should be a minimum of 40 psi.
Refer to TABLE 3-1 for line size and TABLE 2-1 for average flow rate at various water
temperatures.
Flushing Water In. Flushing water (blowdown) is necessary to melt ice fines and flush dissolved
solids from the water tank during the thawing (harvest) cycle. This function is important and helps
to maintain good ice quality. If water quality is superior, this blowdown can be reduced by installing
a smaller orifice in the flushing outlet elbow. Make sure there is enough flushing water to prevent
the accumulation of excessive ice fines in the tank.
If make-up and flushing water are from the same source, they can be connected by a common line to
the machine.
Compressor Cooling Water In and Out. This water supply should be a maximum temperature of
85°F (29°C). It is used for cooling the oil and compressor heads. A thermometer and water
regulating valve are installed at the cooling water outlet. The regulating valve should be adjusted to
maintain a water outlet temperature of 100°F (37.8°C) when the compressor is running. A solenoid
valve is installed at the cooling water supply inlet to prevent water flow through the oil cooler and
heads when the compressor is not operating. This is to avoid condensation of refrigerant in the
compressor during shut-down periods. The cooling water outlet should be extended to an open sump
or drain in order to observe water flow and temperature and to make sure there is no water flow
12/20/12
! CAUTION !
! CAUTION !
Compressor
Cooling
Water In
3/4” FPT 1” FPT 3” FPT 2” FPT 3” FPT
3/4” FPT 1” FPT 5” FPT 2” FPT 3” FPT
Compressor
Cooling
Water Out
Condenser
Water
In and Out
TABLE 3-1
Water Supply and Drain Connections
(See FIGURE 1-1 through 1-8 for locations)
P24A & P34A Service Manual
Water
Tank
Drain
Water
Tank
Overflow
P24A & P34A Service Manual
through the heads during shutdown. Do not connect this drain line into a common header with any
drain line from the water tank. Note: The water regulating valve contains a 1/8” orifice through inter
gate to permit some flow though the compressor if the solenoid is open.
Water Tank Drain. This valve and connection is for the purpose of flushing and draining the water
tank of impurities, foreign material and cleaning chemicals used during servicing. It should be piped
to an open drain or sump for visible discharge. It can be tied in with the overflow line but no others.
Water Tank Overflow. A 3” FPT connection on the side of the water tank is provided to carry
away overflow water during the thawing (harvest cycle). This water contains ice fines accumulated
during harvesting and dissolved solids accumulated during the freezing cycle. Do not reduce the
size of this line. Three inches is needed to provide sufficient area for ice fines to be flushed out,
especially if the incoming flushing water is 55°F (13°C) or below. This overflow line should not tie
in with any other drain line except the water tank drain.
Condenser Water In and Out. One end of the condenser has two water connections. The lower
connection is the inlet and the upper connection is the outlet. See TABLE 3-2 for water
requirements and machine total heat rejection. The condenser water outlet must be extended to an
open drain or sump for visible discharge.
The condenser water outlet must not be connected onto a pressure tight common
header with the water tank due to the possibility that contaminated condenser
Cooling Tower. When selecting a cooling tower, careful attention must be given to operating wet
bulb conditions. It is advisable to check with your local cooling tower distributor for their
recommendations based on actual operating conditions in your area. An average wet bulb of 78°F is
typical in the U.S., but many localities have designed wet bulbs as low as 72°F or as high as 82°F.
The cooling tower water pump must be capable of delivering the required volume of water through
the condenser. Due to cooling tower location and pressure drop through water lines and regulating
valves, the water pump must be sized for each installation. Refer to TABLE 3-2 for condenser water
requirements. The water piping for the cooling tower and the installation of the pump must be in
accordance with the manufacturer’s instructions. Caution must be used to prevent the condenser
water pump from losing it’s prime during off cycles.
Proper water treatment for the prevention of mineral and foreign matter accumulation in the
condenser or cooling tower is recommended. A water analysis should be obtained to determine the
proper chemicals to use. The use of a 40 mesh strainer in the condenser water supply line is also
recommended.
INSTALLING YOUR TUBE-ICE MACHINE
! CAUTION !
water may back up into the water tank. The condenser water
outlet must be piped separate from the drain or sump.
! CAUTION !
3-11
12/20/12
3-12
INSTALLING YOUR TUBE-ICE MACHINE
P24A Condenser Water P34A Condenser Water
Entering
Water
85°F
80°F
75°F
70°F
65°F
60°F
55°F
50°F
Total Heat Rejection
THR = 981,300 BTUH
Condenser water flow is based on pulldown of 30°F SST and 105°F SDT. Condenser water
pressure drop does not include water regulating valve. Consult factory for sizing if desired.
Flow
GPM
Cond.
PSID
196 14
131 6
98 3
79 2
66 2
56 1
49 1
44 1
Entering
Water
85°F
80°F
75°F
70°F
65°F
60°F
55°F
50°F
Flow
GPM
371 12
241 5
185 3
148 2
124 1
106 1
93 1
82 1
Total Heat Rejection
THR = 1,852,500 BTUH
P24A & P34A Service Manual
Cond.
PSID
TABLE 3-2
Condenser Water Requirements
The following table show the model of Marley cooling tower required for operating at various wet
bulbs to cool 91°F (33°C) entering water to 85°F (29.4°C) exiting water.
Model
GPM
Cond. PD
PSIG
75°°°°F
76°°°°F
77°°°°F
78°°°°F
79°°°°F
80°°°°F
P24A 195 14 494G 494G 494G 494G 494G 494G
P34A 375/400* 13 496K 496K
* Note: P34A with a condenser containing carbon steel tubes, require 375gpm water flow. P34A with a
condenser containing stainless steel tubes, require 400gpm water flow.
496K
496K (2) 495K (2) 496K
TABLE 3-3
Marley Cooling Tower Recommendations
Tower nozzles will be selected based on GPM required for condenser.
The condenser water pump should be sized on GPM required for condenser at 80 ft. total discharge
head for a typical installation. However, due to cooling tower location and pressure drop through
water lines, the water pump should be sized for each installation.
The ice machine is supplied with a fan control switch for cycling the cooling tower fan on and off,
thereby maintaining the proper operating head pressure. If the condenser inlet water temperature is
expected to be below 75°F/24°C, a water regulating valve should be installed in the condenser water
inlet line and adjusted to maintain a head pressure of not less than 175 psig.
See FIGURES 3-5 through 3-8 for possible cold climate installations with indoor sump.
Safety Valves. Four safety pressure relief valves are an integral part of the packaged Tube-Ice
machine. Two are located in the low side of the system on the freezer, and two are 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. Refer to the International Institute of Ammonia
Refrigeration (IIAR) standard for specific requirements and instructions.
12/20/12
P24A & P34A Service Manual
3-13
INSTALLING YOUR TUBE-ICE MACHINE
12/20/12
FIGURE 3-7
Cooling Tower Piping Diagram
3-14
COOLING TOWER
INDOOR SUMP
CHECK VALVE
COOLING TOWER
INDOOR SUMP
CHECK VALVE
INSTALLING YOUR TUBE-ICE MACHINE
WATER
COOLED
CONDENSER
P24A & P34A Service Manual
FIGURE 3-8
1 PUMP/2-WAY VALVE
* Poor Freeze Protection
Because low flow rate = high freeze chance
WATER
COOLED
CONDENSER
Only enough water to
maintain head pressure
Same flow rate
to cooling tower
12/20/12
FIGURE 3-9
1 PUMP/3-WAY VALVE
* Better Freeze Protection
P24A & P34A Service Manual
COOLING TOWER
INDOOR SUMP
CHECK VALVE
WATER
COOLED
CONDENSER
3-15
INSTALLING YOUR TUBE-ICE MACHINE
12/20/12
Outdoor pump is off until
indoor sump needs cooling
FIGURE 3-10
2 PUMP/2-WAY VALVE
* Best Freeze Protection
Wiring and Electrical Connections.
! WARNING !
Only service personnel experienced in refrigeration and qualified
to work with high voltage electrical equipment should be allowed
to install or work with the Tube-Ice machine.
! WARNING !
A fused disconnect must be provided near the Tube-Ice machine. The control panel and
compressor motor starter are attached to the structurals on the front of the Tube-Ice machine (see
FIGURE 3-11). Incoming 3 phase power will be connected at the compressor motor starter (1M).
Terminals L1, L2, L3 for operation of the Tube-Ice machine and its controls. Rotation checking of
the compressor, cutter motor, and water pump is required (see rotation check). Also, if one leg of the
3 phase power is higher or lower (“wild”), then it should be connected to terminal L3. Connect the
ground wire to the “ground” terminal provided.
Make sure wires #22 and #27 are connected to the elapse time (ET) indicator in the control panel.
3-16
INSTALLING YOUR TUBE-ICE MACHINE
Voltage Unbalance. Voltage unbalance can cause motors to overheat and fail. Voltage imbalance
between any two legs should be no greater than 2%.
Example: Supply voltage = 230-3-60
Voltage Readings: AB = 220 Volts
BC = 225 Volts Average = (220 + 225 + 227)/3 = 224 Volts
AC = 227 Volts
(AB) 224-220 = 4 Volts (Highest Deviation)
(BC) 225-224 = 1 Volts
(AC) 227-224 = 3 Volts
% Voltage Unbalance = 100 x (4/224) = 1.78% “Acceptable”
Important: If the supply voltage phase unbalance is more the 2%, contact your local electric
utility company.
Current Unbalance. Voltage unbalance will cause a current unbalance, but a current unbalance
does not necessarily mean that a voltage unbalance exists. A loose terminal connection or a buildup
of dirt or carbon on one set of contacts would cause a higher resistance on that leg than on the other
two legs. Current follows the path of least resistance, therefore if terminal connection L1 is loose or
dirty, L2 and/or L3 will have higher current.
P24A & P34A Service Manual
FIGURE 3-11
Power Supply Connections
12/20/12
P24A & P34A Service Manual
Higher current causes more heat to be generated in the motor windings. The maximum acceptable
current unbalance is 10%.
Example:
Current Readings: L1 = 96 Amps
L2 = 91 Amps Average = (96 + 91 + 98)/3 = 95Amps
L3 = 98 Amps
(L1) 96-95 = 1 Amps
(L2) 95-91 = 4 Amps (Highest Deviation)
(L3) 98-95 = 3 Amps
% Current Unbalance = 100 x (4/95) = 4.2% “Acceptable”
Rotation Check. The compressor, cutter, and pump motor rotation are factory synchronized, but
must be checked at installation. For cylinder ice production, the cutter disc as viewed at the ice
discharge opening should turn from left to right.
Check rotation by the following procedure:
1. Turn the power to the machine on and check voltages.
2. Make sure the water tank is full of clean water.
3. Turn the Hand-Auto switch (ISS) to HAND position. The water pump will start and the freezing
(1LT) and the liquid feed (2LT) pilot lights will illuminate. Check pump rotation.
4. Push the MANUAL HARVEST button. The water pump will stop, the “Freezing and Liquid
Feed” lights will go out, and after 20-30 seconds, the cutter motor will start. The thawing gas
solenoid valve will open and the “Thawing” pilot light (3LT) will illuminate.
5. Check the cutter disc rotation. It should be turning from left to right (CCW looking from the
top).
6. Turn the HAND-AUTO switch to AUTO to stop the cutter.
To change rotation, follow this procedure:
1. Disconnect power to the machine and lock it out to make sure it can’t be turned back on.
2. Check for power at L1, L2, L3 with a volt meter to make sure it is off.
3. At the compressor motor starter (1M) or at the power disconnect, reverse wires L1 and L2.
4. Make sure these terminals are tight and restore power to the machine.
5. Perform rotation check again to confirm that it is correct.
Do not attempt to start the compressor motor until first making sure all
INSTALLING YOUR TUBE-ICE MACHINE
! CAUTION !
conditions listed in the Installation Review Checklist and all
necessary valves have been opened for operation.
! CAUTION !
3-17
12/20/12
3-18
INSTALLING YOUR TUBE-ICE MACHINE
Auxiliary Controls or Equipment. When connecting other equipment such as tower fan,
condenser pump, conveyor motors, bin level control, etc., refer to the control panel wiring drawing
for the proper connecting terminals and instructions. See Figure 6-3.
Be sure to follow the wiring schematic when incorporating overloads of
conveyor, fan, or pump motor starters (i.e., 5 MOL, 6 MOL, 7 MOL). Also
remove jumpers as instructed. This is necessary to provide proper
protection for the Tube-Ice
Installation Review: A Checklist. Make a visual check to be sure these steps have been taken
BEFORE continuing.
CHECK: _____ PRIOR TO OPENING VALVES, check all joints for leaks which may have
developed during shipment. (NOTE: the machine was shipped with a positive pressure of 20-25
PSIG, which should be indicated on the suction and discharge gages.)
CHECK: _____ All water supply and drain connections for conformity to requirements stipulated in
this manual and properly connected to inlets and outlets.
CHECK: _____ Electrical supply for proper size of fuses and for compliance to local and national
codes. See the machine nameplate for minimum circuit ampacity and maximum fuse size.
CHECK: _____ All field installed equipment (augers, conveyors, cooling towers, bin level controls,
etc.) for proper installation.
CHECK: _____ The applicable portion of the warranty registration/start-up report for proper
completion.
CHECK: _____ Cutter gear reducer oil level oil should run out of side pipe plug when removed.
CHECK: _____ The water distributors at top of freezer to make sure they are all in position (one
seated firmly in each tube with a vent tube in each distributor).
The crankcase heater should be energized for a minimum of
four hours and the oil temperature should be 100-110°°°°F
! IMPORTANT !
machine and its component parts.
! IMPORTANT !
! CAUTION !
before attempting to start the compressor.
! CAUTION
P24A & P34A Service Manual
12/20/12
P24A & P34A Service Manual
4. How Your Tube-Ice Machine Works
HOW YOUR TUBE-ICE MACHINE WORKS
4-1
8/25/05
®
Operating Features. Your packaged Tube-Ice
machine is an efficient ice producing plant. If
installed and maintained properly, it will give many years of operation with a minimum amount of
repairs. Refer to piping schematics, FIGURE 4-1 and 4-2 to identify component parts while
following the information and instructions in this manual.
The machine is manually started and stopped by the START and STOP push buttons. The machine
will automatically stop by safeties such as compressor, cutter and pump overloads, as well as other
auxiliary motor overloads. It will also stop automatically by high head pressure, low suction
pressure or low compressor oil pressure. The circulating water pump can be operated independently
for chemically cleaning the freezer tubes and water tank by use of the HAND/AUTO selector
switch. The machine can be manually forced into a harvest cycle with the manual harvest push
button.
Principle of Operation. The freezer (2) is a shell and tube-type vessel. During the freezing period
(cycle), water is constantly recirculated through the vertical tubes of the freezer by a centrifugal
pump (6). Make-up water is maintained by a float valve (12) in the water tank (7). The float switch
(10) opens and closes the liquid feed “A” solenoid valve (20) and maintains the desired refrigerant
level in the freezer (2) (evaporator).
Refrigerant gas from the top of the freezer (2) passes through the suction accumulator (88) and to the
compressor (3). Here, the cool gas is compressed to a high temperature, high pressure gas which
discharges through the oil separator (14), then through the heat coil of the condenser and then into
the P24 condenser/receiver (15). P34A condenser (15C)/receiver (15R). In the condenser, heat is
removed and the gas is condensed to a high temperature, high pressure liquid. The high pressure
liquid goes out the liquid line through a strainer (43), liquid “A” solenoid valve (20) check valve
(101), and hand expansion valve (17). At the hand expansion valve (17), the refrigerant expands
from a saturated high pressure liquid state to a low pressure, low temperature liquid. This cold
liquid enters the freezer (2) where it absorbs heat from the circulating water in the freezer tubes.
Cool gas is again pulled out of the freezer through the suction outlet, thereby completing the circuit.
The freezing period is completed by action of the freezer pressure switch (2PS) in the control panel.
The water pump (6) stops and the “A” solenoid valve (20) closes. After a delay of 20-30 seconds,
the cutter motor starts, the thawing gas “D” solenoid valve (18) opens, and the harvest (thawing)
timer (2TR) is activated. Warm gas from the receiver is discharged through the thawing chamber
(16), check valve (101), and into the freezer. There it warms the refrigerant and the outer surface of
the freezer tubes, allowing the ice to release on the inside of the tubes and drop down onto the
rotating cutter for sizing. After sizing, the ice drops on the tines cutter disc and discharged through
the ice discharge opening.
See “Freeze Period” and “Harvest Period” for more detailed description of machine.
Freeze Period. The Tube-Ice
®
is frozen inside the stainless steel tubes of the freezer (2) by the
direct application of refrigerant to the outside shell side of the tubes. Ice is produced from
constantly recirculating water down each tube. As the ice thickness increases, the freezer suction
pressure decreases. At a set pressure, the freezer pressure switch (2PS) energizes the relay (1CR),
which stops the water pump, closes the “A” liquid feed solenoid valve (20), turns out the two pilot
lights, ammonia feed and freezing.
4-2
HOW YOUR TUBE-ICE MACHINE WORKS
Harvest Period. About 20-30 seconds after the 1CR relay is energized, the thaw gas valve (18)
opens, the “H” water flush solenoid valve (63) opens, the compressor unloads, the cutter motor
starts, the thaw timer (2TR) is energized, the red thawing gas light illuminates, and auxiliary
equipment such as conveyors etc. start. When the refrigerant in the freezer is warmed sufficiently to
allow the ice in the tubes to release and be sized, the ice is discharged into the customer’s ice
handling equipment. See “Ice Handling” for more information on this subject. The thaw timer
(2TR) is adjustable and should be set for the time required for all the ice to clear the freezer plus 30
seconds more.
Make sure all the ice clears the freezer with at least 30 seconds
to spare before the next freezer period begins. This is to prevent
refreezing and to allow the ice moving augers etc. to clear.
1 Control Panel 36 Oil Trap
1PG Suction Pressure Gauge 37 Oil Charging/Drain Valve
2PG Discharge Pressure Gauge 39 Water Tank Drain Valve
2 Freezer 41 Condenser Water Regulator
3 Compressor 41A Condenser Pressure Control
4PS Dual High/Low Pressure Switch 43 Strainer
5M Cutter Motor 44 Receiver Drain Valve
5R Gear Reducer 45 Compressor Cooling Water Inlet Valve
6 Water Pump 50 Receiver Safety Valve
7 Water Tank (includes cutter assembly) 51 Freezer Safety Valve
8 Water Distributing Chamber 52 3-Way Valve
9 Water Tank Overflow (3” FPT) 54 Compressor Water Regulating Valve
10 Refrigerant Float Switch 55 Discharge Line Stop Valve
12 Make-Up Water Float Valve 56 Freezer/Pressure Switch (2PS)
13 Heat Exchanger 58 Liquid Outlet Valve (King Valve)
14 Oil Separator 59 Receiver Purge Valve
15 Condenser 61 Freezer Oil/Ammonia Drain Valve
15R Receiver 62 Make-up Water Inlet Valve
16 Thawing Chamber 63 Water Flush Solenoid Valve
17 Hand Expansion Valve 64 Compressor Cooling Water Solenoid Valve
18 Thawing Gas Solenoid Valve “D” 69 Low Suction Pressure Stop Valve
20 Liquid Feed Solenoid Valve “A1” 70 Oil Return Stop Valve
23 Condenser Water Inlet W/C Machines 75 Strainer Purge Valve
24 Condenser Water Outlet (W/C Machines) 76 Freezer Purge Valve
25 Water Tank Drain Connection (1” FPT) 77 Compressor Suction Purge Valve
28 Refrigerant Charging Valve 78 Compressor Discharge Purge Valve
29 Liquid Line Stop Valve 82 Discharge Pressure Gage Stop Valve
29A Float Switch Stop Valve 88 Accumulator
30 Sight Glass 90 Thawing Gas Stop Valve
31 Gage Glass Stop Valve 92 Receiver Liquid Return Stop Valve
34 Compressor Suction Service Valve 94 Compressor Oil Pressure Safety Control (OPS)
35 Compressor Discharge Service Valve 101 Check Valve
P24A & P34A Service Manual
! CAUTION !
! CAUTION !
Piping Nomenclature
8/25/05
P24A & P34A Service Manual
HOW YOUR TUBE-ICE MACHINE WORKS
4-3
8/25/05
FIGURE 4-1
Piping Schematic for P24A
4-4
HOW YOUR TUBE-ICE MACHINE WORKS
P24A & P34A Service Manual
8/25/05
FIGURE 4-2
Piping Schematic for P34A
P24A & P34A Service Manual
START-UP & OPERATION
5. Start-Up & Operation
Refrigeration System Review. The refrigeration system uses anhydrous ammonia (R-717)
refrigerant. Following the piping schematic (Figure 4-1 or 4-2), you will see that during the
machine’s freeze cycle, the compressor discharge gas goes through the oil separator (14) to remove
any oil present in the discharge gas and return the oil to the compressor crankcase. From the oil
separator, the discharge gas continues through a heat coil in the lower part of the condenser/receiver
(15).1 It is then discharged into the condenser and condensed into a liquid by the removal of heat by
water passing through the condenser tubes. A reservoir of liquid R-717 (approximate 375 lbs for
P24A and 625 lbs. for P34A) is accumulated in the receiver and is required for thawing purposes.
Liquid from the receiver flows through the strainer to the “A” solenoid valve (20) which opens and
closes by action of the low side float switch (10). The liquid is then expanded through the hand
expansion valve (17) and into the evaporator (2) (freezer). The cold wet R-717 refrigerant floods the
evaporator and is in contact with the outside of the ice making tubes which water is being circulated
through. The heat contained in the water passes through the wall of the tubes, lowering the
temperature of the water causing it to freeze and form a long tube of ice that adheres to the inside of
freezer tubes. Since the purest water freezes first, the circulating water continues to wash the
dissolved solids down into the sump area of the water tank. The flushing valve helps to rid the water
tank of increased dissolved solids by flushing them out the overflow during the harvest (thawing)
period.
The wet suction gas leaves the freezer and passes through the suction accumulator (88), where liquid
droplets are removed, allowing dry gas to enter the suction side of the compressor. The suction gas
is then compressed and discharged once again, completing the cycle. As ice continues to form in the
freezer tubes, the suction pressure steadily decreases until the freezer pressure switch is satisfied and
the contact closes, initiating the thaw (harvest) cycle.
Note: Freezing time will vary, depending on make-up water temperature and thickness of ice
produced.
During the harvest period, the “D” thawing gas valve (18) opens and the compressor unloads,
allowing the warm high pressure gas from the receiver to enter the freezer. As the tubes warm up to
slightly above freezing, the ice inside the tubes releases and falls down onto the rotating cutter for
sizing and discharging. Harvesting requires about three minutes, but can vary depending on ice
thickness, suction pressure, and discharge pressure (thawing gas temperature).
! IMPORTANT !
It is a good idea and will be profitable for you to observe and
become familiar with the proper operating characteristics of your
Tube-Ice
irregularities as they occur in order to help prevent major problems.
machine. It will help you to recognize and correct minor
“An ounce of prevention is worth a pound of cure.”
! IMPORTANT !
5-1
1
Note: in the P24A the condenser and receiver are combined. In the P34A the condenser and the receiver are separated. The P34A receiver
contains the heating coil.
12/10/12
5-2
START-UP & OPERATION
Start-up Checklist. Be sure to complete and return the “Warranty Registration/Start-up Report”
located in the front of the manual.
1. See that the water-inlet connections are attached properly. The water inlet shutoff valve (62) for
the water tank should be open. The water level in the water tank should be at a height where the
make-up float valve will be closed when the machine is idle and water is not running out of the
overflow (9).
2. See that the condenser cooling water is connected properly and the valves are opened for
circulation.
3. Fill the cooling tower sump and check the tower manufacturer’s installation and operation
instructions to make sure it is ready to run.
4. Check condenser cooling water pump rotation.
5. Check rotation of augers or ice handling equipment to make sure they are rotating the proper
direction.
6. Check all tagged valves and make sure they are in their correct operational position (opened,
closed, or automatic).
7. See that the electrical disconnect is closed and the proper power is supplied to the machine.
8. See that the compressor oil temperature is 100-110°F and there is no liquid ammonia in the
crankcase. The oil level should be 1/2-3/4 of the sight glass.
9. Check the elapsed time indicator (ET) and make sure wire #22 and #27 are attached.
10. Reconfirm “Rotation Check” for compressor, cutter and water pump (See Section 3).
Refrigerant Charge. Prior to charging the machine with anhydrous ammonia (R-717) make sure
the system is leak tight and free of non-condensibles or other contaminants.
The machine will require a full charge of pure anhydrous ammonia. Make sure it is from a reputable
supplier who can and will furnish quality ammonia of Refrigeration or Federal Technical grade.
Grade
Fertilizer 99.50% 5000 PPM 5 PPM N/A
Refrigeration 99.98% 150 PPM 3 PPM .2 ml/g
Federal Technical 99.98% 200 PPM 5 PPM None
Metallurgical 99.99% 33 PPM 2 PPM 10 ml/g
Research 99.999% 5 PPM 1 PPM 7 PPM
NOTE: Do not use Fertilizer grade ammonia.
Total ammonia (R717) charge required is approximately;
P24A = 800 lbs. P34A = 1600 lbs.
Special precautions to be observed when charging refrigeration systems. Only technically
qualified persons, experienced and knowledgeable in the handling of anhydrous ammonia refrigerant
and operation of refrigeration systems should perform the operations described in this manual. All
local, federal, and EPA regulations must be strictly adhered to when handling ammonia (R717)
refrigerants. See “Material Safety Data Sheet”, MSDS Code5B81-83, located in the Appendix A.
12/10/12
P24A & P34A Service Manual
Minimum
Ammonia Content
Maximum
Water Content
Maximum
Oil Content
Maximum Non-
condensable
TABLE 5-1
Ammonia Specification By Grade
(Reference IIAR Ammonia Data Book Chapter 1, General Information)
P24A & P34A Service Manual
Charging From Tank Truck. The machine may be charged by bulk from a tank truck and be
pumped directly into the receiver through the drain valve (44).
Follow these instructions with caution:
1. Using a ammonia approved charging hose, connect one end to the charging valve (44) in the
bottom of the receiver.
2. Connect the other end of the charging hose to the tank truck. It is best to have a gage in this line
to indicate pressure.
3. Open the charging valve (44) and the fill valve from the tank truck.
4. Fill the receiver to the indicated mark on the sight glass (30).
Charging From Cylinders. The machine may also be charged from refrigerant cylinders. To charge
from cylinders, the compressor will have to operate to transfer the ammonia from the freezer to the
receiver. Again, make sure all the necessary valves are opened for operation and the compressor
crankcase heater has been energized for a minimum for four hours.
Follow these instructions with caution:
1. Using a approved for ammonia charging hose, connect one end to the charging valve (28) in the
liquid line near the freezer.
2. Lay a full cylinder of anhydrous ammonia horizontally with the cylinder valve outlet pointing up
to withdraw liquid and the bottom end raised about 2” higher than the top end.
3. Connect the other end of the charging hose to the cylinder valve. It is recommended that a gage
be attached to this line to indicate cylinder pressure.
4. Close the liquid line stop valve (29) or (58).
5. Open charging valve (28) and carefully purge air from the charging hose.
6. Open the cylinder valve slowly, checking for leaks in the line and allow the suction pressure to
build up to approximately 40 psig and check again for leaks in the system.
7. With the power off, open the control panel door and disconnect wire #24 from the freezer
pressure switch (2PS), then turn the power back on.
8. Check compressor rotation by starting and stopping the compressor momentarily using the green
“Start” push button (2PB) and the red “Stop” push button (1PB). Correct compressor rotation is
indicated by an arrow on the outer rim of the oil pump assembly (opposite the shaft end of the
compressor.
9. Set the Hand/Auto switch (1SS) to the “Hand” position allowing the circulating water pump to
circulate water through the freezer.
10. As the pressure continues to rise in the freezer, start the compressor and pump the ammonia into
the receiver. Make sure water is circulating through the condenser and freezer tubes.
5-3
START-UP & OPERATION
! CAUTION !
Do NOT attempt to bulk charge the machine through the freezer
charging valve (28). The freezer will not hold the full charge
without exposing the compressor to serious damage.
! CAUTION !
12/10/12
5-4
START-UP & OPERATION
If a refrigeration system is being charged from refrigerant cylinders, disconnect each cylinder when
empty or when the system is fully charged. A gage should be installed in the charging line to
indicate refrigerant cylinder pressure. The cylinder may be considered empty of liquid R-717
refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder. Close
the refrigerant charging valve and cylinder valve before disconnecting the hose from the cylinder.
Loosen the union in the refrigerant charging line--carefully to avoid liquid ammonia release into the
atmosphere.
thawing cycle if refrigerant cylinder is connected. Never leave a refrigerant
Transferring refrigerant from a refrigeration system into a cylinder can be very dangerous
and is not recommended.
As the machine is being charged, continually observe the following operating characteristics:
a) Discharge pressure - 175 psi to 200 psi maximum
b) Compressor oil pressure - (Mycom) 18-27 psi above suction, (Vilter 35-50 psi above suction)
c) Liquid level in receiver - marked on gage glass guard
d) Compressor cooling water - 100°F outlet temperature
e) Compressor oil level - approximately 1/2 glass
While charging the machine, the low pressure switch will stop operation at approximately 15 psi
suction pressure. The switch will automatically reset at 35 psi at which time you can restart the
machine. It is best to use warm water in the tank and open the tank drain valve somewhat to allow
cold water to exit and warm water to enter continually. The idea is to prevent ice from freezing in
the tubes as much as possible while charging. It may be necessary to initiate a short harvest cycle to
dispel any ice made. To initiate a harvest cycle, close the charging valve and push the manual
harvest push button (3PB) while the compressor is running. As soon as all the ice clears the cutter
area, turn the Hand/Auto switch to “Hand” and then back to “Auto”. This will stop the harvest and
start another freeze to continue the charging procedure. When the liquid level in the receiver is near
the pumpdown level and the freezer is down to 15 psi suction with little of no frost on the shell, you
can stop the charging procedure and disconnect the cylinder. Make sure the charging valve is closed
and the cylinder valve is closed before attempting to disconnect the cylinder. Loosen the union in the
charging line gradually to relieve the ammonia pressure slowly.
When charging is complete, stop the machine, disconnect and lock-out the power. Open the control
panel door and reconnect wire #24 to the freezer pressure switch. Open valves #29 and #58 in the
liquid line and you will hear liquid refrigerant flowing through to the liquid solenoid valve #20.
Turn main power disconnect to the on position and the machine is read for start-up and ice
production.
12/10/12
P24A & P34A Service Manual
! CAUTION !
Immediately close system charging valve at commencement of defrost or
cylinder connected to system except during charging operation. Failure
to observe either of these precautions can result in transferring
refrigerant from the system to the refrigerant cylinder, over-filling it,
and possibly causing the cylinder to rupture because of pressure
from expansion of the liquid refrigerant.
! CAUTION !
P24A & P34A Service Manual
Start-Up. Starting the machine can be accomplished as follows:
1. Make sure the crankcase oil temperature is approximately 100°F and there is no liquid ammonia
in the compressor crankcase.
2. Turn the Hand/Auto switch (1SS) to the “Hand” position and allow the water tank to refill.
MAKE SURE THE DRAIN VALVE IS CLOSED.
3. Push the green “Start” push button to start the compressor and immediately observe the oil
pressure, the oil level, the discharge pressure, and listen for any unusual sounds. The compressor
starts unloaded and will load automatically after several seconds by action of the delay timer
(DT).
4. Turn the Hand/Auto switch to the “Auto” position.
5. When the discharge pressure increases to about 170 psi, push the “Manual Harvest” button to
initiate the harvest cycle. See “Harvest Period”.
6. When the suction pressure raises to 50-55 psig, any ice made should release and discharge. After
all of the ice clears the cutter and auger, turn the Hand/Auto switch to “Hand” and back to
“Auto”. This will interrupt the harvest cycle and start another freeze cycle. See “Freeze Cycle”.
As the machine continues its freezing cycle, the liquid ammonia will feed into the freezer until the
level float switch (10) is satisfied. The float switch will open and close the liquid line solenoid valve
(20) to maintain that level of ammonia in the freezer during the freeze cycle. When the suction
pressure pulls down to the setting of the freezer pressure switch (2PS), the switch will close and
initiate the harvest cycle. See “Harvest Period”.
Be sure to observe several complete cycles of ice production to confirm the satisfactory operation of
the machine.
5-5
START-UP & OPERATION
FIGURE 5-1.
Control Panel
12/10/12
5-6
START-UP & OPERATION
Complete the remaining part of the “Warranty/Registration Start-Up Report”
Check the refrigerant level at the receiver liquid gage glass to make sure it is near the operating level
mark.
Adding Refrigerant. Add refrigerant while the machine is running by the following procedure:
1. With a cylinder of anhydrous ammonia laying on its side, cylinder valve outlet pointing up and
bottom end raised two inches higher than the valve end, connect an “approved for ammonia”
charging hose between the freezer charging valve (28) and the cylinder valve.
2. Purge all air from the charging hose and open the cylinder valve gradually to check for possible
leaks around the packing nut or hose fittings. Then open the cylinder valve fully.
3. While the “ammonia feed light is not illuminated, open the charging valve (28) and ammonia
will flow from the cylinder to the freezer.
4. Close the cylinder valve immediately when the ammonia feed light comes on and reopen it when
the light goes out. Repeat until properly charged.
Disconnect it immediately when the machine is charged or the cylinder is empty.
Operating Tips.
• Make sure the machine is left running in the “Auto” position. This will assure a complete
shutdown if a safety or overload is tripped.
• To initiate a harvest cycle, simply push the Manual Harvest push button (3PB).
• To interrupt the harvest cycle and revert to a freeze cycle, turn the Hand/Auto switch to “Hand”
and back to “Auto”.
• Too much ammonia in the condenser/receiver can contribute to high discharge pressure. Do not
go above 13 ½” for the P24A or 25” for the P34A from the center of the lower gage glass cock
while in normal operation. A higher level can begin to cover the condenser tubes and reduce
condenser efficiency.
• The circulating water overflow tubing will show that water is being slightly lifted up the tubing
near the end of the freezing cycle. If this action ceases and water begins overflowing from the
top water box, it is an indication that the tubes are freezing solid and the machine should begin a
harvest cycle. It is best not to freeze the ice solid with no hole.
• To cease ice production manually, allow the machine to complete the harvest period and start the
freeze period. When the “liquid feed” light comes on at the beginning of the freeze period, push
the “Stop” button to cease ice production.
P24A & P34A Service Manual
! IMPORTANT !
and return it to Vogt Tube Ice, L.L.C.
! IMPORTANT !
! CAUTION !
Do not leave a refrigerant cylinder attached to the machine unattended.
! CAUTION !
12/10/12
P24A & P34A Service Manual
Your packaged Tube-Ice machine is equipped with a compressor motor starter (1M) as required for
your particular voltage and a transformer (if required) for the control circuit power. The motor
starter and transformer are mounted on the machine front side (see Figures 1-1 or 1-8).
The control panel wiring schematic, FIGURE 6-3, illustrates these components as well as provisions
for auxiliary equipment which may be incorporated by the customer such as:
(FU1) Main power disconnect
(5M) Conveyor motor starter and overload (5MOL)
(6M) Tower fan starter and overload (6MOL)
(7M) Condenser pump starter and overload (7MOL)
When adding motor starters for auxiliary equipment, be sure to incorporate the overload protection
as indicated between terminals #12-#13 and remove the jumper wire. This will assure that the
machine will shutdown when any auxiliary equipment fails.
Bin Level Control. Included in the wiring schematic is provision for a bin level control (BLC). The
NC contract of your control should be wired between terminals #8-#9 and the jumper wire removed
as indicated. Installation in this manner will allow the machine to finish the harvest period before
shutdown. However, the machine will still need to be manually started to resume production.
Safety Switches. The machine is also equipped with the following safeties and control switches,
which are mounted to the frame near the compressor. Refer to the wiring schematic FIGURE 6-3 for
their circuitry.
• High/Low dual pressure switch (1PS) to stop the machine if the compressor suction pressure
goes too low (15-20 psi) or the compressor discharge pressure goes too high (225-250 psi). See
“High/Low Pressure Switch”.
• Oil failure pressure switch (0PS) to stop the machine if the compressor oil pressure drops to 15
psi net (suction pressure minus oil pressure gage reading). See “Oil Pressure Switch”.
• Fan control switch to maintain a desirable head pressure (discharge pressure) of 175 to 200 psi
during operation. See “Fan Control Switch”.
6-1
ELECTRICAL CONTROLS
6. Electrical Controls
12/17/12
6-2
For making and breaking circuits during freezing and thawing.
ELECTRICAL CONTROLS
(1M) Not shown Compressor Motor
(2M) Pump Motor Starter Provides power to the circulating water pump during the freezer
(3M) Cutter Motor Starter Provides power to the cutter during the harvest period.
(1CR) Control Relay With
(2CR) Control Relay
(2TR) Thawing Timer Controls the time of the harvest (thawing) period.
(DT) Delay Timer Allows the compressor to start unloaded by delaying the energizing
(2PS) Freezer Pressure Switch Controls the desired ice thickness (hole size) by sensing the freezer
(ET) Elapsed Time Indicator Indicates total hours of machine operation. Is powered when the
(CB4) Circuit Breaker Overload and short circuit protection for crankcase heater and the
(CB2) Circuit Breaker Secondary protection for the circulating water pump motor.
(CB3) Circuit Breaker Secondary short circuit protection for the cutter motor.
(TB) Terminal Block Numbered for multiple wire connections and ease of
12/17/12
FIGURE 6-1
Control Panel (Door Opened)
Provides power to the compressor motor. Continuously energized
Starter
Pneumatic Timer
during freezing and thawing with auxiliary hold contact and
auxiliary contact to de-energize the compressor crankcase heater
when the motor is running.
period or when the Hand/Auto switch is in the “Hand” position to
circulate water or ice machine cleaner, etc.
For making and breaking various circuits during freezing and
thawing period with pneumatic timer to delay the actual thawing
process. Energized during thawing.
Energized during freezing, thawing, and hand. Momentarily deenergized at the end of the harvest.
Energized during the harvest period.
of the “UR-SOL” (unloader solenoid) valve. This gives lower in
rush amps and helps prevent belt slippage at start-up.
suction pressure and initiating the harvest period.
compressor is running.
control circuit.
troubleshooting.
TABLE 6-1
Description of Control Panel Parts (Inside)
P24A & P34A Service Manual
P24A & P34A Service Manual
ELECTRICAL CONTROLS
FIGURE 6-2
Control Panel (Hinged Door)
(1LT) Blue Pilot Light - Freezing Illuminated during the freeze period or whenever the
circulating water pump is running.
(2LT) Clear Pilot Light - Liquid Feed Illuminated when the circulating water pump is running and
the float switch (10) is closed. Indicates that the liquid line
solenoid valve (20) is opened.
(3LT) Red Pilot Light - Thawing Illuminated when the machine is in a harvest period.
(2PB) Green Push Button - Start For starting the compressor motor and ice production. (NO)
(1PB) Red Push Button - Stop For stopping the compressor motor and ice production. (NC)
(3PB) White Push Button - Manual
Harvest
(1SS) Selector Switch - Hand/Auto “Hand” position for running the circulating water pump
For manually initiating a harvest cycle. (NO)
independently at start-up or for cleaning the freezer tubes and
water tank.
“Auto” position for provision of automatic system shutdown
if there is a control circuit power interruption.
TABLE 6-2
Description of Control Panel Parts (Outer Door)
6-3
12/17/12
6-4
ELECTRICAL CONTROLS
Electrical Schematic for P24A and P34A all Voltages, 50-60 Hz.
P24A & P34A Service Manual
FIGURE 6-3
12/17/12
P24A & P34A Service Manual
1M1 Motor Starter contactor #1 Used to start compressor motor. Energizes first.
1M1OL Overload Relay #1 Provide over-current protection for one half of motor
1M2 Motor Starter contactor #1 Used to start compressor motor. Is energized approximately 1 second after
1M2OL Overload Relay #1 Provides over-current protection for one half of motor
CB1 Circuit Breaker – 3 pole Provides short circuit protection and a disconnecting means to lowside
FB1 Fuse Block #1 Provides short circuit protection for one half of motor (3 fuses)
FB2 Fuse Block #2 Provides short circuit protection for one half of motor (3 fuses)
R1 Relay Relay used to energize 1M2 contactor.
TB1 Terminal Block #1 Main Power connection.
TB2 Terminal Block #2 Secondary terminal block. Connections to Lowside panel.
TR Delay Timer Used to delay second motor starter (1M2). Timer either connected to R1
DS1
(not shown)
CE panel - Highside Disconnect Used to disconnect power from panel when panel door opened.
6-5
ELECTRICAL CONTROLS
FIGURE 6-4
Part Wind Start Compressor Motor Starter
1M1 is energized.
control panel. Supplies power to lowside unit.
Note: R1 is a control relay used on machines where contactor 1M2 is too
large for TR to energize.
or 1M2 coil connection.
12/17/12
TABLE 6-3
Description of Control Panel Parts
6-6
ELECTRICAL CONTROLS
1M Motor Starter contactor Used to start compressor motor.
1MOL Overload Relay Provide over-current protection for compressor motor.
CB1 Circuit Breaker – 3 pole Provides short circuit protection and a disconnecting means to lowside
TB Terminal Block Used for connections to Lowside panel.
DS1
(not shown)
P24A & P34A Service Manual
FIGURE 6-5
Across the Line Compressor Motor Starter
control panel. Supplies power to lowside unit.
CE panel - Highside Disconnect Used to disconnect power from panel when panel door opened.
12/17/12
TABLE 6-4
Description of Control Panel Parts
P24A & P34A Service Manual
1M Compressor Run Relay Used to start compressor motor.
CB1 Circuit Breaker – 3 pole Provides short circuit protection and a disconnecting means to lowside
F Fan Enclosure Fan
FR Fault Relay Energizes when soft start fault occurs
LT Fault Light “ON” when soft start fault occurs
SS Soft Start Compressor Motor Soft Start
TB Terminal Block Used for connections to Lowside panel.
DS1
(not shown)
CE panel - Highside Disconnect Used to disconnect power from panel when panel door opened.
6-7
ELECTRICAL CONTROLS
FIGURE 6-6
Compressor Soft Start Motor Starter
control panel. Supplies power to lowside unit.
12/17/12
TABLE 6-5
Description of Control Panel Parts
6-8
ELECTRICAL CONTROLS
12/17/12
P24A & P34A Service Manual
FIGURE 6-7
Allen Bradley Soft Start Motor Wiring
P24A & P34A Service Manual
Dip
Setting
Soft Start Settings
Description
Current Limit or Softstart
Initial Torque (% of LRT)
Start Time t1 (sec)
Kick Start Time t2 (sec)
Soft Stop Time t3 (sec)
Aux #1 (Normal/Up to Speed)
Overload Trip Class
Overload Reset (Man/Auto)
Phase Rotation
Line or Delta
Switch #
3 On Soft Start
4 On
5 On
1 Off
2 On 10 sec
8 Off
9 Off
10 Off
6 Off
7 Off
14 Off Normal
11 On
12 On
13 Off Manual
16 Off Enabled
15 On Line
On/Off Setting
6-9
ELECTRICAL CONTROLS
65%
Off
Off
20
Faults
LED description (Number of Flashes)
1. Overload
2. Overtemperature
3. Phase Reversal
4. Phase Loss/Open Load
5. Phase Imbalance
6. Shorted SCR
7. Test
TABLE 6-6
Allen Bradley Soft Start Settings and Faults
12/17/12
6-10
ELECTRICAL CONTROLS
P24A & P34A Service Manual
12/17/12
TABLE 6-7
Allen Bradley Soft Start Dip Switch Settings
P24A & P34A Service Manual
MAINTENANCE
7. Maintenance
Preventative Maintenance. A careful inspection of the Tube-Ice machine for leaks and correct
operational functions at the time of installation and start-up will begin its long satisfactory life of
service. In order to insure this degree of dependability, a systematic maintenance program is
necessary. Therefore, the following schedule is suggested as a minimum.
A. Daily
1) Check operating pressures (suction, discharge, oil).
2) Check ice quality.
3) Check “ice out” time (maintain 30 seconds of continued harvest after last ice is out).
4) Check compressor oil level.
5) Check refrigerant operation level.
6) Check frost pattern on freezer shell and oil trap.
7) Check make-up water float valve adjustment.
8) Rotate the Mycom-Cuno oil filter - tee handle two complete turns.
B. Weekly (in addition to daily checks)
1) Check all belts for proper tension. Do not use belt dressings.
2) Check for leaks after 400 hours or four weeks of operation
C. Monthly (in addition to weekly checks)
1) Check calibration and operation of all controls (high and low pressure switches, oil pressure
switch, etc).
2) Check cooling tower spray nozzles and pump suction screen for scaling and algae (consult
water treatment suppliers for corrective measures).
3) Check water distributors in freezer for scale accumulation.
4) Check water tank for solids to be removed.
5) Check all motor drive units (compressor, cutter and pump motors, cooling tower fan, and
pump, etc) for abnormal noise and/or vibrations.
6) Check oil level in gear reducer.
7) Check one complete freeze/thaw cycle, record data and compare with production check of
Registration/Start-up Report.
D. Yearly (in addition to weekly and monthly)
1) Check entire system for leaks.
2) Drain water from condenser and cooling tower and check condenser tubes. Check closely
for damage by corrosion or scale.
3) Remove all rust from all equipment, clean, and paint.
4) Check all motors for shaft wear and end play.
5) Check operation and general condition of all electrical controls, relays, motor starters, and
solenoid valves.
6) Check freezing time, ice release time, and ice out time.
7) Change oil in gear reducer box once a year.
8) Lubricate compressor motor bearings.
9) Drain compressor oil, open compressor, inspect and clean inside crankcase. Change oil
filter and add new oil. Inspect compressor suction strainer.
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7-2
MAINTENANCE
P24A & P34A Service Manual
PREVENTATIVE MAINTENANCE FORM
This form can be removed and duplicated for record keeping.
Date: _____________ Model #: ________________________ Serial #: _____________
The following service performed and checked:
Hour meter reading _______________ , Ambient temperature (inside)_______ °F
Make-Up water float valve adjusted properly
Water distributors clean and in place
All drains freely draining
Cleaned and flushed water tank
Compressor oil changed
Cleaned and inspected inside compressor crankcase
Changed compressor oil filter
Checked/adjusted compressor belt tension
Lubricate compressor motor bearings
Check/change cutter gear reducer oil
Check/adjust cutter drive gear meshing
Leak check entire system
Check liquid refrigerant level in receiver
Drained oil from oil trap
Compressor crankcase heater working
Compressor net oil pressure (gage reading less suction)
Motor amps: Compressor ________ Cutter ________ Pump ________
Suction psig (end of freeze) __________ Discharge psig (end of freeze)_____________
Suction psig (end of thaw) __________ Discharge psig (end of thaw) _____________
Compressor water out ____°F Tower fan cycles ___ On ___ Off
Production Check
Test
Cycle
Make-up
Water
Temp
Freezing
Time
Min/Sec
Harvest
Time
Min/Sec
First
Ice Out
Min/Sec
All
Ice Out
Min/Sec
Avg.
Hole
Size
Ice lb.
Per Harvest
(est)
#1
#2
#3
#4
Comments: _______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Name: __________________________________
Ice lb.
Per Day
(est)
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P24A & P34A Service Manual
MAINTENANCE
Ice Making Section. The ice making section of the Tube-Ice machine should be cleaned at least
twice a year (more often if water conditions cause mineral build up). Use an approved food-grade
ice machine cleaner. The water pump is used to circulate the cleaner through the system. For
complete instructions, follow the “Cleaning Procedure” below.
Cleaning Procedure.
1. Stop the machine at the end of harvest.
2. Shut off make-up water supply.
3. Drain the water tank, flushing out any loose sediment.
4. Close the drain valve and fill the tank with warm water. Warm water promotes faster cleaning.
5. Cover the ice discharge opening to prevent water from splashing out and contaminating any
stored ice.
6. Add sufficient ice machine cleaner to the water tank.
P24 tank = 2.5 gallons water per inch of water height in tank, 13” = 32.5 gallons
P34 tank = 4.7 gallons water per inch of water height in tank, 13” = 60.6 gallons
Mix cleaning solution according to manufacturer’s recommendations.
7. Remove top water box cover, inspect distributors, remove any hard particles from orifices, and
make sure all distributors are in place. Replace cover.
8. Turn Hand/Auto switch to “Hand” position and circulate the cleaning solution until deposits are
dissolved or the solution is neutralized. After draining, the pump may have to be stopped and
restarted to dispel air.
9. Turn switch to “Auto” position to stop the pump. Drain and flush the water tank. Repeat
cleaning as necessary.
10. After cleaning, fill the tank with fresh water, start the pump again, and circulate for 15 minutes.
11. Stop the pump, drain and flush the tank and again refill with fresh water.
12. Remove the cover from the ice discharge opening, and clean any area that may have been
splashed with solution during cleaning.
13. Make sure the make-up water float valve is adjusted properly and the drain valve is closed.
14. Start and stop the pump again to make sure it is circulating water and it is not air bound.
You are now ready to produce ice.
Water Distributors. The water distributors are located under the top freezer cover. These
distributors are similar in design to those used in mid-size and small machines (i.e. P18F, P118, etc.)
except they have a small vent tube. It is important that this plastic vent tube remain in place in each
distributor. The distributors may require occasional or periodic cleaning to remove solids, foreign
particles, or mineral deposit accumulated from the circulating make-up (ice making) water. The
frequency of cleaning operation will depend on the characteristics of the water supply. The
distributors need inspection when the inside diameter of a large portion of the ice becomes irregular
(due to channeling of water), if some of the ice is opaque or if there is a noticeable decrease in ice
capacity and quality.
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7-4
MAINTENANCE
Tube Size 1 1/2” 1 1/4” 1”
Model Number of Distributors
P24A 144 198 264
P34A 306 420 564
TABLE 7-1
Water Distributors
You may look through the plastic freezer cover to inspect the water distributors if the view is clear.
For a closer inspection you should stop the unit, remove the nuts and retaining ring sections and lift
off the top cover. Make sure the two orifices in the side of each distributor are open, the vent tubes
are in place, and a distributor and vent tube assembly is installed firmly in each tube.
To remove the water distributors for cleaning:
1. Grip the top of the distributor body (not at the vent tube) with adjustable pliers.
2. Hold and twist the distributor while pulling upward.
3. Lift the distributor out of the hole.
To install the distributors:
1. Insert one in each tube hole and seat firmly by using a short piece of pipe or conduit.
2. Slide the pipe or conduit down over the vent tube and gently tap the distributor in place.
3. Do not allow the distributor to be recessed below the top of the tube sheet.
To replace the cover:
1. Replace water distributor box cover gasket.
2. Install the cover over the bolt studs.
3. Install the four (4) cover retaining rings sections and nuts.
4. Tighten the wing nuts firmly to prevent foreign materials from entering the water box.
Note: The freezer cover and gasket are not intended to hold the pressure of the circulating water
in the event of a freeze up. Therefore every effort should be made to prevent the Tube-Ice from
freezing solid (with no hole).
Tube Size 1 1/2” 1 1/4” 1”
Hole Size 1/4”-3/8” Avg. 1/8”-3/16” Avg. 1/16”-1/8” Avg.
TABLE 7-2
Average Hole Size In Tube-Ice
Water Tank. The production of opaque ice can indicate that the water in the water tank contains a
concentrated amount of solids or salts. See Troubleshooting, “Poor Ice Quality”.
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MAINTENANCE
To clean the water tank:
1. Stop the machine at the end of harvest.
2. Shut off the make-up water supply.
3. Open the drain valve and drain the tank.
4. Remove the water box cover and flush out any loose sediment from the tank. The wire mesh
screen can be removed if necessary.
5. If further cleaning is needed, follow “Cleaning Procedure”.
6. If further cleaning is not needed, close the drain valve and refill the tank with fresh water.
7. Make sure the float valve is adjusted properly and install the water box cover.
8. Start and stop the pump again to make sure it is circulating water and is not air bound.
Water Cooled Condenser Cleaning. As water evaporates from a cooling tower, the solid
impurities remain and must be flushed from the system to prevent a scale build-up in the condenser
and cooling tower. This can be accomplished by a continuous bleed off valve located in the pump
discharge line. The valve should be adjusted to bleed off an equal amount of water which is
evaporated. If water hardness is very high, a higher bleed off rate or chemical treatment may be
required. Consult your local water treatment company for recommendations.
If after a period of time, scale has formed inside the tubes, mechanical cleaning may be necessary.
See “Servicing Section--Condenser”.
Cooling Tower/Evap Condenser. See Figure 3-7 for parts location.
1. Bleed off valve. The bleed off valve should be checked monthly to assure that is not blocked and
that water is flowing as required. If the unit is controlled by a water treatment system, the bleed
off valve may not be required.
2. Strainer. The pan or sump strainer is located in the bottom of the sump at the suction connection
to the pump. The strainer should be inspected monthly and kept clean. Do not operate the unit
without the strainer in place.
3. Make-up water float valve. This valve should be checked monthly for proper operation and
adjustment. It should be adjusted to maintain a water level below the overflow and high enough
to prevent the pump from cavitating when the system is in operation.
4. Spray nozzles. The spray nozzles should be checked monthly to make sure none are restricted
and the spray pattern is complete and even.
5. Pump motor and fan motor. The motors should be checked and/or lubricated every six months
according to the motor manufacturer’s recommendations.
6. Fan bearings. The fan bearings should be lubricated every six months. Make sure the proper
grade of grease is used (normally conforms to NLCI-Grade 2) and it is best to use a hand grease
gun.
7. Fan belts. The fan belt tension should be checked weekly for the first two weeks of operation,
then monthly during continuous use.
The best tension for a V-belt is the lowest tension at which the belt will not slip under its full load.
Never use dressing on V-belts. Keep belts and grooves clean and free of oil, grease, and foreign
material. Clean with non-flammable, non-toxic degreasing agent or commercial detergent and water.
! CAUTION !
Follow all lock-out and tag-out procedures before servicing any electrical equipment.
! CAUTION !
7-5
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7-6
MAINTENANCE
P24A & P34A Service Manual
Service/Frequency Start-Up Monthly Six Months Shutdown
Clean debris from unit X X X
Clean strainer and flush sump X X X
Check fan and pump rotation X
Clean spray nozzles X X
Check belt tension X X
Check for noise/vibration X X
Check/adjust make-up water valve X X
Check/adjust bleed rate X X
Check/lubricate fan bearings X X
Lubricate motor base adj. screw X X X
Drain sump and piping X
TABLE 7-3
Cooling Tower Maintenance Schedule
Compressor. In starting and charging the unit, the oil sight glass should be continually checked to
make sure an adequate oil level is maintained. The oil level should be 1/4-3/4 of the sight glass. If
the oil level drops below 1/4 of the glass, add two quarts of 300 SSU viscosity refrigeration oil as per
the compressor manufacturer recommendations. Never allow the oil level to be out of sight, above
or below the sight glass when the compressor is operating.
! CAUTION !
The crankcase heater should be energized for a minimum of
four hours and the oil temperature should be 100°°°°-110°°°°F
before attempting to start the compressor.
! CAUTION !
During operation, the specified net oil pressure should be maintained for proper lubrication and
operation of the cylinder unloader mechanism.
Mycom N&W Series net oil pressure: 17-28 psig
Vilter 450 Series net oil pressure: 35-50 psig
Note: Net oil pressure is calculated by subtracting the compressor suction pressure from the oil
pressure gage reading while the compressor is running.
Example: Oil pressure gage reading: 65 psig
Suction pressure gage reading: 40 psig
Net Oil Pressure: 25 psig
The compressor oil should be changed at close intervals during initial break-in operation and up to
the first 1000 hours (see Table 7-4 below). Your machine was test operated at the factory and
compressor oil was drained, crankcase cleaned, suction strainer sock cleaned, new oil filter installed
(if applicable), and clean oil added prior to shipping.
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MAINTENANCE
Note: It is the owner’s responsibility to make sure normal maintenance is initiated to insure that the
compressor is not subjected to premature wear or failure due to neglect or lack of sufficient
maintenance and care.
Frequency
1st 2nd 3rd 4th Thereafter
Change oil 200 hr. 500 hr. 1500 hr. 4000 hr. every 4000 hrs.
Clean suction strainer cloth 200 hr. 500 hr. Remove if clogging is minimal
TABLE 7-4
Compressor Maintenance
The above maintenance is only a guide. The compressor should be inspected anytime there is
unusual noise, damage is suspected or the oil becomes discolored. The oil should be changed any
time the compressor is opened. For specific recommendations and instructions, refer to the
particular compressor manufacturer’s manual. See “Compressor Oil Changing and Inspection”
Although the ice machine is equipped with an oil separator which has an automatic return, some oil
will pass through the separator and eventually settle in the oil trap (36), which is offset from the base
of the freezer. This oil trap will have evidence of frost on its surface during the freeze cycle and may
be more pronounced at the end of a normal freeze cycle just before the harvest. Where there is oil in
the trap, there will not be frost. Where there is frost, there will not be oil. When the trap is 1/2 to
3/4 full of oil, it should be drained.
The machine should be shutdown for at least 12 hours before attempting to drain oil from the trap.
Follow the procedure outlined in the service section, “Draining Oil Trap”.
! CAUTION !
Only qualified refrigeration service personnel familiar and
experienced in the handling and use of anhydrous ammonia (R717) should be
authorized to perform the “Draining Oil Trap” procedure.
! CAUTION !
Cutter Gear Reducer. The oil level of the gear reducer should be checked monthly or when there is
any evidence of leakage. The correct level is indicated by the pipe plug in the side of the gear
housing. The oil should run out of the hole when the plug is taken out. If low, add oil through one
of the top plugged holes. A high grade lubricant such as Mobil 600W or SAE 140 gear oil should be
used. The oil should be changed annually. Drain the oil and flush the gear case with mineral spirits.
Drain the mineral spirits completely and refill with the proper oil.
Note: If a USDA high food grade lubricant is desired, use Chevron FM Lubricating Oil 460X.
! CAUTION !
Follow all lock-out and tag-out procedures before servicing any electrical equipment.
! CAUTION !
7-7
12/17/2012
7-8
MAINTENANCE
V-Belt Maintenance. Belts should be kept clean, free of oil and protected from sunlight as much as
possible. To clean belts, they should be wiped with a dry cloth. The safest way to remove dirt and
grime is to wash the belt with soap and water and rinse well. BELT DRESSING SHOULD
NEVER BE USED ON A V-BELT DRIVE.
The tension on a 5 rib, banded V-belt can be checked as follows:
1. Apply 50-75 pounds of deflection force uniformly across the belt, midway between the pulley
centers. Lay a straight edge across the sheaves to measure the deflection. The deflection should
be 5/8” to 3/4”.
2. When installing a new belt, move the sheaves together to allow the belt to slide across the
sheaves. Rotate the belt and sheaves to obtain proper seating. Remove the slack from the belt
and measure the outside circumference to the nearest 1/4”. Multiply this reading by .0075 and
.001, add these amounts to the circumference reading. Elongate the belt to the new length.
Example: 105 x .0075 = .7875, 105+ .7875 = 105.7875=105 3/4” min.
105 x .001 = 1.05, 105+ 1.05 = 106.05=106 1/16” max.
3. Check compressor sheave and motor sheave with a straight edge to be sure they are parallel and in
the same plane.
4. The tension should be checked after 24 to 48 hours of operation to compensate for initial stretch
and wear-in. Periodic checks should be made and tension restored as necessary.
General Rules:
1. The best tension for a V-belt drive is the lowest tension at which the belt will not slip under the
highest load. Too much tension shortens belt and bearing life.
2. Check tension often during the first 48 hours of operation and periodically afterwards.
3. Keep belts and sheaves free of any foreign material which may cause slippage.
4. If a belt slips, tighten it.
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P24A & P34A Service Manual
Note: Your machine’s electrical system has several built-in safety and overload protection features
to stop operation when a single component fails or there is a problem from an outside source
such a power supply. Make sure all auxiliary equipment is connected to incorporate safety
and overload circuits and protect all related equipment.
When the machine stops, it must be manually restarted by pushing the “Start” button. If it stopped
while in a freeze cycle, it should be manually harvested to remove all ice from the freezer. This is
done by pushing the white “Manual Harvest” button.
Always check the machine operation thoroughly after remedying the problem. Be sure to correct the
source or cause of the problem to prevent the problem from occurring again.
Symptom Page
Machine stopped 8-2
Freeze-up due to extended freeze period 8-4
Freeze-up due to ice failing to discharge 8-5
Low ice capacity 8-6
Poor ice quality 8-7
High discharge pressure 8-8
Low discharge pressure 8-9
High suction pressure 8-9
Compressor running unloaded during freeze 8-9
Compressor oil pressure low 8-10
Compressor loosing oil excessively 8-10
Machine short cycles 8-11
Shut down by oil pressure switch 8-11
High compressor discharge temperature 8-11
Suction line frosting to compressor 8-12
Notice: Opening the compressor for observation or determination of failure does NOT void the
warranty.
Contact your distributor first for technical service assistance about operation problems not covered in
this manual.
Also feel free to contact the factory for additional service (502) 635-3235.
8-1
TROUBLESHOOTING
8. Troubleshooting
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8-2
any defective part and reset circuit breaker.
TROUBLESHOOTING
Symptom: Machine Stopped
Power failure or interruption Check fused disconnect or circuit breaker
Circuit breaker (CB4) for control circuit
tripped
Compressor motor starter overload (1MOL)
tripped
Water pump, cutter motor, tower fan, tower
pump, conveyor motor, overload tripped
Freezer water pump motor overload (2MOL)
tripped
Cutter motor overload (3MOL) tripped Check for loose terminal connections and
Bin level control (optional) open Adjust or replace control as required. If bin
P24A & P34A Service Manual
Possible Cause Possible Remedy
supplying power to the machine. If power has
been off, make sure the crankcase heater is
energized and there is no liquid refrigerant in
the compressor crankcase prior to restarting the
compressor. If ice is in the freezer, initiate a
manual harvest.
Check compressor crankcase heater, coils of
relays, contactors, starters, solenoid valves, and
thawing timer for a ground. Repair or replace
Make sure there is no liquid refrigerant in the
compressor crankcase prior to restarting the
machine.
Check for a loose connection on all motor
starter and motor terminals which could cause
excessive amp draw. Reset overload and
restart the machine, check amperage, power
supply, and head pressure. (Check TR in part
wind starts only).
Check for loose connection on all terminals
which could cause excessive amp draw. Reset
the overload and manually run that particular
motor to check actual voltage and amperage
against motor rating.
Check for loose terminal connections and/or
defective breaker (CB2), reset the overload and
start the pump by turning the selector switch
(1SS) to “Hand”. Check voltage and amperage
against motor rating. Confirm proper rotation.
blown fuse, reset the overload. Clear all ice
that may have jammed cutter. Turn the selector
switch (1SS) to “Hand” and push the “Manual
Harvest” button. Check voltage and amps
against motor rating. If tripping repeats but ice
is not jammed, check the gear reducer for
resistance, cutter bearings for wear, drive gear
and ring gear for proper engagement, and
reducer motor for defect or single phasing.
level control is not used, make sure jumper
wire #8 and #9is installed at of the terminal
block.
12/17/12
P24A & P34A Service Manual
in” setting.
4, Section 9 (Oil Pressure Switch).
TROUBLESHOOTING
Symptom: Machine Stopped (con’t)
Possible Cause Possible Remedy
High/Low pressure safety switch (1PS) tripped If the machine stops by low pressure cutout, the
switch will reset automatically when the
pressure raises to the “cut-in” setting. Check
thaw gas valve (18) to make sure it opens
during harvest time.
If the machine stops by high pressure cutout,
the switch will have to be manually reset after
the pressure drops below the “cutCheck the head pressure during the next freeze
cycle. See FIGURE 9-2, Section 9 (High/Low
Pressure Switch).
Low oil pressure tripped (OPS) Manually reset the switch after the switch
heater cools. Check the crankcase oil level
(1/4-3/4 full). Add oil if below 1/4 glass before
attempting to restart the machine.
Restart the machine and check net oil pressure
(net oil pressure = oil pump line pressure
minus crankcase suction pressure). See
FIGURE 9See “Low Compressor Oil Pressure”.
Net oil pressure range:
Mycom = 17-28 psig
Vilter = 35-50 psig
Defective control panel component such as
1PB, 1SS, 1M contact, 2CR contact
See FIGURE 6-3, Wiring Schematic, and
check for open circuit. Refer to FIGURES 6-1
and 6-2, Control Panel to identify parts. Check
for loose wires. Replace defective part, restart
machine, check power supply, and current
draw.
Circuit breaker (CB2 or CB3) for pump or
cutter motor tripped.
Check for loose connection on all terminals,
reset breaker and check amp draw against
breaker rating. Check voltage and current
unbalance, Section 3. Replace breaker if
defective.
8-3
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8-4
is in the automatic position (stem screwed in).
freeze cycle.
TROUBLESHOOTING
Symptom: Freeze-up due to extended freeze period
Freezer pressure switch (2PS) set too low or
defective
Water tank drain valve, make-up water float
valve or flushing valve stuck or opened
Thaw gas solenoid valve (18) leaking through
during freeze
Compressor running unloaded If the compressor is running unloaded, the
P24A & P34A Service Manual
Possible Cause Possible Remedy
Adjust switch or replace if defective. See
FIGURE 9-1.
Close, repair, or replace valve as needed. The
float valve should be adjusted low enough that
water should not run out the tank overflow
during the freeze cycle.
Check the manual opening stem to make sure it
Check for leakage by sound, temperature
difference and frost during the
Leakage should stop by closing the hand stop
valve downstream of thaw gas valve. Isolate
and repair or replace the valve as needed.
motor amp draw will only be 60%-70% of the
normal amp draw of a loaded compressor.
Check the delay timer (DT) electrical circuit to
make sure the “UR-SOL” coil is not energized.
Refer to the compressor manual for normal oil
pressure needed to load the compressor
cylinders and any further procedures to check
the mechanical function of the unloader
mechanism.
12/17/12
P24A & P34A Service Manual
broken gear teeth or sheared shaft key.
TROUBLESHOOTING
Symptom: Freeze-up due to ice failing to discharge
Possible Cause Possible Remedy
Extended freeze period Check freezer pressure switch (2PS)
adjustment. See FIGURE 9-1 for adjustment
and TABLE 7-2 for average hole size. Make
sure all water distributors are in place (one in
each tube).
Thaw time too short Adjust thaw timer (2TR) to allow all ice to
clear the cutter and ice discharge opening with
at least 30 seconds to spare. Replace defective
timer.
Insufficient heat for thawing due to low
condensing pressure
The head pressure should be maintained form
175-190 psi (maximum 200) usually by a water
regulating valve or fan cycling switch. Check
to make sure these controls are working
properly. Cold prevailing wind can also be a
factor.
Insufficient heat due to non-condensables
(usually air) in the system
If non-condensables are present with the
refrigerant, the saturated temperature will not
relate to the pressure reading at the receiver
and the refrigerant will be cooler, although
pressure will be high. Air can be purged from
the system by following the procedure in the
Section 9, “Purging Non-Condensables”.
Insufficient heat due to low refrigerant charge The refrigerant level in the receiver should be
near the operating mark at the end of a freezing
cycle to provide enough volume of warm gas
for harvesting. DO NOT OVERFILL
RECEIVER.
Cutter or cutter disc does not turn Check cutter gear reducer and drive gear for
proper operation and alignment. Check for
8-5
Compressor not running unloaded during thaw
cycle.
12/17/12
Replace defective parts.
Check compressor motor Amp draw. During
the thaw cycle, the compressor motor Amp
draw should be 60 - 70% of normal amp draw
during the freeze cycle. Check compressor
unloader solenoid coil (UR) to make sure it is
energized and the valve opening during the
thaw cycle.
8-6
2).
leaking compressor suction or discharge valves.
TROUBLESHOOTING
Symptom: Low ice capacity.
Suspicions of low ice capacity should be confirmed by accurate calculations of actual ice product.
Much weight can be lost by melting and off fall through augers and other ice handling equipment.
1. Time the total freeze and thaw cycle for the cycle which is to be caught and weighed.
2. Catch all the ice at the ice discharge opening of the machine.
3. Weight the total amount of ice caught.
Lbs. ice per cycle
Cycle time minutes X 1440 = _____ lbs. production per 24 hours
More than one cycle should be caught and weighed to get an accurate average.
Inadequate water for ice making Water pressure of 40 psig minimum is required
Water distributors may be stopped up Check distributors and clean orifices as needed.
Freezer pressure switch or thaw timer out of
adjustment
Excessive ice chips in the water tank, causing
short cycling
Compressor running unloaded or not pumping
full volume
P24A & P34A Service Manual
Possible Cause Possible Remedy
to assure proper water supply. Check water
pressure. Check for a restriction in the incoming
line or at the make-up water float valve.
Check hole size in Tube-Ice (See TABLE 7-
Crushed ice should be 3/16”-1/4” thick. Check
and adjust thawing time. Thawing should be 30
seconds longer than it takes for all the ice to
clear the freezer.
Check incoming water temperature (45°F
minimum). Check flushing valve to make sure
ice chips are being melted and flowing out the
tank overflow during the harvest cycle.
Check compressor motor amp draw. Check for
belt slippage and tighten as needed. Check for
Restriction in the refrigerant liquid line or float
switch not operating properly
Low refrigerant charge, causing re-freeze Check the receiver gage glass mark for the
Warm make-up water for ice making Capacity of the machine is proportional to ice
12/17/12
Refer to your compressor manual. See other
related symptoms.
Check for a partially closed valve or an
obstruction at the strainer, solenoid valve, or
hand expansion valve. The liquid line will
normally have frost on the downstream side of a
restriction, especially as the suction pressure
decreases.
proper level. Check for and repair leaks. Add
refrigerant.
making water temperature. Warmer water will
reduce the ice making capacity. Refer to Section
10, Capacity Table. Check float adjustment and
water tank drain valve.
P24A & P34A Service Manual
is in the automatic position (stem screwed in).
ycle.
Symptom: Low ice capacity (cont.)
Excessively high head pressure Check cooling tower or evap condenser to
Thawing gas solenoid valve (18) leaking
through during freeze cycle
Symptom: Poor ice quality
Excessive concentration of solids in the water
tank usually indicated by a build-up of mineral
deposit on the sides and bottom of the tank and
opaque ice production. Also, water distributors
restricted.
Insufficient water supply indicated by a low
level in the tank
Water pump rotation wrong direction Check rotation in relation with arrow on pump
Low refrigerant charge, causing an ice out
problem and re-freeze
Restriction in liquid line, causing short freeze
cycle
8-7
TROUBLESHOOTING
Possible Cause Possible Remedy
make sure sufficient water is provided for
cooling and the equipment is operational to
cool the water. Also see “Symptom High Head
Pressure”.
Check the manual opening stem to make sure it
Check for leak by sound, temperature
difference and frost during a freeze c
Close the stop valve (90) to confirm suspicion
of leakage. Repair or replace the valve.
Possible Cause Possible Remedy
Perform a cleaning procedure as well as
removing the freezer cover and cleaning the
water distributors. Make sure the flushing
valve (63) is functioning and the tank overflow
piping is not restricted.
Check water pressure, 40 psig is recommended
minimum. Check for a water line restriction,
partially closed valve, or defective make-up
water float valve. Make sure the water tank
drain is closed.
housing and reverse two wires at the motor if
necessary.
Check refrigerant level mark on the receiver
and on the painted portion of the gage glass
guard. Be sure to keep the gage glass cocks
closed when finished checking the level.
Check for closed valve, defective solenoid
valve (20), float switch defective or strainer
restricted. The liquid line will normally have
frost on the down-stream side of a restriction,
especially as the suction pressure decreases.
12/17/12
8-8
relate to the pressure reading at the receiver.
TROUBLESHOOTING
Symptom: High discharge pressure (check gage accuracy)
Insufficient water flow through the cooling
tower or condenser
Fan control out of adjustment Check adjustment. Refer to FIGURE 9-3, “Fan
Non-condensable in system. If non-condensables are present with the
Cooling tower or evap condenser in need of
maintenance
Dirty condenser tubes Visually inspect the condenser tubes to see if
Too much liquid in condenser/receiver
covering tubes causing inefficiency
P24A & P34A Service Manual
Possible Cause Possible Remedy
Check the condenser water pump to make sure
it is pumping enough water as specified in
TABLE 3-2. Check sump strainer screen and
clean. Check condenser pump direction of
rotation.
Control”. Replace if defective.
refrigerant, the saturated temperature will not
The refrigerant will be cooler, although the
pressure will be high. Air can be purged from
the system by following instructions in Section
9, “Purging Non-Condensables”.
Check fan motor and fan belts for proper
operation and tension. Check spray nozzles,
tubes, sump, and sump screen, for
accumulation of mineral deposit and clean as
required. Check tower blowdown and
chemical treatment if applicable.
there is any build-up of mineral deposit which
would reduce the cooling effect of the tubes
and water. Clean chemically or mechanically
as applicable.
Remove refrigerant so all tubes will be above
liquid refrigerant level.
12/17/12
P24A & P34A Service Manual
TROUBLESHOOTING
Symptom: Low discharge pressure (check gage accuracy)
Possible Cause Possible Remedy
Fan cycling switch out of adjustment or
defective
Compressor running unloaded or not pumping
efficiently
Check adjustment. Refer to FIGURE 9-3, “Fan
Control”. Replace if defective.
Check compressor motor amp. If the
compressor is running unloaded, the amperage
will only be approximately 60% of normal amp
draw (FLA). Refer to the compressor manual.
Ambient temperature low and prevailing winds
blowing through tower
Too much cold water circulating through
condenser
Shield tower from prevailing winds to prevent
excessive cooling. Install an indoor sump.
Install a water regulating valve in the water line
form the condenser and control flow by
receiver pressure.
Thaw gas valve #18 leaking through Make sure manual opening stem is in the
automatic (screwed in) position. Repair or
replace defective parts.
Symptom: High suction pressure (check gage accuracy)
Possible Cause Possible Remedy
Compressor running unloaded or not pumping
efficiently
Check compressor motor amp. If the
compressor is running unloaded, the amperage
will only be approximately 60% of normal amp
draw. Refer to the compressor manual.
Thaw gas valve #18 leaking through Make sure manual opening stem is in the
automatic (screwed in) position. Repair or
replace defective parts.
Defective gage Check pressure with accurate gage and replace
as necessary.
Symptom: Compressor running unloaded during freeze
Possible Cause Possible Remedy
Low oil pressure Check compressor net oil pressure.
Net oil pressure = oil pressure gage reading
less suction pressure.
Mycom = 17-28 psig
Vilter = 35-50 psig.
Refer to the compressor manual for “Oil
Pressure Adjustment”.
Unloader solenoid valve open Check solenoid coil to make sure it is not
energized. If valve is stuck open, replace
valve.
Unloader mechanism not working properly Refer to compressor manual. Mycom
compressor can be loaded manually.
8-9
12/17/12
8-10
ion.
TROUBLESHOOTING
Symptom: Compressor oil pressure low (check gages)
See Section 7, for compressor oil pressure requirements.
Oil diluted with refrigerant Oil will be very foamy. Check liquid feed
Oil pressure regulating valve out of adjustment Adjust valve to increase oil pressure. Turn
Compressor rotation incorrect Check rotation direction by arrow indicat
Restriction strainer, oil filter, pick-up tube or
oil passage
Compressor thrust bearing installed upside
down
Symptom: Compressor loosing oil excessively
Non-effective oil separator or float The oil separator will normally return a good
Liquid refrigerant in crankcase Check liquid feed to make sure it is not
Compressor piston rings seized or broken Check compressor efficiency. If rings are
Leaking shaft seal A few drops per minute is okay. If ammonia is
P24A & P34A Service Manual
Possible Cause Possible Remedy
control for overfeed problem.
stem in to increase, out to decrease.
Reverse rotation, if necessary.
Clean strainer or restriction in passage or
replace filter.
The Mycom compressor thrust bearing on the
shaft seal end has an oil passage hole which
has to be in the proper position when installing
the thrust bearing. Hole up for “WA” and
“WB” series Mycom compressor. Refer to
your compressor manual.
Possible Cause Possible Remedy
portion of oil leaving the compressor, if it is
working properly. Check the oil float and
return line to see it is not restricted.
overfeeding and that the solenoid valve #20 is
not leaking through when the machine is
stopped.
seized or broken, replace defective parts.
leaking, replace the seal.
12/17/12
P24A & P34A Service Manual
nt water level.
TROUBLESHOOTING
Symptom: Machine short cycles
Possible Cause Possible Remedy
Freezer pressure switch (2PS) set too low or
defective
Adjust switch or replace if defective. See
FIGURE 9-1.
Freeze-up See “Freeze-up due to extended freezer period”
and “Freeze-up due to ice failing to discharge”.
Clogged water distributors Clean water distributors.
Lack of water for making ice Check water tank for sufficie
Check for restriction in water line, defective
float valve, open drain valve, excessive ice
chips or low water pressure and correct.
Lack of sufficient liquid refrigerant feed Check float and float switch, solenoid valve
and coil #20 in liquid line, strainer, and
refrigerant level in receiver.
Water pump rotation incorrect or pump
defective
Check pump motor rotation. Check for leaking
pump seal or defective motor and repair or
replace as needed.
Symptom: Shut down by oil pressure switch
Possible Cause Possible Remedy
Switch adjusted too high or defective Check switch adjustment and cutout pressure
activation against an accurate gage. Replace
switch if defective. See Figure 9-4.
Oil pressure low See “Compressor oil pressure low”.
Low oil level Add oil.
Defective thawing timer causing long harvest
Replace defective timer.
cycle and oil dilution
Symptom: High compressor discharge temperature
Possible Cause Possible Remedy
High head pressure Check gage accuracy and “High discharge
pressure”.
Defective suction or discharge valves Feel the compressor heads for hot spots or one
head running hot. Replace worn or leaking
valves.
Restriction in the discharge gas line Check all hand and check valves to make sure
they are fully opened and not stuck. Repair or
replace as needed.
Internal relief valve leaking Check the compressor manual to see if your
compressor is so equipped. Replace
accordingly.
8-11
12/17/12
8-12
functioning properly. Replace if defective.
t or oil for water contamination.
TROUBLESHOOTING
Symptom: Suction line frosting to compressor
Liquid refrigerant overfeed Check float switch to make sure it is
Refrigerant contaminated with water Test refrigeran
P24A & P34A Service Manual
Possible Cause Possible Remedy
Check solenoid valve #20 to make sure it is not
leaking through. Repair or replace if defective.
Completely pump the freezer out (pumpdown)
and blow excess water out through the oil trap
drain valve #61. Refer to Service, Section 9
“Removing Excess Water”.
12/17/12
P24A & P34A Service Manual
SERVICING OPERATIONS
9. Servicing Operations
Automatic Blowdown (harvest cycle). A feature of this machine is a solenoid activated flushing
valve (63) which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of
the water tank. This flushing during the harvest cycle helps to remove salts or solids accumulated in
the water as a result of the freezing action. It also helps melt ice chips which fall into the water tank
during harvest. The flushing valve is opened (energized) during each thaw cycle when the water
pump stops and the water in the freezer tubes returns to the water tank. If water quality is superior,
this blowdown can be reduced by installing a smaller reducer bushing in the outlet elbow.
The flushing action carries accumulated salts, solids, and ice chips (fines) out through the water tank
overflow pipe. This overflow should be kept open at all times to allow the water to drain freely and
keep the water level below the cutter disc and ice discharge opening. If the flushing solenoid valve
leaks through during the freeze cycle, it can be disassembled and cleaned, then reassembled.
Cleaning Ice Making Section. Refer to Section 7, Maintenance for instructions for cleaning the
circulating water tubes, water distributors, and water tank.
Float valve (make-up water). The make-up water float valve (12) maintains the proper pumping
level in the water tank for ice making. The valve should be set to maintain a water level in the water
tank during the freezing period, so that there will be a quantity of blowdown only during the thaw
mode. The water level during the freeze mode should always be below the overflow piping to
prevent excessive waste of cold water, resulting in loss of ice capacity.
9-1
If it should become necessary to clean the float valve, close the stop valve in the make-up water line
to the machine and remove the float valve. After the valve has been cleaned and reinstalled, check to
ascertain if the proper water level is being maintained. After the machine is stopped and the water in
the tank seeks its normal level, there should be no water flow through the float valve or out the
overflow.
It is advisable to install a large area strainer in the water supply line to protect the float valve from
dirt or solids in the water which would necessitate frequent cleaning. A strainer of 40 mesh screen is
usually satisfactory.
Float Switch. The float switch is installed on a header assembly that is attached to the freezer shell.
Valves are provided for isolation of the float switch assembly if replacement or servicing is
necessary. The float switch closes as the level of refrigerant in the freezer rises and opens as the
level falls.
The float switch is connected to the “A1” solenoid valve coil. This is the solenoid valve directly
before the hand expansion valve. Therefore when the refrigerant level in the freezer drops, the float
switch closes, thereby energizing and opening the “A1” liquid feed solenoid until sufficient level has
been reached to open the float switch. The float switch has a fixed 1/2” differential.
The float switch is installed at the correct height at the factory and should not need to be adjusted.
The float switch is installed at the position which provides highest capacity. The correct height will
produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30° F.
12/18/12
9-2
SERVICING OPERATIONS
Hand Expansion Valve. The hand expansion valve is located directly after the “A1” solenoid
valve. This valve should be set at a point where the float switch is open for a length of time
approximately equal to the time it is closed.
Freezer Pressure Switch. The freezing time period for producing ice of a desired thickness is
controlled by the freezer pressure switch (2PS), Figure 9-1, located inside the control panel.
The original switch was set at the factory to produce ice of recommended thickness. Look at the
“Certificate of Test” which was provided with the machine for a sample set of pressure readings with
corresponding time periods and water temperatures. Also see TABLE 11-8/ 11-9, Operating Vitals
for typical settings. When making adjustments, allow two ice discharging cycles between
adjustments. Switch adjustment is as follows: See Figure 9-1.
1. Turn the low signal adjustment nut CCW until low signal setting indicator is fully down. Turn
the high signal adjustment nut until high signal setting indicator is slightly beyond the actuation
setting of 55 psig.
2. Starting with the pressure above the actuation pressure, reduce the pressure to desired actuation
pressure of 55 psig, contact opens.
3. Advance the low signal adjusting nut until the switch actuates and contact closes.
P24A & P34A Service Manual
12/18/12
FIGURE 9-1
ASCO Freezer Pressure Switch (2PS)
It is preferable that the freezing cycle be such that a small diameter hole remain in the center of the
ice cylinder (1/16” diameter for 7/8” diameter ice, 1/8” diameter for 1 1/8” diameter ice, 1/4”
diameter for 1 3/8” diameter ice). This insures that the freezing cycle is not extended unnecessarily
and eliminates a possible opaque core in the center of the ice, as well as a loss of production.
High-Low Pressure Switch. The high-low pressure switch (1PS), Figure 9-2, is a two pole dual
function switch mounted to the frame near the compressor. It protects the machine from possible
damage due to abnormal pressure during operation.
P24A & P34A Service Manual
SERVICING OPERATIONS
! CAUTION !
When this switch causes the machine to stop, the cause should be
identified and corrected before resuming normal operation.
! CAUTION !
The LOW pressure cut-in should be set at 35 psig and the cut-out set at 15 psig. After tripping at the
cut-out setting, the switch will reset automatically when the pressure rises to the cut-in setting.
The HIGH pressure cut-out should be set at 250 psig. After tripping, reset the switch manually.
Note: Do not rely on the switch calibration for accuracy. For accurate adjustment, check settings
with a test gage.
9-3
12/18/12
FIGURE 9-2
High-Low Pressure Switch (1PS)
Fan Control (cooling tower). The fan control switch is used to cycle the cooling tower fan on and
off, thereby maintaining the proper operating head pressure. This switch is mounted on the frame of
your machine and should be adjusted to maintain a head pressure between 175-190 psig (max. 200
psig). The fan control supplies power to the starter coil for the tower fan motor(s) (6M not furnished
by Vogt). See FIGURE 9-3 for adjustment instructions.
FIGURE 9-3
Fan Control Switch
9-4
SERVICING OPERATIONS
Compressor Crankcase Heater. When electrical power is supplied to terminals 12 and 22 of the
control panel (see Figure 6-3), the crankcase heater is energized when the compressor is not running.
It is deenergized when the compressor is operating. Adjust the heater to maintain a temperature of
the oil in the crankcase at 100-110°F (38-43°C) when the compressor is not running. This will
prevent the migration of refrigerant to the compressor during off periods.
Oil Pressure Switch. The compressor is protected by a manual reset type low oil pressure safety
switch which is set at 15 psig. The oil pressure switch has a built-in 60 second time delay. If the net
oil pressure (pump pressure minus suction pressure equals net oil pressure) falls below the switch
setting for a time period of 60 seconds and the pressure does not increase at least 5 psi above the
setting during that 60 seconds, the switch contact will open and stop the machine. After a period of
time as the delay heater cools, the switch can be manually reset and the machine restarted. The
compressor should not be operated under low oil pressure or low oil level conditions.
If oil is added to the compressor crankcase to resume operation after a loss of oil, be sure to observe
several cycles to make sure the oil level remains stable. See “Troubleshooting”, “Low Oil Pressure
Switch Tripped”.
P24A & P34A Service Manual
If it is necessary to install a new oil pressure switch, see FIGURE 9-4 for adjusting.
! CAUTION !
When this switch causes the machine to stop, the cause should be identified
and corrected before resuming operation.
! CAUTION !
FIGURE 9-4
Oil Pressure Switch
Control Circuit Protection. The electrical control circuit of the machine is protected by a 6 amp
circuit breaker (CB4). If this breaker should open, the machine will immediately stop. Before
resetting the circuit breaker, open the disconnect switch and lock-out all power to the control panel.
Reset CB4 and restore power. Check circuitry with a volt meter. If the machine was off for an
extended time, the crankcase heater must be energized for a minimum of four (4) hours and no liquid
refrigerant in the crankcase before restarting the machine. When ready to restart the machine,
depress the “Start” button. As usual, initiate a harvest cycle if there is ice remaining in the freezer.
Check Amp draw through the breaker for excessive load or unbalance.
12/18/12
P24A & P34A Service Manual
timing
Crouzet Timer
0 - 30
Light blinks while "timing"
Light solid when "timed
Thawing Timer. The thawing timer (2TR), Figure 9-5, governs the ice thawing period. It is located
inside the control panel (FIGURE 6-1). It is started by action of the freezer pressure switch (2PS)
which energized the “1CR” relay. This timer is set prior to shipment for approximately a three
minute period. To replace the timer, simply pull the timer from its base and plug in another, set to
“X1” and “Min” and set the thawing period for at least 30 seconds longer than the time required to
harvest the entire discharge of ice. If it should be necessary to change the setting of the timer, turn
the adjustment dial clockwise to increase the time or counter-clockwise to decrease the time. Check
thaw time after each adjustment.
Note: Thicker ice may require a longer thaw period, due to slower ice release time.
Light
indicates
timer has
timed out
Light
indicates
timer is
Up Light (red)
Light off while "timing"
Range: Set to
“0 to 12”
Time
Range
adjustment
0 - 1.2
0 - 3
0 - 12
12/18/12
Syrelec Timer (Orange)
Scale: Set to
“X1”
Thawing Timer (2TR)
Range: Set
to “1-10
min”
Voltage rating: 24-240V
Time Base:
Set to “min”
Allen Bradley Timer (White)
POWER
UP
2
RANGE
6
4
0
Min
8
10
12
UNIT
FIGURE 9-5
SERVICING OPERATIONS
Light flashing when timing
Light Solid when timed out
Power Light (green)
Light solid when "timed
Units: Set to “min”
Unit
adjustment
sec
min
hrs
9-5
9-6
SERVICING OPERATIONS
Condenser Cleaning. There are 124- 1 1/4” OD x 84” long steel tubes in the P24A condenser/
receiver. These tubes are approximately 1 1/32” inside diameter (contact the factory for P34A
condenser tube sizing). Any brush or cleaning tool should be sized accordingly so as not to damage
the tubes during cleaning. The cleaning tools should be rotated at the specified speed for the
particular tool used. The tubes should be kept wet during cleaning After cleaning the tubes should
be flushed thoroughly and all foreign material removed. Contact your distributor or Vogt’s Service
Department to obtain the proper cleaning tools.
The following is the condenser cleaning procedure:
1. Refer to the space diagrams to, Section 2, to make sure ample room is provided for removing the
condenser heads and using the mechanical cleaning equipment.
2. Order replacement cover gaskets for use at the time of reassembly.
3. Disconnect and lock-out power to the ice machine and auxiliary equipment.
4. Disconnect water piping and drain the condenser. Additional water can be drained by loosening
the cover (heads) hex nuts and separating the covers from the condenser end.
P24A & P34A Service Manual
12/18/12
5. Remove the heads stud bolts and gasket completely.
6. Inspect the tubes for excessive corrosion and possible ammonia leaks to determine whether or not
further cleaning is feasible.
7. Clean the inside of each tube as well as possible, being careful not to damage the tube. Follow
the instructions for the particular tool being used.
8. Flush each tube with water to remove all loose material to prevent contamination of the cooling
tower and sump.
9. Clean the ends of the tube sheets, so the new gasket will seal properly.
10.Insert the stud bolts to the proper depth and install the replacement gasket. Make sure the gasket
does not cover the extended tube ends.
11.Install the end covers (heads) and fasten securely in place with the hex nuts.
12. Reconnect the water piping, turn on the power. Check for leaks by turning the Hand-Auto switch
to Hand allowing the condenser pump to run.
13. Turn the switch back to Auto and wait for the crankcase heater to warm-up compressor before
starting the machine.
Cutter Gear Reducer. The cutter motor and gear reducer (54), Figure 9-5B, drive the ring gear of
the cutter assembly. It is important that the teeth of the drive gear and the ring gear mesh properly
both vertically and horizontally. The drive gear and hub can be raised or lowered on the gear reducer
shaft to obtain maximum vertical tooth engagement and the reducer assembly can be moved in or out
horizontally to obtain the proper tooth depth for maximum gear life.
Note: The motor and gear reducer are an integral unit. Only qualified personnel should attempt to
disassemble and repair this unit.
P24A & P34A Service Manual
Drive Gear Replacement.
1. Disconnect and lock-out all power to the machine.
2. Remove the top and side bolts holding the mounting plate to the support bracket. Lift the plate
and gear reducer from the bracket and rest the assembly on a stable work table sitting next to the
tank. Leave the electrical conduit connected to the gear reducer motor.
3. Inspect the drive gear teeth for proper vertical alignment and wear pattern.
4. If the wear pattern indicates less than a full width of tooth engagement, measure the difference
and make a note to correct at the time of reassembly.
5. Measure and record the dimension from the drive gear to the bottom side of the mounting plate.
6. Remove the three or four cap screws holding the drive gear to the split taper bushing.
7. Using two of the same cap screws in the threaded holes of the bushing, jack the gear off the
bushing and remove both from the gear reducer shaft.
8. Clean the split bushing and tapered hole of the new drive gear and insert the bushing into the
drive gear making sure the tapers match.
9. Slide the split hub and gear onto the keyed shaft with the key in place, positioning the hub (by
measurement previously recorded) so the full width of the gear teeth will engage when assembled
and tightened.
10. Tighten the cap screws (three or four) progressively and uniformly around the hub and recheck
the location measurement. If it is not correct, loosen the cap screws, hub and gear assembly and
make correction. Then retighten the cap screws.
11. Install the reducer and mounting plate assembly on the water tank bracket and fasten in place
with the side and top cap screws.
12. Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount
of backlash between the gear teeth.
NOTE: There should be only a slight amount of backlash (more specifically “tooth tip
clearance”). Too much clearance will cause premature wear and possible tooth damage. When
the cutter runs under a no load condition, it should have a smooth uniform sound. For
lubrication, see Section 7, Maintenance.
13. If the tooth tip clearance needs adjusting, loosen the four hex nuts holding the reducer to the
mounting plate and move the reducer as required for proper tooth engagement. Tighten the hex
nuts securely and recheck backlash.
12/18/12
SERVICING OPERATIONS
9-7
9-8
SERVICING OPERATIONS
Gear Reducer Replacement.
1. Disconnect and lock out all power to the machine.
2. Disconnect electrical wires and conduit from the motor.
3. Remove the top and side bolts holding the mounting plate to the support bracket and lift the plate
and gear reducer assembly from the tank bracket.
4. Inspect the drive gear teeth for proper vertical alignment and wear pattern. If the wear pattern
indicates less than a full width of tooth engagement, measure the distance so correction can be
made at the time of reassembly.
5. Measure and record either the distance of the drive gear from the mounting plate or the split hub
from the shaft end for future reference when reassembling.
6. Remove the three or four cap screws from the split taper bushing.
7. Use two of the cap screws in the threaded holes of the busing as jacking screws for pushing the
drive gear from the hub.
8. Drive a wedge in the split of the hub (bushing) and slide both the hub and gear from the shaft.
9. Remove the four hex nuts and lock washers from the carriage bolts around the reducer base and
mounting plate and separate the plate and reducer.
10. Install the replacement gear reducer and motor onto the mounting plate using the carriage bolts,
lock washers, and hex nuts. Tighten the nuts snug only for later adjustment.
11. Clean the split hub and drive gear, insert the hub into the gear, making sure the tapers of the two
match and slide the hub and gear onto the shaft.
12. Position the hub on the shaft (note measurements previously taken) so the full width of the gear
teeth will engage when assembled and tightened.
13. Tighten the cap screws (three or four) progressively and uniformly around the hub, checking the
measurements and adjusting as necessary.
14. Install the reducer and mounting plate assembly on the water tank bracket and fasten in place
with the side and top cap screws.
15. Rotate the cutter and disc assembly by hand and stop at the point where you feel the least amount
of backlash between the gear teeth.
16. If the gear tooth tip clearance needs adjusting, loosen the four hex nuts around the reducer base
and move the reducer as required for proper tooth clearance. Tighten the hex nuts securely and
recheck for backlash.
17. Reconnect the electrical wires and conduit to the motor.
18. Check cutter rotation and correct as necessary.
NOTE: When the cutter runs under a “no-load” condition, it should have a smooth uniform
sound.
P24A & P34A Service Manual
12/18/12
P24A & P34A Service Manual
SERVICING OPERATIONS
The weights listed in TABLE 9-1 will give you an idea of manpower or equipment needed when
servicing and handling the various parts of the water tank and cutter. Be sure to use safe lifting and
handling practices to prevent bodily injury and/or damage to parts. If additional information is
needed, you should contact your distributor or the factory.
To inspect the cutter assembly and make repairs or replace parts, it will be necessary to lower and
remove the water tank from its mounting to the bottom of the freezer. The water tank has metal
casters allowing it to be rolled out from under the freezer for inspection and servicing.
Weight (lbs.)
Description P24 P34
Water tank (bare) 333 428
Bearing bracket assembly and cutter disc 106 150
Cutter assembly and ring gear 89 164
Water tank and cutter assembly 528 742
Cutter disc 57 97
Cutter drive gear 8 14
Gear reducer and motor 56 96
Water pump 85 85
TABLE 9-1
Water Tank and Cutter Parts Weights
Water Tank Removal
1. Disconnect and lock-out all power to the machine.
9-9
2. There should be ample space to roll the water tank from under the machine. It may be necessary
to provide a flat level surface such as a sheet of plywood sufficiently supported to hold the
weight of the tank and cutter assembly. See TABLE 9-1.
3. Turn off water supply, drain water, and disconnect water and drain lines from the tank.
4. Remove the overflow tubing from the water tank and remove the circulating water tubing from
the pump.
5. P34A only - the water pump is mounted to the structural frame of the machine and will have to
be disconnected from the tank at the pump inlet bolted flange before moving the water tank.
6. Disconnect the ice discharge chute or hopper from the ice discharge opening of the water tank,
making sure the tank is free to be moved.
7. Remove the mounting bolts from around the flange of the tank, allowing the tank to be lowered
to rest on its casters.
8. P34A only - the channel support at the right side base of the machine (opposite from the pump
side) will have to be removed for the tank to be rolled out from under the freezer.
9. Roll the water tank from under the freezer, turning it as you go to clear the gear reducer and
motor. It is now accessible for inspecting and/or repair of the cutter assembly.
12/18/12
9-10
SERVICING OPERATIONS
Cutter Assembly Removal and Installation.
1. Follow water tank removal instructions, Steps 1-9. See Figure 9-5B.
2. Remove the socket head cap screw from the center of the cutter shaft and lift out the retainer and
gasket.
3. Lift the cutter straight up and off the shaft, taking care to catch the shaft key as it is removed.
4. To install the cutter, lower it down onto the shaft, allowing the ring gear to mesh with the drive gear.
5. Rotate the cutter, aligning the shaft and hub key way and inserting the key to its full depth.
6. Install the gasket, the retainer, and the socket head cap screw and tighten to approximately 15 ft.
lb. torque.
7. Check and adjust the cutter height per “Cutter Height Adjustment” instructions.
Bearing Bracket and Cutter Disc Removal.
1. Remove the cutter assembly per instructions.
2. Match mark the bearing bracket support arms with the water tank for reassembly reference.
P24A & P34A Service Manual
3. Remove the splash shield and ice deflector plate from the ice discharge opening.
4. Support the bearing bracket to keep it from falling in the tank. Loosen and remove the four cap
screws and lock washers from the ends of the bearing bracket support arms.
5. Lift the bracket and cutter disc from the tank. Be sure the support arms are match marked for
reassembly. You may have to gently drive the support arms up or down to release them from the
tank walls.
6. With the bracket and disc assembly turned upside down, remove the cotter pin from the shaft.
7. Loosen and remove the slotted hex nut, spring washer, and spacer.
8. Lift the cutter disc from the keyed shaft, being careful not to loose the shaft key.
The cutter shaft and bearings are sealed in the bearing bracket assembly. The cavity between the
bearings has been filled with a food-grade grease to prevent the presence of moisture and prolong the
life of the unit. If there is any vertical or side movement of the shaft or if the bearings feel rough or
tight when turning the shaft, the assembly should be dismantled and rebuilt. Refer to the cutter tank
assembly drawing, Figure 9-5B, for parts location and identification.
Cutter Shaft and Bearing Removal.
Note: Use only a soft mallet or other soft tool for fitting all parts into place.
12/18/12
1. With the bearing bracket assembly removed from the tank, press the shaft out of the housing
from the bottom up.
Note: The two top bearings may come out with the shaft along with the upper seal and excluder.
2. Turn the bracket over and press the bottom bearing out the bottom, along with the lower seal.
3. There are three spacers on the shaft which should be removed and labeled as to their location.
Remove them as they are made accessible.
4. Clean and inspect all parts for wear or damage. Discard all parts showing any indication of
damage.
P24A & P34A Service Manual
SERVICING OPERATIONS
Cutter Shaft and Bearing Installation.
1. Clean the inside of the bearing housing of grease or foreign matter. Further clean the top bearing
housing with pro-lock cleaner and primer (or a suitable substitute) and remove the pipe plugs
from the side of the housing.
2. Apply a thin coat of Loctite RC/609 retainer (or a suitable substitute) to the inner surface and
bearing shoulder of the top of the bearing bracket.
9-11
3. Insert a bearing in the top housing and set it in place.
4. Clean the cutter shaft and press the top bearing onto the shaft.
5. Slide the upper bearing spacer on the shaft and begin driving the shaft down through the middle
bearing of the housing. Do not start the top shaft bearing in the housing.
6. Partially fill the housing with grease (MPG-2 or a USDA approved grease). Use enough to fill
the area between the two upper bearings, forcing some out the pipe plug hole when the shaft and
top bearing are seated.
7. Finish driving the shaft and bearing into the housing until it is firmly seated.
8. Turn the bracket and shaft upside down and fill the housing around the shaft with MPG-2 (or
suitable substitute) grease.
9. Slide the lower bearing spacer over the shaft and into the housing.
10. With the top end of the shaft supported, install the lower bearing on the shaft driving it down into
the housing firmly against the housing shoulder.
11. Slide the seal spacer (ridged end in, flat end out) and seal (open face out) onto the shaft together.
12. Uniformly tap the seal into the housing against its shoulder.
NOTE: The purpose of the seals and excluders are to prevent moisture from entering the housing
area not to hold the grease in.
12/18/12
13. Wipe off excess grease and install the two pipe plugs.
14. Install the largest excluder on the bracket as illustrated by the assembly drawing.
15. Install the tines disc, the 1/4 x 1/4 key, spacer, spring washer, castle nut, and cotter pin.
16. Turn the assembly right side up and install it in the water tank, locating the support arms as they
were match marked when removed and secure in place using the 5/8” stainless steel cap screw
and lock washer maximum torque should be 90 ft. lbs.
17. Install the top seal (open side facing out*), tapping it uniformly into the housing until it seats.
18. Install the top water excluder.
19. Install the splash shield and ice deflector plate in the ice discharge opening.
20. Install the cutter assembly, using the 1/4” X 1/4” X 3 3/16” lg. stainless steel key to align the key
ways and lock the cutter and shaft together.
21. Install the red rubber gasket, retainer, and 3/8” stainless steel socket head cap screw. Tighten to
approximately 15 ft. lbs.
22. Check and adjust the cutter height per “Cutter Height Adjustment” instructions.
9-12
SERVICING OPERATIONS
Cutter Height Adjustment. The height of the cutter can be adjusted by the four bolts holding the
bearing bracket assembly in place. These bolts are threaded into holes in the end of each arm through
holes in the water tank. The current design has these washers welded in place after the cutter height is
properly adjusted. This helps to insure proper adjustment during servicing. Using a true straight edge
long enough to reach across the top flange of the water tank (30” for P24 and 40” for P34), the top of
the cutter rim and blade should be 1/8” ± 1/16” below the top of the water tank flange.
Keep one end of the straight edge at the same point and swing the other end across the tank at
various points to check the clearance.
Also, rotate the cutter to check all points. If adjustment is necessary, loosen the four side bolts and
raise or lower each arm as needed. Tighten the bolts securely to approximately 90 ft. lb.
Water Tank Installation.
1. Place the 3/16” thick gum rubber gasket on the top of the tank flange. It can be held in place
with narrow strips of tape through the bolt holes.
2. Push the water tank in and under the freezer aligning the bolt holes and installing the mounting
bolts around the flange and tightening the nuts securely.
P24A & P34A Service Manual
3. Reconnect the discharge chute or hopper to the ice discharge opening.
4. Mount the water pump (P34 only) and attach the circulating water tubing and overflow tubing.
5. Reconnect all water piping such as drain, overflow, and make-up water lines. Turn water on and
check for leaks.
6. Fill the water tank with water and make sure the drain valve is closed.
When ready, turn the power “On” to the machine, but don’t operate the compressor until the oil is
warm and there is no liquid refrigerant in the crankcase.
Figure 9-5A
P24A Cutter Assembly
12/18/12
P24A & P34A Service Manual
9-13
SERVICING OPERATIONS
12/18/12
Figure 9-5B
P24A Water Tank Assembly
9-14
SERVICING OPERATIONS
Item # Description P24A Part Number P34A Part Number
1 Water Tank Assembly 19T4500S24 19T4500S34
2 Water Box Cover (Not Shown) 19T2150C01 19T2150C02
3 Water Pump See Pump Model # See Pump Model #
6 2” Red Rubber Gasket 12A 2600R07 12A 2600R08
7 2 1/2” Red Rubber Gasket 12A 2600R08 12A 2600R09
8 5/8” S.S. Hex Nut (8) 12A 2240A113 12A 2240A113
9 5/8” S. S. Lock Washer (8) 12A 2250B113 12A 2250B113
10 PVC Ell 2” MPT x Insert 12A 2450E12 12A 2450E16
11 2” PVC Round Flange 12A 2535F0706 12A 2532F0606
12 2” FPT Valve 12A 4200G1401 12A 4200G1401
13 WC 45° Ell 7/8” ODC 12A 2409W0006 NA
14 7/8” OD Copper Tubing 12A 4180A0008 12A 41080A0009
15 3/4” MPT x FPT PVC 90° Ell 12A 2450E07 12A 2450E07
16 3/4” S.S. Pipe Nipple 12A 3050S0401 12A 3050S0401
17 3/4” FPT Solenoid 12A 4200A0602 12A 4200A0602
18 Thermometer 12A 4170T01 12A 4170T01
19 1/2” MPT x 1/4” Brass Bushing 12A 2451B03 NA
20 1/2” FPT x 7/8” ODC Adapter 12A 2401W012 NA
21 WC Tee 7/8” ODC 12A 2422W0009 12A 2422W001
22 WC 90° Ell 7/8” ODC 12A 2417W0004 12A 2417W0005
23 3/4” Brass Service Valve (1” for P34A) 12A 4205G0601 12A 4205G0602
24 3/4” MPT x 1/2” PVC Bushing 12A 2450B04 12A 2450B04
25 1/2” MPT x 1/4” PVC Bushing 12A 2450B05 12A 2450B05
26 3/4” MPT x 7/8” ODC Adapter 12A 2400W0023 12A 2400W0023
27 3/4” MPT Float Valve 12A 4200H0601 12A 4200H0601
28 Float Valve Stem 12A 4200HP01 12A 4200HP01
29 Valve Float 12A 4200HP02 12A 4200HP02
30 WC 3/4” FPT x 7/8” ODC Adapt. 12A 2401W0007 NA
31 Key 1/4” x 1/4” x 3 3/16” S.S. 12A 2785S04 12A 2785S04
32 Cutter Adapter Plate 19T2010A11 19T2010A05
33 Bearing 12A 2020M02 12A 2020M02
34 Bearing Bracket 19T2025B0105 19T2025B0106
35 Cutter Blade 19T2035B0100 19T2035B0200
36 Breaker Cutter Assembly 19T2160C0401 19T2160C0501
37 Tines Disc Assembly 19T2163D0302 19T2163D0403
38 Top Excluder 12A 2210E01 12A 2210E01
39 Bottom Excluder 12A2210E04 12A2210E04
44 Carriage Bolt, 3/8-16x1 1/4” (4 ) 12A 2218H1112 12A 2218H1112
45 Mach Screw 3/8”-16 x 2” Flat (8) 12A 2226H1115 12A 2226H1115
46 Hex Nut, 3/8-16 S.S. (12) 12A 2240A1309 12A 2240A1309
47 Slotted Nut, 1-14 NF S.S. 12A 2240E1216 12A 2240E1216
48 Lock washer 5/16” S.S. 12A 2250B108 12A 2250B108
49 Lock washer 3/8” S.S. 12A 2250B109 12A 2250B109
50 Lock washer 5/8” S.S. 12A 2250B113 12A 2250B113
51 1/4” S.S. Sq. Head Pipe Plug (2) 12A 2475T0001 12A 2475T0001
52 Gasket, 3/4” OD x 7/16” ID 12A 2600R02 12A 2600R02
53 Key, 3/8” x 5/16”x 3/4” S.S. 12A 2785S01 12A 2785S01
54 Gear Motor 12A 2900M0702 12A 2900M0702
55 Cotter Pin, 3/16” x 1 1/2” S.S. 12A 3040S06 12A 2900M0801
56 Cutter Support Washer 19T4001S0224 19T4001S0224
57 Retainer 19T4065R0100 19T4065R01
58 Seal 12A 4080S02 12A 4080S02
59 Cutter Shaft 19T4090S03 19T4090S03
60 Upper Bearing Spacer 19T4130C01 19T4130C01
61 Tines Disc Spacer 19T4130C02 19T4130C02
62 Seal Spacer 19T4130C03 19T4130C03
63 Lower Bearing Spacer 19T4130C04 19T41030C04
64 Spacer, 5/8” OD x 7/8” Long (8) 19T4130T04 19T4130T04
65 Disc Spring 12A 4138S01 12A 4138S01
66 Split Taper Bushing 12B 2060B04 12B 2060B01
67 Drive Gear 12B 2615D03 12C 2615D05
68 Splash Curtain Holder 19T4001S0162 19T4001S0163
69 Splash Curtain Bottom Plate 19T4001S0415 19T4001S0411
70 Splash Curtain 12A 4078C03 12A 4078C02
12/18/12
P24A & P34A Service Manual
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