Vogt Tube-ice 03tb User manual

2/18/16

03TB

TUBE-ICE®

MACHINE

(Includes models HE60 & P112F)

Part Number 12A4171M07

Revision 3

Service Manual

$50

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 502-635-

3000 or FAX at 502-635-3024.

IMPORTANT: To activate the machine warranty, the Product Registration

Form MUST be completed and returned to the factory promptly after the

official start-up. Product Registration Form is located in the Owners Packet

or can be found online at www.vogtice.com/registration.htm.

Please return to: VOGT ICE, LLC

Suite #19

1000 W. Ormsby Ave.

Louisville, KY 40210

4/11/14

VOGT ICE







, LLC, located in

Louisville, Kentucky since 1880.

Sales - (800) 959-8648

Service - (502) 635-3000

Parts - Your Local Distributor

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

Since 1880, Manufacturers of Quality

Tube-Ice

Machines

Vogt



Tube-Ice



Machines

Installation, Service Manual and Parts Catalog #12A4171M07

03TA Model

Revision 3.0

03TA Service Manual

TABLE OF CONTENTS

4/11/14

TABLE OF CONTENTS

Vogt

TUBE-ICE

MACHINES

Model 03TA

Page No.

1. INTRODUCTION

A Brief History of Our Company ..................................................................................................................................1-1

Vogt Energy-Savings Tube-Ice® Machines ..................................................................................................................1-1

Preview .....................................................................................................................................................................1-1

Important Safety Notice.................................................................................................................................................1-2

Special Precautions To Be Observed When Charging Refrigeration Systems...............................................................1-2

Safety Symbols and What They Mean...........................................................................................................................1-3

Assembly Drawing Model 03TB Air-Cooled, FIGURES 1-1, 1-2, & 1-3.....................................................................1-4, 1-5, 1-6

Assembly Drawing Model 03TB Water-Cooled, FIGURES 1-4, 1-5, & 1-6 ................................................................1-7, 1-8, 1-9

2. RECEIPT OF YOUR TUBE-ICE MACHINE

Inspection .....................................................................................................................................................................2-1

Safety Valves.................................................................................................................................................................2-1

Machine Room ..............................................................................................................................................................2-1

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

3. INSTALLING YOUR TUBE-ICE MACHINE

Bin Installation ..............................................................................................................................................................3-1

Setting the Ice Machine on the Bin................................................................................................................................3-1

Ice Chute Location/Machine Footprint, FIGURE 3-1....................................................................................................3-1

Forklift and Blocks Method, FIGURE 3-2 ....................................................................................................................3-2

Forklift and Ropes or Lifting Strap Method, FIGURE 3-3 ............................................................................................3-3

Connections and Space Diagram (Air-Cooled Machine), FIGURE 3-4 ........................................................................3-4

Connections and Space Diagram (Water-Cooled Machine), FIGURE 3-5....................................................................3-5

Piping and Drain Connections .......................................................................................................................................3-6

Water Supply and Drain Sizes, TABLE 3-1 ..................................................................................................................3-6

Cooling Tower...............................................................................................................................................................3-7

Wiring and Electrical Connection..................................................................................................................................3-8

Control Panel Power Connections, FIGURE 3-6...........................................................................................................3-8

Electrical Specifications, TABLE 3-2 ...........................................................................................................................3-8

Phase Check...................................................................................................................................................................3-9

Voltage Unbalance.........................................................................................................................................................3-9

Current Unbalance.........................................................................................................................................................3-9

Air-Cooled Condenser Installation Instructions.............................................................................................................3-10

Pounds of Refrigerant To Add Vs. Liquid Line Length, TABLE 3-3............................................................................3-11

Air-Cooled Condenser Data...........................................................................................................................................3-12

Condenser Dimensions, FIGURE 3-7............................................................................................................................3-13

Condenser Field Piping (Cold Weather Valve Kit), FIGURE 3-8 .................................................................................3-14

03TA Service Manual

TABLE OF CONTENTS

Page No.

3. INSTALLING YOUR TUBE-ICE MACHINE (Cont.)

Condenser Equivalent Line Size Worksheet..................................................................................................................3-15

Equivalent Feet Due To Friction, TABLE 3-5...............................................................................................................3-15

Minimum Traps For Discharge Lines, FIGURE 3-9 .....................................................................................................3-15

Air-Cooled Condenser Wiring.......................................................................................................................................3-16

Wiring for 2 Fan Condenser, FIGURE 3-10..................................................................................................................3-16

Air-Cooled Connections ................................................................................................................................................3-17

Rota-lock Connector Torque Ratings, TABLE 3-6........................................................................................................3-17

Pressure Relief Valves...................................................................................................................................................3-17

Ice Bin Thermostat Sensor Installation..........................................................................................................................3-18

Ice Bin Thermostat Location, FIGURE 3-11.................................................................................................................3-18

Programming the Electronic Ice Bin Thermostat...........................................................................................................3-

Storing Ice ....................................................................................................................................................................3-20

Saigle Ice / Dual Ice ......................................................................................................................................................3-20

Installation Review : A Checklist ..................................................................................................................................3-21

4. HOW YOUR TUBE-ICE MACHINE WORKS

Principle of Operation....................................................................................................................................................4-1

Freeze Period .................................................................................................................................................................4-2

Harvest Period ...............................................................................................................................................................4-2

Piping Nomenclature, TABLE 4-1 ................................................................................................................................4-2

Water-Cooled Piping Schematic, FIGURE 4-1 .............................................................................................................4-3

Air-Cooled Piping Schematic, FIGURE 4-2..................................................................................................................4-4

5. START-UP AND OPERATION

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

Refrigerant Charge.........................................................................................................................................................5-1

Start-Up Checklist .........................................................................................................................................................5-2

Start-Up .....................................................................................................................................................................5-3

Control Panel Switch Layout, FIGURE 5-1 .................................................................................................................5-3

Adding Refrigerant ........................................................................................................................................................5-4

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

6. ELECTRICAL CONTROLS & THEIR FUNCTIONS

Control Panel FIGURE 6-1............................................................................................................................................ 6-1

Control Panel (Standard), FIGURE 6-2 .........................................................................................................................6-2

Control Panel Door, FIGURE 6-2A...............................................................................................................................6-3

Control Panel (Australian & CE approved), FIGURE 6-2B ..........................................................................................6-4

Description of Control Panel Parts, TABLE 6-1............................................................................................................6-5

Description of Control Panel Component Function, TABLE 6-2 ..................................................................................6-6

Electrical Schematic All Voltages 50-60 Hz. (Standard/Australian/CE), FIGURE 6-3.................................................6-7

Compressor Wiring Detail

, FIGURE 6-4..................................................................................................................6-8

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TABLE OF CONTENTS

4/11/14

iii

Page No.

7. MAINTENANCE

Ice-Making Section........................................................................................................................................................7-1

Cleaning Procedure........................................................................................................................................................7-1

Sanitizing Procedure ..................................................................................................................................................... 7-2

Water Distributors .........................................................................................................................................................7-3

Water Tank ....................................................................................................................................................................7-3

Water-Cooled Condensers, Checking Operation ...........................................................................................................7-3

Water-Cooled Condensers, Draining .............................................................................................................................7-4

Water-Cooled Condenser Cleaning ...............................................................................................................................7-4

Lubrication ....................................................................................................................................................................7-

Compressor....................................................................................................................................................................7-6

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

Preventive Maintenance.................................................................................................................................................7-8

Daily /Weekly / Monthly / Yearly Check List .........................................................................................................7-8

Pressure Relief Valve Replacement Note ................................................................................................................7-8

Note To Manager or Owner.....................................................................................................................................7-9

Preventive Maintenance Program............................................................................................................................7-10

8. TROUBLESHOOTING

List Of Symptoms..........................................................................................................................................................8-1

Machine Won’t Run ......................................................................................................................................................8-2, 8-3

Freeze-Up Due To Extended Freezing Period ...............................................................................................................8-4

Freeze-Up Due To Ice Failing To Discharge.................................................................................................................8-5

Low Ice Capacity...........................................................................................................................................................8-6

Low Compressor Oil Level............................................................................................................................................8-7

Poor Ice Quality.............................................................................................................................................................8-8

High Head Pressure (Water-Cooled) .............................................................................................................................8-9

High Head Pressure (Air-Cooled)..................................................................................................................................8-10

9. SERVICE OPERATIONS

Adjustable Blowdown (For Clearer Ice)........................................................................................................................9-1

Water Pump/ Blowdown Assembly, FIGURE 9-1 ........................................................................................................ 9-1

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

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

Thermal Expansion Valve, FIGURE 9-2.......................................................................................................................9-2

Superheat / Checking Superheat .................................................................................................................................9-2

Freezer Pressure Switch.................................................................................................................................................9-3

Freezer Pressure Switch (Allen-Bradley), FIGURE 9-3 ................................................................................................9-3

High-Low Pressure Switch ............................................................................................................................................9-4

High-Low Pressure Switch, FIGURE 9-4......................................................................................................................9-4

Head Pressure ................................................................................................................................................................9-4

Water-Cooled Units.......................................................................................................................................................9-4

Air-Cooled Units ...........................................................................................................................................................9-5

Water Regulating Valve, FIGURE 9-5A .......................................................................................................................9-5

Condenser Fan Switch, FIGURE 9-5B ..........................................................................................................................9-5

03TA Service Manual

TABLE OF CONTENTS

Page No.

9. SERVICE OPERATIONS (Cont.)

Oil Separator, FIGURE 9-6 ........................................................................................................................................... 9-6

Solenoid Valve ..............................................................................................................................................................9-5

Solenoid Valve (“D” & "X" Valve Before Aug 2006), FIGURE 9-7A .........................................................................9-6

Solenoid Valve (“D” & "X" Valve After Aug 2006), FIGURE 9-7B............................................................................9-6

Solenoid Valve (“A” Valve), FIGURE 9-7C .................................................................................................................9-6

Compressor Crankcase Heater.......................................................................................................................................9-7

Compressor Connections, FIGURE 9-8.........................................................................................................................9-7

Sentronic Oil Pressure Safety Control, FIGURE 9-9A..................................................................................................9-8

Oil Pressure Sensor..................................................................................................................................................9-9

Sentronic Oil Pressure Safety Control .....................................................................................................................9-8

CoreSense Protection.....................................................................................................................................................9-9

CoreSense Protection Faults / Connection, Figure 9-9B...............................................................................................9-10

Control Circuit Protection .......................................................................................................................................... 9-10

Circulating Water Pump Motor, FIGURE 9-10 .............................................................................................................9-11

Cutter Gear Reducer, FIGURE 9-11 ........................................................................................................... 9-11

Thawing Timer, FIGURE 9-12A ................................................................................................................ 9-12

Thawing Timer Pin Connections, FIGURE 9-12B...................................................................................... 9-12

Condenser Cleaning.......................................................................................................................................................9-13

Pump Down ...................................................................................................................................................................9-13

Removal Of Refrigerant From Machine ........................................................................................................................9-13

Refrigerant Leaks...........................................................................................................................................................9-14

Non-Condensable Gases ................................................................................................................................................9-14

Compressor Motor Burnout ...........................................................................................................................................9-15

Capacity Control Valve (Internal Construction) ............................................................................................................9-16

Copeland Compressor Unloader Valve, FIGURE 9-13 .................................................................................................9-16

Loaded Operation (Freeze Period), Unloaded Operation (During Thaw Only) .......................................................9-16

Component Removal and Replacement Operations.......................................................................................................9-17

Cutter Motor ............................................................................................................................................................9-17

Water Tank ..............................................................................................................................................................9-18

Cutter & Bearing .....................................................................................................................................................9-18

Cutter/Tank Assembly Nomenclature, TABLE 9-1.......................................................................................................9-19

Cutter, Water Tank & Drive Gear Assembly, FIGURE 9-14 ........................................................................................9-20

Water Tank & Pump Assembly, FIGURE 9-15.............................................................................................................9-21

Crushed Ice Production..................................................................................................................................................9-22

10. OPTIONS AND ACCESSORIES

Power Monitor, FIGURE 10-1 .....................................................................................................................................10-1

Power Monitor Parameters, TABLE 10-1 ....................................................................................................................10-1

PLC (Programmable Logic Controller) ........................................................................................................................10-4

Mitsubishi HMI (E1012), FIGURE 10-2 ......................................................................................................................10-5

PLC, FIGURE 10-3 ......................................................................................................................................................10-6

PLC, Input / Output Table, TABLE 10-2 .....................................................................................................................10-6

Wiring Schematic

, FIGURE 10-24.............................................................................................................................10-6

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Page No.

11. TABLES AND CHARTS

03TA Ratings (60 Hz., 7.5 HP), TABLE 11-1...............................................................................................................11-1

03TA Ratings (50 Hz., 10 HP), TABLE 11-1................................................................................................................11-1

03TA Capacity Ratings, TABLE 11-2...........................................................................................................................11-2

03TA Condenser Water Usage, TABLE 11-3 ...............................................................................................................11-3

03TA Make-up Water Usage, TABLE 11-4 ..................................................................................................................11-3

03TA Normal Operating Vitals, TABLE 11-5...............................................................................................................11-3

Recommended Spare Parts List .....................................................................................................................................11-4

Temperature - Pressure Chart for Common Refrigerants, TABLE 11-6........................................................................11-5

Conversion Factors: English to Metric, TABLE 11-7 ...................................................................................................11-6

Constants, TABLE 11-8 ................................................................................................................................................11-6

12. INDEX