Vogt TUBE-ICE P-118F User manual

P-118F
TUBE-ICE®
MACHINE
Service Manual
$5000
1/6/09

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 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 Tube-Ice
Suite #135
Louisville, KY 40201

1/6/09
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 Tube-Ice , Suite #135, Louisville, KY 40201

The Henry Vogt Machine Co., located in
Louisville, Kentucky since 1880.
Sales - [phone]
Service - [phone]
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
1/6/09

P118F Service Manual
TABLE OF CONTENTS
1/6/09
i
TABLE OF CONTENTS
Vogt® TUBE-ICE®MACHINES
Model P118F C-Series
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 P118F Air-Cooled, FIGURES 1-1, 1-2, & 1-3 ...................................................................1-4, 1-5, 1-6
Assembly Drawing Model P118F 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 ..............................................................................................................................................................2-2
Storage (prior to installation and start-up).....................................................................................................................2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Piping and Drain Connections, TABLE 3-1..................................................................................................................3-1
Cooling Tower...............................................................................................................................................................3-1
Space Diagram (Water Cooled Machine), FIGURE 3-1................................................................................................3-2
Space Diagram (Air-Cooled Machine), FIGURE 3-2....................................................................................................3-3
Wiring and Electrical Connection FIGURE 3-3............................................................................................................3-4
Voltage and Current unbalance ......................................................................................................................................3-5
Rotation Check..............................................................................................................................................................3-5
Air-Cooled Condenser Installation................................................................................................................................3-6
Air-Cooled Condenser Data, TABLE 3-3......................................................................................................................3-8
Minimum Traps For Discharge Lines, FIGURE 3-4 .....................................................................................................3-9
Equivalent Feet Due To Friction, TABLE 3-4 ..............................................................................................................3-9
Condenser Piping (Cold Weather Valve Kit), FIGURE 3-5..........................................................................................3-10
Wiring For HDD-311 & HDD-361 (3 phase), FIGURE 3-6..........................................................................................3-11
Ice Bin Thermostat Location, FIGURE 3-7...................................................................................................................3-12
Installation Review: A Checklist...................................................................................................................................3-13

P118F Service Manual
TABLE OF CONTENTS
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Page No.
4. HOW YOUR TUBE-ICE MACHINE WORKS
Principle of Operation....................................................................................................................................................4-1
Freeze Period.................................................................................................................................................................4-2
Harvest Period ...............................................................................................................................................................4-2
Piping Nomenclature.....................................................................................................................................................4-2
Water Cooled Piping Schematic, FIGURE 4-1..............................................................................................................4-3
5. START-UP AND OPERATION
Refrigeration System Review........................................................................................................................................5-1
Refrigerant Charge ........................................................................................................................................................5-1
Start-Up Checklist .........................................................................................................................................................5-2
Start-Up .....................................................................................................................................................................5-3
Adding Refrigerant........................................................................................................................................................5-4
Operating Tips...............................................................................................................................................................5-5
6. ELECTRICAL CONTROLS & THEIR FUNCTIONS
Control Panel, FIGURE 6-1...........................................................................................................................................6-1
Description of Control Panel Parts, TABLE 6-1 ...........................................................................................................6-2
Electrical Schematic All Voltages 50-60 Hz. Across Line Start, FIGURE 6-2.............................................................6-3
7. MAINTENANCE
Ice-Making Section........................................................................................................................................................7-1
Cleaning Procedure........................................................................................................................................................7-1
Water Distributors .........................................................................................................................................................7-2
Water Tank....................................................................................................................................................................7-2
Water Cooled Condenser Cleaning................................................................................................................................7-2
Water Cooled Condenser Service, FIGURE 7-1............................................................................................................7-3
Lubrication ....................................................................................................................................................................7-3
Compressor..............................................................................................................................................................7-3
Cutter Gear Reducer................................................................................................................................................7-4
Preventive Maintenance.................................................................................................................................................7-4
Daily Check List......................................................................................................................................................7-5
Note To Manager Or Owner....................................................................................................................................7-5
Preventive Maintenance Program............................................................................................................................7-6
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

P118F Service Manual
TABLE OF CONTENTS
1/6/09
iii
Page No.
High Head Pressure (Water Cooled)..............................................................................................................................8-9
High Head Pressure (Air-Cooled)..................................................................................................................................8-10
9. SERVICE OPERATIONS
Adjustable Blowdown (For Clearer Ice)........................................................................................................................9-1
Automatic Blowdown (Harvest Cycle)..........................................................................................................................9-1
Float Valve (Make-Up Water).......................................................................................................................................9-1
Float Switch...................................................................................................................................................................9-2
Hand Expansion Valve..................................................................................................................................................9-2
Capillary By-pass ..........................................................................................................................................................9-2
Freezer Pressure Switch.................................................................................................................................................9-3
Freezer Pressure Switch (Allen-Bradley), FIGURE 9-1................................................................................................9-3
Allen-Bradley Switch ....................................................................................................................................................9-3
High/Low Pressure Switch ............................................................................................................................................9-4
High/Low Pressure Switch, FIGURE 9-2......................................................................................................................9-4
Head Pressure................................................................................................................................................................9-5
Water Cooled Units .......................................................................................................................................................9-5
Air-Cooled Units ...........................................................................................................................................................9-5
Water Regulating Valve, FIGURE 9-3A.......................................................................................................................9-5
Condenser Fan Switch, FIGURE 9-3B..........................................................................................................................9-5
Compressor Crankcase Heater.......................................................................................................................................9-5
Compressor Motor Protection .......................................................................................................................................9-6
High Potential Testing..............................................................................................................................................9-7
Field Troubleshooting ..............................................................................................................................................9-7, 9-8
Electrical Installation Diagram, FIGURE 9-4 ..........................................................................................................9-8
Oil Pressure Safety Control ...........................................................................................................................................9-9
Oil Pressure Sensor ..................................................................................................................................................9-9
Oil Pressure Module.................................................................................................................................................9-9
Thawing Timer, FIGURE 9-5........................................................................................................................................9-10
Thawing Timer..............................................................................................................................................................9-10
Control Circuit Protection..............................................................................................................................................9-10
Condenser Cleaning.......................................................................................................................................................9-10
Air-Cooled Condenser...................................................................................................................................................9-10
Cutter Gear Reducer......................................................................................................................................................9-10
Pump Down...................................................................................................................................................................9-11
Removal Of Refrigerant From Machine........................................................................................................................9-11
Refrigerant Leaks ..........................................................................................................................................................9-12
Non-Condensable Gases................................................................................................................................................9-12
Compressor Motor Burnout...........................................................................................................................................9-12
Solenoid Valve ..............................................................................................................................................................9-13
Solenoid Valve ( “D” Valve), FIGURE 9-6 ..................................................................................................................9-13

P118F Service Manual
TABLE OF CONTENTS
iv
Page No.
Circulating Water Pump Motor .....................................................................................................................................9-13
Compressor Unloader....................................................................................................................................................9-13, 9-14
Suction Cut-Off Unloader, FIGURE 9-7.......................................................................................................................9-14
Loaded Operation (Freeze Period).............................................................................................................................9-14
Unloaded Operation (During Thaw Only)..................................................................................................................9-14
Cylinder Head Sensor....................................................................................................................................................9-14
Cutter Motor..................................................................................................................................................................9-15
Cutter Gear Reducer......................................................................................................................................................9-15
Water Tank Removal.....................................................................................................................................................9-16
Cutter & Bearing Removal/Installation.........................................................................................................................9-16, 9-17
Cutter/Water Tank Assembly, FIGURE 9-8..................................................................................................................9-18
Cutter/Water Tank Parts (cylinder ice), FIGURE 9-9 ...................................................................................................9-19
Cutter Drive Parts, FIGURE 9-10..................................................................................................................................9-20
Cutter/Water Tank Parts (Crushed Ice), FIGURE 9-11.................................................................................................9-21
Crushed Ice Production..................................................................................................................................................9-22
10. OPTIONS AND ACCESSORIES
PLC (Programmable Logic Controller) ........................................................................................................................10-2
Reduced Voltage Compressor Motor Starter ................................................................................................................ 10-14
Power Monitor .............................................................................................................................................................. 10-17
11. TABLES AND CHARTS
P118F Ratings (60 Hz., 30 HP), TABLE 11-1 ...............................................................................................................11-2
P118F Ratings (50 Hz., 35 HP), TABLE 11-2 ...............................................................................................................11-3
P118F Capacity Ratings, TABLE 11-3 ..........................................................................................................................11-4
P118F Condenser Water Usage, TABLE 11-4...............................................................................................................11-5
P118F Make-up Water Usage, TABLE 11-5..................................................................................................................11-5
P118F Normal Operating Vitals, TABLE 11-6..............................................................................................................11-6
Recommended Spare Parts List......................................................................................................................................11-7
Temperature - Pressure Chart for Common Refrigerants, TABLE 11-7........................................................................11-8
Conversion Factors: English to Metric, TABLE 11-8....................................................................................................11-9
Constants, TABLE 11-9.................................................................................................................................................11-9
12. INDEX