Vogt Tube-Ice P-24A User manual

5/31/11
P-24A
&
P-34A
TUBE-ICE®
MACHINE
Service Manual
$50
00

5/31/11

5/31/11
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: Tube Ice, LLC
1000 W. Ormsby, Suite 19
Louisville, KY 40210
Att. Tube-Ice Service Department

5/31/11
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: Tube Ice LLC, 1000 W. Ormsby, Suite #19, Louisville, KY 40210

5/31/11
VOGT



TUBE-ICE
®
MACHINES
P24AL & P34AL Model
Installation, Service Manual, and Parts Catalog #12A-4171L14
Tube Ice, LLC
1000 W. Ormsby Avenue, Suite 19
Louisville, Kentucky, 40210
800-853-8648 •502-635-3000
Fax: [phone]

P24AL & P34AL Service Manual
TABLE OF CONTENTS
5/31/11
i
TABLE OF CONTENTS
Vogt
®
TUBE-ICE
®
MACHINES
Model P24A & P34A
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-Ice

Machine....................................................................................................1-4,1-5,1-6,1-7
Assembly Drawing Model P34A Tube-Ice

Machine....................................................................................................1-8,1-9,1-10, 1-11
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
Storage (prior to installation and start-up) .....................................................................................................................2-2
3. INSTALLING YOUR TUBE-ICE MACHINE
Machine Room ..............................................................................................................................................................3-1
Space Requirements.......................................................................................................................................................3-1
Lifting Procedures .........................................................................................................................................................3-1
P24A Space Diagram, FIGURE 3-1 ..............................................................................................................................3-2,3-3
P24A Foundation Layout, FIGURE 3-2 ........................................................................................................................3-4
P34A Space Diagram, FIGURE 3-3 ..............................................................................................................................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

P24AL & P34AL Service Manual
TABLE OF CONTENTS
5/31/11
ii
Page No.
Cooling Tower...............................................................................................................................................................3-11
Condenser Water Requirements TABLE 3-2 ................................................................................................................3-12
Marley Cooling Tower Recommendations TABLE 3-3 ................................................................................................3-12
Safety Valves ................................................................................................................................................................3-13
Cooling Tower Piping Diagram, FIGURE 3-7 ..............................................................................................................3-14
Freeze Protection, FIGURES 3-8, 3-9, 3-10 ..................................................................................................................3-15,3-16
Wiring and Electrical Connections .................................................................................................................................3-16
Power Supply Connections, FIGURE 3-11 ....................................................................................................................3-17
Voltage Unbalance..........................................................................................................................................................3-17
Current Unbalance..........................................................................................................................................................3-17
Rotation Check ...............................................................................................................................................................3-18
Auxiliary Controls or Equipment....................................................................................................................................3-19
Installation Review: A Checklist ...................................................................................................................................3-20
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

P24AL & P34AL Service Manual
TABLE OF CONTENTS
5/31/11
iii
Page No.
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 ....................................................................................................................................7-3
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 .....................................................................................................7-5
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 ...........................................................................................................................8-11

P24AL & P34AL Service Manual
TABLE OF CONTENTS
5/31/11
iv
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 ............................................................................................................................................9-3
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......................................................................................................................................................9-5
Cutter Gear Reducer ......................................................................................................................................................9-6
Drive Gear Replacement................................................................................................................................................9-6
Gear Reducer Replacement ...........................................................................................................................................9-7
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 ................................................................................................................................9-11
Cutter Shaft and Bearing Installation.............................................................................................................................9-11
Cutter Height Adjustment..............................................................................................................................................9-12
Water Tank Installation .................................................................................................................................................9-13
P24A Cutter Assembly, FIGURE 9-5A.........................................................................................................................9-13
P24A Water Tank Assembly, FIGURE 9-5B ................................................................................................................9-14
P24A and P34A Cutter and Water Tank Part No., TABLE 9-2.....................................................................................9-15, 9-16
Cutter Ring Gear Replacement ......................................................................................................................................9-16
Cutter Blade Replacement .............................................................................................................................................9-16
Cutter Blade and Adapter Plate Adjustment, FIGURE 9-6............................................................................................9-17
Cutter Adapter Plate Installation....................................................................................................................................9-17
Pumpdown.....................................................................................................................................................................9-18
Removal of Ammonia Refrigerant from the Machine ...................................................................................................9-18

P24AL & P34AL Service Manual
TABLE OF CONTENTS
5/31/11
v
Page No.
Refrigerant Leaks...........................................................................................................................................................9-19
Non-Condensable Gases ................................................................................................................................................9-19
Purging Non-Condensables ...........................................................................................................................................9-19
Draining the Oil Trap.....................................................................................................................................................9-20
Removing Excess Water from Ammonia ......................................................................................................................9-21
Circulating Water Pump Motor .....................................................................................................................................9-22
The Thaw Gas Solenoid Valve ......................................................................................................................................9-22
Thaw Gas Solenoid Valve, FIGURE 9-7.......................................................................................................................9-23
The Liquid Feed Solenoid Valve ...................................................................................................................................9-23
The Liquid Feed Solenoid Valve, FIGURE 9-8.............................................................................................................9-24
Water Flush Solenoid Valve ..........................................................................................................................................9-24
Compressor Cooling Solenoid Valve ( dedicated high side only)..................................................................................9-24
Compressor Oil Changing .............................................................................................................................................9-24
Compressor Inspection ..................................................................................................................................................9-25
Belt Tension...................................................................................................................................................................9-25
Compressor Servicing....................................................................................................................................................9-26
10. OPTIONS AND ACCESSORIES
Crushed Ice Production .................................................................................................................................................10-2
Length of Ice .................................................................................................................................................................10-2
PLC (Programmable Logic Controller) ........................................................................................................................10-3
Reduced Voltage Cutter Motor Starter ......................................................................................................................... 10-13
Power Monitor...............................................................................................................................................................10-14
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
12. APPENDIX