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Vogt TUBE-ICE 05TA Service Manual

Includes model p118f/he100
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05TA
®
TUBE-ICE
MACHINE
(Includes model P118F/HE100)
Manual Part Number 12A4171M06
Revision 1
Service Manual
00
$50
12/08/00

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Summary of Contents for Vogt TUBE-ICE 05TA

  • Page 1 05TA ® TUBE-ICE MACHINE (Includes model P118F/HE100) Manual Part Number 12A4171M06 Revision 1 Service Manual 12/08/00...
  • Page 2 NOTICE This manual is the property of the owner of this particular Tube-Ice® machine. Model #____________________ Serial #____________________. It is to be left on the premises with this machine at all times. After start- up, it should be stored in a safe place where it can be readily available when needed for future reference in maintaining troubleshooting or servicing.
  • Page 3 (Medium & Large Machines) Model Number: __________________________ Serial Number: __________________________ This form must be filled out completely and signed by the customer in order to assure acceptance by Vogt. Date of Start-Up: _______________________________ Form Completed By: _____________________________________ AC Condenser Model Number: _____________________...
  • Page 4 ® Vogt ® Tube-Ice Machines Installation, Service Manual and Parts Catalog #12A4171M06 05TA Model...

  • Page 5: Table Of Contents

    Inspection ................................2-1 Safety Valves.................................2-1 Machine Room...............................2-2 Storage (prior to installation and start-up) ......................2-2 Vogt Model Nomenclature, FIGURE 2-1........................2-2 3. INSTALLING YOUR TUBE-ICE MACHINE Piping and Drain Connections, TABLE 3-1 ......................3-1 Space Diagram (Air-Cooled Machine), FIGURE 3-1 ....................3-2 Space Diagram (Water Cooled Machine), FIGURE 3-2 ..................3-3 Wiring and Electrical Connection FIGURE 3-3 ......................3-4...
  • Page 6 05TA Service Manual TABLE OF CONTENTS Page No. 4. HOW YOUR TUBE-ICE MACHINE WORKS Principle of Operation ............................4-1 Freeze Period .................................4-2 Harvest Period ...............................4-2 Piping Nomenclature..............................4-2 Water Cooled Piping Schematic, FIGURE 4-1......................4-3 Air-Cooled Piping Schematic, FIGURE 4-2 ......................4-4 5. START-UP AND OPERATION Refrigeration System Review ..........................5-1 Refrigerant Charge..............................5-1 Start-up Procedure ..............................5-2...
  • Page 7 05TA Service Manual TABLE OF CONTENTS Page 8. TROUBLESHOOTING List Of Symptoms ..............................8-1 Machine Won’t Run...............................8-1, 8-2 Freeze-Up Due To Extended Freezing Period ......................8-2 Freeze-Up Due To Ice Failing To Discharge ......................8-3 Poor Ice Quality ..............................8-3 Low Ice Capacity..............................8-4 Low Compressor Oil Level.............................8-4 High Head Pressure (Water Cooled)........................8-5 High Head Pressure (Air-Cooled)...........................8-5 9.
  • Page 8 05TA Service Manual TABLE OF CONTENTS Page No. Pump Down ................................9-10 Removal Of Refrigerant From Machine........................9-10 Refrigerant Leaks..............................9-11 Non-Condensable Gases............................9-11 Compressor Motor Burnout ............................9-11 Solenoid Valves ..............................9-12 Thawing Gas Solenoid Valve ( “D” Valve), FIGURE 9-6A..................9-12 Liquid Feed Solenoid Valve ( “A1” & “A2” Valve), FIGURE 9-6B................9-12 Circulating Water Pump Motor ..........................9-13 Capacity Control Valve (Compressor Unloader) .....................9-13, 9-14 Copeland Compressor Unloader Valve, FIGURE 9-7....................9-13...

  • Page 9: Introduction

    1. Introduction ® ® TUBE ICE , LLC A Brief History Of Our Company. Henry Vogt Machine Co. was founded as a small machine shop in Louisville, Kentucky in 1880. In 1938, Vogt built the first Tube-Ice ® machine and revolutionized the ice-making industry.

  • Page 10: Important Safety Notice

    05TA Service Manual INTRODUCTION Important Safety Notice. This information is intended for use by individuals possessing adequate backgrounds of electrical, refrigeration and mechanical experience. Any attempt to repair major equipment may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.
  • Page 11 05TA Service Manual INTRODUCTION 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.
  • Page 12 05TA Service Manual INTRODUCTION (51) FREEZER SAFETY VALVE (50) RECEIVER SAFETY VALVE (59) RECEIVER PURGE VALVE 1/4” FLARE (32) CONDENSER SERVICE CONNECTION (101) CHECK VALVE (90) THAWING GAS STOP VALVE (1) CONTROL PANEL (31) RECEIVER GAGE GLASS STOP VALVE (30) RECEIVER GAGE GLASS (88) SUCTION ACCUMULATOR/ HEAT EXCHANGER (18) THAW GAS SOLENOID...
  • Page 13 05TA Service Manual INTRODUCTION (2) FREEZER (91) LIQUID RETURN STOP VALVE (15R) RECEIVER (13) HEAT EXCHANGER (48) COMPRESSOR (46) LIQUID LINE (35) COMPRESSOR DISCHARGE (3) COMPRESSOR (34) COMPRESSOR SUCTION (7) WATER TANK (25) WATER TANK DRAIN FIGURE 1-2 Assembly (Air-Cooled) Rear View 8/13/01...
  • Page 14 05TA Service Manual INTRODUCTION (53) COLD WEATHER SOLENOID VALVE (“X” VALVE) (55) DISCHARGE LINE STOP VALVE (22) FLOAT SWITCH (14) OIL SEPARATOR (34) LIQUID OUTLET STOP VALVE (KING VALVE) FIGURE 1-3 Assembly (Air-Cooled) Right Side View 8/13/01...
  • Page 15 05TA Service Manual INTRODUCTION (41) CONDENSER WATER REGULATOR (51) FREEZER SAFETY VALVE (50) RECEIVER SAFETY VALVE 5/8” FLARE (59) RECEIVER PURGE VALVE 1/4” FLARE (15) CONDENSER (90) THAWING GAS STOP VALVE (1) CONTROL PANEL (31) RECEIVER GAGE GLASS STOP VALVE (88) SUCTION ACCUMULATOR/ HEAT EXCHANGER (30) RECEIVER GAGE GLASS...
  • Page 16 05TA Service Manual INTRODUCTION (2) FREEZER (91) LIQUID RETURN STOP VALVE (15R) RECEIVER (13) HEAT EXCHANGER (48) COMPRESSOR DISCHARGE MUFFLER (46) LIQUID LINE FILTER DRIER (48) COMPRESSOR DISCHARGE SERVICE VALVE (3) COMPRESSOR (48) COMPRESSOR SUCTION SERVICE VALVE (7) WATER TANK (48) WATER TANK DRAIN CONNECTION 1”...
  • Page 17 05TA Service Manual INTRODUCTION (22) FLOAT SWITCH (14) OIL SEPARATOR (58) LIQUID OUTLET STOP VALVE (KING VALVE) FIGURE 1-6 Assembly (Water Cooled) Right Side View 8/13/01...

  • Page 18: Receipt Of Your Tube-Ice Machine

    The machine was shipped with a full charge of refrigerant stored in the receiver. Visually check all lines for mechanical damage. If a leak is suspected, check all joints with a Halogen Leak Detector. All leaks should be reported to the Henry Vogt Machine Co. to obtain authorization for repair. CAUTION The approximate weight of the machine is 2450 pounds.

  • Page 19: Storage (Prior To Installation And Start-Up)

    "NC" - No Condenser "21" - 230-1-60 Product Variation Codes (An alphanumeric designator assigned to specific variations.) "000 or Blank" – Standard Product If unsure of the product code shown on your machine please consult the factory. Figure 2-1 Vogt Model Nomenclature 8/13/01...
  • Page 20 Important Notice. The Warranty Registration / Start-Up Form must be completed and returned to ® Vogt Tube-Ice to initiate and assure a full warranty. A postage paid envelope is provided or you may fax the report to 800-770-8648. Piping and Drain Connections Figure 3-1 (Air Cooled) and 3-2 (Water Cooled) show locations and sizes for all connections.

  • Page 23: Installing Your Tube-Ice Machine

    05TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE Wiring and Electrical Connection WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage ® electrical equipment should be allowed to install or work on the Tube-Ice machine. WARNING Refer to TABLE 3-2 below to properly size wiring connections.
  • Page 24 05TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE Phase Check CAUTION DO NOT attempt to start machine without priming pump and insuring proper rotation of both cutter and pump. Refer to FIGURE 3-1 & 3-2 (space diagram) for connection locations. CAUTION Cutter and pump motor rotation are factory synchronized but must be checked at installation.

  • Page 25: Air-Cooled Condenser Installation Instructions

    COMPRESSOR WARRANTY WILL NOT BE HONORED. WARNING 1. Use only Vogt approved condensers. Any exceptions to this policy must be obtained in writing from Vogt prior to installation and operation of the ice machine. 2. Outdoor condensers must be installed with vertical air flow. Indoor condensers used for heat recovery may be installed with either horizontal or vertical air flow.

  • Page 26: Pounds Of R-22 To Add Vs. Liquid Line Length, Table 3-3

    05TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE 14. When extreme cold conditions are expected or encountered (temperatures below 0°F and wind greater than 15 MPH), it may be necessary to install a protective enclosure around the condenser. Apparatuses such as louvers may also be used for varying conditions. Contact the factory for suggestions.
  • Page 27 05TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE Ice Machine Model 05TA 05TA Electrical Frequency, Hz. Recommended Condenser DD-311 DD-361 Total Heat Rejection (BTU/hr) 181,200 193,250 Fans: Number HP, Each Total CFM 22,000 22,500 Full Load Amps (FLA): 3 ph., 208/230V., 60 hz. 3 ph., 460V., 60 hz.
  • Page 28 05TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-4 Condenser Dimensions (Condenser pictured: DD-231) Note: Dash lines indicate customer supplied piping. FIGURE 3-5 Condenser Field Piping (Cold Weather Valve Kit) 8/13/01...
  • Page 29 05TA Service Manual 3-10 ® INSTALLING YOUR TUBE-ICE MACHINE CONDENSER EQUIVALENT LINE SIZE WORKSHEET Discharge Gas Line O.D. ___________________ Fitting Type Number Used Factor Total Globe Valve (open) Angle Valve (open) 90° Elbow 45° Elbow Feet of Straight Copper Used Total Fitting Factor Total Equivalent Feet Copper Tubing Type “L”...
  • Page 30 05TA Service Manual 3-11 ® INSTALLING YOUR TUBE-ICE MACHINE Air-Cooled Condenser Wiring FIGURE 3-7 Wiring For #DD-311 and #DD-361 Condenser (3 phase motors) Air-Cooled Connections (See FIGURE 3-1 for connection sizes) Follow these procedures to make a tight joint: 1. Silver solder or braze condenser tubing ends to the female Rota-lock connectors. 2.

  • Page 31: Cooling Tower

    05TA Service Manual 3-12 ® INSTALLING YOUR TUBE-ICE MACHINE Cooling Tower. For water cooled machines only. When selecting a cooling tower, careful attention must be given to operating wet bulb conditions. It is advisable to check with your local cooling tower distributor for their recommendations based on actual operating conditions in your area.

  • Page 32: Programming Electronic Bin Thermostat

    05TA Service Manual 3-13 ® INSTALLING YOUR TUBE-ICE MACHINE Programming the Electronic Bin Thermostat The electronic bin thermostat has an LCD readout that displays the temperature in the bin at the sensor. The control has been preset and locked out at the factory to shut the machine down at 38° ° F and to re-start at 40°...

  • Page 33: Installation Review: A Checklist

    05TA Service Manual 3-14 ® INSTALLING YOUR TUBE-ICE MACHINE IMPORTANT Be sure to follow the wiring schematic and electrical specification table when incorporating overloads. This is necessary to provide proper protection ® ® for the Tube-Ice machine and its component parts. IMPORTANT Installation Review: A Checklist.

  • Page 34: How Your Tube-Ice Machine Works

    05TA Service Manual ® HOW YOUR TUBE-ICE MACHINE WORKS ® How Your Tube-Ice Machine Works Principle of Operation For a detailed description of the functions of each control panel component, see Section 6. Operation of the machine is controlled by “Clean/Off/Ice”, “Start” and “Stop” switches located in the control panel of the freezing unit.

  • Page 35: Freeze Period

    05TA Service Manual ® HOW YOUR TUBE-ICE MACHINE WORKS activated. Warm gas from the receiver is discharged into the freezer through valve (18), thereby slightly thawing the outer edge of the ice, which drops on the rotating cutter for sizing. See “Freezer Period and Harvest Period”...
  • Page 36 WATER OUT DISCHARGE CONDENSER WATER IN LIQUID RETURN 2 - FREEZER RECEIVER LIQUID CONTOL PANEL LIQUID LINE HI-LO CUTTER MUFFLER MOTOR 23A-WATER IN SEP. OIL RETURN 25-WATER OUT 6-PUMP WATER TANK...
  • Page 37 FLOW DISCHARGE CONDENSER ETURN 2 - FREEZER CONTROL THAW GAS LIQUID LINE HI-LO VALVE "X" MUFFLE CUTTER 23A-WATER IN 7-WATER TANK SEP. OIL RETURN 25-WATER OUT 6-PUMP 3 - COMPRESSOR...

  • Page 38: Start-Up And Operation

    05TA Service Manual START-UP AND OPERATION 5. Start-Up and Operation The refrigeration system uses R-22 or R-404a refrigerant, a Refrigeration System Review. compressor, a refrigerant float switch, a flooded evaporator (freezer), and warm gas defrost. Following the schematic, notice that during the freeze period of the machine’s cycle, the condenser discharge gas leaves the compressor and goes to the condenser where it is condensed into liquid by the removal of heat by either air or water passing through the condenser.
  • Page 39 05TA Service Manual START-UP AND OPERATION Start-up Checklist. Be sure to complete and return the “Warranty Registration/Start-Up Report” located at the front of the manual. _____ 1. See that water-inlet connections are attached properly. The water inlet shutoff valves for the water tank and condenser should be open. The water level in the water pan should be at a height where the make-up water float valve will be closed when the machine is idle.
  • Page 40 At the termination of the harvest (thaw) period, the machine will begin the freeze period. Be sure to observe several cycles of ice production to confirm the satisfactory operation of the machine. Complete the remaining part of the “Warranty Registration/Start-Up Report” and return it to the Henry Vogt Machine Co. 8/13/01...
  • Page 41 05TA Service Manual START-UP AND OPERATION CAUTION If it should become necessary to add refrigerant to the system, charging valve (28) is provided for this purpose. Be sure to follow all local and federal regulations regarding the handling of refrigerants and their illegal emission into the atmosphere. CAUTION Check the refrigerant level after the machine has operated for a few cycles.

  • Page 42: Operating Tips

    05TA Service Manual START-UP AND OPERATION OPERATING TIPS • If the operation of your machine is not controlled by a timer, bin level control or some other mechanism to automatically start and stop ice production, you should use ONLY the “On/Off” toggle switch to start and stop machine.

  • Page 43: Control Panel (Cover Removed), Figure 6-2

    05TA Service Manual ELECTRICAL CONTROLS 6. Electrical Controls FIGURE 6-1 Control Panel (Cover Removed) 8/13/01...

  • Page 44: Control Panel Components And Part Numbers, Table 6-1

    05TA Service Manual ELECTRICAL CONTROLS Item No. Vogt Part No. Description 12A7516E30 Compressor Motor Contactor (72 Amp, 3 Pole, 208/240V Coil) 12A7518E30 Aux. Contact (3 Amp, 1 NO/1 NC, Side Mount) 12A7518E31 Aux. Contact (3 Amp, 2 NO, Side Mount) 12A7518E32 Aux.
  • Page 45 05TA Service Manual ELECTRICAL CONTROLS Description of Component Function Provides power to the compressor motor. Continuously energized during freezing and thawing. Auxiliary CC – contacts control main power for control circuit components, crankcase heater, control relay and harvest timer. CB1 – Secondary pump/cutter motor protection.
  • Page 46 05TA Service Manual ELECTRICAL CONTROLS FIGURE 6-2 Electrical Schematic All Voltages, 50-60 Hz. 8/13/01...

  • Page 47: Maintenance

    05TA Service Manual MAINTENANCE 7. Maintenance ® Ice Making Section. The ice-making section of the Tube-Ice machine should be cleaned at least twice a year (more often if water conditions cause mineral build-up). Use an approved food-grade ice machine cleaner. The water pump is used to circulate the cleaner through the system by setting the “Clean/Off/Ice”...

  • Page 48: Water Distributors

    05TA Service Manual MAINTENANCE Water Distributors. The water distributors are located under the freezer cover (8) at the top of the freezer. There are 72 distributors used in the models that have a 1 1/2” suffix (i.e., Models 05TA-1 1/2), 102 distributors in models with suffix 1 1/4” (i.e., Models 05TA-1 1/4), and 156 distributors are used in the models have 1”...
  • Page 49 05TA Service Manual MAINTENANCE Non-condensables in system or faulty head pressure gauge? Check standby pressures against refrigerant tables. Incorrectly set or defective water regulator valve? Check its setting and operation. Partly closed compressor discharge service valve? Check its setting. Stem should be backseated.
  • Page 50 CAUTION Chemical Cleaning. Vogt Tube-Ice® makes no recommendation for any particular chemical preparation. The same chemical may not be effective for all situations. a) Use only preparations from an established, reliable source. b) Follow directions exactly, particularly regarding amounts to use, and flushing or neutralizing procedure after cleaning.

  • Page 51: Lubrication

    05TA Service Manual MAINTENANCE These surfaces have been coated with a special material that will give years of protection against corrosion unless damaged. Never use a wire brush or a strong caustic on these surfaces. Flush condenser tubes clear with air, water, or a piece of rag on a stick or wire. In many cases this is all that is required.
  • Page 52 05TA Service Manual MAINTENANCE Cutter Gear Reducer. The oil level for the gear reducer should be checked if there is evidence of a leak. It should be level with the plugged opening in the side of the gear housing. Use Mobile 600W cylinder oil or equal.
  • Page 53 05TA Service Manual MAINTENANCE For The Manager Who Depends Upon This Machine For Efficient Operation. “Preventive Maintenance” simply means that you or a delegated employee makes a daily visual check ® of your Tube-Ice machine. Here is what to look for and why: Daily checklist: 1.
  • Page 54 05TA Service Manual MAINTENANCE Preventive Maintenance Program This form can be removed and duplicated for keeping accurate records. Model # ___________________ Serial # ____________________ Date _____________ Customer/Address ___________________________________________________________ ____________________________________________________________ Mgr. Name ______________________ Service Tech Name __________________________ The following service performed and checked: _____ Last maintenance performed (approx.

  • Page 55: Troubleshooting

    05TA Service Manual TROUBLESHOOTING 8. Troubleshooting NOTE: With the exception of bin control, anytime the machine stops, it must be manually re-started by pushing the "Start" push-button. If it stopped while in a freeze cycle, it will then start in a thawing cycle.
  • Page 56 05TA Service Manual TROUBLESHOOTING SYMPTOM: Machine won't run. POSSIBLE CAUSE POSSIBLE REMEDY Power failure ++ Intermittent power Check electrical fused disconnect or circuit interruption breaker supplying power to the machine. If power has been off, make sure the compressor crankcase heater is energized, the crankcase is warm, and there is no liquid refrigerant in the crankcase prior to running the machine.
  • Page 57 05TA Service Manual TROUBLESHOOTING SYMPTOM: Machine won't run (CONT.) POSSIBLE CAUSE POSSIBLE REMEDY Low oil pressure switch tripped. If the machine stops by low oil pressure cut- out, the switch will have to be manually reset. Check the crankcase oil level. Restart the machine by pushing the "Start"...

  • Page 58: Float Switch

    05TA Service Manual TROUBLESHOOTING SYMPTOM: Freeze-up due to extended freeze period. POSSIBLE CAUSE POSSIBLE REMEDY Freezer pressure switch setting too low. Adjust freezer pressure switch, or replace if defective. See FIGURE 9-1, Section 9. Water tank drain valve (39) open or leaking, or Close valve, repair, or replace as necessary.
  • Page 59 05TA Service Manual TROUBLESHOOTING SYMPTOM: Freeze-up due to ice failing to discharge. POSSIBLE CAUSE POSSIBLE REMEDY Insufficient heat for thawing because of low The head pressure should be maintained at condensing pressure, non-condensables (usually approximately 210 PSIG for R-22 or 250 air) in system, low refrigerant charge, or thaw PSIG for R-404a, which relates to 105 gas pressure switch adjusted too low.
  • Page 60 05TA Service Manual TROUBLESHOOTING SYMPTOM: Low ice capacity. POSSIBLE CAUSE POSSIBLE REMEDY Low refrigerant charge. Check for and repair leaks, and add refrigerant. Restriction in liquid line. Check for a partially closed valve or an obstruction at the drier, strainer, solenoid valve, or expansion valve.
  • Page 61 05TA Service Manual TROUBLESHOOTING SYMPTOM: Low compressor oil level. POSSIBLE CAUSE POSSIBLE REMEDY Oil separator not returning oil. Check oil separator float and oil return stop valve (70) and line for a restriction. The oil return line should above ambient temperature most of the time as it returns oil.
  • Page 62 05TA Service Manual TROUBLESHOOTING SYMPTOM: Poor ice quality. POSSIBLE CAUSE POSSIBLE REMEDY Excessive concentration of solids in the water Perform a cleaning procedure as well as tank usually indicated by a build-up of mineral removing the freezer cover and cleaning the deposits on the sides and bottom of the tank.
  • Page 63 05TA Service Manual TROUBLESHOOTING SYMPTOM: High head pressure. (Water cooled machine) POSSIBLE CAUSE POSSIBLE REMEDY Misadjusted or defective water regulating valve Adjust or replace the valve. Never adjust the valve stem as far open as it will turn, because it will not close when the head pressure drops.
  • Page 64 05TA Service Manual 8-10 TROUBLESHOOTING SYMPTOM: High head pressure (Air-cooled machine). POSSIBLE CAUSE POSSIBLE REMEDY Condenser fan(s) not running. Defective motor, fan control switch, fan contactor, or tripped circuit breaker in control panel (CB2) Replace defective part. Check condenser fan disconnect for thrown switch, or blown fuse.
  • Page 65 05TA Service Manual SERVICE OPERATIONS 9. Service Operations Adjustable Blowdown (for clearer ice). A petcock is installed on the overflow of the water pump to provide means for obtaining blowdown from the water tank during the freezing period. The petcock was set at the factory to discharge enough water during the freeze cycle to produce clear ice. After installation it should be adjusted to the minimum rate required to maintain clear ice and checked after a few days of ice making.
  • Page 66 05TA Service Manual SERVICE OPERATIONS This switch was set at the factory to produce ice of recommended thickness. Look at the “Certificate of Test” which was provided with the machine for a sample set of pressure readings with corresponding time periods and water temperatures. Also see TABLE 10-6, Operating Vitals for typical settings.
  • Page 67 05TA Service Manual SERVICE OPERATIONS It is preferable that the freezing cycle be such that a small diameter hole remains in the center of the ice cylinder. (1/16” diameter for 7/8” diameter ice, 1/8” diameter for 1 1/8” diameter ice, 1/4” diameter for 1 3/8”...

  • Page 68: Head Pressure

    05TA Service Manual SERVICE OPERATIONS Turn the adjusting screws clockwise to raise the pressure setting. Turn counter-clockwise to lower the setting. Adjust the switch to the indicated pressure settings and test with an accurate gage to be sure the switch functions properly before installation. Head Pressure.
  • Page 69 05TA Service Manual SERVICE OPERATIONS The solid state sensor protectors provide excellent protection against high motor temperatures resulting from locked rotor, loss of charge, or motor overload. The combination of low voltage sensing and time delay provide positive protection against low voltage conditions which can occur in the pilot circuit in the event of a single phase condition on a three phase circuit.
  • Page 70 05TA Service Manual SERVICE OPERATIONS Electronic Motor Protector Field Trouble Shooting. In the event the motor compressor is inoperable or is not operating properly, the solid state control circuit may be checked as follows: 1. If the compressor has been operating and tripped on the protector, allow the compressor to cool for at least one hour before checking.
  • Page 71 05TA Service Manual SERVICE OPERATIONS FIGURE 9-4 Sentronic Oil Pressure Safety Control. All Sentronics utilize a pressure sensor and an electronic control module to precisely measure oil pump differential pressure. The main advantage of Sentronic is the elimination of the traditional capillary tubes, bellows, and pressure connections that mechanical pressure switches require to measure differential oil pressure.
  • Page 72 05TA Service Manual SERVICE OPERATIONS A second advantage of Sentronic is in the use of a precise electronic clock for the two minute time out circuit. Traditional mechanical controls use resistance heaters to provide the time to trip in the event of low oil pressure.

  • Page 73: Thawing Timer

    05TA Service Manual SERVICE OPERATIONS FIGURE 9-5 Thawing Timer Thawing Timer. The thawing timer 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 (FPS) which energizes the “CR”...
  • Page 74 05TA Service Manual 9-10 SERVICE OPERATIONS Pumpdown. The function of the pumpdown is to transfer all the liquid refrigerant from the freezer (evaporator) into the receiver. Pump-down should only be performed when the freezer is clear of ice. Its main purposes are: To check the total refrigerant charge.
  • Page 75 05TA Service Manual 9-11 SERVICE OPERATIONS WARNING It is not recommended that refrigerant be transferred from a refrigeration system into a cylinder. If such a transfer is made, the refrigerant cylinder must be an approved CLEAN cylinder-- free of any contaminants or foreign materials--and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements.
  • Page 76 05TA Service Manual 9-12 SERVICE OPERATIONS Whenever there is a compressor failure due to a motor burnout, it is important that they system be thoroughly cleaned before replacing the damaged compressor or otherwise the new compressor may also be damaged. Solenoid Valves.
  • Page 77 05TA Service Manual 9-13 SERVICE OPERATIONS Capacity Control (Internal) Valve Construction. A schematic illustration of the internal valve operation is shown in FIGURE 9-7. In the normal (full capacity) operating position with the solenoid valve de-energized, the needle valve is seated on the lower port, and the unloading plunger chamber is exposed to suction pressure through the suction port.

  • Page 78: Cutter Gear Reducer

    05TA Service Manual 9-14 SERVICE OPERATIONS Cutter Motor. The cutter motor’s bearings are prelubricated and sealed and require no further lubrication. If the motor needs replacing, proceed as follows: 1. Turn power off and lock out disconnect. 2. Check terminals with volt meter to confirm power is off. 3.
  • Page 79 05TA Service Manual 9-15 SERVICE OPERATIONS 9. Be sure the gear and hub is properly positioned on the shaft so it will have a full vertical mesh with the cutter ring gear. 10. Final gear meshing should be adjusted so there is only a slight amount of play between the ring gear and drive.
  • Page 80 05TA Service Manual 9-16 SERVICE OPERATIONS 8. Loosen and remove the three cap screws from the bearing support ends and lift the support out of the water tank. 9. Drive the 3/16” x 1/2” pin located in the side of the support hub in and through the bearing wall. 10.
  • Page 81 05TA Service Manual 9-17 SERVICE OPERATIONS FIGURE 9-8 Cutter Assembly FIGURE 9-9 Cutter Parts (cylinder ice) 8/13/01...
  • Page 82 05TA Service Manual 9-18 SERVICE OPERATIONS FIGURE 9-10 Cutter Drive Parts 8/13/01...
  • Page 83 05TA Service Manual 9-19 SERVICE OPERATIONS FIGURE 9-11 Cutter Parts (crushed ice option) 8/13/01...
  • Page 84 05TA Service Manual 9-20 SERVICE OPERATIONS ® Crushed Ice Production. Your 05TA Tube-Ice machine is capable of producing crushed ice with no loss of capacity. However, there are certain changes to be made in order to convert to crushed ice production: Add: 1.
  • Page 85 05TA Service Manual 10-1 OPTIONS AND ACCESSORIES 10. Options and Accessories PLC (Programmable Logic Controller) ---------------- Page 10-2 Power Monitor ---------------------------------------------- Page 10-14 8/13/01...
  • Page 86 05TA Service Manual 10-2 OPTIONS AND ACCESSORIES PLC (Programmable Logic Controller) This section of the service manual applies only to 05TA models equipped with a Mitsubishi Fx programmable controller and 10DUE operator interface. The PLC version of the 05TA enhances the operation of the standard version by providing: Selectable automatic restart after a power failure, choice of timed or pressure switch controlled freeze cycles, programmable blowdown adjustment, diagnostic indicators, power failure indication, alarm relay, built in cutter delay, programmable...
  • Page 87 05TA Service Manual 10-3 OPTIONS AND ACCESSORIES Automatic Restart. 05TA machines are equipped with a power failure relay. This relay prevents the machine from automatically restarting in the event of a power failure. The machine should have power on the crankcase heater for a minimum of two hours before it is restarted with the start switch. The PLC allows the user to select between having to restart the machine manually or restarting automatically, two hours after power is restored.
  • Page 88 05TA Service Manual 10-4 OPTIONS AND ACCESSORIES hole in the ice, however the weight per cycle should remain relatively constant from cycle to cycle. The PLC uses this information coupled with the freeze and harvest times to report the capacity based on the last cycle in lbs of ice per day.
  • Page 89 05TA Service Manual 10-5 OPTIONS AND ACCESSORIES The operator interface displays two lines of text, however the message or instructions may be longer than can be displayed on two lines. The rest of the text can be accessed by pressing the up and down arrows (scrolling).
  • Page 90 05TA Service Manual 10-6 OPTIONS AND ACCESSORIES When the machine is pumping down the operator interface will indicate “PUMPING DOWN”. During the pumpdown sequence the compressor is running and the liquid feed valve (A-Valve) is closed. The machine will complete one harvest cycle then the compressor will continue to run until the freezer pressure reaches the low pressure safety switch setting.
  • Page 91 05TA Service Manual 10-7 OPTIONS AND ACCESSORIES MACHINE FAULTS Hi/Low Pressure. The interface will display the message shown below if the combination high/low pressure safety switch opens. The machine will stop immediately. FAULT:HI/LOW RESET “A” FOR RESTART B=SILENCE ALARM When the low pressure switch resets or the manual reset button for the high pressure safety is depressed and the pressure is in the acceptable range, the interface will display “PRES OK”.
  • Page 92 05TA Service Manual 10-8 OPTIONS AND ACCESSORIES Compressor Overload: The interface will display the message shown below if the compressor motor safety overload switch opens. The machine will stop immediately. The compressor overload will reset automatically after the compressor has time to cool off. FAULT:COMP OL FAULT:COMP OL WAIT...
  • Page 93 05TA Service Manual 10-9 OPTIONS AND ACCESSORIES CHANGING THE SETUP VALUES Several operating parameters of the machine can be modified. The set up screen must be accessed to make any modifications. The set up screen can be accessed by pressing the “C” button on the operator interface.
  • Page 94 05TA Service Manual 10-10 OPTIONS AND ACCESSORIES From the set up screen two additional screens can be displayed by pressing “B” on the operator interface. These two screens are refereed to as monitor screens. The first screen displays the cycles and lbs of ice produced since the operator has reset the counter.
  • Page 95 05TA Service Manual 10-11 OPTIONS AND ACCESSORIES FIGURE 10-3 Control Panel Parts 8/13/01...
  • Page 96 05TA Service Manual 10-12 OPTIONS AND ACCESSORIES * (CMS) Compressor Motor Contactor Provides power to the compressor motor. Continuously energized during freezing and thawing. Auxiliary contact to provide power to oil pressure control and de-energize crankcase heater. * (CB1) Circuit Breaker Secondary pump/cutter motor protection.
  • Page 97 05TA Service Manual 10-13 OPTIONS AND ACCESSORIES FIGURE 10-4 Wiring Schematic 8/13/01...
  • Page 98 OPTIONS AND ACCESSORIES Power Monitor All Vogt Tube-Ice machine models are available from the factory with a three phase line voltage power monitor with LCD display. The units are also available for after market or retrofit installation. These units monitor line voltage inputs from 190 to 610 volts and provide protection against line voltage variances that can damage or destroy the compressor motor.
  • Page 99 05TA Service Manual 10-15 OPTIONS AND ACCESSORIES Phase Unbalance Use the arrow keys to set the Phase Unbalance percentage (2 to 20%) of incoming 3 Phases. This will turn off equipment for a specified time if incoming Phase Unbalance exceeds set percentage. The Default is 5% which is the recommended value for normal operation.
  • Page 100 05TA Service Manual 10-16 OPTIONS AND ACCESSORIES Contrast Adjustment When the SETUP, READ and FAULT LED’s are all off the unit is in the monitor mode. While in the monitor mode the UP and DOWN arrow keys will control the display contrast. NOTE: LCD display contrast will vary with changes in ambient temperature, and under extreme temperature conditions the LCD display may be dark or clear.
  • Page 101 05TA Service Manual 10-17 OPTIONS AND ACCESSORIES Wiring The power monitor should be wired to the “line” and “load” side of the compressor contactor with 1 amp fused connections. The connections labeled “control” should be wired to a 230 volt power source.
  • Page 102 05TA Service Manual 10-18 OPTIONS AND ACCESSORIES Troubleshooting SYMPTOM DISPLAY LED’s SOLUTION Load will not energize. System on line. LOAD LED not Check control input. lit. Parameters will not change when Indicates Normal. Parameters are locked out. See “Locking arrows pressed. parameters when Out Setup Menu”.
  • Page 103 05TA Service Manual 11-1 TABLES & CHARTS 11. Tables & Charts 8/14/01...
  • Page 104 (4) Condenser flow rate is for 85°F entering water temperature and 100°F condensing. (5) Tower sized for 80°F wet bulb temperature. (6) Recommended air-cooled condenser is based on 15°F TD. Vogt reserves the right to change designs and specifications without notice. Table 11-1 8/14/01...
  • Page 105 (4) Condenser flow rate is for 85°F entering water temperature and 100°F condensing. (5) Tower sized for 80°F wet bulb temperature. (6) Recommended air-cooled condenser is based on 15°F TD. Vogt reserves the right to change designs and specifications without notice. Table 11-2 8/14/01...
  • Page 106 05TA Service Manual 11-4 TABLES & CHARTS 05TA Capacity Ratings Makeup Rated Capacity (lbs/day) Water 60Hz 50Hz Temp. Cylinder Crushed Cylinder Crushed (°F) 1" 1 1/4" 1 1/2" 1" 1 1/4" 1 1/2" 1" 1 1/4" 1 1/2" 1" 1 1/4" 1 1/2" 13000 11800 11100...
  • Page 107 05TA Service Manual 11-5 TABLES & CHARTS Condenser Water Usage 05TA Condensing Entering Water Leaving Water Water Flow Pressure Average Drop Total Heat Temp. °F Temp. °F Temp. °F of Rejection 170,000 170,000 170,000 170,000 170,000 170,000 170,000 170,000 170,000 170,000 Table 11-4 Make-Up Water Usage (gpm)
  • Page 108 05TA Service Manual 12-1 INDEX 12. Index Condenser, Water Cooled Maintenance ------------------------- 7-4 A Valve (Liquid Feed) ---------------------------------- 4-1, 5-1, 9-12 Control Circuit Protection-------------------------------------------- 9-9 Accumulator ------------------------------------------------------4-1, 5-1 Control Panel----------------------------------------------------------- 6-1 Adding Refrigerant-----------------------------------------------------5-4 Control Panel Parts --------------------------------------------------- 6-2 Air - cooled Condenser Wiring (3 phase) ---------------------- 3-12 Control, Relay (CR)--------------------------------------------------- 6-2 Air-Cooled Condenser ------------------------------------------------9-9 Cooling Tower --------------------------------------------------------- 3-1...
  • Page 109 Non-Condensable Gases ------------------------------------------ 9-11 Symptoms, Troubleshooting---------------------------------------- 8-1 Normal Operating Vitals -------------------------------------------- 11-6 Note To Manager-------------------------------------------------------7-7 Technical Service Bulletin (Water Quality) --------------------9-20 Telephone Number, Vogt-------------------------------------------- 1-1 Oil Pressure Safety Control------------------------------------------9-8 Temperature-Pressure Chart--------------------------------------11-8 On/Off Switch ----------------------------------------------5-3, 5-5, 6-2 Thawing, Chamber --------------------------------------------------- 4-2...
  • Page 110 HE100 Series Service Manual 12-3 INDEX Unloader - Loaded Operation (Freeze Period) ---------------- 9-13 Vitals, Operation------------------------------------------------------ 11-6 W arranty (Basic Product) ------------------------ inside back cover W ater Conditioning ---------------------------------------------------3-1 W ater Cooled Condenser --------------------------------------3-1, 7-2 W ater Cooled Condenser Cleaning -------------------------------7-4 W ater Cooled Machine, Installation--------------------------------3-1 W ater Cooled Piping Schematic------------------------------------4-3 W ater Cooled Units----------------------------------------------------9-4...
  • Page 111 05TA Service Manual 12-4 INDEX 8/13/01...

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