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Vogt TUBE-ICE 03TB Service Manual

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03TB
TUBE-ICE
®
MACHINE
(Includes models HE60 & P112F)
Part Number 12A4171M07
Revision 3
Service Manual
$50
00
2/18/16

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Summary of Contents for Vogt TUBE-ICE 03TB

  • Page 1 03TB TUBE-ICE ® MACHINE (Includes models HE60 & P112F) Part Number 12A4171M07 Revision 3 Service Manual 2/18/16...
  • Page 2 Form MUST be completed and returned to the factory promptly after the official start-up. Product Registration Form is located in the Owners Packet or can be found online at www.vogtice.com/registration.htm. ® Please return to: VOGT ICE , LLC Suite #19 1000 W. Ormsby Ave. Louisville, KY 40210...
  • Page 3 ® ® ® ® VOGT ICE , LLC, located in Louisville, Kentucky since 1880. Sales - (800) 959-8648 Service - (502) 635-3000 Parts - Your Local Distributor Call your local distributor first for all of your parts and service needs.
  • Page 4 ® Vogt ® Tube-Ice Machines Installation, Service Manual and Parts Catalog #12A4171M07 03TA Model Revision 3.0...

  • Page 5: Table Of Contents

    MACHINES Model 03TA Page No. 1. INTRODUCTION A Brief History of Our Company ..........................1-1 Vogt Energy-Savings Tube-Ice® Machines ........................1-1 Preview ..................................1-1 Important Safety Notice ..............................1-2 Special Precautions To Be Observed When Charging Refrigeration Systems ............... 1-2 Safety Symbols and What They Mean ...........................
  • Page 6 03TA Service Manual TABLE OF CONTENTS Page No. 3. INSTALLING YOUR TUBE-ICE MACHINE (Cont.) Condenser Equivalent Line Size Worksheet ........................3-15 Equivalent Feet Due To Friction, TABLE 3-5 ....................... 3-15 Minimum Traps For Discharge Lines, FIGURE 3-9 ..................... 3-15 Air-Cooled Condenser Wiring ............................3-16 Wiring for 2 Fan Condenser, FIGURE 3-10 ........................
  • Page 7 03TA Service Manual TABLE OF CONTENTS Page No. 7. MAINTENANCE Ice-Making Section ................................ 7-1 Cleaning Procedure ................................ 7-1 Sanitizing Procedure ..............................7-2 Water Distributors ................................. 7-3 Water Tank ..................................7-3 Water-Cooled Condensers, Checking Operation ......................7-3 Water-Cooled Condensers, Draining ..........................7-4 Water-Cooled Condenser Cleaning ..........................
  • Page 8 03TA Service Manual TABLE OF CONTENTS Page No. 9. SERVICE OPERATIONS (Cont.) Oil Separator, FIGURE 9-6 ............................9-6 Solenoid Valve ................................9-5 Solenoid Valve (“D” & "X" Valve Before Aug 2006), FIGURE 9-7A ................. 9-6 Solenoid Valve (“D” & "X" Valve After Aug 2006), FIGURE 9-7B ................9-6 Solenoid Valve (“A”...
  • Page 9 03TA Service Manual TABLE OF CONTENTS Page No. 11. TABLES AND CHARTS 03TA Ratings (60 Hz., 7.5 HP), TABLE 11-1 ....................... 11-1 03TA Ratings (50 Hz., 10 HP), TABLE 11-1 ........................ 11-1 03TA Capacity Ratings, TABLE 11-2 ........................... 11-2 03TA Condenser Water Usage, TABLE 11-3 ....................... 11-3 03TA Make-up Water Usage, TABLE 11-4 ........................
  • Page 10 Blank page 5/24/11...

  • Page 11: Introduction

    ® ® ® ® VOGT 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 12: Important Safety Notice

    03TA 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 13 03TA 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 14 03TA Service Manual INTRODUCTION FIGURE 1-1 Assembly (Air-Cooled) Front View 4/21/14...
  • Page 15 03TA Service Manual INTRODUCTION FIGURE 1-2 Assembly (Air-Cooled) Rear View 4/21/14...
  • Page 16 03TA Service Manual INTRODUCTION FIGURE 1-3 Assembly (Air-Cooled) Right Side View 4/21/14...
  • Page 17 03TA Service Manual INTRODUCTION FIGURE 1-4 Assembly (Water Cooled) Front View 4/21/14...
  • Page 18 03TA Service Manual INTRODUCTION FIGURE 1-5 Assembly (Water Cooled) Rear View 4/21/14...
  • Page 19 03TA Service Manual INTRODUCTION FIGURE 1-6 Assembly (Water Cooled) Right Side View 4/21/14...
  • Page 20 03TA Service Manual 1-10 INTRODUCTION BLANK 4/21/14...

  • Page 21: 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 Vogt Ice , LLC to obtain authorization for repair. CAUTION The approximate weight of the machine is 2000 pounds.

  • Page 22: 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 3/31/14...

  • Page 23: Installing Your Tube-Ice Machine

    03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE 3. Installing Your Tube-Ice ® Machine WARNING Only service personnel experienced and certified in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work ® on this Tube-Ice machine.
  • Page 24 03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE ® FIGURES 3-2 & 3-3 illustrate two methods of lifting & setting Tube-Ice machine on an ice storage bin. CAUTION The approximate weight of the machine is 2000 pounds. Always use equipment with adequate load-carrying capacity. CAUTION REMOVE CASINGS FROM MODEL HE60 BEFORE PLACING MACHINE ON BIN...
  • Page 25 03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE REMOVE CASINGS FROM MODEL HE60 BEFORE PLACING MACHINE ON BIN ROPE OR STRAPS TUBE-ICE MACHINE ICE STORAGE BIN FIGURE 3-3 Forklift-&-Rope or Lifting Straps Method You need: extra head room forklift with adequate load and height capacities 1/2”...

  • Page 26: Connections And Space Diagram (Air-Cooled Machine), Figure 3-4

    03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-4A Connections and Space Diagram (Air Cooled Machine) 4/2/14...

  • Page 27: Connections And Space Diagram (Water-Cooled Machine), Figure 3-5

    03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-4B Connections and Space Diagram (Water Cooled Machine)

  • Page 28: Piping And Drain Connections

    03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE Piping and Drain Connections Figure 3-4A (Air Cooled) and 3-4B (Water Cooled) show locations and sizes for all connections. CAUTION External shut-off valves must be provided in the water inlet lines. The minimum inlet water pressure for satisfactory operation of the machine is 30 psig. The maximum allowable pressure is 100 psig.

  • Page 29: Cooling Tower

    03TA Service Manual ® INSTALLING YOUR TUBE-ICE MACHINE Water-Cooled Connections Connect water supply to the water regulator valve on condenser water inlet connection (bottom connection on condenser). Connect the condenser water out line to the top connection on the condenser. 1 1/4”...

  • Page 30: Wiring And Electrical Connection

    03TA 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 31: Phase Check

    03TA 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 3-4A & 3-4B (space diagram) for connection locations. CAUTION Cutter and pump motor rotation are factory synchronized but must be checked at installation.

  • Page 32: 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 33 Recommended condensers provide the indicated total heat rejection at 90°F ambient, 100°F condensing. Vogt Ice, LLC is not responsible for head pressure problems if other than the recommended condensers are used. For continuous operation at ambient temperature above 105°F, consult the factory about using a larger condenser.

  • Page 34: Air-Cooled Condenser Data

    03TA Service Manual 3-12 ® INSTALLING YOUR TUBE-ICE MACHINE Ice Machine Model 03TA (Standard) 03TA (High Ambient) Electrical Frequency, Hz. 60/50 60/50 Recommended Condenser BNHS02A011 BNHS02A011(12) Total Heat Rejection (BTU/hr) 157,500 / 144,900 172,500 / 159,700 Fans: Number HP, Each 1 1/2 Total CFM 20,500...

  • Page 35: Condenser Dimensions, Figure 3-7

    03TA Service Manual 3-13 ® INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-7 Condenser Dimensions Machine Bohn Part # Vogt Part # Coil Split P112 (Standard) BNHS02A011 12A2115B07 50/50 P112 (High Ambient) BNHS02A011(12) 12A2115B08 50/50 Note: Condensers listed above are 200/208/230V, 50/60hz. 400/460V, 50/60hz available...

  • Page 36: Installing Your Tube-Ice Machine (Cont.)

    03TA Service Manual 3-14 ® INSTALLING YOUR TUBE-ICE MACHINE Note: Liquid return lines are customer supplied. The Check Valve in the return line (labeled “Output Liquid Return Line”) is supplied with the condenser. FIGURE 3-8 Condenser Field Piping / 50-50 Coil Split 4/21/14...

  • Page 37: Condenser Equivalent Line Size Worksheet

    03TA Service Manual 3-15 ® 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 Tube O.D.

  • Page 38: Air-Cooled Condenser Wiring

    03TA Service Manual 3-16 ® INSTALLING YOUR TUBE-ICE MACHINE Air-Cooled Condenser Wiring FIGURE 3-10 Wiring For BOHN BNHS02A011/BNHS02A011(12) with Cold Weather Valve and Two Fan, 50/50 Condenser Split 4/21/14...

  • Page 39: Air-Cooled Connections

    LOCAL AND NATIONAL CODE. VALVE REPLACEMENT SHOULD BE MADE BY PROPERLY TRAINED PERSONNEL ONLY. NOTE: IF RELIEF VALVE DISCHARGES, VALVE MUST BE REPLACED AFTER DISCHARGING BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED. CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES. PHONE: 502-635-3000...

  • Page 40: Ice Bin Thermostat Sensor Installation

    03TA Service Manual 3-18 ® INSTALLING YOUR TUBE-ICE MACHINE Ice Bin Thermostat Sensor Installation Each machine is equipped with an electronic ice bin thermostat. To assure proper protection for the machine, the sensor of the ice bin thermostat must be located so that ice will contact it when the bin is full (See FIGURE 3-11).

  • Page 41: Programming The Electronic Ice Bin Thermostat

    03TA Service Manual 3-19 ® 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 42: Storing Ice

    03TA Service Manual 3-20 ® INSTALLING YOUR TUBE-ICE MACHINE Storing Ice. When storing ice in a bin, make sure the bin control sensors are mounted in the bin properly. Dual ice machines require a storage bin with a divider and must have two bin controls. A machine making one type of ice will not have a bin divider and will require only one bin control.

  • Page 43: Installation Review : A Checklist

    03TA Service Manual 3-21 ® 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 44 Blank page 5/24/11...

  • Page 45: How Your Tube-Ice Machine Works

    03TA 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. “Clean/Off/Ice”, “Start” and “Stop” switches located in the control panel of the freezing unit control operation of the machine.

  • Page 46: Freeze Period

    03TA Service Manual ® HOW YOUR TUBE-ICE MACHINE WORKS discharge line, and a check valve (101) in the liquid return line to the receiver. These valves prevent the migration of refrigerant to the condenser when the machine is not operating. ®...

  • Page 47: Water-Cooled Piping Schematic, Figure 4-1

    03TA Service Manual ® HOW YOUR TUBE-ICE MACHINE WORKS FIGURE 4-1 Water-Cooled Piping Schematic 4/11/2014...

  • Page 48: Air-Cooled Piping Schematic, Figure 4-2

    03TA Service Manual ® HOW YOUR TUBE-ICE MACHINE WORKS FIGURE 4-2 Air-Cooled Piping Schematic 3/31/2014...

  • Page 49: Start-Up And Operation

    03TA Service Manual START-UP AND OPERATION 5. Start-Up and Operation Refrigeration System Review. The refrigeration system uses R-22 or R-404a refrigerant, a 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 compressor 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 50: Start-Up Checklist

    03TA 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 and outlet 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 51: Start-Up

    At the termination of the harvest period, the machine will begin the freeze period. NOTE: 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 Vogt Ice LLC. 3/31/2014...

  • Page 52: Adding Refrigerant

    03TA 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.

  • Page 53: Operating Tips

    03TA 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 “Clean/Off/Ice”...
  • Page 54 Blank page 5/24/11...

  • Page 55: Control Panel Figure 6-1

    03TA Service Manual ELECTRICAL CONTROLS 6. Electrical Controls FIGURE 6-1 Control Panel (Standard) 3/31/14...
  • Page 56 03TA Service Manual ELECTRICAL CONTROLS FIGURE 6-2 Control Panel Components (Standard) 4/17/14...
  • Page 57 03TA Service Manual ELECTRICAL CONTROLS OPTIONAL POWER MONITOR LOCATED ON BACK OF ENCLOSURE DOOR. SWITCHES LOCATED ON OUTSIDE OF CONTROL PANEL DOOR FIGURE 6-2A Control Panel Door (Standard) and Optional Power Monitor 3/31/14...
  • Page 58 03TA Service Manual ELECTRICAL CONTROLS FIGURE 6-2B Control Panel Components (CE & Australian Approved) 3/31/14...
  • Page 59 03TA Service Manual ELECTRICAL CONTROLS Item No. Vogt Part No. Description 12A7518E33UL Aux Trip Indicator, 6A, 1NO / 1NC 12A2117G09 Bin Thermostat Control Circuit Breaker, 6 Amp, 2 Pole (400V & 460V 12A7515E22 machines only) 12A7516E33 Compressor Motor Contactor (85 Amp, 3 Pole) 12A7518E30 Aux.

  • Page 60: Description Of Control Panel Component Function, Table 6-2

    03TA Service Manual ELECTRICAL CONTROLS Description of Component Function Auxiliary trip indicator for manual motor starters. Switches when cutter or pump motor starter AX – trips. Overload and short circuit protection for control circuit and crankcase heater. (400/460V machines CB2 – only) Provides power to the compressor motor.
  • Page 61 03TA Service Manual ELECTRICAL CONTROLS FIGURE 6-3 Electrical Schematic All Voltages, 50-60 Hz. 3/31/14...
  • Page 62 03TA Service Manual ELECTRICAL CONTROLS FIGURE 6-4 Compressor Schematic Detail All Voltages, 50-60 Hz. 3/31/14...

  • Page 63: Maintenance

    03TA 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 64: Sanitizing Procedure

    03TA Service Manual MAINTENANCE Sanitizing Procedure 1. After pumping machine down, set “Clean/Off/Ice” selector switch (SS) to the “Off” position. 2. Remove ice from storage area. 3. Shut off water supply and drain water tank (7) by opening drain valve (39). Remove any loose sediment from tank.

  • Page 65: Water Distributors

    (one in each tube) may then be removed with pliers for cleaning. Use pliers on the distributor’s top part with a twisting upward motion. Note: When re-installing distributors on the outside row, make sure holes are away from the gasket Vogt Part # Size Ice Number of Tubes...

  • Page 66: Water-Cooled Condenser Cleaning

    03TA Service Manual MAINTENANCE It is advisable to double-check the system to make sure that fouling is actually causing the trouble. High head pressure alone does not mean a fouled condenser. The following possibilities should always be checked before cleaning is undertaken: Non-condensables in system or faulty head pressure gauge? Check standby pressures against refrigerant tables.
  • Page 67 03TA Service Manual MAINTENANCE 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 68: Lubrication

    03TA Service Manual MAINTENANCE Any type tool to be considered should be tried first on a piece of copper tubing held in a vise or flare block. Nylon, brass, or copper brushes are recommended. If any flakes of copper appear or if score marks are made inside the tube, the tool should not be used.

  • Page 69: Cutter Gear Reducer

    03TA Service Manual MAINTENANCE Compressor Oil Charge (oz) 3DE3R & 3DEHR 3DP3R & 3DPHR TABLE 7-3 Compressor Oil Capacity An oil pump should be used to force any oil that may be required into the system. Oil may be added to the compressor through the low pressure test connection adjacent to the high/low pressure switch or through the compressor suction service valve.

  • Page 70: Preventive Maintenance

    BEFORE REPLACING RELIEF VALVE, REVIEW REQUIREMENTS PER CURRENT LOCAL AND NATIONAL CODE. NOTE: IF RELIEF VALVE DISCHARGES, VALVE MUST BE REPLACED BECAUSE SETTING OR SEAT TIGHTNESS MAY BE ALTERED. CONTACT VOGT ICE PARTS DEPARTMENT FOR REPLACEMENT VALVES. PHONE: 502-635-3000 3/31/14...

  • Page 71: Note To Manager Or Owner

    03TA 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 72: Preventive Maintenance Program

    03TA Service Manual 7-10 MAINTENANCE Note To Manager or Owner: This page is a complete Preventive Maintenance Schedule that should be performed each 90 days. The Preventive Maintenance page may be copied and given to your service person. It should be signed, dated, and returned to you for permanent record.

  • Page 73: Troubleshooting

    03TA 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 74 03TA 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 75 03TA 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 cutout, the switch will have to be manually reset. Check the crankcase oil level. Restart the machine by pushing the "Start"...
  • Page 76 03TA 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 9-3, Section 9. Water tank drain valve (39) open or leaking, or Close valve, repair, or replace as necessary.
  • Page 77 03TA 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 approximately 210 PSIG for R-22 or 250 (usually air) in system, low refrigerant charge, PSIG for R-404a, which relates to 105 or thaw gas solenoid valve stuck closed.
  • Page 78 03TA 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 79 03TA 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 80 03TA 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 81 03TA Service Manual TROUBLESHOOTING SYMPTOM: High head pressure. (Water-cooled machine) POSSIBLE CAUSE POSSIBLE REMEDY Misadjusted or defective water regulating Adjust or replace the valve. Never adjust the valve valve stem as far open as it will turn, because it will not close when the head pressure drops. Insufficient water supply.
  • Page 82 03TA 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. Replace defective part. Check condenser fan disconnect for thrown switch, or blown fuse. Replace fuse and reset switch. If the condenser is split, check the normally open solenoid valve to make sure it is open;...

  • Page 83: Service Operations

    03TA 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.

  • Page 84: Thermal Expansion Valve, Figure 9-2

    If considerably less ice than shown in TABLE 11-5 is being produced per discharge, check the water supply, circulating water pump, water distributors, liquid line valve, refrigerant level, freezer pressure switch and all other avenues BEFORE changing the factory setting of the expansion valve. Vogt Part #: 12A4200C0503 FIGURE 9-2 Thermal Expansion Valve Superheat.

  • Page 85: Freezer Pressure Switch

    Also see TABLE 10-6, Operating Vitals for typical settings. Do not make adjustments until several ice discharging cycles have been completed. Vogt Part #: 12A2117E04 Turn top screw to adjust the pressure setting (also referred to as the Range)

  • Page 86: High-Low Pressure Switch

    Set at 52 PSIG (R-404A) (CW Raises Setting) (CW Raises Setting) Reset Button High Pressure Adjustment Set at 300 PSIG (R-22) Vogt Part #: 12A2117D02 Set at 350 PSIG (R-404A) (CW Raises Setting) Differential Factory Set Low Pressure Test Connection...

  • Page 87: Air-Cooled Units

    Set at 200 PSI (R-22) Set at 250 PSIG (R-404A) Set at 235 PSI (R-404A) (CW Lowers Setting) (CW Lowers Setting) Vogt Part #: 12A4200E1001 Cut Out Adjusting Screw Set at 190 PSIG (R-22) Set at 230 PSIG (R-404A) (CW Raises Setting) 1 1/4”...
  • Page 88 This means the stem is backed all the way out. Correct direction of stem rotation should be labeled on the stem seal nut. Replacement Coil – MKC-2 Vogt Part #: 12A2105C16 Sporlan 1 1/8” Solenoid Valve Vogt Part #: 12A4200A0904 Rebuild Kit –...

  • Page 89: Compressor Crankcase Heater

    03TA Service Manual SERVICE OPERATIONS Vogt Part #: 12A7509E12 Compressor Crankcase Heater. When electrical power is supplied to terminals L1, L2 & L3 of the control panel, the crankcase heater is energized when the machine is not operating. It is de-energized when the compressor is operating.

  • Page 90: Sentronic Oil Pressure Safety Control

    03TA Service Manual SERVICE OPERATIONS 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 91: Coresense Protection

    03TA Service Manual SERVICE OPERATIONS Sentronic Sensor (2D, 3D, 4D & 6D compressors before March 2011). The same oil pressure sensor is used for all Sentronics. It mounts directly into the oil pump. The Sentronic sensor measures oil pump differential pressure. It has an internal contact that opens on low oil pressure and signals the Sentronic electronic control module to begin time out.

  • Page 92: Control Circuit Protection

    # of Flashes Condition Oil Pressure Motor Protection Trip Discharge Temperature (optional add-on) Current Sensor Fault Communication Error FIGURE 9-9B CoreSense Protection Description Vogt # Copeland # Crankcase Heater 100 W (insert type) 12A7509E12 518-0028-01 Sentronic3 Oil Pressure safety switch 12A2117A05 585-1076-02...
  • Page 93 03TA Service Manual 9-11 SERVICE OPERATIONS Circulating Water Pump Motor. The motor bearings are prelubricated and sealed. They require no further lubrication. The pump should operate with the water level above the impeller housing. The pump is equipped with a mechanical seal that is self-adjusting and requires no lubrication. However, the pump should not be operated unless circulating water.
  • Page 94 03TA Service Manual 9-12 SERVICE OPERATIONS Thawing Timer. The thawing timer governs the ice thawing period. It is located inside the control panel (FIGURE 6-2). It is started by action of the freezer pressure switch (FPS) which energizes the “CR” relay. This timer is set prior to shipment for approximately a two minute period. Crouzet Timer (White) Syrelec Timer (Orange) Timer Part #: 12A7503E22...

  • Page 95: Condenser Cleaning

    03TA Service Manual 9-13 SERVICE OPERATIONS Condenser Cleaning. See “Water Cooled Condensers”, “Maintenance”, Section 7. Air-Cooled Condenser. Visual inspection will indicate if dirt is accumulating and clogging the fin face of the condenser. A vacuum cleaner, compressor air or a brush may be used to remove any accumulation of dirt from the fin section of the condenser.

  • Page 96: Refrigerant Leaks

    03TA Service Manual 9-14 SERVICE OPERATIONS Removal Of Refrigerant From The Machine. To transfer the refrigerant charge from the machine into a separate container, proceed as instructed above under “Pumpdown”. This will isolate most of the refrigerant in the receiver and the recovery unit can be connected to the access port (44) of the hand stop valve (58) at the bottom of the receiver.

  • Page 97: Compressor Motor Burnout

    03TA Service Manual 9-15 SERVICE OPERATIONS Compressor Motor Burnout. There are several causes of compressor motor burnout. Some of these are described below. 1. Low line voltage. A compressor motor is designed to operate within the range of plus or minus 10% of its nameplate voltage.
  • Page 98 03TA Service Manual 9-16 SERVICE OPERATIONS Capacity Control (Internal) Valve Construction. A schematic illustration of the internal valve operation is shown in FIGURE 9-13. 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 99: Component Removal And Replacement Operations

    03TA Service Manual 9-17 SERVICE OPERATIONS Component Removal and Replacement 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 lockout disconnect. 2.

  • Page 100: Water Tank

    03TA Service Manual 9-18 SERVICE OPERATIONS Water Tank Removal 1. Turn off and lock out power to the machine. 2. Turn off water supply and disconnect lines from the tank. 3. Drain the tank and disconnect pump suction tube and drain line tubing and water lines. 4.

  • Page 101: Cutter/Tank Assembly Nomenclature, Table 9-1

    03TA Service Manual 9-19 SERVICE OPERATIONS Item No. Vogt Part Number Description Cutter Ring Gear – part of cutter casting 12A3040S02 Spring Pin 19T2160C0101 Cast Cutter 12A2226F1108 1/4” Flat Head Screw 19T2010A01 Cutter Adapter Plate 19T4090S01 Cutter Shaft 12B2020R04 UHMW Cutter Bearing...
  • Page 102 03TA Service Manual 9-20 SERVICE OPERATIONS FIGURE 9-14 Cutter, Water Tank and Drive Gear Assembly 4/2/14...

  • Page 103: Crushed Ice Production

    03TA Service Manual 9-21 SERVICE OPERATIONS FIGURE 9-15 Water Tank and Pump Assembly ® Crushed Ice Production Your 03TA 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.
  • Page 104 Blank page 5/24/11...

  • Page 105: 10. Options And Accessories

    Wagner Model #: DTP-3 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 which can damage or destroy the compressor motor.

  • Page 106: Power Monitor Parameters, Table 10-1

    10-2 03TA Service Manual OPTIONS AND ACCESSORIES Parameter limits Parameter Minimum Maximum Default Recommended Settings Unit Line Side Voltage Supply voltage Volts (Nominal Voltage) Over Voltage (tolerance) Under Voltage (tolerance) Phase Unbalance Lockout Time Seconds (Delay on Break) Delay Time Seconds (Delay on Make) Response Time...
  • Page 107 10-3 03TA Service Manual OPTIONS AND ACCESSORIES Notes If you press SELECT and do not change a parameter by pressing the up or down arrow keys, the DTP-3 automatically returns to displaying the line voltage in a few seconds. The new settings are saved in permanent memory when the display returns to displaying the line voltage.

  • Page 108: Plc (Programmable Logic Controller)

    10-4 03TA Service Manual OPTIONS AND ACCESSORIES PLC (Programmable Logic Controller) ® Tube-Ice machines are available with a Mitsubishi Fx 24MR programmable controller, -8ER expansion module and a Mitsubishi E1012 Operator interface. The E1012 interface contains a real-time clock and 6 programmable function keys that allow for easy screen ®...

  • Page 109: Mitsubishi Hmi (E1012), Figure 10-2

    Cycle History log (10 cycles) will also be created and viewed with the interface. The PLC I/O Status screen can be used to view PLC Inputs and Outputs without opening the control panel door. A Total cycle counter and hour meter can also be view with the. VOGT TUBE-ICE -------------------------- PLC I/O...
  • Page 110 10-6 03TA Service Manual OPTIONS AND ACCESSORIES MITSUBISHI Mitsubishi FX -24MR PLC and FX -8ER-ES/UL FIGURE 10-3 Mitsubishi PLC Inputs Description Outputs Description Not used Not used High Side Control Interlock Not used Conveyor Control Contact Start / Manual Harvest Button ET - Elapsed Timer Selector Switch (Clean position) Water Pump motor starter...
  • Page 111 10-7 03TA Service Manual OPTIONS AND ACCESSORIES FIGURE 10-4 Wiring Schematic – Mid Size Machine (P112, P118 & P18XT)
  • Page 112 Blank page 5/24/11...
  • Page 113 (5) Tower sized for 80°F wet bulb temperature (3) Makeup water is maximum value and includes 10 gallons per cycle blowdown. . (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 4/10/14...
  • Page 114 03TA Service Manual 11-2 TABLES & CHARTS 03TA Capacity Ratings Makeup Rated Capacity (lbs/day) Water 60Hz 50Hz Temp. Cylinder Crushed Cylinder Crushed Deg. F 1" 1 1/4" 1" 1 1/4" 1" 1 1/4" 1" 1 1/4" 6955 6592 7233 6856 6816 6460 7088...
  • Page 115 03TA Service Manual 11-3 TABLES & CHARTS Water Average Total Condensing Entering Water Leaving Water Pressure Flow Heat Drop Temp. °F Temp. °F Temp. °F of Rejection 122,000 122,000 122,000 122,000 122,000 122,000 122,000 122,000 122,000 122,000 Condenser Water Usage Table 11-3 Cylinder Ice Crushed Ice...
  • Page 116 03TA Service Manual 11-4 TABLES & CHARTS RECOMMENDED SPARE PARTS LIST ® Vogt Model 03TA Tube-Ice Machine QTY PART NUMBER DESCRIPTION 12A2117E04 Freezer pressure switch 12A7503E22 Thawing timer 12A7517E27 CR Relay, 208/230v, 50/60hz. 12A7516E23 Cutter, Pump and PF Contactor, 9A, 208/230v, 50/60hz...
  • Page 117 03TA Service Manual 11-5 TABLES & CHARTS TEMPERATURE - PRESSURE CHART FOR COMMON REFRIGERANTS DegF R-12 R-22 R-502 R-134a MP-39 R-404a HP-80 DegF R-12 R-22 R-502 R-134a MP-39 R-404a HP-80 -7.6 -3.0 -9.0 -9.1 46.7 84.0 97.4 45.5 45.3 102.9 111.4 -7.2 -2.4...
  • Page 118 03TA Service Manual 11-6 TABLES & CHARTS REFERENCE INFORMATION CONVERSION FACTORS: English to Metric To Convert From Multiply by Area 9.2903e-2 6.416 e-4 Energy Joule (J) 1054.48 BTU/Hr 2546.2 1.34 Length 0.3048 0.0254 Pressure Lbf/ft 47.88 Lbf/in (psi) 6894.76 In. Hg 0.491 In H 0.03612...
  • Page 119 03TA Service Manual 12-1 INDEX 12. Index Control Panel ---------------------------------------------------------- 6-1 A Valve (Liquid Feed Solenoid Valve) ------------- 4-1, 5-1, 9-6 Control Panel Parts -------------------------------------------------- 6-5 Accumulator ----------------------------------------------------- 4-1, 5-1 Control, Relay (CR) -------------------------------------------------- 6-5 Adding Refrigerant --------------------------------------------------- 5-4 Cooling Tower --------------------------------------------------------- 3-7 Air - cooled Condenser Wiring (3 phase) ------------------- 3-16 Crankcase Heater ---------------------------------------------- 7-6, 9-7 Air-Cooled Condenser -------------------------------------------- 9-13...
  • Page 120 Mechanical Cleaning ------------------------------------------------ 7-5 Suction Cut-Off Unloader ---------------------------------------- 9-16 Symptoms, Troubleshooting -------------------------------------- 8-1 NEMA -------------------------------------------------------------------- 2-1 Nomenclature, Piping Schematic -------------------------------- 4-2 Telephone Number, Vogt ------------------------------------------ 1-1 Non-Condensable Gases ---------------------------------------- 9-14 Temperature-Pressure Chart ------------------------------------ 11-5 Normal Operating Vitals ------------------------------------------ 11-5 Thawing, Chamber --------------------------------------------------- 4-1...
  • Page 121 03TA Service Manual 12-3 INDEX Water Cooled Condenser ------------------------------------ 3-7, 7-3 Water Cooled Condenser Cleaning ---------------------------- 7-5 Water Cooled Machine, Installation ----------------------------- 3-5 Water Cooled Piping Schematic --------------------------------- 4-3 Water Cooled Units -------------------------------------------------- 9-4 Water Distributors ---------------------------------------------------- 7-3 Water Pump Motor ------------------------------------------------- 9-10 Water Regulating Valve -------------------------------------------- 9-5 Water Supply and Drain, Water Cooled ------------------------ 3-6 Water Supply and Drains, Air-cooled --------------------------- 3-6...
  • Page 122 03TA Service Manual 12-4 INDEX 4/21/14...

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