HEC SERVICE MANUAL
HEC-Series Service Manual i TABLE OF CONTENTS Table Of Contents Models HEC-10, HEC-20, HEC-30 & HEC-40 Page No. 1. INTRODUCTION A Brief History of Our Company ................................................................................................................ 1-1 Vogt Energy-Saving Tube-Ice® Machines................................................................................................... 1-1 Preview ....................................................................................
HEC-Series Service Manual ii TABLE OF CONTENTS Page No. Condenser Field Piping, FIGURE 3-7......................................................................................................... 3-11 Equivalent Feet of Fittings Due to Friction, TABLE 3-4 ............................................................................ 3-12 Minimum Traps For Discharge Lines, FIGURE 3-8 ................................................................................... 3-12 Condenser Piping, FIGURE 3-9 ........
HEC-Series Service Manual iii TABLE OF CONTENTS Page No. PLC Features & Functions........................................................................................................................... 6-5 PLC Control Sequence Flow Chart, FIGURE 6-3................................................................................ 6-6 PLC Mode Identification & Operation ................................................................................................. 6-7 PLC Start-Up Mode..................
HEC-Series Service Manual iv TABLE OF CONTENTS Page No. Lubrication .................................................................................................................................................. 7-6 Compressor........................................................................................................................................... 7-6 Cutter Gear Reducer .....................................................................................................................
HEC-Series Service Manual v TABLE OF CONTENTS Ice Selector Switch, FIGURE 9-7................................................................................................................ 9-8 Ice Selector Switch ...................................................................................................................................... 9-8 Control Circuit Protection ...........................................................................................................................
HEC-Series Service Manual vi TABLE OF CONTENTS Page No. 11. TABLES AND CHARTS Ice Capacity TABLE 11-1 ........................................................................................................................... 11-1 Normal Operating Vitals, TABLE 11-2 ...................................................................................................... 11-2 Temperature-Pressure Chart, TABLE 11-3 ................................................................................................
HEC-Series Service Manual 1-1 INTRODUCTION 1. Introduction Henry Vogt Machine Co. A Brief History Of Our Company. Henry Vogt Machine Co. was founded as a small machine shop in Louisville, Kentucky in 1880. Today, Vogt Tube Ice, LLC is one of the world’s leading producers of ice-making equipment. In 1938, Vogt built the first Tube-Ice® machine and revolutionized the ice-making industry.
HEC-Series Service Manual 1-2 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.
HEC-Series Service Manual 1-3 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. These safety symbols will alert you when special care is needed. Please heed.
HEC-Series Service Manual 1-4 INTRODUCTION VOGT TUBE-ICE MACHINE FIGURE 1-1 Tube-Ice machine shown atop a typical ice storage bin with a condensate drain pan. The bin and drain pan are optional equipment NOTICE! The ice storage bin is shown for illustration purposes only. Vogt Tube Ice, LLC accepts no responsibility for the selection or use of any ice bin in conjunction with the Tube-Ice machine.
HEC-Series Service Manual 1-5 INTRODUCTION FIGURE 1-2A Assembly Model HEC-30 Air-Cooled Front View 10/24/01
HEC-Series Service Manual 1-6 INTRODUCTION FIGURE 1-2B Assembly Model HEC-30 Air-Cooled Rear View 10/24/01
HEC-Series Service Manual 1-7 INTRODUCTION FIGURE 1-2C Assembly Model HEC-30 Water Cooled Front View 10/24/01
HEC-Series Service Manual 1-8 INTRODUCTION FIGURE 1-3B Assembly Model HEC-30 Water Cooled Rear View 10/24/01
HEC-Series Service Manual 1-9 INTRODUCTION PIPING SCHEMATIC NOMENCLATURE 1. Freezer 3. Compressor 4PS. High/Low Safety Pressure Switch 30. Gage Glass 5M. Cutter Motor 32. AC Condenser Service Connection 5R. Cutter Gear Reducer 34. Compressor Suction Service Valve 6. Water Pump 35. Comp. Discharge Service Valve 7. Water Tank (reservoir) 39. Water Tank Drain Valve 8. Freezer Cover 40. Automatic Blowdown Piping 12. Make-Up Float Valve 41. Condenser Water Regulating Valve 13.
HEC-Series Service Manual 2-1 RECEIPT OF YOUR TUBE-ICE MACHINE 2. Receipt Of 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. ! WARNING ! Inspection. As soon as you receive your machine, inspect it for any damage. If damage is suspected, note it on the shipper’s papers (i.e., the trucker’s Bill of Lading).
HEC-Series Service Manual 3-1 INSTALLING YOUR TUBE-ICE MACHINE 3. Installing Your Tube-Ice Machine Note: A video production is available through your distributor. Installation Without Bin. Machine must be installed on a drainable condensate drip pan. Bin Installation. Set the bin on solid, level footing. Inside the bin you will find the four legs. Screw these legs to the bottom of the bin.
HEC-Series Service Manual 3-2 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-1 Forklift-&-Blocks Method You need: + + + + forklift truck with adequate load and height capacities (8) 2X4 wood blocks 8 in. long (2) wooden 2X4’s measuring 3-ft. long pry bar Step 1. Position Tube-Ice® machine on forks. ! CAUTION ! The Tube-Ice machine may be somewhat top heavy on the rear. ! CAUTION ! ® Step 2. Step 3. Step 4. Step 5. Step 6. Stack wood blocks in each corner of the drip pan on top of the ice storage bin.
HEC-Series Service Manual 3-3 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-2 Forklift-&-Rope or Lifting Straps Method You need: + extra head room + forklift with adequate load and height capacities + 1/2” rope or four lifting straps to bind forks to top angles Step 1. Remove front, rear, and top access panels. Step 2. Position fork truck so that forks are resting flat on top angles of Tube-Ice® machine. Step 3. Use the rope or straps to securely bind forks to the top angles.
HEC-Series Service Manual 3-4 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 ! FIGURE 3-3 Electrical Connections for Machine Power & AC Connections A fused disconnect must be provided near the Tube-Ice® machine.
HEC-Series Service Manual 3-5 INSTALLING YOUR TUBE-ICE MACHINE Piping and Drain Connections. All connections are located at the rear of the machine. Look for four water connections on the freezing unit of each water cooled machine. See Space Diagram, FIGURE 3-4 for correct utility connections. ! CAUTION ! Exterior 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.
3-6 FIGURE 3-4 Space Diagram Water Cooled Machine INSTALLING YOUR TUBE-ICE MACHINE 10/21/01 HEC-Series Service Manual
HEC-Series Service Manual 10/21/01 3-7 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-5 Space Diagram Air-Cooled Machine
HEC-Series Service Manual 3-8 INSTALLING YOUR TUBE-ICE MACHINE Air-Cooled Condenser Installation Instructions. ! WARNING ! Using a non-Vogt condenser will void the compressor warranty. ! WARNING ! Certain installation guidelines must be followed to obtain reliable operation from air-cooled ice machines. If these guidelines are not followed, the compressor warranty will not be honored. Any exceptions to this policy must be obtained in writing prior to installation and operation of the ice machine. 1.
HEC-Series Service Manual 3-9 INSTALLING YOUR TUBE-ICE MACHINE 11. Condensers with multiple fans must be provided with a thermostat to turn off unneeded fans in cold weather, per FIGURE 3-9. Turning off unneeded fans reduces on-off cycling of the fan(s) and allows for a steadier condensing pressure. 12. 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.
HEC-Series Service Manual 3-10 INSTALLING YOUR TUBE-ICE MACHINE Catalog energy efficiency ratings of the ice machines are based on use of the recommended condenser. Condensers supplied by Vogt must be utilized. The use of non-Vogt condensers will void the compressor warranty. For continuous operation at ambients above 105°F, consult the factory about using a larger condenser. Ice Machine Model Electrical Frequency, Hz Recommended Condenser Total Heat Rejection: BTU/hr at 60 hz. BTU/hr at 50 hz.
HEC-Series Service Manual 3-11 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-6 Condenser Dimensions (Condenser pictured: DD-101 or DD-131) Note: Dash lines indicate customer supplied piping. The Check Valve in the return line (labeled “Output To Machine”) is supplied with the condenser.
HEC-Series Service Manual 3-12 INSTALLING YOUR TUBE-ICE MACHINE CONDENSER EQUIVALENT LINE SIZE WORKSHEET Discharge Gas Line O.D. _____________ Fitting Type Globe Valve (open) Angle Valve (open) 45° Elbow 90° Elbow Number Used Factor Total Feet of Straight Copper Used Total Fitting Factor Total Equivalent Feet Fitting Factors Copper Tube O.D. Type “L” 1/2” 5/8” 7/8” 1 1/8” Globe Valve (open) 14 16 22 28 Angle Valve (open) 7 9 12 15 45° Elbow .5 1 1 1.
HEC-Series Service Manual 3-13 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-9 Condenser Piping With Cold Weather Valve Kit 10/21/01
HEC-Series Service Manual 3-14 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-10 Wiring For DD-61 With Cold Weather Valve and Single Fan FIGURE 3-11 Wiring For DD-101 & DD-131 With Cold Weather Valve And Dual Fans 10/21/01
HEC-Series Service Manual 3-15 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-12 Air-Cooled Condenser Enclosure 10/21/01
HEC-Series Service Manual 3-16 INSTALLING YOUR TUBE-ICE MACHINE FIGURE 3-13 Field Attachment, Air Cooled Condenser Refrigerant Tubing 10/21/01
HEC-Series Service Manual 3-17 INSTALLING YOUR TUBE-ICE MACHINE Ice Bin Thermostat Bulb Installation. Each machine is equipped with an ice bin thermostat. To assure proper protection for the machine, the control bulb of the ice bin thermostat must be located so that ice will contact it when the bin is full. For a divided bin, locate the control bulbs as illustrated in FIGURE 3-14.
HEC-Series Service Manual 3-18 INSTALLING YOUR TUBE-ICE MACHINE The control panel is electrically connected so that the bin thermostat will stop the machine only upon the completion of a harvest period. When both cylinder and crushed ice are produced and separately stored in a divided bin, the control bulb of thermostat BT1 is placed in the crushed ice section of the storage bin (left side) and the control bulb of thermostat BT2 is placed in the cylinder ice section (right side of bin).
HEC-Series Service Manual 3-19 INSTALLING YOUR TUBE-ICE MACHINE Installation Review: A CHECKLIST Make a visual check to be sure these steps have been taken BEFORE continuing. CHECK: _____ PRIOR TO OPENING VALVES, check all joints for leaks which may have developed during shipment. {NOTE: The required charge of Refrigerant 22 has been isolated in the Receiver (15R).} CHECK: _____ All water supply and drain connections for conformity to requirements stipulated in this manual.
HEC-Series Service Manual 4-1 HOW YOUR TUBE-ICE MACHINE WORKS 4. How Your Tube-Ice Machine Works Principle Of Operation. The manual operation of the machine is controlled by the “Ice” and “Start” switches located in the switch box of the freezing unit.
HEC-Series Service Manual 4-2 HOW YOUR TUBE-ICE MACHINE WORKS HEC, Water Cooled -- Piping Schematic FIGURE 4-1 HEC, Air Cooled -- Piping Schematic 10/21/01
HEC-Series Service Manual 4-3 HOW YOUR TUBE-ICE MACHINE WORKS Dual ice type (crushed and cylinder). Divider in bin (cylinder and crushed ice separately stored). With the selector switch on “Auto”, the machine will automatically produce cylinder ice until the cylinder-ice bin is filled. This action will open the cylinder ice thermostat switch in the cylinder ice bin and will automatically change the machine over to crushed ice production--PROVIDED THE CRUSHED ICE BIN IS NOT FULL.
HEC-Series Service Manual 4-4 HOW YOUR TUBE-ICE MACHINE WORKS When ice bin thermostats are NOT used. With the selector switch set on either “Auto” or “Cyl”, the machine will produce cylinder ice. If the switch is changed to “Cru” while the unit is producing cylinder ice, after the first 5 minutes of a cycle, it will complete the freeze and evacuation of the cylinder ice before changing to the production of crushed ice. The next cycle will produce crushed ice.
HEC-Series Service Manual 4-5 HOW YOUR TUBE-ICE MACHINE WORKS Ice Bin Capacity. Crushed or cylinder ice weighs approximately 35 pounds per cubic ft. (35 lb/ft3 ). As ice drops into a bin, it will pile up and slope naturally at about a 45° angle. This natural slope should be taken into account when locating the bin thermostat bulb (or other bin level control) and when calculating the normal bin capacity.
HEC-Series Service Manual 5-1 INITIAL START UP AND OPERATION 5. Initial Start-Up & Operation Start-Up Checklist Be sure to complete and return the Warranty Registration/Start-Up report located at the front of the manual. In order to prepare the machine for start-up, it will be necessary to remove the front panels for access to the various valves and for observation. _____ 1. See that water-inlet connections are attached to the proper couplings (water cooled units) and to water for ice making.
HEC-Series Service Manual 5-2 INITIAL START-UP AND OPERATION If the machine does not start, put the “Ice” button in the “Off” position. Put the “Clean” button in the “On” position and push the “Start” button. This will put the machine in the clean mode and tell the PLC that the machine is pumped down. Now put the “Clean” button in the “Off” position, shutting off the water pump, and the “Ice” button in the “On” position.
HEC-Series Service Manual 5-3 INITIAL START UP AND OPERATION Refrigerant Charge. Check the refrigerant level after the machine has operated for a few cycles. It should be slightly above the operating level, as indicated on the receiver, a few minutes prior to start of a thawing period. If this level is low at this time, sufficient refrigerant should be added to the system to raise the level above this point. One inch (1”) is equivalent to 5 lbs. in the receiver. Add only a small quantity (5 lbs.
5-4 INITIAL START-UP AND OPERATION 10/21/01 FIGURE 5-2 Piping Schematic, Air-Cooled HEC-Series Service Manual
HEC-Series Service Manual 10/21/01 FIGURE 5-3 Piping Schematic, Water Cooled 5-5 INITIAL START UP AND OPERATION
HEC-Series Service Manual 6-1 ELECTRICAL CONTROLS & THEIR FUNCTIONS 6.
HEC-Series Service Manual 6-2 ELECTRICAL CONTROLS & THEIR FUNCTIONS Description of Control Panel Parts. *BT1 and BT2. Bin Thermostats. Ice bin thermostats for automatically stopping and starting the machine based on the ice level in the storage bin. BT1 (Crushed Ice). BT2 (Cylinder Ice). C. Compressor Motor Contactor. Provides power to the compressor motor. Energized during freezing and thawing. Normally closed contact provides power to the compressor crankcase heater when the machine is off. P.
HEC-Series Service Manual 6-3 ELECTRICAL CONTROLS & THEIR FUNCTIONS Switch Box Parts FU100 FU200 PBL1 PBL2 PB1 PB2 *SS S1 S2 *1LT *2LT 3LT 4LT 12A 7504E10000000 12A 7504E10000000 12A 7500E36000000 12A 7500E36000000 12A 7500E03000000 12A 7500E02000000 12A 7500E07000000 12A 7515E01000000 12A 7515E07000000 12A 7520E10000000 12A 7520E10000000 12A 7520E09000000 12A 7520E09000000 Fuse 2.5 amp Fuse 2.
HEC-Series Service Manual 6-4 ELECTRICAL CONTROLS & THEIR FUNCTIONS FU100 and FU200, 2.5 Amp Fuses. Overload and short circuit protection for crankcase heater and the control circuit. PB1, Start Push Button. For starting the machine in the ice making mode. (Momentary contact). Will also bypass the built in 120 minute start-up mode. Will also terminate a harvest mode. PB2, Manual Harvest Push Button. Initiates a thaw period immediately when manually depressed.
HEC-Series Service Manual 6-5 ELECTRICAL CONTROLS & THEIR FUNCTIONS PLC Features & Functions (Condensed Description) The PLC provides many beneficial features as follows: 1. 2. 3. 4. 5. 6. 7. 8. 10/21/01 Identifies machines faults and stores the identity of the last fault. Automated total pump down prior to a clean mode. Performs partial pump down when machine cycles off by “Bin Stat” or “Ice” switch. Provides fault identification: a. Short cycle fault b. Long freeze cycle fault c.
HEC-Series Service Manual 6-6 ELECTRICAL CONTROLS & THEIR FUNCTIONS FIGURE 6-3 Control Sequence Flow Chart 10/21/01
HEC-Series Service Manual 6-7 ELECTRICAL CONTROLS & THEIR FUNCTIONS “PLC” (Programmable Logic Controller) Sequence Of Controller & Machine Operation Explanation. The HEC-Series Tube-Ice® machine is controlled by a PLC (Programmable Logic Controller). The PLC controls the sequence of events and monitors the ice machine functions. The operational sequences of the HEC-Series Tube-Ice® machine can be best described as a series of eight different modes.
HEC-Series Service Manual 6-8 ELECTRICAL CONTROLS & THEIR FUNCTIONS Standby Mode. The standby mode is a decision making mode. It monitors the position of all the various switches in the control circuitry and at the proper time decides which mode to advance to next. Initiated by the following action: 1. After the two hour period in the start-up mode. 2. After pushing the “Start” button. 3. After pushing the “Ice” button to the “Off” (and the harvest cycle and partial pumpdown cycles are complete). 4.
HEC-Series Service Manual 6-9 ELECTRICAL CONTROLS & THEIR FUNCTIONS Partial Pumpdown Mode. The partial pumpdown modes precedes the normal off or standby mode. Its purpose is to transfer a portion of the liquid from the suction accumulator and freezer into the receiver prior to shutdown of the machine (standby mode). This will discourage any migration of liquid refrigerant to the compressor during the off or standby mode.
HEC-Series Service Manual 6-10 ELECTRICAL CONTROLS & THEIR FUNCTIONS 1. 2. 3. 4. Set the “Ice Selector” switch to the position desired. See that the “Clean” switch is in the “Off” position. Push the “Ice” button to the “On” position. Push the “Start” button. (Make sure the compressor crankcase is warm and there is no liquid refrigerant in with the oil before pushing the “Start” button.
HEC-Series Service Manual 6-11 ELECTRICAL CONTROLS & THEIR FUNCTIONS Initiated by the following: 1. Open the SVI switch. 2. Set the “Clean” button to the “On” position. 3. Set the “Ice” button to the “On” position. 4. Push both the “Harvest” and “Start” buttons simultaneously. At this point, the machine “fault” can be identified and necessary corrections or adjustments can be made for returning the machine to good working order.
HEC-Series Service Manual 6-12 ELECTRICAL CONTROLS & THEIR FUNCTIONS NOTE: Part #12A-7536M01000000. PLC must be pre-programmed for specific model.
HEC-Series Service Manual 6-13 ELECTRICAL CONTROLS & THEIR FUNCTIONS In 0 1 S10 - Start 2 3 4 5 6 7 In ¢ ¢ ¢ ¢ ¢ l l l Out 0 1 2 3 4 0 1 S11 - Standby 2 3 4 5 5 Out ¢ ¢ ¢ ¢ ¢ ¢ 7 0 1 2 3 4 5 ¢ ¢ ¢ ¢ ¢ ¢ Note: Inputs # 0 or # 1 may be “on”. If machine has shut off due to a High pressure fault, input 6 will be “off”. Note: If Ice button, Input # 5 is “off”, Input # 0 or # 1 may be “on”.
HEC-Series Service Manual 6-14 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-15 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-16 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-17 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-18 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-19 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-20 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 6-21 ELECTRICAL CONTROLS & THEIR FUNCTIONS Use Copper Conductors Only. Protected against primary single phase failure.
HEC-Series Service Manual 7-1 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) using an approved food-grade ice machine cleaner. The water pump is used to circulate the cleaner through the system by setting the “Clean” push button switch to the “On” position (button in) and starting and stopping the pump by this push button switch and the start button.
HEC-Series Service Manual 7-2 MAINTENANCE 12. Make sure the water tank drain valve is closed, the adjustable blowdown petcock is adjusted properly, the adjustable blowdown tubing is inserted into the drain bypass line, the “Clean” button is in the “Off” position, and the selector switch is in the desired ice making position. 13. Push the “Ice” button to the “On” position and push the “Start” button for immediate start-up in the ice production mode. Water Distributors.
HEC-Series Service Manual 7-3 MAINTENANCE Proper operation of cooling towers will increase the interval between cleaning considerably. The tower overflow rate should be checked frequently. If a tower is operated with insufficient overflow, nominal 1-1/2 to 3 GPH bleed depending on water quality, the resulting mineral concentration in the water can cause rapid and heavy flooding inside the condenser tubes, requiring excessively frequent cleaning. Also, these conditions often lead to severe corrosion.
HEC-Series Service Manual 7-4 MAINTENANCE Chemical Cleaning. The Henry Vogt Machine Co. makes no recommendation for any particular chemical preparation. The same chemical may not be effective for all situations. ! CAUTION ! The following directions and precautions should be observed when cleaning is undertaken. The warranty on condensers is void if they are damaged by improper cleaning tools or methods.
HEC-Series Service Manual 7-5 MAINTENANCE 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. If the inside surfaces are smooth, even though discolored, further cleaning is not necessary. It is useless to try and get a bright copper surface on the inside of the tubes. They will discolor almost immediately in service and the condenser has been designed with an adequate reserve for moderate fouling on these surfaces.
HEC-Series Service Manual 7-6 MAINTENANCE Lubrication Compressor. In starting and charging the unit, the oil sight glass (33) in the crankcase of the compressor should be watched carefully for the first hour to make certain the proper lubrication is being maintained. The oil may become low in the crankcase on an initial start-up if the electrical current has been interrupted to the machine, thus de-energizing the compressor crankcase heater.
HEC-Series Service Manual 7-7 MAINTENANCE Preventive 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. Is the machine running or is the bin full 2. Bin doors kept closed 3. Thermostat bulb in bracket 4. Ice quality (clarity and uniformity) 5. Does all ice discharge during harvest 6. Cleanliness 7.
HEC-Series Service Manual 7-8 MAINTENANCE Preventive Maintenance Program Model # ___________________ Customer/Address Serial # ____________________ Date _____________ ___________________________________________________________ ___________________________________________________________ Mgr. Name ______________________ Service Tech Name __________________________ The following service performed and checked: Last maintenance performed (approx.
HEC-Series Service Manual 8-1 TROUBLESHOOTING 8. Troubleshooting Always check the machine thoroughly after remedying the problem to prevent the same cause from reoccurring. Symptom: Machine won’t run. (See Fault Identity, Section 6, TABLE 6-2) Possible Cause Possible Remedy Intermittent power interruptions or power If there is a power failure or a power failure. Fault #16 interruption, the machine will advance to a start-up mode when power is restored.
HEC-Series Service Manual 8-2 TROUBLESHOOTING Symptom: Freeze up due to extended freezing period. Check for Fault #15, Long Freeze Cycle (see note below) Possible Cause Freezer pressure switch setting too low. Possible Remedy See Freezer Pressure Switches, Section 9 FIGURE 9-1, and Operating Vitals, Section 11, TABLE 11-2. Warm condenser water entering water tank (7) Pipe water outlet (24) and drain (25) separately through overflow connection (40). WATER to floor drain.
HEC-Series Service Manual 8-3 TROUBLESHOOTING Symptom: Freeze-up due to ice failing to discharge. Check for Fault #14 Short Cycle (see note below) Possible Cause Low condensing pressure during freezing resulting in insufficient heat for thawing. Thawing timer setting too short to allow ice to clear freezer. Insufficient heat for thawing due to low refrigerant charge. Non-condensable gases (usually air) in system. Cutter does not turn. Possible Remedy See Head Pressure, Section 9.
HEC-Series Service Manual 8-4 TROUBLESHOOTING Symptom: Low ice capacity. Possible Cause Low refrigerant charge in freezer. Restriction in liquid line. Possible Remedy Add refrigerant and check for leaks. Check for obstruction at filter drier (46), strainer (43), solenoid valve (20) or TXV (17). The liquid line will normally have frost on the downstream side of a severe restriction. Check Solenoid valve (18) may be leaking warm Repair or replace solenoid valve.
HEC-Series Service Manual 8-5 TROUBLESHOOTING Symptom: Safety pressure switches stop machine. Possible Cause Low pressure switch opens. Possible Remedy Compressor suction service valve (34) may be either closed or partially closed. Open valve wide. Check switch for improper setting (too high opening pressure). See Section 9, FIGURE 9-2. High pressure switch opens. Compressor discharge service valve (35) closed or partially closed. Open valve wide. Check cleanliness of condenser.
HEC-Series Service Manual 8-6 TROUBLESHOOTING Symptom: Motor overload protectors stop machine. Possible Cause Compressor motor overload (CD-OL) stops machines. NOTE: Overloads are automaticreset type, located in junction box of compressor, Models HEC-30 & HEC-40 only. Compressor internal temperature thermal switch (CD-TS) stops machine. HEC-30 & HEC-40 will reset automatically after the motor has cooled sufficiently.
HEC-Series Service Manual 8-7 TROUBLESHOOTING Symptom: Motor overload protectors stop machine. (Cont.) One of the 2.5 amp fuses in the switch box Check compressor crankcase heater, coil of fan stops machine. contactor and PLC for a ground. Repair or replace defective part. Replace fuse. Make sure the compressor crankcase heater is energized for at least two hours and there is no liquid refrigerant in the crankcase prior to running the machine.
HEC-Series Service Manual 9-1 SERVICE OPERATIONS 9. Service Operations Adjustable Blowdown (for clearer ice). A petcock is installed on the overflow from water pump to provide means for obtaining blowdown from the water tank during the freezing period. This supplements the blowdown that is discharged during the thawing period through the bypass piping connected to the drain of the water tank. (See “Automatic Blowdown” below).
HEC-Series Service Manual 9-2 SERVICE OPERATIONS TXV Adjustment By Superheat. Superheat is the difference between the refrigerant vapor temperature and its saturation temperature. (Translate the pressure reading to saturated temperature and subtract it from the actual temperature reading.) Follow this procedure: 1. Attach an accurate pressure gage to the low pressure test connection. 2.
HEC-Series Service Manual 9-3 SERVICE OPERATIONS When installing a new valve, be sure to use the proper soldering techniques to prevent overheating the valve body which could damage the superheat spring and result in flood back problems. When soldering: 1. Wrap a wet cloth around the valve body and element. 2. Direct the flame away from the valve body. 3. Apply only enough heat to flow the alloy material into all the joint areas. Do not overheat. 4.
HEC-Series Service Manual 9-4 SERVICE OPERATIONS Allen Bradley Switch. The following procedure is recommended for initially setting an AB pressure switch which has not been previously adjusted: 1. Turn the bottom screw (differential) approximately 1/2 turn to the left (counter clockwise). The pointer arrow, which is at the top middle of the switch, will be at the “F” setting. See FIGURE 9-1. 2. Turn the top screw (range adjustment) approximately 4 1/2 turns to the left (counter clockwise).
HEC-Series Service Manual 9-5 SERVICE OPERATIONS FIGURE 9-2 High-Low Pressure Switch NOTE: High-low pressure switch contains both high and low voltage circuits. Line numbers 22 and X6 supply a low voltage signal to the PLC. Line numbers 15 and 30 supply power to the compressor contactor coil. If it becomes necessary to install a new high/low pressure switch, the following procedure is recommended for its adjustment: Turn the adjusting screws clockwise to raise the pressure setting.
HEC-Series Service Manual 9-6 SERVICE OPERATIONS FIGURE 9-3. Water Regulating Valve. FIGURE 9-4. Condenser Fan Switch. Water-Cooled Units. A water regulating valve (FIGURES 1-3B & 9-3) located in the condenser water inlet line is used to control the water flow through the condenser. This valve should be adjusted to maintain a head pressure of 190-210 psig. Increasing the water flow lowers the head pressure and decreasing the water flow raises the head pressure.
HEC-Series Service Manual 9-7 SERVICE OPERATIONS FIGURE 9-5 Ice Bin Thermostat (Dual Ice Type) 1. Cover bulb with ice. Use a continuity tester to see if the contacts are open. It should take approximately 10-15 seconds for the contacts to open. 2. Remove bulb from ice. Check the time it takes for the contacts to close. It should take a minimum of 3 minutes (4 to 5 minutes preferred) for the contacts to close when the bulb hangs free in a bin approximately 1/2 full of ice with the bin doors closed. 3.
HEC-Series Service Manual 9-8 SERVICE OPERATIONS FIGURE 9-6 Thawing Timer. (Part of PLC) Thawing Timer. The thawing timer governs the ice thawing period. It is built into the PLC located inside the control panel. It is started by action of one of the freezer pressure switches (FPS1 or FPS2) or the manual harvest button. This timer is set prior to shipment for approximately a 90 second period.
HEC-Series Service Manual 9-9 SERVICE OPERATIONS Control Circuit Protection. The electrical control circuit of the machine is protected by two 2.5 amp fuses (FU100 & FU200). If either of these fuses should blow, the machine will immediately stop. Before replacing a fuse, open the disconnect switch to machine and set the “Ice” push button to the “Off” position. If the machine was off for an extended time, the crankcase heater must be energized for a minimum of two hours before restarting the machine.
HEC-Series Service Manual 9-10 SERVICE OPERATIONS 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 an accumulation of dirt from the fin section of the condenser. See Section 7. 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.
HEC-Series Service Manual 9-11 SERVICE OPERATIONS Cutter and Gear Drive. To remove the ice cutter (21), when and if necessary, proceed as follows: 1. Turn machine off. 2. Close the stop valve in the make-up water line to water pan. 3. Drain the tank, disconnect the make-up water line and drain line from the water tank. 4. Separate motor from the cutter drive reducer by removing four cap screws.
HEC-Series Service Manual 9-12 SERVICE OPERATIONS FIGURE 9-8 Cutter/Water Tank Assembly With Water Pump and Cutter Motor 10/21/01
HEC-Series Service Manual 9-13 SERVICE OPERATIONS FIGURE 9-9 Cutter/Water Tank Parts 10/21/01
HEC-Series Service Manual 9-14 SERVICE OPERATIONS FIGURE 9-10 Cutter Drive Parts 10/21/01
HEC-Series Service Manual 9-15 SERVICE OPERATIONS FIGURE 9-11 Cutter Parts 10/21/01
HEC-Series Service Manual 9-16 SERVICE OPERATIONS NOTE: Deflector door assembly and chute deflector may be removed if there is no divider in the bin, see “How Ice Is Stored”, Section 4.
HEC-Series Service Manual 9-17 SERVICE OPERATIONS Pumping Down Freezer. If it should become necessary to pump the refrigerant out of the freezer, sufficient vapor should be retained to hold one pound of pressure in the freezer so that air will not enter if the system is opened. A total pumpdown is the first phase of the clean mode. Refer to Section 6, Total Pumpdown Mode to perform this function. After the pumpdown is accomplished, push the “Clean” button to “Off” to stop the water pump.
HEC-Series Service Manual 9-18 SERVICE OPERATIONS Refrigerant Leaks. In addition to testing the machine for leaks as instructed under “Refrigerant Charge”, it is advisable to again make a leak test after the unit has been in operation approximately one week. Any noticeable change in operating conditions, other than shown on the “Certificate of Test” may indicate a loss of refrigerant due to a leak. Always remove the refrigerant pressure from the vessel or tubing before repairs are attempted.
HEC-Series Service Manual 9-19 SERVICE OPERATIONS Note: “X” Valve #53 (air-cooled units only) FIGURE 9-13 Solenoid Valves Solenoid Valves. The solenoid valves (#18, #20 and #53) are pilot-operated with “floating” type diaphragm. For satisfactory operation, be sure that the manual opening stem, which is located in the valve bonnet on the outlet side of the Jackes-Evans valve and on the bottom of the Sporlan valve, is in the “automatic” or “closed” position.
HEC-Series Service Manual 9-20 SERVICE OPERATIONS ! WARNING ! Acid can cause serious burns or blindness. Always add the acid to the water for dilution. Wear eye and body protection. ! WARNING ! Water Tank. The production of opaque ice usually indicates that the water in the water tank contains a concentrated amount of solids or salts. Remove cover plate, open drain valve (39) and clean tank thoroughly by flushing out with a hose and scrubbing with a stiff brush.
HEC-Series Service Manual 9-21 SERVICE OPERATIONS Adjustment instructions: 1. Connect an accurate pressure gage to the low pressure test connection. 2. Remove the protective cover from over the CPR adjustment screw. 3. While the machine is in a harvest cycle, turn the adjustment screw CW to raise the gage pressure to 58-60 psig. Then turn the screw CCW (out) gradually until the pressure reaches the recommended setting (TABLE 9-2) and remains constant during the harvest. 4. Replace the protective cover.
HEC-Series Service Manual 9-22 SERVICE OPERATIONS Machine HEC-10S HEC-10M HEC-20S HEC-20M HEC-30S HEC-30M HEC-40S HEC-40M Cylinder Ice (psig) 42 - 44 39 - 41 43 - 45 38 - 40 38 - 40 35 - 37 31 - 33 25 - 27 Crushed Ice (psig) 45 - 47 43 - 45 46 - 48 41 - 43 41 - 43 39 - 41 36 - 38 31 - 33 TABLE 9-3 Recommended Freezer Pressure Settings Turn top screw to adjust the pressure setting (also referred to as the Range) Clockwise = increase pressure setting Counterclockwise = decrease pressure setting The bot
HEC-Series Service Manual 9-23 SERVICE OPERATIONS • The pressure switch should be adjusted until the desired ice thickness is obtained--See table below for recommended ice weights Machine HEC-10S HEC-10M HEC-20S HEC-20M HEC-30S HEC-30M HEC-40S HEC-40M Cylinder Ice (lbs.) 39 - 41 37 - 39 39 - 41 37 - 39 38 - 40 36 - 38 38 - 40 36 - 38 Crushed Ice (lbs.) 29 - 31 27 - 29 29 - 31 27 - 29 28 - 30 26 - 28 28 - 30 26 - 28 TABLE 9-4 Recommended Ice Weights per cycle Single To Dual Ice Conversion.
HEC-Series Service Manual 10-1 MODEL NUMBER STRUCTURE 10.
HEC-Series Service Manual 11-1 TABLES AND CHARTS 11.
HEC-Series Service Manual 11-2 TABLES & CHARTS TEMPERATURE - PRESSURE CHART FOR COMMON REFRIGERANTS DegF -50 -48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 R-12 -7.6 -7.2 -6.8 -6.3 -5.8 -5.4 -4.9 -4.4 -3.8 -3.3 -2.7 -2.1 -1.5 -0.8 -0.1 0.6 1.3 2.1 2.8 3.7 4.5 5.4 6.3 7.2 8.2 9.2 10.2 11.2 12.3 13.5 14.6 15.8 17.1 18.4 19.7 21.0 22.4 23.9 25.4 26.9 28.5 30.1 31.7 33.4 35.2 36.9 38.8 40.
HEC-Series Service Manual 11-3 TABLES AND CHARTS All pressures are in lbs/in2 gage (psig). REFERENCE INFORMATION CONVERSION FACTORS: English to Metric To Convert Area From ft2 in2 To m2 m2 Multiply by 9.2903e-2 6.416 e-4 Energy BTU hp kW Joule (J) BTU/Hr hp 1054.48 2546.2 1.34 Length ft. in. m. m. 0.3048 0.0254 Pressure lbf/ft2 lbf/in2 (psi) in. Hg in H2O Paschals Paschals psi psi 47.88 6894.76 0.491 0.03612 °F °C °C °F TC=5/9*(TF - 32) TF=(9/5*TC) + 32 ft3 gal(U.S.) ft3 m3 m3 gal(U.S.
HEC-Series Service Manual 12-1 TECHNICAL SERVICE BULLETINS 12. Technical Service Bulletins No. 88-5 All Models Subject: Water Conditioning For Ice Cube Machines The quality of the ice produced by a commercial ice cube machine can only be as high as the quality of the water which is used. Water which contains turbidity or sediment or which has a high concentration of dissolved minerals or gases will produce cloudy or opaque ice.
HEC-Series Service Manual 13-1 INDEX 13.
HEC-Series Service Manual 13-2 INDEX FIGURE 3-1 ---------------------------------------------- 3-2 G FIGURE 3-2 ---------------------------------------------- 3-3 Gear Reducer-------------------------------------- 7-6,9-10 FIGURE 3-3 ---------------------------------------------- 3-4 FIGURE 3-4 ---------------------------------------------- 3-6 H FIGURE 3-5 ---------------------------------------------- 3-7 Harvest Cycle, Wiring Schematics (Dual Ice) --- 6-18 FIGURE 3-6 ----------------------------
HEC-Series Service Manual 13-3 INDEX N S NEMA ------------------------------------------------------ 2-1 Safety, Codes--------------------------------------------- 1-4 Nomenclature, Piping Schematic -------------------- 1-9 Safety, Symbols ------------------------------------------ 1-2 Non-Condensable Gases ---------------------------- 9-18 Safety, Valves (First Arrival) --------------------------- 2-1 Normal Operating Vitals ------------------------------ 11-2 Selector Switch (SS) --------------
HEC-Series Service Manual 13-4 INDEX V Vitals, Operation --------------------------------------- 12-2 W Warranty (Basic Product)-----------------------Rear Pg. Warranty Registration--------------------------- Front Pg.
