m529 Sunwell - Manual

deepchillTM Ice System
Installation, Operation & Service Manual
2007 Sunwell Technologies Inc.
Operations & ControlSystem Customization
Amendments
Drawings
Safety and Installation

Guideline
Ice Generator Service
Manual
Brine System User
Manual
IG Troubleshooting
Guide
OEM Manuals
Letter of Acceptance
The undersigned representative of __________________________________________
hereby certifies that the ice plant and system supplied by Sunwell Technologies Inc. to
________________________________________ of ____________________________
______________________________________________________________________
pursuant to the ice making machines and components described in
Customer Purchase Order _________________________________________________
and Sunwell Job/Quotation number __________________________________________
(hereinafter the system) has been fully and properly installed and started up and is
capable of continuous industrial operation according to order specifications and design
parameters.
This letter further certifies that
All system parts and components included in Sunwells scope of supply have been
received.
System start up, balancing and adjustment is complete.
System ice production and ice delivery is in accordance with other specifications and
design parameters.
Service and maintenance training of service personnel is complete.
Instruction manuals for system operation and components have been received.
A copy of Sunwells standard warranty terms have been received and will be
effective as of the date of execution of this letter.
DATE:_______________
________________________________
______________________________c/s
I have the authority to bind the company.
Sunwell Technologies Inc.
________________________________
Authorized Sunwell Representative
Sunwell Technologies Inc. 180 Caster Avenue, Woodbridge, Ontario, Canada L4L 5Y7
Tel. (905) 856-0400 Fax. (905) 856-1935 email: inquiries@sunwell.com website: www.sunwell.com
deepchillTM
Ice System
Operation & ControlsSystem Customization
OPERATION AND CONTROL
SUNWELL DEEPCHILL SYSTEM

I. System Description
The DeepChill Ice System consists of a containerized system (with ice generators,
a pump/control station, chillers, and a heat exchanger inside), an ice silo and a
chilled water silo. DeepChillTM will be generated inside the ice generator and
circulated to the silo. The system is designed to operate with a sea water supply.
The silo will store the ice in the form of an iceberg. Dry crystals are harvested from
the silo and water is added to the crystals to obtain the desired ice fraction. The ice
slurry will fall down a chute. The control panel includes a programmable logic control
(PLC) device to assure the operation and the protection of the ice generator, pump
and ice silo tank.
In the following sections, the operation and the control of the ice generating and ice
delivery systems will be presented. Recommendation on the operation settings will
also be provided. At certain points of description, please refer to the P&ID and
Control/Electrical diagrams in the Drawings section.
The system needs to be configured during the start-up installation by a Sunwell
representative. The system configuration needs to be maintained and checked even
after the start-up installation. The configuration procedures will be presented in later
sections.
Ice System Main Components

1
1
1
Containerized System, consisting of the following

2 - DeepChill Ice Generator, model IG-12VM-F-R404A-380
1 - Pump Station with 6 variable area flow meters and 5 solenoid valves
4 - Chiller Units with centrifugal pump

1 - Heat Exchanger
2 - Control Panel with programmable logic control
Ice Silo
Chilled Water Silo
OPERATION - PAGE 1 OF 15
II. Control Panel Layout
A. Main Control Panel

(d)
(a)
(e)
(f)
(b)
(g)
(c)
(a)
TP 177 Operator Interface

This touch screen is used for communication between the control
and the operator. Troubleshooting signals will be displayed on the
screen. Function keys are provided for controlling purposes.
(b)
Emergency Shutdown Push Button

This is used when emergency system shutdown is needed for any
case of unknown disturbances. This will disable all the controls of
the ice generating system by disconnecting the power to the
programmable logic control (PLC) and the output control power
supply. During emergency shutdown, the crankcase heater(s) for
the compressor will still be on.
(c)
Alarm acknowledgement Push-button and pilot light

Used to acknowledge any new alarm generated by the system.
The pilot light will be flashing if at least one unacknowledged alarm
is present in the system. It will remain On if all alarms are present
and acknowledged.
(d)
Control Panel Box Door Lock

These are used to lock and secure the control panel door. Ice
(e)
Delivery On/Off Switch

This switch is used to enable and disable the ice delivery process.
(f)
Power On Pilot Light

This light is used to indicate that the control panel is powered.
(g)
Alarm Buzzer
Turns On when there is at least one unacknowledged alarm
present in the system.
B. Secondary Control Panel

(e)
(a)
(f)
(b)
(g)
(c)
(d)
(a)
Power On Pilot Light

This light is used to indicate that the control panel is powered.
(b)
IG #3&4 On/Off Switch

This switch is used to turn On/Off the 2nd ice generating system
(c)
Chiller #2 On/Off Switch

This switch is used to turn On/Off the 2nd chiller system
(d)
Emergency Shutdown Push Button

This is used when emergency system shutdown is needed for any
case of unknown disturbances. This will disable all the controls of
the ice generating system by disconnecting the power to the
programmable logic control (PLC) and the output control power
supply. During emergency shutdown, the crankcase heater(s) for
the compressor will still be on.
(e)
Control Panel Box Door Lock

These are used to lock and secure the control panel door.
(f)
IG #1&2 On/Off Switch

This switch is used to turn On/Off the 2nd ice generating system
(g)
Chiller #1 On/Off Switch

This switch is used to turn On/Off the 2nd chiller system
C. Remote Control Panel
(b)
(c)
(a)
(a)
Ice Delivery ON/OFF Push Button

To turn the Ice Delivery process On, the Ice Delivery switch on the
Main Control Panel must be in the On position. To initiate ice
delivery, press this button for 3 seconds. To stop ice delivery,
press for 1 second and then release.
(b)
Ice Delivery ON/OFF Light Indicator

A solid green light indicates that the system is prepared to delivery
ice. While ice is being delivered, this light will blink for 1-second
intervals.
(b)
Ice Delivery Alarm Indicator Light

This light is used to indicate that the system is not ready to deliver
ice.
I. Introduction
A. General Information
1. The system is operated automatically and all processes are controlled by
the PLC (SIEMENS CPU 224).
2. There is one main electrical panel with a TP177 touch screen panel. All
messages and information about system alarms are shown on the
TP177. All messages are displayed in ENGLISH.
3. The system is designed to produce slurry with an ice fraction of 50%.
4. The system is designed to operate at a salinity of 3.5% or higher. If
needed, a Sunwells representative will determine the initial addition of
salt at the start-up of the system.
B. TP177 Screen Functions

1. Main Screen with Full ice, low ice, and low water level message. The four buttons
at the bottom will take you to the IGs, Chillers, Temperature Monitoring, and Service
Screens.
2. IGs # 1&2 Status Screens.
3. IGs # 3&4 Status Screens
4. Chiller System #1 Status Screen.
5. Chiller System #2 Status Screen.
6.Temperature Monitoring Screen.
7. Service Screen
8. Setup screen #2
9. Start-Up Control Screen
II. System Operating Procedures

Please refer to the nomenclature from the P&ID in the System Drawing section.
A. System Start-Up
1. Make sure the control panel is powered (the pilot light is on) and the
emergency shutdown button is pulled out.
2. Make sure the compressor crankcase is warm. (i.e. the system has to be
powered for at least 4 hours for warming up the compressor crankcase). See
the compressor service guide (provided in the OEM Manual section) for more
details.
B. Ice Making
1. To begin put the Ice Making switch in the On position (the PLC program will
start making ice in the Silo. If there are no alarms in the system, the TP177
display will show the real time clock and the "SUNWELL TECHNOLOGIES -- DEEPCHILL --- " strings.
2. If the silo is not full of ice and the low water alarm is OFF, the Circulation
pump between the silo and the Ice Generator (IG) will start. The pump will
keep running if there are no system alarms (e.g. overload, temperature, level
in Mix tank, etc.).
3. The system will simultaneously send a signal to start the IG condenser water
pump to start and start the IG Agitator motor and condenser water pump.
4. Compressors will start 4 seconds after, if:
The agitator motor, condenser water pump, and circulation pump are
running
There is enough salt in the silo: Default SP 4.0%
Compressor pressures are normal
Silo is not full of ice
5. If the salinity inside the tank is less than 4.0% for 10s the IG compressors will
be stopped. When the salinity inside the silo is above 4.0% for 30 seconds
the pump will stop.
6. Ice making will stop when the silo is full of ice.
7. To stop the Ice Making, turn the Ice Making switch to the Off position. This
will result in the consecutive stop of each device involved in the Ice Making
process. The stop order will be opposite to the one described at the
beginning of the current chapter (see paragraphs 2 to 4 above).
When the salinity in the silo goes above 6.5%, the system will desalinate the silo.
Desalination entails draining cold high salinity water from the silo through a heat
exchanger. On the other side of the heat exchanger the system will pump warm
seawater (about 3.5 4.5% salinity). This process helps retain the energy spent to
cooling the water. In the case where the warm water is chilled too much by the cold
high salinity water the system will have the cold high salinity water by pass the chiller
to prevent the warm seawater from freezing in the heat exchanger.
C. Ice Delivery
Put the Ice delivery switch in the ON position. The system will indicate that it is
ready to deliver ice by a solid green LED on the remote control panel. The
system will indicate that it is not prepared to deliver ice by a blinking green LED
or a solid red LED on the Remote Control Panel. A green blinking LED indicates
that there is a temporary alarm, such as low ice in the silo. The temporary ice
delivery alarm will disappear with time. A solid red LED indicates that there is a
permanent alarm that must be repaired before delivery can begin check the
TP177 for alarm messages.
To start ice delivery press the solid green LED button for 3 seconds. The green
LED button will now be blinking indicating that the system is delivering ice.
The sequence for ice delivery is as follows:
1. Harvester will start and the make-up water valve will open
2. As ice is detected at the harvester the valve for the remote location will open
and delivery will begin
3. Chute water valve will open
This process may take a minute depending on the level of the iceberg.
The delivery process will last until the silo is empty, or the green blinking LED is
pressed for 1 second to turn Off the delivery process.
C. Chiller
1. To begin put the Chiller switch in the On position (the PLC program will start
making ice in the Silo. If there are no alarms in the system, the TP177
display will show the real time clock and the "SUNWELL TECHNOLOGIES -- DEEPCHILL --- " strings.
2. The chiller pump (between the Chilled water silo and the chillers) will start
3. The system will then send a signal to start the Chiller condenser water pump
4. The compressor will start at 50% capacity in 30sec, if there are no alarms
and the temperature at the exit of the chiller is above 8C (the High
temperature alarm this can be set on the TP)
5. There are 3 level of operation for the chillers they are 0 which is off, 1 which
is running at 50% capacity, and 2 which is running at 100% capacity.
6. After the compressor is on if the chiller exit temperature is below the

temperature set point (5C), the chiller capacity will drop 1 level
7. After the compressor is on if the chiller exit temperature is 1.5 above the
temperature set point (5C), the chiller capacity will increase 1 level
The Chilled Water Silo level is controlled independent of the chiller switches. The
level in the Chilled Water Silo will be controlled when the system is powered.
D. System Protection
The system has an auto harvest option to prevent the iceberg surface from
becoming hard. Auto harvest only works when the ice delivery switch is on. If
ice has been stored for 24 hours without being harvested, ice will be
automatically discharged for 5 minutes. The 24 hours and 5 minute timers can
be changed on setup screen #3 (Section I. B. TP177 Screen Functions screen
# 12). On this screen, auto harvest can also be disabled.
The system has an auto washout cycle every 60 minutes. The washout cycle
time is 100 seconds.
Please note that there will be no washouts while the system is in chilling mode
(products temperature is above +4C). When the temperature is lowered below
+3C and the system is entering ice-making mode, there will be an initial washout
cycle performed during 1 min after the ice-making mode is confirmed.
Afterwards, the regular 60 min. washout cycles will commence.
III.Recommended System Settings

A. Configuring Condensing Water Flow
The condensing water flow rate is very important in ensuring the ice generating
systems performance. The requirements for the configuration are provided in the
following.
1. Use a pressure gage to measure the discharge pressure of the compressor.
2. When the compressor starts, carefully adjust the flow rate of the condensing
water and watch the change of the discharge pressure of the compressor.
3. Use the condensing water flow rate to configure the compressor discharge
pressure into the range of 200 to 230psig1. (Use higher flow to reduce the
discharge pressure)
The stated pressure is valid for condensing water temperature below 24C.
Note:
The compressor discharge pressure must be checked from time to time.

Regulate the condensing water flow rate accordingly as its temperature
may vary throughout the year.
deepchillTM
Ice System
Drawings
- System Drawings
- Mechanical Drawings
- Electrical Drawings
deepchillTM
Ice System
Installation
Ice System Safety & Installation
CONTENT
Table of Content
Section
1. Safety & Precautions
Page
01-04
I. Important Safety Information

A. Training & Experience .................................................................................... 01
B. Accordance with Instructions .......................................................................... 01
C. System Modification ....................................................................................... 01
II. Precautions
A. General........................................................................................................... 02
B. Electrical .................................................................................................... 02-03
C. Refrigerant System......................................................................................... 03
D. System Operation...................................................................................... 03-04
2. Receiving
05-06
I. Checking The Shipment

....................................................................................................................... 05
II. Placing The Ice Generator
.................................................................................................................. 05-06
3. Piping
07-09
I. General Guidelines
A. Checklist ......................................................................................................... 07
B. Piping Units .................................................................................................... 07
C. After Piping Installation.............................................................................. 07-08
II. Brine Piping
A. Piping Material................................................................................................ 08
B. Piping Accessories ......................................................................................... 08
III. Ice Slurry Piping
A. Piping Material................................................................................................ 08
IV. Condensing Water Piping
A. Water Supply .................................................................................................. 09
C. Piping ............................................................................................................. 09
Ice System Installation Handbook i
Ice System Safety & Installation
CONTENT
Table of Content
Section
4. Electrical
Page
10-12
I. System Wiring
A. Guidelines & Recommendations .................................................................... 10
B. After Installation.............................................................................................. 10
II. Compressor Terminal Wiring
.................................................................................................................. 11-12
5. System Start-Up
13-14
I. System Start-Up Checklist

A. Before Power Is Supplied to Control Panel .................................................... 13
B. When IG First Started................................................................................ 13-14
Ice System Installation Handbook ii
Safety & Precautions
SAFETY
I. Important Safety Information

A. Training & Experience
The information in this manual is intended for individuals with a comprehensive understanding
of electrical, refrigeration and mechanical systems. Any attempt to repair heavy machinery may
result in personal injury and/or property damage. The manufacturer or seller is not responsible
for the interpretation of information in this manual, nor assumes any liability in connection with
its use.
B. Accordance with Instructions

Prior to installation and operation of Sunwell equipment, please read this manual carefully. It is
important to have a thorough understanding of the operating principles of this equipment prior to
operating, adjusting or servicing any system components.
If any clarification is required or questions exist, please contact the manufacturer:
180 Caster Avenue
Woodbridge, Ontario, Canada
L4L 5Y7
Tel:
(905) 856-0400
Fax: (905) 856-1935
Email: inquiries@sunwell.com
A qualified technician will be pleased to address your inquiry.
C. System Modification
No modification can be made to the IG unit without the prior consent of the manufacturer. For
your safety, use spare parts and accessories authorized by the manufacturer. The use of other
parts exempts the manufacturer from any and all responsibility
Ice System Installation Pg. 1 of 15
SAFETY
II. Precautions
A. General
Installation, maintenance and servicing of this equipment can be hazardous due to system
pressures, electrical components and equipment location. When working on the equipment,
observe all precautions in the manuals, tags, stickers and labels attached to the equipment and
any other safety precautions that apply.
Read and follow the manufacturers instruction.
y
y
y
y
y
y
y
y
y
y
Follow all safety codes.

Wear safety shoes, safety glasses, safety hat and protective gloves.
Exercise caution when working on the equipment.
Make sure the power to the equipment is shut off before performing maintenance or
service.
Never operate the equipment with any guards removed.
Never service equipment that is still in motion. Stop it and lock off the power.
Never use the equipment for purposes other than it is intended.
Never operate the equipment with safety controls bypassed.
Never attempt to modify settings or the design of the equipment without consulting the
manufacturer.
If the system is to be shut down during the winter, and if the ambient temperatures may
drop below freezing (0C) when the system is not in operation, the binary liquid should
be drained to eliminate the possibility of freeze-up and damage to the system.
B. Electrical
y The power supply, voltage, frequency and phase must coincide with specifications on all
motor (compressor, wiping mechanism, drive, harvester, pumps etc.) and electrical
panel nameplates.
y Field wiring must comply with local and national codes.
y All wiring should be guarded against abrasion.
y All switches should be of the sealed type, recommended by the manufacturer for use in
wet environments.
y Electrical cables connecting split units should have a watertight cable cover, or should
be run in conduit.
y All wiring should be fastened securely to prevent chafing, and should be clearly identified
by wire marking and/or following the applicable color code.
y For the safety of operating and maintenance personnel, the electrical system should be
grounded to the frame, and the frame in turn grounded to the ground. All components
SAFETY
should be grounded from one to the other. Cables to remote sources of power should
carry an extra wire for grounding purposes at the supply end.
y Installing emergency stop switch (or multiple switches in series if necessary) on or
around the machine of the system is highly recommended. This switch should be hardwired between "manual/auto/off" switches and motor starter coils in the motor starter
control circuits of individual motors. The engagement of any of these switches will
immediately stop the relevant motor.
y Installing individual lockable safety stop switches on, around or within sight of all the
motors is highly recommended. The switch(es) should be hard-wired on or interlocked
with the "live" line supplying the control circuitry of the complete system (a machine,
multiple machines or the entire plant). The engagement of this "master" switch (or any
of the multiple switches) will result in immediate and complete shut down of the entire
system and all of its components.
C. Refrigerant System
y Absolute cleanliness is essential in a refrigeration system in order to insure a reliable,
trouble free operation. Take extreme care to keep foreign materials out of the system
when it is opened for service.
y Never heat the equipment.
y Never expose refrigerant cylinders/jackets to the direct sunlight.
y Never place an electric resistance heater in direct contact with a refrigerant jacket.
y Never apply a direct flame to a jacket.
y Never weld onto equipment charged with refrigerant.
y Do not damage, dent, or otherwise abuse refrigeration cylinders/jackets. Always keep
the valve cap and head cap in place when the cylinder is not in use. Always open all
refrigerant valves slowly.
y The system contains refrigerant under pressure. Never tamper with safety cutout
pressure settings.
D. System Operation
WARNING: Before performing any maintenance or inspection, make certain that all power
has been disconnected and locked in the OFF position. The system/machine is
under automatic control. It can start at any moment without warning!
Installation, start-up and servicing of this equipment can be hazardous due to system pressures,
electrical components and equipment location. When working on the equipment, please follow
all general precautions listed in Part A.
SAFETY
The water supply, which is entering the ice generating system, must equip with a properly
selected filter and/or strainer to prevent solid impurities or particles (e.g. sand or corrosion dirt
that might score wiped heat exchanger surfaces). These foreign matters may accumulate on
the IG inner surface and seize wiping mechanism bearings and bushings, thus overload the
wiping mechanism drive motor.
When the system is not in operation, engage and lock all field on/off safety switches to the
OFF position. This applies to all pumps, electrical motors and compressors. Please realize
that motor starters for the above equipment can be located in various enclosures such as
individual motor starter boxes, control panels, Motor Control Centre (MCC) cubicles or
compartments. It is recommended to turn all the selector switches on control circuits on all
related motor starter enclosure covers (doors) to OFF or, if not available, manual position.
During extended shut down periods when the system is unmanned, it is recommended to put all
the circuit breakers on power lines as well as on control lines inside all related motor starter
enclosures to OFF position.
If the system is to be shut down during the winter, and if the ambient temperatures may drop
below freezing point (0C) when the system is not in operation, the binary liquid should be
drained to eliminate a possibility of freeze-up and damage to the system.
Receiving
INSTALLATION
I. Checking The Shipment

Assign a dependable individual to receive the equipment at the job site. Each shipment should
be checked carefully against the bill of lading. The shipping receipt should not be signed until
all items listed on the bill of lading have been accounted for.
Inspect the shipment carefully for visible and/or concealed damage. Any shortage or damage
should be claimed immediately with the insuring company. The carrier must be notified in
writing within 3 days with a receipt of the equipment for an Intent to Claim.
Visually check all refrigerant lines for damage. If a leak is suspected, check all joints with a
Halogen Leak Detector.
II. Placing The Ice Generator

Thoroughly inspect the units prior to installation to ensure that there is no visible damage. Use
care when handling units to avoid marring or chipping the painted surfaces. Any damage to the
paint may result in rusting of the surface and must be repaired immediately. Make sure the unit
are thoroughly cleaned and that all packing materials are removed.
WARNING: The Ice Generator (IG) must not be exposed to direct sunlight or unusual air
currents for a prolonged period of time.
Ensure the unit is installed in a well-ventilated area that is not subjected to ambient temperature
below 4C (40F) or above 40C (104F). It should also be away from areas of soot, dust and
moisture (e.g. boiler steam exhaust).
CAUTION: Keep chemicals such solvents, gasoline etc. away from the equipment. They
could cause damage to the system components upon contact.
The IG should be positioned to allow sufficient space:
y For all piping connections,
y For servicing of the compressor and controls,
y For easy access to the electrical panel(s),
y For removing and servicing the IG shafts, and
y To comply with all local building and electrical codes.
CAUTION: Ice Generator is heavy. Always use equipment with adequate load carrying
capacity to move the units.
The IG is provided with lifting brackets on the four corners of the base. When lifting using these
brackets, use a spreader bar to avoid developing stresses which might distort the unit.
Receiving
INSTALLATION
The unit should be placed on a flat, level foundation that is suitable for supporting heavy
equipment. It should be mounted level to within 10mm/m (1/8 per foot). Locate near drain unit.
The following figure shows the tilting diagram of an IG tube.
Fig. 1) Tilting Diagram
Piping
INSTALLATION
I. General Guidelines
A. Checklist
All piping should be done in accordance with local codes and must follow good piping
practice.
All pipes should be plumb, level and done in a neat workmanlike manner.
When a pipe is cut, de-burr internal and external edges before joining, to insure smooth
flow for ice.
Inspect all openings for foreign material
Remove all plugs, caps and shipping covers
NOTE:
DO NOT expose the internal surfaces of the equipment to the atmosphere for long
periods of time. Moisture or contaminates may enter the units and cause corrosion
or damage.
B. Piping Units
Pipe clamping should be given an allowance for free movement so as to allow the pipe
to contract freely to the applicable low temperatures.
Piping should be set up to connect all equipment as shown in the piping diagram(s) (P &
ID). All piping material and layout recommendations provided by the manufacturer
should be carefully followed.
NOTE:
If you cannot follow the diagrams, for any reason, please advise the manufacturer,
providing an outline of your proposed piping layout.
All piping should be properly secured, supported and should be sloped to provide proper
drainage by gravity if needed.
Connections on the ice-generating unit are not intended to be used as piping anchor
points. NO external piping loads should be transmitted to the unit.
Allow sufficient space in the piping layout to drain the equipment at the lowest points.
C. After Piping Installation
Piping
INSTALLATION
After all the piping is complete, the entire system should be pressure tested. For a satisfactory
system, the installation must be leak tight.
Water pressure must not be greater than 1000 kPa (150 psig) -- check for leaks.
As a further check, it is recommended that the pressure be kept on the system for 8
hours a noticeable drop in the pressure is an indication of a leak in the system.
Adequately insulate all the piping (i.e. ice generator supply the return lines) to prevent
condensation and excessive heat gain. Recommended method is 3/8 thick Armaflex insulation
or equal.
II. Brine Piping

A. Piping Material
For systems using sodium chloride brine, suitable piping materials are:
Heavy duty PVC, CPVC, or Polyethylene or
Stainless steel 316L.
Stainless steel of 400 grade and 304 grade are not recommended because they will rust in an
atmosphere saturated with brine.
B. Piping Accessories
All water sources to the ice generator piping should be equipped with properly selected filter
and/or strainer to prevent solid impurities or particles which may score the internal surface from
entering the ice generator tubes and other heat transfer surface. The filter or strainer should be
capable of removing all sand, weld slag, rust and objects larger than 0.4 mm (1/64)
III.Ice Slurry Piping

A. Piping Material
Piping carrying the ice slurry should have a smooth internal surface without sharp bends,
transitions or obstructions. Suitable piping materials are:
Heavy duty PVC, CPVC
Polyethylene, or
Stainless steel 316L.
Piping
INSTALLATION
WARNING: Piping must not be subjected to any impact, load and/or stress as it may
become brittle at low temperature. Socket or flange type connections are
recommended for all joints. Any excessive glue must be removed to avoid
forming a reducing rim inside the pipe. Pipeline diameter reduction is not
allowed in all ice line without the approval from the manufacturer.
Fittings should be used for ice slurry piping:
Long radius elbow, or 3R elbows (not short radius)
Y connections (not T connections)
Fittings should be used for all welded piping:
Butt weld fittings or
Socket weld fittings
Full bore type ball valves should be used on all ice slurry piping. Butterfly, diaphragm, pinch or
gate valves may be used for low concentration slurry lines. DO NOT use:
8 Backing rings
8 Threaded fittings
8 Globe valves
IV. Condensing Water Piping

A. Water Supply
Water supply to the condenser must meet the specifications for minimum pressure,
minimum flow rate, and maximum supply temperature given by Sunwell, within the project
specifications.
Acceptable sources of cooling water are city water, well water, seawater and cooling
towers.
It is recommended that an analysis of the water be made and an appropriate treatment
system be installed.
The water supply line should be equipped with an adequate filter or strainer to remove all
solid impurities and to prevent fouling of the condenser.
Where hard water is used, adequate treatment should be provided to prevent scaling.
The water piping system requires an appropriate method of controlling the water
temperature and/or flow rate.
Piping
INSTALLATION
C. Piping
Open outlet water drain is recommended to monitor condenser fouling.
For installations where there are multiple units, do not pipe the outlet connections to a
common manifold this makes it difficult to determine if the individual condensers are
operating properly.
Electrical
INSTALLATION
I. System Wiring
A. Guidelines & Recommendations
Check the supply voltage, power, frequency and phase of each motor (compressor and
electric motors). They must coincide with the specifications listed on the equipment
nameplates.
Field wiring should be done carefully and comply with all local codes. The wiring should
be connected in accordance with the electrical wiring diagram(s).
The power and control wiring should run in separate conduits. In some cases the
electrical fields created by the higher voltage power wiring can affect the controls.
All electrical equipment should be properly grounded in compliance with local codes. The
grounding system should have a resistance of not more than 10 ohms.
B. After Installation
After completing the connections, check for proper direction of rotation of:
The ice generators drive motors
The ice generator circulation pumps
The condenser water pumps
All other pumps and rotating equipment
Before starting the equipment, the quality of the supply voltage and ampere must be checked.
The supply voltage must be within 10% and the phase imbalance must not exceed 2% of the
equipment nameplate rating. Total amperage supplied to the system must meet the minimal
requirement as stated in Sunwells electrical system design notes. If a problem exists, contact
your local electric utility company before starting the equipment.
Make sure all the cables or wires, which are exposed to outdoor weather, are covered properly.
For example, in system with storage tank unit, the cable from level probes to electrical panel
has to be shield.
Electrical
INSTALLATION
Low pressure
switch (blue)
Figures 2 below shows the compressor terminal wiring.

installation section of the IG User Manual.
High & Low
Pressure
Switch
This section is also in the
Agitator
L1
L2
L3
Agitator
power lines
Temperature
protection
L1
L3
L2
Compressor
power lines
High pressure
switch (black)
3
2
8
OPC
Sensor
Cable
PLC Inputs
power
Oil Lube
Sensor Cable B
Heater
Cable
Crankcase
Heater Cable
Fig. 2.1) 10 HP Compressor Terminal Wiring Connection
Low pressure
switch (blue)
Electrical
INSTALLATION
High & Low

Pressure
Switch
Agitator
L1
L2
L3
Agitator
power lines
Temperature
protection
L1
L3
L2
Compressor
power lines
1
High pressure
switch (black)
3
9
2
8
OPC
Sensor
Cable
PLC Inputs
power
Oil Lube
Sensor Cable
Heater
Cable
Crankcase
Heater Cable
Fig. 2.2) 15 HP Compressor Terminal Wiring Connection
System Start-Up
INSTALLATION
I. System Start-Up Checklist

NOTE:
Unless stated in the section of Operation Notes and Amendments or approved by

Sunwell Technologies Inc., only Sunwell representatives are allowed to start-up any
Sunwell installations.
NOTE:
Prior to start-up, please review all information from the section of Operation Notes
and amendments and System Configuration and Operation to determine the proper
procedures and precautions for system start-up.
A. Before Power Is Supplied to Control Panel...

The "ON-OFF" switch on all panels should be in the "OFF" position.
The existence of proper ground connection.
The settings of the overload protection for I.G. drive motor, compressor, and all pumps.
All circuit breakers and manual motor starters are in "ON" position.
All tanks and piping must be clean and free of debris. If necessary, clean tanks and flush
all piping.
The concentration of binotherm solution (brine).
All field piping and connections have been made as shown in the flow diagram, all
circulation valves are open, and drain valves closed.
All water piping has been pressurized and checked for any leaks.
Compressor valves (suction and discharge valves) must be fully open.
WARNING: Before the power is supplied to the I.G. control panel, be sure that the panel
door is closed and the on/off switch is in the "OFF" position!
B. When IG First Started...

The "power on" light is illuminated.
Check the temperature controller set point.
Check the rotating direction of each motor. The agitator of the ice generator and the gear
motor at the storage tank always rotates clockwise, other motors such as pumps and
gear motor at the mix tank shall rotate in a manner that correspond to the flow direction
and/or attachments orientation. All rotations are viewed from the motors end. If any one
System Start-Up
INSTALLATION
of the motors is NOT rotating in the right direction, stop the process and turn main power
supply off. Disconnect the power supply and reverse its polarity. If all motors are rotating
in the wrong direction, then simply disconnect the incoming power lines to the control
panel.
WARNING: Failure to follow the recommendation above could result in damage to the
compressor(s) as a result of the reverse rotation. The compressor must continue
to rotate in the same direction that was initially established during factory
testing.
Check that the compressor crankcase heater(s) are activated automatically when the
power is supplied to the control panel. Check, by touching the bottom of the compressor,
if the crankcase is warm.
WARNING: Before initial start up or after any prolonged shut down of the unit (more than 12
hours) the crankcase heater has to be ON for 24 hours. Disconnecting the
heater or reducing the warming time could damage the compressor!
Check and adjust the binotherm (brine) flow at recommended flow rate.
Check the compressor sight glass for oil level.
Check condenser and brine water flow directions are in accordance with arrows indicated
on the unit
deepchillTM
Ice System
Maintenance and
Service Manual
Ice Generator
IG-06VM
Ice Generator Service Manual
CONTENT
Table of Content
Section
1. IG & System Maintenance
Page
01-03
I. General Information
A. Mechanical/Structural Checklist...................................................................... 01
B. Daily (Start-Up)............................................................................................... 01
C. Monthly........................................................................................................... 01
D. Semi-Annually ................................................................................................ 02
E. Annually.......................................................................................................... 02
2. V-Drive Maintenance & Installation
04-06
I. Inspection
A. Inspection While Running............................................................................... 04
B. Sheaves ......................................................................................................... 04
C. Belts .......................................................................................................... 04-05
D. Bearing ........................................................................................................... 05
II. Installation
A. Installing Belts ................................................................................................ 06
B. Tensioning V-Belt Drives ................................................................................ 06
3. Electrical Wiring
07-09
I. Precautions.......................................................................................................... 07
II. Compressor Terminal Wiring .......................................................................... 08-09
4. Replacement Procedures
10-20
I. Top Flange Assembly

A. Pilot Flange Bearing .................................................................................. 10-13
B. Mechanical Seal ............................................................................................. 14
C. O Ring.......................................................................................................... 15
II. Bottom Flange Assembly
A. Marine Bearing .......................................................................................... 16-17
III.Shaft Assembly
A. Blade ......................................................................................................... 18-20
IG Service Manual i
IG Maintenance
MAINTENANCE
1. IG Maintenance
I. General Information
Preventive maintenance is essential to ensure a reliable operation of the system. In general,
maintaining good housekeeping in and around the ice generator (IG) will pay dividends with
respect to general appearance and reduce nuisance faults. Table 1.1 is a summary of the type
of services and their occurrences.
NOTICE:
The brine solution used maybe concentrated and thus prolong exposure to
brine solution may cause corrosion to many metals, and as such, any
spillage or leaks of salt or brine solution should be swept away and hosed
down as soon as practical.
WARNING: Before the system components are taken apart for inspection, make sure
the power supply, condensing water and brine make-up to the IG is
disconnected and isolated. The ice/brine mixture in the IG tube and piping
should be drained.
A. Mechanical/Structural Checklist
Ensure the shaft belts are tightened.

Check the shaft blades whether they are damaged or running in good condition. If they
are damaged, replace in accordance with Blade Replacement Procedure on Pg. 13 of
this manual.
Check whether the machine frame is free of rust.
Check whether brine is leaking through the drain line (see Fig 4.1, part no. 12). If there
is leakage, the mechanical seal is broken. Replace it in accordance with Mechanical
Seal Replacement Procedure on Pg. 14 of this manual.
B. Daily (Start-Up)
Inspect all strainers and filters and clean if necessary.

Inspect the entire system while in operation. Look and listen for any unusual or change
in behaviour. Particular attention should be given to the V-belt drive of the cooling tower.
C. Monthly
Manually operate the agitator motor and drive. Examine for defective bearings and
replace them as required.
Inspect all shaft seals for leaks. Replace them as required.
Tighten all electrical connections and dust out terminal plates.
Inspect for refrigerant or oil leaks. Repair leaks as required and add refrigerant as
required (consult manufacturer prior to adding refrigerant).
IG Service Manual Pg. 1 of 20
IG Maintenance
MAINTENANCE
Inspect the V-belt drive of the cooling tower to determine whether the washer on the
adjusting bolt is aligned with the adjusting gauge (as during start-up).
Inspect the cooling tower for calcium and debris build-up due to hard water. See local
water treatment authorities for possible solutions, addition of chemicals, and/or the
installation of a treatment bleeder.
D. Semi-Annually
Remove IG shaft and inspect for broken blades, springs, rods, bearings and shaft seals.
De-scale condenser water tubes from calcium build-up using liquid scale dissolver. See
Figures A and B below for an example of calcium accumulation.
E. Annually
Remove IG shaft and reassemble with new blades, springs, rods, bearings and shaft
seals.
Disassemble circulation pump and reassemble with new shaft seals and bearings.
Inspect for signs of corrosion. Clean and treat it as required.
Inspect condenser tubes for scale build-up. Clean and treat as required.
Figure A: Cross-section of condenser tube
Figure B: Calcium build-up over original copper
IG Maintenance
Type of Services
Clean Debris from IG Unit
Clean and Flush:
Condenser Tubes
Sleeve Bearings, Caps &
Connection
Check and Adjust:
Agitator Drive Belt
Brine Flow Rate
Discharge & Suction Pressure
Cooling Tower V-belt Drive
Check for Unusual Noise or Vibration:
IG Tube
Compressor
Agitator Motor
Check General Operation of:
Marine Bearings
Compressor Crankcase Heater
Check Level of:
Agitator Motor Voltage & Current
Compressor Oil
Check Rotation without Obstruction:
Agitator Motor
Check for Proper Rotation for:
Agitator Motor
Routine Inspection & Cleaning
Strainers & Filters
Inspect General Condition of:
Equipment
Protective Finish on Equipment
Shaft and Blades
For Extended Shut Down1:
Rotate IG shaft by hand
Table 1.1.) Summary of service types
MAINTENANCE
Start-Up/
Routine
Monthly
Annually
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
More than one month
V-Drive Maintenance & Installation
MAINTENANCE
2. V-Drive Maintenance & Installation

I. Inspection
WARNING: The power supply must be disconnected before belt top cover is being
removed.
A. Inspection While Running

V-Drive Noise
y Can be caused by the slapping of belts against the drive guard or other obstruction due to
improperly installed guard.
y Check for an improperly installed guard, loose belts or excessive vibration.
Squealing of Belt During Start-up or While Running
y Usually caused by a poorly tensioned drive and/or by a build-up of foreign material in the
sheave grooves.
y Can also be caused by oil or grease between the belt and the sheave groove.
B. Sheaves
Smooth and Uniform
y Keep all sheave grooves smooth and uniform
y Burrs and rough spots along the sheave rim can damage belts.
y Dust, oil and other foreign matter can lead to pitting and rust should be avoided as much as
possible.
Shinny Groove Bottom
y This indicates that either the sheave, the belt or both are badly worn and the belt is bottoming
in the groove.
y Badly worn grooves cause one or more belts to ride lower than the rest of the belts
differential driving.
Differential Driving
y A sure sign of differential driving is when one or several belts on the tight side are slack.
y The belts riding high in the grooves travel faster than the belts riding low in a drive under
proper tension.
Drive Alignment
y Improperly aligned sheaves cause excessive belt and sheave wear.
y When the shafts are not parallel, belts on one side are drawn tighter and pull more than their
share of the load.
y Overloaded belts wear out faster, reducing the service life the entire set.
y If misalignment is between the sheaves, belts will enter and leave the grooves at an angle,
causing excessive cover and sheave wear and premature failure.
MAINTENANCE
C. Belts
Cleaning
y Belt should be wiped with a dry cloth occasionally to remove any build-up of foreign material.
y If the belts were splattered with grease and/or oil, clean them with methyl chloroform or soap
and water.
Belt Tension
y Belts that are too loose will slip, causing excessive belt and sheave wear.
y Belts that sag too much are snapped tight suddenly when the motor starts or when peak
loads occur.
Alignment
y If drive shafts are not parallel, belts on one side are drawn tighter and pull more than their
share of the load. These belts will wear out faster as a result.
y If sheaves are not aligned, belts will enter and leave the grooves at an angle, causing
excessive belt cover and sheave wear.
D. Bearing
Hot Bearing
y Could be due to improper lubrication.
y Could also be due to improper drive tension either too tight or too loose.
MAINTENANCE
II. Installation
A. Installing Belts
WARNING:
DO NOT USE LUBRICANTS IN THIS INSTALLATION.
1. Shorten the center distance between the driven and driver sheave so the belts can be put on
without the use of force. This can be done by adjusting the bolts on the agitator mount.
2. While the belts are still loose on the drive, rotate the drive
until all the slack is on one side. Then increase the center
distance until the belts are snug. The drive is now ready for
tensioning.
Fig 2.1
Note:
Never roll or pry the belts into the sheave grooves. This can damage
the belt cords and lead to belt turnover, short life or actual breakage.
Moreover, it is both difficult and unsafe to install belts this way.
B. Tensioning V-Belt Drives

1. Reduce the center distance so that the belts may be placed over the sheaves and in the
grooves without forcing them over the sides of the grooves. Arrange the belts so that both
the top and bottom spans have about the same sag. Apply tension to the belts by increasing
the center distance until the belts are snug. See Fig 2.2.
2. Operate the drive (IG) for a few minutes to seat the belts in the sheave grooves. Observe the
operation of the drive under its highest load condition. A slight bowing of the slack side of the
drive indicates proper tension. Excessive bowing or slippage indicates insufficient tension. If
the belts squeal as the motor comes on or at some subsequent peak load, they are not tight
enough to deliver the torque demanded by the drive machine. The drive should be stopped
and the belts tightened.
Too tight
Too loose
Slight bow
Fig 2.2.) Tensioning Drive Belt
Electrical Wiring
INSTALLATION
3. Electrical Wiring
I. Precautions
y
y
y
y
y
y
The supply power, voltage, frequency and phase must coincide with specifications on all
motor (compressor and agitator motor).
Field wiring must comply with local and national codes.
All wiring should be guarded against abrasion.
Electrical cables connecting split units should have a watertight cable cover, or should be
run in conduit.
All wiring should be fastened securely to prevent chafing, and should be clearly identified by
wire marking and/or following the applicable color code.
For the safety of operating and maintenance personnel, the electrical system should be
grounded to the frame, and the frame in turn grounded to the ground. All components
should be grounded from one to the other. Cables to remote sources of power should carry
an extra wire for grounding purposes at the supply end.
Electrical Wiring
INSTALLATION
Low pressure
switch (blue)

High & Low
Pressure
Switch
Agitator
L1
L2
L3
Agitator
power lines
Temperature
protection
L1
L3
L2
Compressor
power lines
High pressure
switch (black)
3
2
8
OPC
Sensor
Cable
PLC Inputs
power
Oil Lube
Sensor Cable B
Heater
Cable
Crankcase
Heater Cable
Fig 3.1) 10 HP Compressor Terminal Wire Connection
Low pressure
switch (blue)
Electrical Wiring
High & Low
Pressure
Switch
INSTALLATION
Agitator
L1
L2
L3
Agitator
power lines
Temperature
protection
L1
L3
L2
Compressor
power lines
1
High pressure
switch (black)
3
9
2
8
OPC
Sensor
Cable
PLC Inputs
power
Oil Lube
Sensor Cable
Heater
Cable
Crankcase
Heater Cable
Fig 3.2) 15 HP Compressor Terminal Wire Connection
Replacement Procedures
SERVICE
4. Replacement Procedures
WARNING: The power supply must be disconnected. The IG tube must be empty
during replacement.
I. Top Flange Assembly
Fig 4.1.) Top Flange Cross-Section

No. Part
1
IG Shaft
2
Set Screw
3
Pilot Flange Bearing Housing
4
Hex Bolt
6
Mechanical Seal (Seal)
7
Mechanical Seal (Spring)
8
Nylon Lock Nut
9
Pilot Flange Bearing Insert
10
Tub Top Flange
11
Top Shaft Flange
12
Drain Line
13
IG Inner Tube
14
Insulation
Components to Be Replaced
3, 9 Pilot Flange Bearing (Housing, Insert)
6, 7 Mechanical Seal (Seal, Spring)
5
O Ring
Description
x L
1
UNC x L1
1
1
5/16
1
1
5
/8 Plate x 8 OD
Qty.
1
2
1
4
1
1
4
1
1
1
1
1
Part No.
5910-009 P
5910-009 P
5247-417 P
5960-150 P
5960-150 P
5248-060 P
5910-009 P
1
1
5910-009 P
5960-150 P
Neoprene
5290-300 P
Step 3
15
Step 4
16
SERVICE
17
18
19
20
No.
15
16
17
18
19
20
21
22
Part
Bolts (3 pc)
Bushing 1
Sheave 1
Bushing 2
Sheave 2
Belt Cover Bottom
Nut (4 pc)
V-belt 40.0 3VX0400
Part No.
5935-000 P
5935-000 P
5935-001 P
5970-008 P
5970-007 P
204A-0539 P
5930-400 P
A. Piloted Flange Bearing

Fig 4.2.) Removal of Sheaves
Step 7
21
Step 8
20
3, 9
11
Fig 4.3.) Removal of Belt Cover (Bottom)
SERVICE
Bearing Insert
hold the Shaft
Drain Line If the
Mechanical Seal
broke, brine will
leak through this
pipe
Bearing Housing
hold the bearing
Mechanical Seal
the Seal, stays
with the top flange
Mechanical Seal
the Spring, stays
with the Shaft
Gap for the Stuck Key
[Top view] The stuck key locks the

shaft and bushing together.
Fig 4.4.) Removal of Mechanical Seal
1. Removal
1. Remove belt cover top.
2. Relief drive tension by shortening the center distance
between driver and driven sheaves. Adjust the
distance between the agitator and the IG tube. Left
off drive belts.
3. Remove the cap screws from bushing 1.
4. Insert the bolts in tapped
removal holes in bushing and
tighten evenly until bushing
becomes loose on shaft.
5. The sheave will slide off from the shaft.

6. Remove the stuck key.
7. Remove nuts (and washers) from belt cover bottom.
8. Lift off belt cover bottom.
9. Remove bolts (and washers) from the flange.
10. Pull the complete shaft assembly out of the IG tube.
Place it on a rack.
11. Release the cap screws on the bearing insert.
12. The bearing insert is now loose from the shaft.
Remove the hex nuts.
13. The bearing housing is loose now. Remove the old
bearing.
Tool
Qty. Item No.
Screwdriver
9/16 Wrench
1
2
---
Screwdriver
Screwdriver
3
3
15
15
-- Wrench
Wrench
--
1
1
4
1
4
--
Allen key
Wrench
2
4
2
8
--
--
3, 9
17
(See Fig 4)
21
20
4
--
SERVICE
14. Replace the bearing unit with a new one. Slide the
bearing insert onto the shaft.
2. Assembly
1. Tighten the hex nuts on the bearing
housing progressively. (Tighten the
nuts diagonally, i.e., 1 4 2 3)
Tool
1
2. Tighten the cap screws on the bearing insert.

3. Put the complete shaft assembly back into the IG
tube.
4. Tighten the bolts, as in procedure A.2.1.
5. Secure belt cover bottom on the shaft with lock nuts
(and washers).
6. Slide sheave 1 onto the shaft.
7. Insert stuck key on shaft.
8. Slide bushing 1 onto the shaft with cap screw heads
to the outside. The bushing should line up with the
end of the shaft.
9. Remove bolts from tapped removal holes. Insert
them into the holes adjacent to them.
10. Tighten bolts evenly and progressively. The top of
the bushing must be inline with the end of the shaft.
11. Insert and tighten the cap screw from the side of
the bearing. This will lock the stuck key in place.
12. Check the alignment of the bushing 1 and 2. They

should be at the same level.
a) If bushing 1 is not level, redo the cap screws until the
bushing is level.
b) If bushing 2 is not level, adjust the nuts that are on
the agitator motor frame.
13. Check the sheaves
alignment. The grooves
should be inline.
a) If they are inline, go to
Step 15.
b) If they are not inline, go
to Step 14.
14. Loosen the cap screw inside bushing 2. Adjust the
height of bushing 2 (and sheave 2) so that the
grooves of both sheaves are inline.
15. Install driving belts (see Section 2.II).
--
--
3, 9
Qty. Item No.
Wrench
Allen key
2
--
2
--
Wrench
Wrench
4
4
4
21
----
1
1
--
(Fig 4.4)
Screwdriver
15
Screwdriver
15
Allen key
--
Level
--
16, 18
Level
A straight edge
--
17, 19
Allen key
18, 19
--
--
17
16
9/16 Wrench
SERVICE
B. Mechanical Seal
Seal on Top Flange
Spring on Shaft
Fig 4.5.) Mechanical Seal
1. Removal
1. Follow procedure A.1.1 to A.1.12 to remove the top
flange from the IG tube.
2. The bearing insert is now loose from the shaft.
Separate the top flange from the shaft.
3. Remove the mechanical seal from the top flange.
4. Remove the spring section of the seal from the shaft.
2. Assembly
1.
2.
2.
3.
Replace seal section onto the top flange.

Replace the spring section onto the shaft.
Put the top flange and shaft assembly together.
Follow procedure A.2 to reassemble the top shaft
flange.
Tool
Qty. Item No.
--
--
--
--
11
---
1
1
6
7
Tool
-----
Qty. Item No.

1
1
---
6
7
---
SERVICE
C. O Ring
O Ring
IG Inner Tube
Insulation
Fig 4.6.) Placement of the O Ring
1. Removal
1. Remove bolts (and washers) from the flange
Place it on a rack.
2. Assembly
1. At the top of the IG tube, replace O ring.
2. Put the top flange and shaft assembly back into the IG
tube.
3. Tighten the bolts.
Tool
Wrench
--
Tool
Qty. Item No.

4
--
4
--
Qty. Item No.
---
1
--
5
--
Wrench
SERVICE
II. Bottom Flange Assembly

1
14
13
25
23
26
24
27
Fig 4.7.) Bottom Flange Cross Section.

No. Part
1
IG Shaft
13
IG Inner Tube
14
Insulation
23
Marine Bearing Flange
24
Marine Bearing Housing
26
Coupling
27
Threaded Pipe Cap
Components to Be Replaced
25
Marine Bearing
Description
Qty.
1
/8 Plate, 6.75OD
2 Pipe x 2.50 SCH160
1 FPT
2 THD SCH80
Part No.
210D-1804
Not a spare part
Not a spare part
Not a spare part
Not a spare part
Not a spare part
7520-020 P
2OD x 5L
5925-050 P
Welded Tube 6 OD
5
A. Marine Bearing
26
24
25
27
Fig 4.8.) Removal of Marine Bearing
1. Removal
Place it on a rack.
3. Remove the pipe cap.
4. Push the marine bearing out from the inside of the IG
tube.
2. Assembly
1.
2.
3.
4.
Replace the marine bearing at the bottom of the tube.

Put the pipe cap back onto the bearing.
Place the whole shaft assembly back into the IG.
Tighten the bolts.
SERVICE
Tool
Qty.
Item No.
Wrench
--
4
--
4
--
Strap wrench
Long rod
1
1
27
25
Tool
Qty.
Item No.
Hammer
Hammer
- Wrench
1
1
-4
25
27
-4
SERVICE
III. Shaft Assembly
Fig 4.9.) Exploded Blade Assembly

No.
28
29a,b
30a,b
31a,b
32a,b
33a,b
34
35
36
37
38
39
Note:
Part
Female Blade
Spring
Lock Nut
Bushing
Mandrel
Blade Holder
Sleeve Bearing
Round HD Screw
End Pin
Male Blade
Hex Nut
Rod
Description
L 19
#10-24 UNC
x L
x L
0.253 x L 0.5
#10-24 UNC x 1
0.363 x L 0.97
L 19
#10-24 UNC
3
/16 Round Rod
Qty.
1
2
2
2
2
2
4
1
2
1
1
1
Part No.
210C-1307 P
210A-0076 P
5248-300 P
210A-0270 P
210A-0271 P
210B-0638 P
5925-000 P
5252-813 P
210A-0269 P
210C-1304 P
5248-079 P
210B-0685 P
The quantity (Qty.) is based on the assembly of a male blade. The assembly of a female blade
will be the same.
SERVICE
Spare Part Kits

Vertical Accessory Kit
No.
29
30
31
32
34
35
36
Part
Spring
Lock Nut
Bushing
Mandrel
Sleeve Bearing
Round HD Screw
End Pin
1695-0000 K
Description
#10-24 UNC
x L
x L
0.253 x L 0.5
#10-24 UNC x 1
0.363 x L 0.97
Qty.
12
12
12
12
24
06
12
Description
L 19
L 19
Qty.
3
3
Description
#10-24 UNC
3
/16
Qty.
6
6
Vertical Blade Kit

No.
28
37
Part
Female Blade
Male Blade
1695-0002 K
Vertical Rod Kit

No.
38
39
Part
Hex Nut
Rod
Part No.
210A-0076 P
5248-300 P
210A-0270 P
210A-0271 P
5925-000 P
5252-813 P
210A-0269 P
Part No.
210C-1307 P
210C-1304 P
1695-0002 K
Part No.
5248-079 P
210B-0685 P
A. Blade
Shaft
Top Section
Shaft
Middle Section
34
37
32
36
29
39
31
38
35
28
Fig 4.10.) Blade Assembly Shaft Top Section (Drive End)
The following procedures are the removal and assembly of one blade, male or female.
SERVICE
Curve end
on top
Cut off
Curve end
on bottom
Cut off
Curve end
on bottom
Top Section
(Drive End)
Middle Section
Bottom Section
(Non Drive End)
Fig 4.11.) Blade Assembly Top, Middle and Bottom Section
A. Removal
2. Pull the complete shaft assembly out of the IG
tube. Place it on a rack.
3. Remove nuts.
4. Remove rod.
B. Assembly
1. Make sure the new blade (taken from spare part
kit) is of the same kind as the damaged one.
2. Install plastic endpin.
3. Drill holes in plastic endpins.
4. Install sleeve bearings through the drilled holes.
5a. Install screw,
b. Plastic bushing and
c. Nut.
6. Set blade as shown in Fig 4.10.
7a. See Fig 4.11 for the orientation of the rod, and
install these in sequence:
b. Plastic mandrel and
c. Spring.
8. Secure spring free end on plastic bushing.
9a. Install plastic bushing,
b. Nut on rod and
c. Set spring free end on plastic bushing.
Tool
Qty. Item No.
Wrench
--
4
--
4
--
Wrench
--
2
1
30a,b
39
Tool
Qty. Item No.
--
--
--
Hammer
Electrical driller,
drill bit
Hammer
Screwdriver
2
2
36
36
4
1
1
1
1
1
1
1
34
35
31a
30a
37
39
32a
29a
2
1
1
1
29a
31
30b
29b
---
---
deepchillTM
Ice System
Brine System
User Manual
BS-90
Brine System BS-90 Manual
CONTENT
Table of Content
Section
Page
....................................................................................................................... 01
II. Brine Tank Drawings
.................................................................................................................. 01-02
III. Salt Refill Procedures
....................................................................................................................... 03
IV. Brine Table
.................................................................................................................. 04-05
Brine System BS-90 User Manual i
Brine System
BS-90
It is essential to maintain the brine make-up solution (salt solution that is feeding into the ice
generator) of an ice system at a specific salinity range. The brine system is an auxiliary unit that
make-up and maintains the salinity in an ice system within the optimal operating range. Brine
system BS-90 is an open-top tank type that contains concentrated brine solution and allows the
user to refill at anytime. When the conductivity cell (at the pump station) senses a low salinity in
the brine make-up, the motorized ball valve that controls the flow from brine tank will open.
Concentrated brine will be fed into the brine make-up to recoup the salinity. The brine tank is
used in freshwater ice systems as well as some seawater ice systems.
II. Brine Tank Drawings

No.
Part
Description
01
02
03
04
05
24 x 48 Tank with cover

1 nipple x 3 (use half)
1 elbow x 45 (sxs)
Ref. Drawing # M448M017
07
08
Tank
Nipple
Elbow
Piping assy
Suction header
Float switch
header
Screener assy
Elbow
09
Pipe
10
Mounting plate
11
Hex-bolt
12
13
14
Flat washer
Nylock nut
Hex nut
06
PVC
PVC
SCH80
SCH80
Qty
.
1
1
1
1
1
Part No.
7699-069 P
7575-106 P
7560-003 P

1 elbow x 90 (sxs)
1 pipe x 2-1/2 approx. (cut
45 at one end)
3/8-16 UNC x 1-1/2 hex
bolt
3/8 flat washer
3/8-16 UNC nylock nut
3/8-16 UNC hex nut
7560-002 P
7696-104 P
PVC
SCH80
1
1
PVC
SCH80
1
1
SS316
5247-303 P
SS316
SS316
SS316
4
2
2
5246-040 P
5248-379 P
5248-075 P
Fig.1.1) BS-90 Brine Tank Component List
Brine System BS-90 User Manual Pg. 1 of 5
Brine System
BS-90
Brine System
BS-90
III. Salt Refill Procedures

Brine tank must be refilled when low salt warning is on the system display (TD 200
display). When the salinity of the brine make up stream is below the preset value, the
control system will stop the ice making process automatically. In order to continue the
ice making process, one must refill the brine tank with salt. Stock of salt should be
readily available for tank refill.
The brine system BS-90 in particular is designed for salt refilling at anytime. It does
not require any system process to be stopped during re-filling. Salt can be poured into
the tank with ease and salt level can be inspected at anytime.
WARNING: Only use high purity and food grade salt. Pellet and cracked types are
allowed. DO NOT use sea-salt or crystallized salt for de-icing.
NOTE:
One full refill of the brine system BS-90 equal approximately 200 kg.
IV. Brine system BS-90 Maintenance

For optimum performance and durability of the brine system BS-90, general
workmanship and tidiness should always be applied. General inspection of the brine
system shall be done every time prior to salt recharge and inspect for foreign objects
and loosen parts.
Complete surface cleaning (inside and outside of the brine system, switch(s) and
valve(s)) should be performed at least once every 6 months.
Brine System
BS-90
IV.Brine Table
Strength of Brine
Freezing Point
Baume Degree
Salometer Degree
SG
Salt in Brine (wt%)
0.0
1.000
0.0000
+32.0
0.3
1.002
0.2640
+31.8
-0.1
0.6
1.004
0.5279
+31.5
-0.3
0.9
1.006
0.7919
+31.3
-0.4
1.1
1.008
1.0558
+31.1
-0.5
1.3
1.010
1.3198
+30.8
-0.7
1.6
1.011
1.5837
+30.5
-0.8
1.9
1.013
1.8477
+30.2
-1.0
2.1
1.015
2.1116
+30.0
-1.1
2.4
1.017
2.3756
+29.6
-1.3
2.7
10
1.019
2.6395
+29.3
-1.5
3.0
11
1.021
2.9035
+29.1
-1.6
3.3
12
1.023
3.1674
+28.8
-1.8
3.5
13
1.025
3.4314
+28.5
-1.9
3.7
14
1.027
3.6953
+28.2
-2.1
4.0
15
1.029
3.9593
+27.9
-2.3
4.2
16
1.031
4.2232
+27.6
-2.4
4.5
17
1.032
4.4872
+27.3
-2.6
4.8
18
1.034
4.7511
+27.0
-2.8
5.0
19
1.036
5.0151
+26.7
-2.9
5.3
20
1.038
5.2790
+26.4
-3.1
5.6
21
1.040
5.5430
+26.1
-3.3
5.8
22
1.042
5.8069
+25.7
-3.5
6.1
23
1.044
6.0709
+25.4
-3.7
6.4
24
1.046
6.3348
+25.1
-3.8
6.7
25
1.048
6.5988
+24.7
-4.1
6.9
26
1.050
6.8627
+24.4
-4.2
7.2
27
1.052
7.1267
+24.0
-4.4
Brine System
BS-90
IV.Brine Table (cont)

Strength of Brine
Freezing Point
Baume Degree
Salometer Degree
SG
Salt in Brine (wt%)
7.4
28
1.054
7.3906
+23.7
-4.6
7.7
29
1.056
7.6546
+23.3
-4.8
7.9
30
1.058
7.9185
+23.0
-5.0
8.2
31
1.060
8.1825
+22.6
-5.2
8.5
32
1.062
8.4464
+22.3
-5.4
8.7
33
1.064
8.7104
+22.0
-5.6
9.0
34
1.066
8.9743
+21.6
-5.8
9.2
35
1.068
9.2383
+21.3
-5.9
9.5
36
1.070
9.5022
+20.9
-6.2
9.7
37
1.072
9.7662
+20.5
-6.4
10.0
38
1.074
10.0301
+20.2
-6.6
10.2
39
1.076
10.2941
+19.8
-6.8
10.5
40
1.078
10.5580
+19.4
-7.0
10.7
41
1.080
10.8220
+19.1
-7.2
11.0
42
1.082
11.0859
+18.7
-7.4
11.2
43
1.084
11.3499
+18.3
-7.6
11.5
44
1.086
11.6138
+17.9
-7.8
11.7
45
1.088
11.8778
+17.5
-8.1
12.0
46
1.090
12.1417
+17.1
-8.3
12.2
47
1.092
12.4057
+16.7
-8.5
12.5
48
1.094
12.6696
+16.2
-8.8
12.7
49
1.096
12.9336
+15.8
-9.0
12.9
50
1.098
13.1975
+15.4
-9.2
13.2
51
1.100
13.4615
+15.0
-9.4
13.4
52
1.102
13.7254
+14.5
-9.7
13.7
53
1.104
13.9894
+14.1
-9.9
13.9
54
1.106
14.2533
+13.7
-10.2
14.1
55
1.108
14.5173
+13.3
-10.4
14.4
56
1.110
14.7812
+12.8
-10.7
14.6
57
1.112
15.0452
+12.3
-10.9
deepchillTM
Ice System
IG Troubleshooting
General Guideline
Troubleshooting Guide
Control Panel Display Messages
Sunwell Technologies Inc.s ice generation systems are normally equipped with number
of operation safety measures. The following guideline is a generic explanation of the possible
system faults and their corresponding remediation actions that may be apply to all Sunwell
system configurations. Due to custom system design and flexible functionality of Sunwells
system, the actual systems display messages may not be limited to the following list. Shall there
be difficulties with applying remediation actions and/or unlisted messages, please contact
Troubleshooting Guide Pg. 1 of 6
TEXT DISPLAY
POSSIBLE CAUSE
REMEDY
IG POWER SWITCHED OFF
Loose power/control wiring
Check and tighten all wirings.
The main switch(es) on the second/ third panel

turned OFF
Turn ON the main power disconnector switch
High condensing temperature
Check condensing pressure, adjust condensing water flow

accordingly.
High suction temperature
Check brine make-up flow rate, adjust flow accordingly.
Defective overload relay
Check the manual motor starter. Replace it if necessary.
Low overload trip setting
Check and correct trip setting (according to compressor service

guide)
Low line voltage
Check and retify power supply.
Low condensing water flow or high condensing

water temperature
Adjust condensing water flow accordingly.
Compressor discharge valve is closed
Open discharge valve.
Abnormal operating conditions
Record operating conditions, contact Sunwell for further

assistance.
High condensing water flow or low condensing

water temperature
Adjust condensing water flow accordingly.
Compressor suction valve is closed
Open suction valve.
COM. OVERLOAD
(Compressor overload)
COMPRESSOR HIGH-DIS.
(High pressure cut-out)
COMPRESSOR LOW-SUC.
(Low pressure cut-out)
TEXT DISPLAY
POSSIBLE CAUSE
REMEDY
COMPRESSOR LOW-SUC.
(Low pressure cut-out)
High salinity
Check the salinity. Reduce it if possible.
Brine make-up rate is low
Adjust brine make-up flow accordingly.
Rotation of Ice Generator agitator is incorrect
Check the agitator rotation. Correct it by switching two wires

connections (two of the three phases).
Severe freeze-up of Ice Generator due to low

salinity
Check brine make-up salinity, increase salinity accordingly.

Check shaft condition (blade, springs, rods).
Brine make-up pumps suction strainer is plugged.
Check and clean mesh screen.
Low oil level in compressor crankcase
DO NOT add oil. Contact Sunwell for further assistance.
Refrigerant charge is low
Add R-404a, maximum of 0.2 kg, then observe operating

condition. Contact Sunwell for further assistance.
Loose communication wiring
Check and tighten communication cable connections.
Defective Oil Lube Control
Check the oil lube control. Replace it if necessary.
Low brine make-up rate
Check and correct flow accordingly.
Rotation of Ice Generator agitator is incorrect
Check and correct agitator rotation.
Current level relay trip setting is higher than

overload setting
Check and adjust current level relay setting accordingly. Adjust

overload setting (according to motor specifications).
Defective current relay
Check the current level relay. Replace it if necessary.
COM. OIL LUBE ALARM

pressure cut-out)
AGITATOR OVERLOAD
(Agitator motor overload)
(Oil
TEXT DISPLAY
POSSIBLE CAUSE
REMEDY
AGITATOR OVERLOAD
Brine make-up pumps suction strainer is plugged.
CLR (current level relay) trip relay adjustment is too

low
Readjust the setting on CLR relay trip. NOTE: the setting has to
be below overload setting.
Blades inside the IG tube worn out
Check the blades and replace if necessary
CLR trip relay - normal condition to protect IG

(up to 30 times in one day is acceptable)
Check CLR trip counter (F4). If the number of the corresponding

IG counter increases rapidly during the day (week), then the IG
flow rate, blades and CLR trip must be checked. Reset counters
by pressing (Shift+F8).
Flow rate is too low
Check the flow rate through this IG.
Low overload trip setting
Check and correct trip setting (according to compressor service

guide).
Defective motor
Check the motor's coils and current on each phase. Replace the
motor if necessary.
Line is blocked/closed
Check all corresponding motorized valves are open. Check all MV

wiring.Clean the pipes.
AG CLR TRIP
CIR. PUMP OVERLOAD

(Circulation pump overload)
TE
XT D
IS P LAY
TEXT
DISPLAY
P
O S S IB LE C
AU S E
POSSIBLE
CAUSE
POSSIBLE CAUSE
R
EMEDY
REMEDY
C O M PR ESSO R LO W -SU C .
COMPRESSOR
LOW-SUC.
AGITATOR
OVERLOAD
(LowDEL
pressure
cut-out)
ICE
PMP
OVERLOAD
H igh salinity
C heck the salinity. R educe it if possible.
TEXT DISPLAY
(Low
pressure cut-out)
(Agitator
(Delivery motor
pump overload)
overload)
High
salinity
Loose
power/control
wiring
Low overload
trip setting
Brine m ake-up rate is low
Brine
make-up
raterelay
is low
Defective
overload
Defective motor
R otation of Ice G enerator agitator is incorrect
Rotation
of Ice pumps
Generator
agitator
is incorrect
Brine make-up
suction
strainer
is plugged.
Loose power/control
wiring
Severe
freeze-up of Ice
G enerator due to low
salinity
AG CLR TRIP
C O M . O IL LU BE ALAR M (O il
HARVESTER
OVERLOAD
pressure cut-out)
(Harvester motor overload)

COM. OIL LUBE ALARM (Oil
pressure cut-out)
Severe
freeze-up
Ice Generator
due to low is too
CLR
(current
levelofrelay)
trip relay adjustment
Mechanical
problem
(e.g.
Loose
pow er/control
w iringsomething fall down from
salinity
low
the top chute to delivery pump)
Loose
power/control
wiring
Blades
the
IGrelay
tube
wornstrainer
out
Brine
minside
ake-up
pum
ps
suction
is plugged.
Defective
overload
Brine
make-up
pumps
suction
strainer
is plugged.
CLR oil
trip
relayin- com
normal
condition
to protect
IG
Low
level
pressor
crankcase
AGITATOR OVERLOAD
Check
brine
increase
salinitythe
accordingly.
Readjust
themake-up
setting onsalinity,
CLR relay
trip. NOTE:
setting has to
Open
check
delivery
pump.
C
heckand
and
tighten
all w(blade,
irings.
Check
shaft
condition
springs, rods).
be below
overload
setting.
Check
and
tighten
all
wirings.
Check
the
and
if necessary
C
heck and
clean m
eshreplace
screen.
Check
the blades
manual
motor
starter.
Replace it if necessary.
the motor's
coils
and current on each phase. Replace the
Check and
tighten all
wirings.
motor
if
necessary.
Check
the
manual
motor
starter. Replace it if necessary.
C heck and correct flow accordingly.
Loose power/control
wiring
Defective
Oil Lube Control
Storage tank is leaking
C
urrent
level
trip
setting isinhigher
Low
brine
make-up
rate
Level
probe
isrelay
frozen
(possible
winterthan
time)
Defective dual level relay (DLR)
Check and
tighten
all wirings.
the oil
lube control.
C heck and correct agitator rotation.
Check and fix the leakage.
C
hecksure
adjust
current
level
relay
setting
accordingly.
Adjust
Check
and the
correct
flowonaccordingly.
Make
heater
the
level
probe
is "ON"
and is heating
overload setting (according to m otor specifications).
the level probe.
Check
motorized
valves
open. Check all MV
C
heck all
thecorresponding
current level relay.
R eplace
it if are
necessary.
Check the DLR.
wiring.Clean
the pipes.
No salt inside the brine tanks
Refill the tanks
Air was not taken from brine tanks
Take air away from brine tanks.
Low overload
trip setting
Loose
communication
wiring
R otation of Ice G enerator agitator is incorrect
overload setting
Line
is blocked/closed
D
efective
current relay
SYSTEM LOW SALINITY!
C heck shaft condition (blade, springs, rods).
Defective
motor
Loose
power/control
wiring
Defective
overload
relay
Low brine m ake-up rate
Defective motor
Loose pow er/control w iring
STOR. TANK LOW WATER

Check
wirings.
connections
(two
ofallthe
three phases).
C
heck and
brinetighten
m ake-up
salinity,
increase salinity accordingly.
Loose
power/control
wiring
D
efective
O il Lube C ontrol
R
efrigerant
is low
Low
oil levelcharge
in compressor
crankcase
Flow rate is charge

too low is low
Refrigerant
Variable speed motor drive overload
AG IT AT O R O VER LO AD
(Agitator m otor overload)
C heck the agitator rotation. C orrect it by sw itching tw o w ires

motor if necessary.
connections
(tw o ofrotation.
the threeCorrect
phases).
Check the agitator
it by switching two wires

Check
and increases
correct triprapidly
settingduring
(based
onday
the(week),
gear motor
IG counter
the
then user
the IG
manual).
flow
rate,
blades
and
CLR
trip
must
be
checked.
Reset
counters
Add R -404a, m axim um of 0.2 kg, then observe operating
DO NOT add oil. Contact Sunwell for further assistance.
condition.
C(Shift+F8).
ontact coils
Sunwand
ell for
further
by
pressing
Check
the motor's
current
onassistance.
each phase. Replace the
motor
if
necessary.
C heck and tighten com m unication cable connections.
Check
the flow
rate through
this
Add R-404a,
maximum
of 0.2
kg,IG.
then observe operating
Switch
OFF/ON
harvester
overload.
Make sure the chute
condition.
Contact
Sunwellmotor
for further
assistance.
C heck and tighten all w irings.
is not blocked by ice. Restart delivery.
correct communication
trip setting (according
to compressor service
Check and tighten
cable connections.
guide).
Check
andoil
tighten
all wirings.
C
heck the
lube control.
R eplace it if necessary.
Lowtooverload
(up
30 timestrip
in setting
one day is acceptable)
Loose com m unication w iring
CIR. PUMP OVERLOAD

(Circulation pump overload)
REMEDY
Check the salinity.

Reduce it if possible.
Check
Check and
and tighten
correct all
tripwirings.
setting (based on the compressor service
guide).brine m ake-up flow accordingly.
Adjust
Adjust
make-up
flowstarter.
accordingly.
Check brine
the motor's
manual
motor
Replace
it ifphase.
necessary.
Check
the
coils
and current
on each
Replace the
Check
(F4).
If the
number
ofassistance.
the corresponding
D
O N OCLR
T addtrip
oil.counter
C ontact
Sunw
ell for
further
TEXT DISPLAY
POSSIBLE CAUSE
REMEDY
ICE DELIVERY LINE !!! HIGH

PRESSURE !!
Loose control wiring
Check and tighten all wirings from the pressure switch to electrical
panel.
Delivery line high pressure
Delivery line is blocked or closed (motorized valve is close).

Clean/wash the lines & check MV power/control wires.
Defective pressure switch
Check the pressure switch (Normally close). Replace it if

necessary.
Storage tank is out of ice
Wait for ice to be made.
Level probe is frozen (possible in winter time)
Make sure the heater on the level probe is "ON" and is heating
the level probe.
Check the DLR. Replace it if necessary.
STOR. TANK LOW ICE
Defective dual level relay (DLR)
deepchillTM
Ice System
OEM Manuals
Refer to P&ID and
Electrical/Control
Drawings for detailed
specifications

180 Caster Avenue, Woodbridge, Ontario, Canada L4L 5Y7
North America Toll Free: +1 866-792-4455
Tel: +1 905-856-0400 Fax: +1 905-856-1935
Website: www.sunwell.com Email: inquiries@sunwell.com
Operation
Instructions
Amendments
Drawings
Safety &
Installation
IG Service
Brine System
IG
Troubleshoot
OEM Manual

m529 Sunwell - Manual

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deepchillTM Ice System

Installation, Operation & Service Manual

2007 Sunwell Technologies Inc.

Operations & ControlSystem Customization

Safety and Installation

Sunwell Technologies Inc.

Operation & ControlsSystem Customization

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

SUNWELL DEEPCHILL SYSTEM

Ice System Main Components

Containerized System, consisting of the following

4 - Chiller Units with centrifugal pump

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

II. Control Panel Layout

A. Main Control Panel

TP 177 Operator Interface

Emergency Shutdown Push Button

Alarm acknowledgement Push-button and pilot light

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

Control Panel Box Door Lock

Delivery On/Off Switch

Power On Pilot Light

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

B. Secondary Control Panel

Power On Pilot Light

IG #3&4 On/Off Switch

Chiller #2 On/Off Switch

Emergency Shutdown Push Button

Control Panel Box Door Lock

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

IG #1&2 On/Off Switch

Chiller #1 On/Off Switch

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

C. Remote Control Panel

Ice Delivery ON/OFF Push Button

Ice Delivery ON/OFF Light Indicator

Ice Delivery Alarm Indicator Light

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

B. TP177 Screen Functions

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

2. IGs # 1&2 Status Screens.

3. IGs # 3&4 Status Screens

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

4. Chiller System #1 Status Screen.

5. Chiller System #2 Status Screen.

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

6.Temperature Monitoring Screen.

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

9. Start-Up Control Screen

2007 Sunwell Technologies Inc.

OPERATION AND CONTROL

II. System Operating Procedures