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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 Sunwell’s 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 Sunwell’s 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 ©2007 Sunwell Technologies Inc.

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. consisting of the following 2 . Ice System Main Components 1 1 1 Containerized System. The system is designed to operate with a sea water supply. Recommendation on the operation settings will also be provided.PAGE 1 OF 15 . The configuration procedures will be presented in later sections. The ice slurry will fall down a chute. At certain points of description. model IG-12VM-F-R404A-380 1 . OPERATION .Heat Exchanger 2 . In the following sections. DeepChillTM will be generated inside the ice generator and circulated to the silo. pump and ice silo tank. System Description The DeepChill™ Ice System consists of a containerized system (with ice generators.DeepChill™ Ice Generator.Pump Station with 6 variable area flow meters and 5 solenoid valves 4 . a pump/control station. The silo will store the ice in the form of an iceberg. please refer to the P&ID and Control/Electrical diagrams in the Drawings section. chillers. Dry crystals are harvested from the silo and water is added to the crystals to obtain the desired ice fraction. and a heat exchanger inside).Chiller Units with centrifugal pump 1 . an ice silo and a chilled water silo.OPERATION AND CONTROL SUNWELL DEEPCHILL SYSTEM I.Control Panel with programmable logic control Ice Silo Chilled Water Silo © 2007 Sunwell Technologies Inc. the operation and the control of the ice generating and ice delivery systems will be presented. The control panel includes a programmable logic control (PLC) device to assure the operation and the protection of the ice generator.

(b) Emergency Shutdown Push Button This is used when emergency system shutdown is needed for any case of unknown disturbances. Troubleshooting signals will be displayed on the screen. the crankcase heater(s) for the compressor will still be on. 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. The pilot light will be flashing if at least one unacknowledged alarm is present in the system. Function keys are provided for controlling purposes.PAGE 2 OF 15 . During emergency shutdown. OPERATION . It will remain “On” if all alarms are present and acknowledged. 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. Control Panel Layout A. (c) Alarm acknowledgement Push-button and pilot light Used to acknowledge any new alarm generated by the system. © 2007 Sunwell Technologies Inc.OPERATION AND CONTROL II.

(g) Alarm Buzzer Turns On when there is at least one unacknowledged alarm present in the system. OPERATION . © 2007 Sunwell Technologies Inc. Ice (e) Delivery On/Off Switch This switch is used to enable and disable the ice delivery process.OPERATION AND CONTROL (d) Control Panel Box Door Lock These are used to lock and secure the control panel door. (f) Power On Pilot Light This light is used to indicate that the control panel is powered.PAGE 3 OF 15 .

During emergency shutdown.OPERATION AND CONTROL B. the crankcase heater(s) for the compressor will still be on. (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. (e) Control Panel Box Door Lock These are used to lock and secure the control panel door. OPERATION . © 2007 Sunwell Technologies Inc.PAGE 4 OF 15 . 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. 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.

OPERATION AND CONTROL (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 © 2007 Sunwell Technologies Inc. OPERATION .PAGE 5 OF 15 .

this light will blink for 1-second intervals. press this button for 3 seconds. © 2007 Sunwell Technologies Inc. While ice is being delivered. the Ice Delivery switch on the Main Control Panel must be in the On position.OPERATION AND CONTROL C. press for 1 second and then release. OPERATION . To initiate ice delivery. Remote Control Panel (b) (c) (a) (a) Ice Delivery ON/OFF Push Button To turn the Ice Delivery process On. To stop ice delivery.PAGE 6 OF 15 . (b) Ice Delivery ON/OFF Light Indicator A solid green light indicates that the system is prepared to delivery ice. (b) Ice Delivery Alarm Indicator Light This light is used to indicate that the system is not ready to deliver ice.

PAGE 7 OF 15 . © 2007 Sunwell Technologies Inc. The system is designed to produce slurry with an ice fraction of 50%. The four buttons at the bottom will take you to the IGs. All messages and information about system alarms are shown on the TP177. The system is operated automatically and all processes are controlled by the PLC (SIEMENS CPU 224). Introduction A. and Service Screens.OPERATION AND CONTROL I.5% or higher. Chillers. If needed. Temperature Monitoring. and low water level message. The system is designed to operate at a salinity of 3. OPERATION . TP177 Screen Functions 1. a Sunwell’s representative will determine the initial addition of salt at the start-up of the system. 4. B. All messages are displayed in ENGLISH. General Information 1. 3. Main Screen with Full ice. low ice. There is one main electrical panel with a TP177 touch screen panel. 2.

OPERATION AND CONTROL 2. 3.PAGE 8 OF 15 . OPERATION . IG’s # 3&4 Status Screens © 2007 Sunwell Technologies Inc. IG’s # 1&2 Status Screens.

© 2007 Sunwell Technologies Inc. Chiller System #2 Status Screen.OPERATION AND CONTROL 4. Chiller System #1 Status Screen. 5. OPERATION .PAGE 9 OF 15 .

PAGE 10 OF 15 .Temperature Monitoring Screen. OPERATION .OPERATION AND CONTROL 6. Service Screen © 2007 Sunwell Technologies Inc. 7.

PAGE 11 OF 15 . Setup screen #2 9.OPERATION AND CONTROL 8. OPERATION . Start-Up Control Screen © 2007 Sunwell Technologies Inc.

Compressors will start 4 seconds after. 4. the TP177 display will show the real time clock and the "SUNWELL TECHNOLOGIES -. System Operating Procedures Please refer to the nomenclature from the P&ID in the “System Drawing” section. If the salinity inside the tank is less than 4. overload. Ice Making 1. the Circulation pump between the silo and the Ice Generator (IG) will start. level in Mix tank. etc. 3. if: The agitator motor. If there are no alarms in the system. (i. the system has to be powered for at least 4 hours for warming up the compressor crankcase).OPERATION AND CONTROL II. The stop order will be opposite to the one described at the beginning of the current chapter (see paragraphs 2 to 4 above). temperature. 2. B.5%. 2. The pump will keep running if there are no system alarms (e. the system will desalinate the silo. and circulation pump are running There is enough salt in the silo: Default SP 4. To stop the Ice Making. 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. 7. A.0% for 10s the IG compressors will be stopped. This will result in the consecutive stop of each device involved in the Ice Making process. OPERATION . If the silo is not full of ice and the low water alarm is OFF. Desalination entails draining cold high salinity water from the silo through a heat © 2007 Sunwell Technologies Inc.0% for 30 seconds the pump will stop. When the salinity inside the silo is above 4. Make sure the compressor crankcase is warm. 6.g.0% Compressor pressures are normal Silo is not full of ice 5.PAGE 12 OF 15 . condenser water pump.DEEPCHILL --. turn the Ice Making switch to the “Off” position. To begin put the Ice Making switch in the “On” position (the PLC program will start making ice in the Silo.). Ice making will stop when the silo is full of ice. Make sure the control panel is powered (the pilot light is on) and the emergency shutdown button is pulled out." strings. System Start-Up 1. When the salinity in the silo goes above 6.e. See the compressor service guide (provided in the OEM Manual section) for more details.

This process helps retain the energy spent to cooling the water. if there are no alarms and the temperature at the exit of the chiller is above 8°C (the High temperature alarm – this can be set on the TP) 5. Harvester will start and the make-up water valve will open 2.PAGE 13 OF 15 . The temporary ice delivery alarm will disappear with time. The green LED button will now be blinking indicating that the system is delivering ice. or the green blinking LED is pressed for 1 second to turn “Off” the delivery process. Chiller 1.5% salinity)." strings. C. If there are no alarms in the system.5 – 4. and 2 which is running at 100% capacity.OPERATION AND CONTROL exchanger. 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. Ice Delivery Put the Ice delivery switch in the ON position. Chute water valve will open This process may take a minute depending on the level of the iceberg. the TP177 display will show the real time clock and the "SUNWELL TECHNOLOGIES -. The system will indicate that it is ready to deliver ice by a solid green LED on the remote control panel. The delivery process will last until the silo is empty. © 2007 Sunwell Technologies Inc. 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. To start ice delivery press the solid green LED button for 3 seconds. To begin put the Chiller switch in the “On” position (the PLC program will start making ice in the Silo. OPERATION . As ice is detected at the harvester the valve for the remote location will open and delivery will begin 3. The sequence for ice delivery is as follows: 1. On the other side of the heat exchanger the system will pump warm seawater (about 3. The compressor will start at 50% capacity in 30sec. 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. 1 which is running at 50% capacity. C. A green blinking LED indicates that there is a temporary alarm. The system will then send a signal to start the Chiller condenser water pump 4. The chiller pump (between the Chilled water silo and the chillers) will start 3. There are 3 level of operation for the chillers they are 0 which is off.DEEPCHILL --. 2. such as low ice in the silo.

the regular 60 min. If ice has been stored for 24 hours without being harvested. ice will be automatically discharged for 5 minutes. After the compressor is on if the chiller exit temperature is below the temperature set point (5°C). 3. The system has an auto washout cycle every 60 minutes. System Protection The system has an auto harvest option to prevent the iceberg surface from becoming hard.OPERATION AND CONTROL 6. Use a pressure gage to measure the discharge pressure of the compressor. 2. Please note that there will be no washouts while the system is in chilling mode (product’s temperature is above +4C). D. On this screen. auto harvest can also be disabled. B. The requirements for the configuration are provided in the following. there will be an initial washout cycle performed during 1 min after the ice-making mode is confirmed. washout cycles will commence.Recommended System Settings A. TP177 Screen Functions – screen # 12). carefully adjust the flow rate of the condensing water and watch the change of the discharge pressure of the compressor. the chiller capacity will increase 1 level The Chilled Water Silo level is controlled independent of the chiller switches. The 24 hours and 5 minute timers can be changed on setup screen #3 (Section I. After the compressor is on if the chiller exit temperature is 1. OPERATION . 1. Configuring Condensing Water Flow The condensing water flow rate is very important in ensuring the ice generating system’s performance. When the compressor starts. Use the condensing water flow rate to configure the compressor discharge pressure into the range of 200 to 230psig1. When the temperature is lowered below +3C and the system is entering ice-making mode. the chiller capacity will drop 1 level 7.5° above the temperature set point (5°C).PAGE 14 OF 15 . The level in the Chilled Water Silo will be controlled when the system is powered. Auto harvest only works when the ice delivery switch is on. (Use higher flow to reduce the discharge pressure) 1 The stated pressure is valid for condensing water temperature below 24°C. © 2007 Sunwell Technologies Inc. III. Afterwards. The washout cycle time is 100 seconds.

OPERATION .OPERATION AND CONTROL 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.PAGE 15 OF 15 . © 2007 Sunwell Technologies Inc.

deepchillTM Ice System Drawings .Mechanical Drawings . .System Drawings .Electrical Drawings ©2007 Sunwell Technologies Inc.

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deepchillTM Ice System Installation ©2007 Sunwell Technologies Inc. .

................................................................................................................................................................. Piping 07-09 I................................................................................................................ 09 IV....................... Checklist ........ 01 II................................................... 01 C............ Piping Accessories .............. 09 © 2007 Sunwell Technologies Inc.............. 05-06 3....... 08 B................................................................................ Piping Units ................................................................................. Piping Material............................. 01 B............. Accordance with Instructions . Safety & Precautions Page 01-04 I.................................................... Piping ................................................. Piping Material............... Refrigerant System........................ After Piping Installation................................................. Water Supply ........... Brine Piping A................... 08 III........ Receiving 05-06 I............... General Guidelines A...................... Precautions A............................ 07-08 II...... General.................................................................................................................................. 03 D.................. System Operation....................................................... 05 II..... Checking The Shipment ............................. Training & Experience .... 09 B.................... Piping Accessories ............................................................................................. 09 C............... 07 B...................................................................Ice System Safety & Installation CONTENT Table of Content Section 1....... Electrical .......... Piping Accessories ...................................... System Modification ..................................................... Condensing Water Piping A......................... 02 B..................... Ice Slurry Piping A...... 03-04 2................................................................................................................... Important Safety Information A.......... 07 C................................................. Placing The Ice Generator ..................... Ice System Installation Handbook – i . 08 B.................................................................................................................................... 02-03 C...........

..................... 10 B................................................ Compressor Terminal Wiring ..................................................................... Before Power Is Supplied to Control Panel .... System Wiring A.................................................. System Start-Up 13-14 I............................... When IG First Started...... Ice System Installation Handbook – ii ...................... 10 II.............. 11-12 5.......... System Start-Up Checklist A....................................................... After Installation.....Ice System Safety & Installation CONTENT Table of Content Section 4........................................... 13-14 © 2007 Sunwell Technologies Inc......... Guidelines & Recommendations .............. Electrical Page 10-12 I.............. 13 B....

For your safety.com A qualified technician will be pleased to address your inquiry. use spare parts and accessories authorized by the manufacturer. B. Any attempt to repair heavy machinery may result in personal injury and/or property damage. Ontario. The use of other parts exempts the manufacturer from any and all responsibility © 2007 Sunwell Technologies Inc. Training & Experience The information in this manual is intended for individuals with a comprehensive understanding of electrical. nor assumes any liability in connection with its use. It is important to have a thorough understanding of the operating principles of this equipment prior to operating. The manufacturer or seller is not responsible for the interpretation of information in this manual. System Modification No modification can be made to the IG unit without the prior consent of the manufacturer. refrigeration and mechanical systems. 180 Caster Avenue Woodbridge. 1 of 15 . If any clarification is required or questions exist. Ice System Installation – Pg. Important Safety Information A. please read this manual carefully. please contact the manufacturer: Sunwell Technologies Inc. adjusting or servicing any system components.Safety & Precautions SAFETY I. Canada L4L 5Y7 Tel: (905) 856-0400 Fax: (905) 856-1935 Email: inquiries@sunwell. C. Accordance with Instructions Prior to installation and operation of Sunwell equipment.

2 of 15 . and the frame in turn grounded to the ground. y y y y y y y y y y Follow all safety codes. If the system is to be shut down during the winter. y All wiring should be fastened securely to prevent chafing. Wear safety shoes. Never attempt to modify settings or the design of the equipment without consulting the manufacturer. Exercise caution when working on the equipment. drive. Never operate the equipment with safety controls bypassed. Read and follow the manufacturer’s instruction.Safety & Precautions SAFETY II. the electrical system should be grounded to the frame. the binary liquid should be drained to eliminate the possibility of freeze-up and damage to the system. and if the ambient temperatures may drop below freezing (0°C) when the system is not in operation. Stop it and lock off the power. Electrical y The power supply. Precautions A. Make sure the power to the equipment is shut off before performing maintenance or service. y For the safety of operating and maintenance personnel. harvester. B. When working on the equipment. and should be clearly identified by wire marking and/or following the applicable color code. stickers and labels attached to the equipment and any other safety precautions that apply. y All wiring should be guarded against abrasion. All components © 2007 Sunwell Technologies Inc. observe all precautions in the manuals. pumps etc. Ice System Installation – Pg. tags. wiping mechanism. y All switches should be of the sealed type. voltage. safety hat and protective gloves. maintenance and servicing of this equipment can be hazardous due to system pressures. y Electrical cables connecting split units should have a watertight cable cover. Never operate the equipment with any guards removed. y Field wiring must comply with local and national codes. safety glasses. electrical components and equipment location. Never service equipment that is still in motion.) and electrical panel nameplates. Never use the equipment for purposes other than it is intended. recommended by the manufacturer for use in wet environments. General Installation. frequency and phase must coincide with specifications on all motor (compressor. or should be run in conduit.

It can start at any moment without warning! Installation. trouble free operation. The engagement of any of these switches will immediately stop the relevant motor. 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. The switch(es) should be hard-wired on or interlocked with the "live" line supplying the control circuitry of the complete system (a machine. dent. y Installing emergency stop switch (or multiple switches in series if necessary) on or around the machine of the system is highly recommended. Take extreme care to keep foreign materials out of the system when it is opened for service. multiple machines or the entire plant). y Installing individual lockable safety stop switches on. D. or otherwise abuse refrigeration cylinders/jackets. C. make certain that all power has been disconnected and locked in the “OFF” position. y Do not damage. Cables to remote sources of power should carry an extra wire for grounding purposes at the supply end. please follow all general precautions listed in Part A. Refrigerant System y Absolute cleanliness is essential in a refrigeration system in order to insure a reliable. The system/machine is under automatic control. Ice System Installation – Pg. y Never heat the equipment. y Never expose refrigerant cylinders/jackets to the direct sunlight. Always open all refrigerant valves slowly. y Never place an electric resistance heater in direct contact with a refrigerant jacket. around or within sight of all the motors is highly recommended. y Never weld onto equipment charged with refrigerant. y The system contains refrigerant under pressure. electrical components and equipment location. start-up and servicing of this equipment can be hazardous due to system pressures. Always keep the valve cap and head cap in place when the cylinder is not in use. When working on the equipment. 3 of 15 . y Never apply a direct flame to a jacket. © 2007 Sunwell Technologies Inc. Never tamper with safety cutout pressure settings. This switch should be hardwired between "manual/auto/off" switches and motor starter coils in the motor starter control circuits of individual motors. System Operation WARNING: Before performing any maintenance or inspection.Safety & Precautions SAFETY should be grounded from one to the other.

“manual” position. control panels.Safety & Precautions SAFETY The water supply. thus overload the wiping mechanism drive motor. Motor Control Centre (MCC) cubicles or compartments. and if the ambient temperatures may drop below freezing point (0°C) when the system is not in operation. These foreign matters may accumulate on the IG inner surface and seize wiping mechanism bearings and bushings. During extended shut down periods when the system is unmanned. It is recommended to turn all the selector switches on control circuits on all related motor starter enclosure covers (doors) to “OFF” or. 4 of 15 . must equip with a properly selected filter and/or strainer to prevent solid impurities or particles (e. When the system is not in operation. Please realize that motor starters for the above equipment can be located in various enclosures such as individual motor starter boxes. the binary liquid should be drained to eliminate a possibility of freeze-up and damage to the system. 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. Ice System Installation – Pg.g. If the system is to be shut down during the winter. electrical motors and compressors. if not available. which is entering the ice generating system. © 2007 Sunwell Technologies Inc. sand or corrosion dirt that might score wiped heat exchanger surfaces). This applies to all pumps. engage and lock all field on/off safety switches to the “OFF” position.

Checking The Shipment Assign a dependable individual to receive the equipment at the job site. Visually check all refrigerant lines for damage. dust and moisture (e.g. Use care when handling units to avoid marring or chipping the painted surfaces. It should also be away from areas of soot. WARNING: The Ice Generator (IG) must not be exposed to direct sunlight or unusual air currents for a prolonged period of time. If a leak is suspected. The IG should be positioned to allow sufficient space: y For all piping connections. CAUTION: Ice Generator is heavy. boiler steam exhaust).Receiving INSTALLATION I. Placing The Ice Generator Thoroughly inspect the units prior to installation to ensure that there is no visible damage. Make sure the unit are thoroughly cleaned and that all packing materials are removed. Always use equipment with adequate load carrying capacity to move the units. Inspect the shipment carefully for visible and/or concealed damage. y For easy access to the electrical panel(s). II. They could cause damage to the system components upon contact. Ensure the unit is installed in a well-ventilated area that is not subjected to ambient temperature below 4°C (40°F) or above 40°C (104°F). and y To comply with all local building and electrical codes. away from the equipment. When lifting using these brackets. check all joints with a Halogen Leak Detector. gasoline etc. The IG is provided with lifting brackets on the four corners of the base. The shipping receipt should not be signed until all items listed on the bill of lading have been accounted for. Any damage to the paint may result in rusting of the surface and must be repaired immediately. Any shortage or damage should be claimed immediately with the insuring company. 5 of 15 . © 2007 Sunwell Technologies Inc. Ice System Installation – Pg. use a spreader bar to avoid developing stresses which might distort the unit. Each shipment should be checked carefully against the bill of lading. y For servicing of the compressor and controls. The carrier must be notified in writing within 3 days with a receipt of the equipment for an “Intent to Claim”. y For removing and servicing the IG shafts. CAUTION: Keep chemicals such solvents.

It should be mounted level to within 10mm/m (1/8” per foot). The following figure shows the tilting diagram of an IG tube. Ice System Installation – Pg. 6 of 15 .Receiving INSTALLATION The unit should be placed on a flat. Locate near drain unit. 1) Tilting Diagram © 2007 Sunwell Technologies Inc. level foundation that is suitable for supporting heavy equipment. Fig.

providing an outline of your proposed piping layout.Piping INSTALLATION I. to insure smooth flow for ice. … Allow sufficient space in the piping layout to drain the equipment at the lowest points. Moisture or contaminates may enter the units and cause corrosion or damage. … Connections on the ice-generating unit are not intended to be used as piping anchor points. for any reason. 7 of 15 . de-burr internal and external edges before joining. B. Checklist … All piping should be done in accordance with local codes and must follow good piping practice. supported and should be sloped to provide proper drainage by gravity if needed. please advise the manufacturer. … All pipes should be plumb. … All piping should be properly secured. Ice System Installation – Pg. level and done in a neat workmanlike manner. … When a pipe is cut. … Inspect all openings for foreign material … Remove all plugs. … Piping should be set up to connect all equipment as shown in the piping diagram(s) (P & ID). NOTE: If you cannot follow the diagrams. After Piping Installation © 2007 Sunwell Technologies Inc. NO external piping loads should be transmitted to the unit. All piping material and layout recommendations provided by the manufacturer should be carefully followed. caps and shipping covers NOTE: DO NOT expose the internal surfaces of the equipment to the atmosphere for long periods of time. 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. General Guidelines A. C.

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. Piping Material For systems using sodium chloride brine. II. Brine Piping A. or … Stainless steel 316L.check for leaks. Stainless steel of 400 grade and 304 grade are not recommended because they will rust in an atmosphere saturated with brine. © 2007 Sunwell Technologies Inc. Suitable piping materials are: … Heavy duty PVC. For a satisfactory system. Ice System Installation – Pg. ice generator supply the return lines) to prevent condensation and excessive heat gain. suitable piping materials are: … Heavy duty PVC. … As a further check.4 mm (1/64”) III. 8 of 15 . CPVC. or Polyethylene or … Stainless steel 316L. the installation must be leak tight. B.Piping INSTALLATION After all the piping is complete. The filter or strainer should be capable of removing all sand. the entire system should be pressure tested. Recommended method is 3/8” thick Armaflex insulation or equal.e. CPVC … Polyethylene.Ice Slurry Piping A. weld slag. 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. … Water pressure must not be greater than 1000 kPa (150 psig) -. Adequately insulate all the piping (i. rust and objects larger than 0. transitions or obstructions. Piping Material Piping carrying the ice slurry should have a smooth internal surface without sharp bends.

minimum flow rate. B. pinch or gate valves may be used for low concentration slurry lines. Pipeline diameter reduction is not allowed in all ice line without the approval from the manufacturer. © 2007 Sunwell Technologies Inc. Piping Accessories Fittings should be used for ice slurry piping: … Long radius elbow. … It is recommended that an analysis of the water be made and an appropriate treatment system be installed. … The water piping system requires an appropriate method of controlling the water temperature and/or flow rate. load and/or stress as it may become brittle at low temperature. within the project specifications. Any excessive glue must be removed to avoid forming a reducing rim inside the pipe. adequate treatment should be provided to prevent scaling. Piping Accessories … 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. seawater and cooling towers. 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. DO NOT use: 8 Backing rings 8 Threaded fittings 8 Globe valves IV. Condensing Water Piping A. Butterfly. B. and maximum supply temperature given by Sunwell. well water. Water Supply … Water supply to the condenser must meet the specifications for minimum pressure. … Acceptable sources of cooling water are city water. … Where hard water is used. 9 of 15 . Ice System Installation – Pg. diaphragm.Piping INSTALLATION WARNING: Piping must not be subjected to any impact. Socket or flange type connections are recommended for all joints.

© 2007 Sunwell Technologies Inc.Piping INSTALLATION C. Piping … Open outlet water drain is recommended to monitor condenser fouling. 10 of 15 . do not pipe the outlet connections to a common manifold – this makes it difficult to determine if the individual condensers are operating properly. Ice System Installation – Pg. … For installations where there are multiple units.

Total amperage supplied to the system must meet the minimal requirement as stated in Sunwell’s electrical system design notes. They must coincide with the specifications listed on the equipment nameplates.Electrical INSTALLATION I. … All electrical equipment should be properly grounded in compliance with local codes. The wiring should be connected in accordance with the electrical wiring diagram(s). in system with storage tank unit. After Installation After completing the connections. contact your local electric utility company before starting the equipment. are covered properly. The grounding system should have a resistance of not more than 10 ohms. B. 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 supply voltage must be within 10% and the phase imbalance must not exceed 2% of the equipment nameplate rating. 11 of 15 . … Field wiring should be done carefully and comply with all local codes. © 2007 Sunwell Technologies Inc. If a problem exists. frequency and phase of each motor (compressor and electric motors). System Wiring A. In some cases the electrical fields created by the higher voltage power wiring can affect the controls. the cable from level probes to electrical panel has to be shield. For example. Guidelines & Recommendations … Check the supply voltage. the quality of the supply voltage and ampere must be checked. which are exposed to outdoor weather. power. Ice System Installation – Pg. Make sure all the cables or wires. … The power and control wiring should run in separate conduits.

installation section of the IG User Manual. 12 of 15 .Electrical INSTALLATION II. Ice System Installation – Pg. High & Low Pressure Switch This section is also in the Agitator L1 L2 L3 Agitator power lines Temperature protection L1 L3 1 L2 9 Compressor power lines High pressure switch (black) 3 2 8 OPC Sensor Cable PLC Inputs power Oil Lube Sensor Cable B R W Heater Cable N Crankcase Heater Cable Fig. Compressor Terminal Wiring Low pressure switch (blue) Figures 2 below shows the compressor terminal wiring.1) 10 HP Compressor Terminal Wiring Connection © 2007 Sunwell Technologies Inc. 2.

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 B R W Heater Cable N Crankcase Heater Cable Fig.2) 15 HP Compressor Terminal Wiring Connection © 2007 Sunwell Technologies Inc. 13 of 15 . 2. Ice System Installation – Pg.

… Compressor valves (suction and discharge valves) must be fully open. 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. … All water piping has been pressurized and checked for any leaks. … The "ON-OFF" switch on all panels should be in the "OFF" position. … All circuit breakers and manual motor starters are in "ON" position. and drain valves closed. NOTE: Prior to start-up. Before Power Is Supplied to Control Panel. … All field piping and connections have been made as shown in the flow diagram. Ice System Installation – Pg.System Start-Up INSTALLATION I. 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 attachment’s orientation. … The "power on" light is illuminated. … Check the rotating direction of each motor. A. If any one © 2007 Sunwell Technologies Inc.. 14 of 15 . … All tanks and piping must be clean and free of debris. … Check the temperature controller set point.G. … The settings of the overload protection for I. only Sunwell representatives are allowed to start-up any Sunwell installations.. and all pumps.. The agitator of the ice generator and the gear motor at the storage tank always rotates clockwise. clean tanks and flush all piping. control panel. … The concentration of binotherm solution (brine).. drive motor. all circulation valves are open. All rotations are viewed from the motor’s end. System Start-Up Checklist NOTE: Unless stated in the section of Operation Notes and Amendments or approved by Sunwell Technologies Inc. When IG First Started. WARNING: Before the power is supplied to the I.G. compressor. … The existence of proper ground connection. If necessary.. be sure that the panel door is closed and the on/off switch is in the "OFF" position! B.

by touching the bottom of the compressor. Disconnecting the heater or reducing the warming time could damage the compressor! … Check and adjust the binotherm (brine) flow at recommended flow rate. if the crankcase is warm. … Check condenser and brine water flow directions are in accordance with arrows indicated on the unit © 2007 Sunwell Technologies Inc. Ice System Installation – Pg. stop the process and turn main power supply off. … Check the compressor sight glass for oil level. … Check that the compressor crankcase heater(s) are activated automatically when the power is supplied to the control panel. Check. WARNING: Failure to follow the recommendation above could result in damage to the compressor(s) as a result of the reverse rotation. then simply disconnect the incoming power lines to the control panel. The compressor must continue to rotate in the same direction that was initially established during factory testing. Disconnect the power supply and reverse its polarity. 15 of 15 .System Start-Up INSTALLATION of the motors is NOT rotating in the right direction. If all motors are rotating in the wrong direction. 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.

deepchillTM Ice System Maintenance and Service Manual Ice Generator IG-06VM ©2007 Sunwell Technologies Inc. .

..... Installing Belts .................................................................... Belts ...................................... Marine Bearing ............................ IG Service Manual – i .............................................................................................. 08-09 4.......................................................... 01 C...........................................................................................................Shaft Assembly A........................ General Information A.................... Tensioning V-Belt Drives ....................................... Semi-Annually ........... 01 D............ “O” Ring........................................................ Daily (Start-Up)............................................................... Pilot Flange Bearing ................................ Monthly... Blade . 04 B........................ 10-13 B....... 18-20 © 2007 Sunwell Technologies Inc............................... Mechanical/Structural Checklist........ V-Drive Maintenance & Installation 04-06 I........................................ 15 II....... Installation A........... Bottom Flange Assembly A............. 05 II.......................................Ice Generator Service Manual CONTENT Table of Content Section 1............ Top Flange Assembly A............................................................................. Compressor Terminal Wiring .... Electrical Wiring 07-09 I...................................................... Sheaves ....................................................... 04-05 D................... 02 E....................................................................................... Bearing ............................................................................................................................................ 06 3.................... Inspection A...... 02 2......... Mechanical Seal ....................... 14 C.......................................................................... IG & System Maintenance Page 01-03 I................................. 06 B.............. Inspection While Running.................................................................. 16-17 III........................................................................................................ 07 II...... Precautions............................................ Replacement Procedures 10-20 I. 01 B.... Annually...................... 04 C....................

Inspect the entire system while in operation. Inspect for refrigerant or oil leaks. 13 of this manual. Table 1. Inspect all shaft seals for leaks. Monthly • • • • Manually operate the agitator motor and drive. Check whether brine is leaking through the drain line (see Fig 4. The ice/brine mixture in the IG tube and piping should be drained. B. and as such. replace in accordance with Blade Replacement Procedure on Pg. 14 of this manual. condensing water and brine make-up to the IG is disconnected and isolated. NOTICE: The brine solution used maybe concentrated and thus prolong exposure to brine solution may cause corrosion to many metals. A. IG Maintenance I. Check whether the machine frame is free of rust.1. Tighten all electrical connections and dust out terminal plates. Replace them as required. General Information Preventive maintenance is essential to ensure a reliable operation of the system. 1 of 20 . Look and listen for any unusual or change in behaviour. IG Service Manual – Pg. the mechanical seal is broken. make sure the power supply. part no. Check the shaft blades whether they are damaged or running in good condition. 12). C. Replace it in accordance with Mechanical Seal Replacement Procedure on Pg. any spillage or leaks of salt or brine solution should be swept away and hosed down as soon as practical. © 2007 Sunwell Technologies Inc.1 is a summary of the type of services and their occurrences. Examine for defective bearings and replace them as required.IG Maintenance MAINTENANCE 1. Daily (Start-Up) • • Inspect all strainers and filters and clean if necessary. WARNING: Before the system components are taken apart for inspection. maintaining good housekeeping in and around the ice generator (IG) will pay dividends with respect to general appearance and reduce nuisance faults. In general. If they are damaged. Repair leaks as required and add refrigerant as required (consult manufacturer prior to adding refrigerant). Particular attention should be given to the V-belt drive of the cooling tower. If there is leakage. Mechanical/Structural Checklist • • • • Ensure the shaft belts are tightened.

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

© 2007 Sunwell Technologies Inc.

Figure B: Calcium build-up over original copper

IG Service Manual – Pg. 2 of 20

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

1

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
9
9

More than one month

© 2007 Sunwell Technologies Inc.

IG Service Manual – Pg. 3 of 20

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.

© 2007 Sunwell Technologies Inc.

IG Service Manual – Pg. 4 of 20

y If the belts were splattered with grease and/or oil. clean them with methyl chloroform or soap and water. 5 of 20 . IG Service Manual – Pg. Alignment y If drive shafts are not parallel. belts will enter and leave the grooves at an angle. y Belts that sag too much are snapped tight suddenly when the motor starts or when peak loads occur. © 2007 Sunwell Technologies Inc.V-Drive Maintenance & Installation MAINTENANCE C. causing excessive belt and sheave wear. causing excessive belt cover and sheave wear. belts on one side are drawn tighter and pull more than their share of the load. Bearing Hot Bearing y Could be due to improper lubrication. D. y Could also be due to improper drive tension – either too tight or too loose. These belts will wear out faster as a result. Belts Cleaning y Belt should be wiped with a dry cloth occasionally to remove any build-up of foreign material. Belt Tension y Belts that are too loose will slip. y If sheaves are not aligned.

Installation A.1 Note: Never “roll” or “pry” the belts into the sheave grooves.V-Drive Maintenance & Installation MAINTENANCE II. 2. B. Arrange the belts so that both the top and bottom spans have about the same sag.) Tensioning Drive Belt © 2007 Sunwell Technologies Inc. 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. 1. Then increase the center distance until the belts are snug. If the belts squeal as the motor comes on or at some subsequent peak load. Operate the drive (IG) for a few minutes to seat the belts in the sheave grooves. This can be done by adjusting the bolts on the agitator mount. A slight bowing of the slack side of the drive indicates proper tension. IG Service Manual – Pg. This can damage the belt cords and lead to belt turnover. 2.2. they are not tight enough to deliver the torque demanded by the drive machine. Observe the operation of the drive under its highest load condition. Fig 2. rotate the drive until all the slack is on one side. it is both difficult and unsafe to install belts this way. short life or actual breakage. See Fig 2. Too tight Too loose Slight bow Fig 2. Tensioning V-Belt Drives 1. 6 of 20 . The drive should be stopped and the belts tightened. Moreover. Installing Belts WARNING: DO NOT USE LUBRICANTS IN THIS INSTALLATION.2. The drive is now ready for tensioning. Apply tension to the belts by increasing the center distance until the belts are snug. Shorten the center distance between the driven and driver sheave so the belts can be put on without the use of force. While the belts are still loose on the drive. Excessive bowing or slippage indicates insufficient tension.

All wiring should be guarded against abrasion. voltage.Electrical Wiring INSTALLATION 3. and should be clearly identified by wire marking and/or following the applicable color code. All wiring should be fastened securely to prevent chafing. All components should be grounded from one to the other. Precautions y y y y y y The supply power. Electrical Wiring I. and the frame in turn grounded to the ground. Cables to remote sources of power should carry an extra wire for grounding purposes at the supply end. For the safety of operating and maintenance personnel. the electrical system should be grounded to the frame. © 2007 Sunwell Technologies Inc. 7 of 20 . or should be run in conduit. Electrical cables connecting split units should have a watertight cable cover. IG Service Manual – Pg. Field wiring must comply with local and national codes. frequency and phase must coincide with specifications on all motor (compressor and agitator motor).

IG Service Manual – Pg. Compressor Terminal Wiring High & Low Pressure Switch Agitator L1 L2 L3 Agitator power lines Temperature protection L1 L3 1 L2 9 Compressor power lines High pressure switch (black) 3 2 8 OPC Sensor Cable PLC Inputs power Oil Lube Sensor Cable B R W Heater Cable N Crankcase Heater Cable Fig 3. 8 of 20 .1) 10 HP Compressor Terminal Wire Connection © 2007 Sunwell Technologies Inc.Electrical Wiring INSTALLATION Low pressure switch (blue) II.

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 B R W Heater Cable N Crankcase Heater Cable Fig 3. 9 of 20 . IG Service Manual – Pg.2) 15 HP Compressor Terminal Wire Connection © 2007 Sunwell Technologies Inc.

I. Spring) 5 “O” Ring © 2007 Sunwell Technologies Inc.) 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. 10 of 20 .1. 9 Pilot Flange Bearing (Housing.Replacement Procedures SERVICE 4. The IG tube must be empty during replacement. 5910-009 P 5910-009 P 5247-417 P 5960-150 P 5960-150 P 5248-060 P 5910-009 P φ1 ¼” 1 1 5910-009 P 5960-150 P Neoprene 1 5290-300 P IG Service Manual – Pg. Description φ⅛” x L¼” φ1 ¼” φ½” UNC x L1 ¾” φ1 ¼” φ1 ¼” φ5/16” φ1 ¼” φ1” 5 /8” Plate x 8 ¾” OD Qty. Replacement Procedures WARNING: The power supply must be disconnected. 1 2 1 4 1 1 4 1 1 1 1 1 Part No. Insert) 6. 7 Mechanical Seal (Seal. Top Flange Assembly Fig 4.

2.3. 9 11 Fig 4. Piloted Flange Bearing Fig 4.) Removal of Belt Cover (Bottom) © 2007 Sunwell Technologies Inc.Replacement Procedures Step 3 15 Step 4 16 SERVICE 17 18 19 20 No. 5935-000 P 5935-000 P 5935-001 P 5970-008 P 5970-007 P 204A-0539 P 5930-400 P A.) Removal of Sheaves Step 7 21 Step 8 20 3. 15 16 17 18 19 20 21 22 Part ¼” Bolts (3 pc) Bushing 1 Sheave 1 Bushing 2 Sheave 2 Belt Cover Bottom ⅜” Nut (4 pc) V-belt 40. IG Service Manual – Pg. 11 of 20 .0 3VX0400 Part No.

9. 8. Item No. 5. Adjust the distance between the agitator and the IG tube. Insert the bolts in tapped removal holes in bushing and tighten evenly until bushing becomes loose on shaft. 12 of 20 . The bearing housing is loose now. 12. 3. Tool Qty. Remove bolts (and washers) from the flange. Removal 1. 9 17 (See Fig 4) 21 20 4 -- IG Service Manual – Pg. Release the cap screws on the bearing insert. Left off drive belts. 13. Pull the complete shaft assembly out of the IG tube. The sheave will slide off from the shaft. stays with the top flange Mechanical Seal – the Spring. 11. Lift off belt cover bottom. Remove the stuck key. Remove the hex nuts. Screwdriver 9/16” Wrench 1 2 --- ¼” Screwdriver ¼” Screwdriver 3 3 15 15 --¼” Wrench ¾” Wrench -- 1 1 4 1 4 -- ⅛” Allen key ⅜” Wrench 2 4 2 8 -- -- 3. Remove the old bearing. 10. 7. Relief drive tension by shortening the center distance between driver and driven sheaves. Fig 4. Remove the cap screws from bushing 1. Remove nuts (and washers) from belt cover bottom. The bearing insert is now loose from the shaft. 6. Place it on a rack. © 2007 Sunwell Technologies Inc. stays with the Shaft Gap for the Stuck Key [Top view] The stuck key locks the shaft and bushing together.4. 2.) Removal of Mechanical Seal 1. 4.Replacement Procedures SERVICE Bearing Insert – hold the Shaft Drain Line – If the Mechanical Seal broke. Remove belt cover top. brine will leak through this pipe Bearing Housing – hold the bearing Mechanical Seal – the Seal.

The bushing should line up with the end of the shaft. -- -- 3. b) If bushing 2 is not level. Check the sheaves alignment. go to Step 15.II). Remove bolts from tapped removal holes. Check the alignment of the bushing 1 and 2. Tighten bolts evenly and progressively. ⅜” Wrench 4 8 ⅓” Allen key 2 -- 2 -- ¾” Wrench ¼” Wrench 4 4 4 21 ---- 1 1 -- (Fig 4. This will lock the stuck key in place. 1 Ö 4 Ö 2 Ö 3) Tool 1 2 3 4 2. Tighten the hex nuts on the bearing housing progressively. b) If they are not inline. Put the complete shaft assembly back into the IG tube. Slide the bearing insert onto the shaft. Tighten the cap screws on the bearing insert. Tighten the bolts. 19 -- 2 -- 17 16 9/16” Wrench IG Service Manual – Pg. Assembly 1. as in procedure A.2. a) If they are inline. They should be at the same level. adjust the nuts that are on the agitator motor frame. 4. 14. 18 Level A straight edge -- 17. Slide bushing 1 onto the shaft with cap screw heads to the outside. 2. Install driving belts (see Section 2.. The grooves should be inline. 9 Qty.Replacement Procedures SERVICE 14. 15. Insert stuck key on shaft. 5.1. go to Step 14. Item No. 6. Replace the bearing unit with a new one. 19 ⅛” Allen key 1 18. Loosen the cap screw inside bushing 2. 11.4) ¼” Screwdriver 3 15 ¼” Screwdriver 1 15 ⅛” Allen key 1 -- Level -- 16.e. © 2007 Sunwell Technologies Inc. Secure belt cover bottom on the shaft with lock nuts (and washers). redo the cap screws until the bushing is level. The top of the bushing must be inline with the end of the shaft. 7. 10. Insert them into the holes adjacent to them. i. 3. Adjust the height of bushing 2 (and sheave 2) so that the grooves of both sheaves are inline. a) If bushing 1 is not level. Insert and tighten the ⅛” cap screw from the side of the bearing. (Tighten the nuts diagonally. 13 of 20 . 13. 8. 12. Slide sheave 1 onto the shaft. 9.

Replace the spring section onto the shaft.1. Item No. 3. Removal 1.5. 1 1 --- 6 7 --- IG Service Manual – Pg. Tool Qty. 2. Follow procedure A. Item No.) Mechanical Seal 1. The bearing insert is now loose from the shaft. Remove the mechanical seal from the top flange.12 to remove the top flange from the IG tube. Remove the spring section of the seal from the shaft. Assembly 1.Replacement Procedures SERVICE B. 3.1. © 2007 Sunwell Technologies Inc. 2. 2. Separate the top flange from the shaft. 14 of 20 .2 to reassemble the top shaft flange.1 to A. Mechanical Seal Seal on Top Flange Spring on Shaft Fig 4. Put the top flange and shaft assembly together. 2. -- -- -- -- 1 11 --- 1 1 6 7 Tool ----- Qty. Replace seal section onto the top flange. Follow procedure A. 4.

Removal 1. 15 of 20 . 2. © 2007 Sunwell Technologies Inc. 3.) Placement of the “O” Ring 1. --- 1 -- 5 -- ½” Wrench 4 4 IG Service Manual – Pg. 4 -- 4 -- Qty. replace “O” ring. Remove bolts (and washers) from the flange 2.6. Tighten the bolts. 2. Place it on a rack. Pull the complete shaft assembly out of the IG tube. Item No. Assembly 1.Replacement Procedures SERVICE C. Tool ½” Wrench -- Tool Qty. At the top of the IG tube. Item No. “O” Ring “O” Ring IG Inner Tube Insulation Fig 4. Put the top flange and shaft assembly back into the IG tube.

16 of 20 .) Bottom Flange Cross Section. 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.Replacement Procedures SERVICE II.7. 6.8. 1 /8” Plate.) Removal of Marine Bearing © 2007 Sunwell Technologies Inc. IG Service Manual – Pg. 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 2”OD x 5”L 1 5925-050 P Welded Tube 6 ¼” OD 5 A.50” SCH160 1” FPT φ2” THD SCH80 1 Part No. Bottom Flange Assembly 1 14 13 25 23 26 24 27 Fig 4.75”OD 2” Pipe x 2. Marine Bearing 26 24 25 27 Fig 4. No.

2. Remove bolts (and washers) from the flange 2. ½” Wrench -- 4 -- 4 -- Strap wrench Long rod 1 1 27 25 Tool Qty. Replace the marine bearing at the bottom of the tube. © 2007 Sunwell Technologies Inc. 3. Removal 1. 4. 2. SERVICE Tool Qty. 17 of 20 . Item No. Push the marine bearing out from the inside of the IG tube.Replacement Procedures 1. Hammer Hammer -½” Wrench 1 1 -4 25 27 -4 IG Service Manual – Pg. Item No. Pull the complete shaft assembly out of the IG tube. Remove the pipe cap. Assembly 1. Tighten the bolts. Place it on a rack. 4. 3. Place the whole shaft assembly back into the IG. Put the pipe cap back onto the bearing.

28 29a.5” #10-24 UNC x 1 ¼” φ 0.97” L 19” #10-24 UNC 3 /16” Round Rod Qty. 18 of 20 .b 32a.b 31a.b 30a. The assembly of a female blade will be the same. © 2007 Sunwell Technologies Inc.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 φ ½” x L ⅜” φ ¾” x L ¾” φ 0.Replacement Procedures SERVICE III. 1 2 2 2 2 2 4 1 2 1 1 1 Part No.253” x L 0.b 33a. IG Service Manual – Pg.9. 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.363” x L 0.) Exploded Blade Assembly No.) is based on the assembly of a male blade. Shaft Assembly Fig 4.

Replacement Procedures

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
φ ½” x L ⅜”
φ ¾” x L ¾”
φ 0.253” x L 0.5”
#10-24 UNC x 1 ¼”
φ 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.

© 2007 Sunwell Technologies Inc.

IG Service Manual – Pg. 19 of 20

Replacement Procedures

SERVICE

Curve end
on top

Cut off
¼”

Curve end
on bottom

Cut off
¼”

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
1. Remove bolts (and washers) from the flange
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 ¼” 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.

© 2007 Sunwell Technologies Inc.

Tool

Qty. Item No.

½” Wrench
--

4
--

4
--

⅜” Wrench
--

2
1

30a,b
39

Tool

Qty. Item No.

--

--

--

Hammer
Electrical driller,
¼” 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

---

---

IG Service Manual – Pg. 20 of 20

deepchillTM
Ice System

Brine System
User Manual
BS-90

©2007 Sunwell Technologies Inc.

........................................................................................................ 01-02 III....................... 03 IV........................................................................................... Brine System BS-90 User Manual – i ................................ 04-05 © 2007 Sunwell Technologies Inc... Brine Table ..................Brine System BS-90 Manual CONTENT Table of Content Section Page I............................................................................... System Description ............................................................................................... Salt Refill Procedures ............... 01 II. Brine Tank Drawings ...........

(cut 45° at one end) Ref. II. When the conductivity cell (at the pump station) senses a low salinity in the brine make-up. 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. Drawing # M448M017 Ref.1) BS-90 Brine Tank Component List © 2007 Sunwell Technologies Inc. Drawing # M448M020 1” elbow x 90° (sxs) 1” pipe x 2-1/2” approx. Drawing # M448M019 1 Ref. Drawing # M448M023 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 2 5247-303 P SS316 SS316 SS316 4 2 2 5246-040 P 5248-379 P 5248-075 P Fig.1. 1 of 5 . the motorized ball valve that controls the flow from brine tank will open. 7699-069 P 7575-106 P 7560-003 P Ref. 1 1 1 1 1 Part No. Brine Tank Drawings No. Brine System BS-90 User Manual – Pg.Brine System BS-90 I. Part Description 01 02 03 04 05 Ø24 x 48” Tank with cover 1” nipple x 3” (use half) 1” elbow x 45° (sxs) Ref. Drawing # M448M018 07 08 Tank Nipple Elbow Piping ass’y Suction header Float switch header Screener ass’y Elbow 09 Pipe 10 Mounting plate 11 Hex-bolt 12 13 14 Flat washer Nylock nut Hex nut 06 PVC PVC SCH80 SCH80 Qty . 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. System Description 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.

2 of 5 .Brine System © 2007 Sunwell Technologies Inc. BS-90 Brine System BS-90 User Manual – Pg.

General inspection of the brine system shall be done every time prior to salt recharge and inspect for foreign objects and loosen parts. In order to continue the ice making process. IV. Salt can be poured into the tank with ease and salt level can be inspected at anytime. one must refill the brine tank with salt. WARNING: Only use high purity and food grade salt. the control system will stop the ice making process automatically. Brine system BS-90 Maintenance For optimum performance and durability of the brine system BS-90. NOTE: One full refill of the brine system BS-90 equal approximately 200 kg. Complete surface cleaning (inside and outside of the brine system. Brine System BS-90 User Manual – Pg. Stock of salt should be readily available for tank refill. DO NOT use sea-salt or crystallized salt for de-icing. The brine system BS-90 in particular is designed for salt refilling at anytime. When the salinity of the brine make up stream is below the preset value. switch(s) and valve(s)) should be performed at least once every 6 months. Pellet and cracked types are allowed. It does not require any system process to be stopped during re-filling.Brine System BS-90 III. © 2007 Sunwell Technologies Inc. 3 of 5 . Salt Refill Procedures Brine tank must be refilled when low salt warning is on the system display (TD 200 display). general workmanship and tidiness should always be applied.

5 6.2 16 1.040 5.8 -0.8627 +24.002 0.2640 +31.3348 +25.3 1 1.7919 +31.046 6.036 5.6953 +28.6 -2.5430 +26.4 -3.9 3.5837 +30.7 10 1.4 © 2007 Sunwell Technologies Inc.8 6.9 26 1.3 2.0151 +26.034 4.0 19 1.1 -3.032 4.3756 +29.023 3.5 -0.013 1.0709 +25.0 -1.6 2 1.7 -4.5 17 1.3 5 1.7 25 1.4 24 1.1 8 1.8 -1.042 5.027 3.3198 +30.044 6.0 2.8477 +30.5 -0.0 15 1.1 5.4 4.031 4.2 -2.1 2.6 4.038 5.0 0 0.1 4.3 5.025 3.048 6.008 1.4 -4.1116 +30.6 6 1.1674 +28.8 22 1.4 -3. 4 of 5 .Brine Table Strength of Brine Freezing Point Baume Degree Salometer Degree SG Salt in Brine (wt%) °F °C 0.Brine System BS-90 IV.9 3 1.3 4.1 0.0 0 1.1 -0.3 -0.2 7.6 3.1 -1.5 1.019 2.9035 +29.1 4 1.9 5.7 -3.3 20 1.8 -0.3 12 1.1 -3.029 3.9 7 1.5988 +24.5 -1. Brine System BS-90 User Manual – Pg.7 6.8 1.2 -1.1 23 1.011 1.5 3.006 0.1267 +24.8069 +25.7 1.5279 +31.0 -2.010 1.8 5.9593 +27.6 21 1.0000 +32.7 -2.017 2.7 14 1.2 27 1.9 -2.000 0.4314 +28.4 1.0558 +31.7511 +27.3 0.4 9 1.004 0.8 3.5 13 1.2232 +27.021 2.050 6.0 -4.2790 +26.6395 +29.6 -1.3 -2.052 7.4872 +27.015 2.0 11 1.1 6.3 -1.8 18 1.

4 14.6546 +23.2 35 1.Brine Table (con’t) Strength of Brine Freezing Point Baume Degree Salometer Degree SG Salt in Brine (wt%) °F °C 7.068 9.106 14.096 12.7 49 1.2 43 1.7 -8.7 -4.058 7.6696 +16.9743 +21.4 28 1.8 9.2383 +21.2 8.3 -5.7 33 1.2 13.078 10.6 -5.9 54 1.7812 +12.2 31 1.0 10.112 15.7 14.0301 +20.7 13.9185 +23.7 45 1.098 13.092 12.076 10.064 8.4 10.108 14.9 30 1.2 -8.9 9.7254 +14.1 -7.8 7.5 -8.4 -9. 5 of 5 .3 -10.6 -5.8 -6.7 -10.0 12.056 7.2 51 1.7 -7.0 -5.070 9.9336 +15.086 11.7104 +22.1 12.104 13.0 34 1.110 14.9 -7.4057 +16.060 8.5 -9.6 10.6 57 1.072 9.1975 +15.4464 +22.4 -7.0 8.8 10.5 -6.4615 +15.5 44 1.8 -9.7 41 1.3906 +23.8 12.0 -9.4 8.7662 +20.066 8.074 10.8 -10.4 52 1.4 13.1 -8.102 13.8220 +19.3 12.054 7.6 9.6 11.6138 +17.6 7.4 56 1.0452 +12.7 53 1.9 © 2007 Sunwell Technologies Inc.2 -6.1 55 1.2533 +13.7 37 1.5022 +20.0 46 1.3 -5.9 50 1.5 48 1.5 40 1.0 42 1.8778 +17.5580 +19.0 -5.2 9.0 38 1.9 13.0859 +18.2 14.7 29 1.084 11.4 11.082 11.2 11.080 10.1 -9.090 12. Brine System BS-90 User Manual – Pg.5173 +13.8 11.9894 +14.Brine System BS-90 IV.9 -6.3 -7.5 36 1.3 -4.5 32 1.100 13.088 11.2 47 1.2941 +19.062 8.1825 +22.5 12.3 -10.3499 +18.094 12.1417 +17.2 39 1.

deepchillTM Ice System IG Troubleshooting General Guideline ©2007 Sunwell Technologies Inc. .

1 of 6 . © 2007 Sunwell Technologies Inc. please contact 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 Sunwell’s system. the actual system’s display messages may not be limited to the following list. Troubleshooting Guide – Pg. Shall there be difficulties with applying remediation actions and/or unlisted messages.Troubleshooting Guide Control Panel Display Messages Sunwell Technologies Inc.

High condensing water flow or low condensing water temperature Adjust condensing water flow accordingly. 2 of 6 . Abnormal operating conditions Record operating conditions. (High pressure cut-out) COMPRESSOR LOW-SUC. Compressor suction valve is closed Open suction valve. Compressor discharge valve is closed Open discharge valve. Defective overload relay Check the manual motor starter. contact Sunwell for further assistance. Loose power/control wiring Check and tighten all wirings. OVERLOAD (Compressor overload) COMPRESSOR HIGH-DIS. COM.Troubleshooting Guide Control Panel Display Messages TEXT DISPLAY POSSIBLE CAUSE REMEDY IG POWER SWITCHED OFF Loose power/control wiring Check and tighten all wirings. adjust flow accordingly. (Low pressure cut-out) © 2007 Sunwell Technologies Inc. Replace it if necessary. High suction temperature Check brine make-up flow rate. adjust condensing water flow accordingly. Troubleshooting Guide – Pg. Low condensing water flow or high condensing water temperature Adjust condensing water flow accordingly. The main switch(es) on the second/ third panel turned OFF Turn ON the main power disconnector switch High condensing temperature Check condensing pressure. Low overload trip setting Check and correct trip setting (according to compressor service guide) Loose power/control wiring Check and tighten all wirings. Low line voltage Check and retify power supply.

Brine make-up pumps suction strainer is plugged. 3 of 6 . Low oil level in compressor crankcase DO NOT add oil. Replace it if necessary. Loose power/control wiring Check and tighten all wirings. Loose communication wiring Check and tighten communication cable connections. COM. Severe freeze-up of Ice Generator due to low salinity Check brine make-up salinity. Defective current relay Check the current level relay. Brine make-up rate is low Adjust brine make-up flow accordingly. Check and clean mesh screen. OIL LUBE ALARM pressure cut-out) AGITATOR OVERLOAD (Agitator motor overload) (Oil © 2007 Sunwell Technologies Inc. increase salinity accordingly. Troubleshooting Guide – Pg.Troubleshooting Guide Control Panel Display Messages TEXT DISPLAY POSSIBLE CAUSE REMEDY COMPRESSOR LOW-SUC. Defective Oil Lube Control Check the oil lube control. Reduce it if possible. Loose power/control wiring Check and tighten all wirings. Check shaft condition (blade. Current level relay trip setting is higher than overload setting Check and adjust current level relay setting accordingly. (Low pressure cut-out) High salinity Check the salinity. Correct it by switching two wires connections (two of the three phases). Contact Sunwell for further assistance. Replace it if necessary. maximum of 0. Refrigerant charge is low Add R-404a. springs. then observe operating condition. rods).2 kg. Rotation of Ice Generator agitator is incorrect Check the agitator rotation. Low brine make-up rate Check and correct flow accordingly. Adjust overload setting (according to motor specifications). Contact Sunwell for further assistance. Rotation of Ice Generator agitator is incorrect Check and correct agitator rotation.

Loose power/control wiring Check and tighten all wirings. Troubleshooting Guide – Pg. 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).Clean the pipes.normal condition to protect IG (up to 30 times in one day is acceptable) Check CLR trip counter (F4). 4 of 6 . then the IG flow rate. Replace the motor if necessary. Replace it if necessary. Defective overload relay Check the manual motor starter. Defective motor Check the motor's coils and current on each phase. Check all MV wiring. PUMP OVERLOAD (Circulation pump overload) © 2007 Sunwell Technologies Inc. Reset counters by pressing (Shift+F8). Blades inside the IG tube worn out Check the blades and replace if necessary CLR trip relay . Replace it if necessary. If the number of the corresponding IG counter increases rapidly during the day (week). Check and clean mesh screen.Troubleshooting Guide Control Panel Display Messages TEXT DISPLAY POSSIBLE CAUSE REMEDY AGITATOR OVERLOAD (Agitator motor overload) Loose power/control wiring Check and tighten all wirings. Line is blocked/closed Check all corresponding motorized valves are open. AG CLR TRIP CIR. blades and CLR trip must be checked. CLR (current level relay) trip relay adjustment is too low Readjust the setting on CLR relay trip. Defective overload relay Check the manual motor starter. Brine make-up pumps suction strainer is plugged. NOTE: the setting has to be below overload setting.

Check all MV C heck all thecorresponding current level relay. the threeCorrect phases).Clean the pipes. 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. Contact Sunwellmotor for further assistance. then observe operating DO NOT add oil. condition. Contact Sunwell for further assistance. C heck the lube control. the oil lube control. connections (tw o ofrotation. C(Shift+F8). the motor's coils and current on each phase. CLR relay trip. PUMP OVERLOAD (Circulation pump overload) REMEDY Check the salinity. Adjust Adjust make-up flowstarter. C hecksure adjust current level relay setting accordingly.g. Check and increases correct triprapidly settingduring (based onday the(week).IG. blades and CLR trip must be checked. Replace it if necessary. C heck and tighten com m unication cable connections. Make heater the level probe is "ON" and is heating overload setting (according to m otor specifications). Adjust Check and the correct flowonaccordingly. Make sure the chute condition. connections (two ofallthe three phases). rods). rods). NOTE: setting has to Open check delivery pump. 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. guide). R eplace it if necessary. AGITATOR OVERLOAD (LowDEL pressure cut-out) ICE PMP OVERLOAD H igh salinity C heck the salinity. Check Check and and tighten correct all tripwirings. C heck and brinetighten m ake-up salinity. TANK LOW WATER Check and clean mesh screen. O IL LU BE ALAR M (O il HARVESTER OVERLOAD pressure cut-out) (Harvester motor overload) COM. increase salinity accordingly. Replace it if necessary. springs. Check the blades manual motor starter. necessary. Replace the Check and tighten all wirings. m axim um of 0. Check and tighten all wirings.brine m ake-up flow accordingly. be below overload setting. Check the flow rate through this Add R-404a. Check (F4). If the number ofassistance. Replace it if necessary.2 kg. accordingly. setting (based on the compressor service guide). Check shaft condition springs. Replace it if necessary. Check the DLR. Defective motor Loose power/control wiring Defective overload relay Low brine m ake-up rate Defective motor Loose pow er/control w iring STOR. C heckand and tighten all w(blade. then observe operating Switch OFF/ON harvester overload. C orrect it by sw itching tw o w ires motor if necessary. Check the agitator it by switching two wires Check and clean mesh screen. No salt inside the brine tanks Refill the tanks Air was not taken from brine tanks Take air away from brine tanks. Check and fix the leakage. Reduce it if possible. Check wirings. the corresponding D O N OCLR T addtrip oil. is not blocked by ice. 5 of 6 . irings. Check the manual motor starter. wiring. Restart delivery. flow rate. Check andoil tighten all wirings.2 kg. gear motor IG counter the then user the IG manual). Check motorized valves open. C heck and correct agitator rotation. R eplace it if are necessary. CLR oil trip relayin. R educe it if possible. Replace the motor if necessary.com normal condition to protect IG Low level pressor crankcase AGITATOR OVERLOAD (Agitator motor overload) Check brine increase salinitythe accordingly.counter C ontact Sunw ell for further Troubleshooting Guide – Pg. Lowtooverload (up 30 timestrip in setting one day is acceptable) Loose com m unication w iring CIR. COMPRESSOR LOW-SUC. 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 heck and correct flow accordingly. Check brine the motor's manual motor Replace it ifphase.Troubleshooting Guide Control Panel Display Messages 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 . the level probe. motor if necessary. each phase. Readjust themake-up setting onsalinity. C heck and tighten all w irings. Check the coils and current on each Replace the © 2007 Sunwell Technologies Inc. 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. Loose power/control wiring Severe freeze-up of Ice G enerator due to low salinity AG CLR TRIP C O M . correct communication trip setting (according to compressor service Check and tighten cable connections. Check the and if necessary C heck and clean m eshreplace screen. maximum of 0. Reset counters Add R -404a. Loose power/control wiring Defective Oil Lube Control Storage tank is leaking Defective overload relay 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. Replace it if necessary. 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. Check the manual motor starter. ontact coils Sunwand ell for further by pressing Check the motor's current onassistance. Defective overload Brine make-up pumps suction strainer is plugged.

Replace it if necessary. TANK LOW ICE Defective dual level relay (DLR) © 2007 Sunwell Technologies Inc.Troubleshooting Guide Control Panel Display Messages 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. Troubleshooting Guide – Pg. STOR. 6 of 6 . Delivery line high pressure Delivery line is blocked or closed (motorized valve is close). Replace it if necessary. Clean/wash the lines & check MV power/control wires. Defective pressure switch Check the pressure switch (Normally close). Check the DLR. 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.

.deepchillTM Ice System OEM Manuals Refer to P&ID and Electrical/Control Drawings for detailed specifications ©2007 Sunwell Technologies Inc.

com Email: inquiries@sunwell.com .Sunwell Technologies Inc. 180 Caster Avenue. Ontario.sunwell. Canada L4L 5Y7 North America Toll Free: +1 866-792-4455 Tel: +1 905-856-0400 Fax: +1 905-856-1935 Website: www. Woodbridge.

Operation Instructions Amendments Drawings Safety & Installation IG Service Brine System IG Troubleshoot OEM Manual .