m529 sunwell.manual

deepchillTM Ice System

Installation, Operation & Service Manual

2007 Sunwell Technologies Inc.

Operations & Control- System 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: [email protected] website: www.sunwell.com

deepchillTM

Ice System

Operation & Controls- System Customization


OPERATION AND CONTROL

2007 Sunwell Technologies Inc. OPERATION - PAGE 1 OF 15

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 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 1 Ice Silo 1 Chilled Water Silo



II. Control Panel Layout

A. Main Control Panel

(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)

(a)

(b)

(c)

(e)

(g)

(f)



(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

(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.

(e)

(a)

(b)

(d)

(f)

(g) (c)



(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

(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.

(c) (b)

(a)



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)

1 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 Drawings

- System Drawings - Mechanical Drawings - Electrical Drawings

Ice System


deepchillTM Installation

Ice System


Ice System Safety & Installation CONTENT

2007 Sunwell Technologies Inc. Ice System Installation Handbook i

Table of Content Section Page 1. Safety & Precautions 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 B. Piping Accessories ......................................................................................... 09 IV. Condensing Water Piping A. Water Supply .................................................................................................. 09 B. Piping Accessories ......................................................................................... 09 C. Piping ............................................................................................................. 09

Ice System Safety & Installation CONTENT

Table of Content Section Page 4. Electrical 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

2007 Sunwell Technologies Inc. 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:

Sunwell Technologies Inc. 180 Caster Avenue Woodbridge, Ontario, Canada L4L 5Y7 Tel: (905) 856-0400 Fax: (905) 856-1935 Email: [email protected]

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

2007 Sunwell Technologies Inc. Ice System Installation Pg. 1 of 15

mailto:[email protected]

Safety & Precautions 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.

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 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.

Field wiring must comply with local and national codes. All wiring should be guarded against abrasion. All switches should be of the sealed type, recommended by the manufacturer for use in

wet environments. 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


Safety & Precautions 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.

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 hard-wired 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.

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

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.

Never heat the equipment. Never expose refrigerant cylinders/jackets to the direct sunlight. Never place an electric resistance heater in direct contact with a refrigerant jacket. Never apply a direct flame to a jacket. Never weld onto equipment charged with refrigerant. 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.

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 & Precautions 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:

For all piping connections, For servicing of the compressor and controls, For easy access to the electrical panel(s), For removing and servicing the IG shafts, and 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.

B. Piping Accessories 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:

Backing rings Threaded fittings 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.

B. 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. 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 II. Compressor Terminal Wiring

Figures 2 below shows the compressor terminal wiring. This section is also in the installation section of the IG User Manual.

9

1

8

3

2

Hig

h p

ress

ure

sw

itch

(bla

ck)

Low

pre

ssur

e

switc

h (b

lue)

L1

L3

L2

Com

pres

sor

pow

er lin

es

Agitator power lines

L1 L2 L3

PLC Inputs power B R W

Oil Lube Sensor Cable N

Crankcase Heater Cable

Temperature protection

OPC Sensor Cable

Heater Cable

High & Low Pressure Switch

Agitator

Fig. 2.1) 10 HP Compressor Terminal Wiring Connection


Electrical INSTALLATION

9

1

8

3

2

Hig

h pr

essu

re

switc

h (b

lack

)Lo

w p

ress

ure

switc

h (b

lue)

L1

L3

L2

Com

pres

sor

pow

er li

nes


L1 L2 L3





OPC Sensor Cable

Heater Cable


Agitator

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 Maintenance and Service Manual

Ice Generator IG-06VM

Ice System


Ice Generator Service Manual CONTENT

Table of Content Section Page 1. IG & System Maintenance 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

2007 Sunwell Technologies Inc. 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).

2007 Sunwell Technologies Inc. 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 MAINTENANCE

Type of Services Start-Up/ Routine Monthly Annually 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 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 Can be caused by the slapping of belts against the drive guard or other obstruction due to

improperly installed guard. Check for an improperly installed guard, loose belts or excessive vibration.

Squealing of Belt During Start-up or While Running Usually caused by a poorly tensioned drive and/or by a build-up of foreign material in the

sheave grooves. Can also be caused by oil or grease between the belt and the sheave groove.

B. Sheaves Smooth and Uniform Keep all sheave grooves smooth and uniform Burrs and rough spots along the sheave rim can damage belts. Dust, oil and other foreign matter can lead to pitting and rust should be avoided as much as

possible. Shinny Groove Bottom This indicates that either the sheave, the belt or both are badly worn and the belt is bottoming

in the groove. Badly worn grooves cause one or more belts to ride lower than the rest of the belts

differential driving. Differential Driving A sure sign of differential driving is when one or several belts on the tight side are slack. The belts riding high in the grooves travel faster than the belts riding low in a drive under

proper tension. Drive Alignment Improperly aligned sheaves cause excessive belt and sheave wear. When the shafts are not parallel, belts on one side are drawn tighter and pull more than their

share of the load. Overloaded belts wear out faster, reducing the service life the entire set. 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.


V-Drive Maintenance & Installation MAINTENANCE C. Belts Cleaning Belt should be wiped with a dry cloth occasionally to remove any build-up of foreign material. If the belts were splattered with grease and/or oil, clean them with methyl chloroform or soap

and water. Belt Tension Belts that are too loose will slip, causing excessive belt and sheave wear. Belts that sag too much are snapped tight suddenly when the motor starts or when peak

loads occur. Alignment 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. 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 Could be due to improper lubrication. Could also be due to improper drive tension either too tight or too loose.


V-Drive Maintenance & Installation 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.

Fig 2.2.) Tensioning Drive Belt

Too tight

Too loose

Slight bow


Electrical Wiring INSTALLATION

3. Electrical Wiring

I. Precautions 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 II. Compressor Terminal Wiring

9

1

8

3

2

Hig

h p

ress

ure

sw

itch

(bla

ck)

Low

pre

ssur

e

switc

h (b

lue)

L1

L3

L2

Com

pres

sor

pow

er lin

es


L1 L2 L3





OPC Sensor Cable

Heater Cable


Agitator

Fig 3.1) 10 HP Compressor Terminal Wire Connection


Electrical Wiring INSTALLATION

9

1

8

3

2

Hig

h pr

essu

re

switc

h (b

lack

)Lo

w p

ress

ure

switc

h (b

lue)

L1

L3

L2

Com

pres

sor

pow

er li

nes


L1 L2 L3





OPC Sensor Cable

Heater Cable


Agitator

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 Description Qty. Part No. 1 IG Shaft 1 2 Set Screw x L 2 5910-009 P 3 Pilot Flange Bearing Housing 1 1 5910-009 P 4 Hex Bolt UNC x L1 4 5247-417 P 6 Mechanical Seal (Seal) 1 1 5960-150 P 7 Mechanical Seal (Spring) 1 1 5960-150 P 8 Nylon Lock Nut 5/16 4 5248-060 P 9 Pilot Flange Bearing Insert 1 1 5910-009 P

10 Tub Top Flange 1 1 11 Top Shaft Flange 5/8 Plate x 8 OD 1 12 Drain Line 1 13 IG Inner Tube 1 14 Insulation

Components to Be Replaced 3, 9 Pilot Flange Bearing (Housing, Insert) 1 1 5910-009 P 6, 7 Mechanical Seal (Seal, Spring) 1 5960-150 P

5 O Ring Neoprene 1 5290-300 P



No. Part Part No. 15 Bolts (3 pc) 5935-000 P 16 Bushing 1 5935-000 P 17 Sheave 1 5935-001 P 18 Bushing 2 5970-008 P 19 Sheave 2 5970-007 P 20 Belt Cover Bottom 204A-0539 P 21 Nut (4 pc) 22 V-belt 40.0 3VX0400 5930-400 P

20

19

18

17

16 Step 4

Step 3 15

A. Piloted Flange Bearing

Fig 4.2.) Removal of Sheaves

21

11

3, 9

20

Step 8

Step 7

Fig 4.3.) Removal of Belt Cover (Bottom)



Fig 4.4.) Removal of Mechanical Seal

1. Removal Tool Qty. Item No.1. Remove belt cover top. Screwdriver 1 -- 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.

9/16 Wrench 2 --

3. Remove the cap screws from bushing 1. Screwdriver 3 15 4. Insert the bolts in tapped

removal holes in bushing and tighten evenly until bushing becomes loose on shaft.

Screwdriver 3 15

5. The sheave will slide off from the shaft. -- 1 17 6. Remove the stuck key. -- 1 (See Fig 4) 7. Remove nuts (and washers) from belt cover bottom. Wrench 4 21 8. Lift off belt cover bottom. 1 20 9. Remove bolts (and washers) from the flange. Wrench 4 4 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. Allen key 2 2 12. The bearing insert is now loose from the shaft.

Remove the hex nuts. Wrench 4 8

13. The bearing housing is loose now. Remove the old bearing.

-- -- 3, 9

Bearing Insert hold the Shaft

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.

Drain Line If the Mechanical Seal broke, brine will leak through this pipe



1 2

4 3

14. Replace the bearing unit with a new one. Slide the bearing insert onto the shaft.

-- -- 3, 9

2. Assembly Tool Qty. Item No.1. Tighten the hex nuts on the bearing

housing progressively. (Tighten the nuts diagonally, i.e., 1 4 2 3)

Wrench 4 8

2. Tighten the cap screws on the bearing insert. Allen key 2 2 3. Put the complete shaft assembly back into the IG

tube. -- --

4. Tighten the bolts, as in procedure A.2.1. Wrench 4 4 5. Secure belt cover bottom on the shaft with lock nuts

(and washers). Wrench 4 21

6. Slide sheave 1 onto the shaft. -- 1 17 7. Insert stuck key on shaft. -- 1 (Fig 4.4) 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.

-- -- 16

9. Remove bolts from tapped removal holes. Insert them into the holes adjacent to them.

Screwdriver 3 15

10. Tighten bolts evenly and progressively. The top of the bushing must be inline with the end of the shaft.

Screwdriver 1 15

11. Insert and tighten the cap screw from the side of the bearing. This will lock the stuck key in place.

Allen key 1 --

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.

Level

9/16 Wrench

-- 16, 18

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.

Level A straight edge

-- 17, 19

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.

Allen key 1 18, 19

15. Install driving belts (see Section 2.II). -- 2 --


Replacement Procedures SERVICE B. Mechanical Seal

Spring on Shaft

Seal on Top Flange

Fig 4.5.) Mechanical Seal

1. Removal Tool Qty. Item No.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.

-- 1 11

3. Remove the mechanical seal from the top flange. -- 1 6 4. Remove the spring section of the seal from the shaft. -- 1 7

2. Assembly Tool Qty. Item No.1. Replace seal section onto the top flange. -- 1 6 2. Replace the spring section onto the shaft. -- 1 7 2. Put the top flange and shaft assembly together. -- -- -- 3. Follow procedure A.2 to reassemble the top shaft

flange. -- -- --



C. O Ring

Insulation

IG Inner Tube

O Ring

Fig 4.6.) Placement of the O Ring

1. Removal Tool Qty. Item No.1. Remove bolts (and washers) from the flange Wrench 4 4 2. Pull the complete shaft assembly out of the IG tube.


2. Assembly Tool Qty. Item No.1. At the top of the IG tube, replace O ring. -- 1 5 2. Put the top flange and shaft assembly back into the IG

tube. -- -- --

3. Tighten the bolts. Wrench 4 4



II. Bottom Flange Assembly

13

23

24

14

26

25

27

1

Fig 4.7.) Bottom Flange Cross Section.

No. Part Description Qty. Part No. 1 IG Shaft 1 210D-1804

13 IG Inner Tube Welded Tube 6 OD Not a spare part 14 Insulation Not a spare part 23 Marine Bearing Flange 5/8 Plate, 6.75OD Not a spare part 24 Marine Bearing Housing 2 Pipe x 2.50 SCH160 Not a spare part 26 Coupling 1 FPT Not a spare part 27 Threaded Pipe Cap 2 THD SCH80 1 7520-020 P

Components to Be Replaced 25 Marine Bearing 2OD x 5L 1 5925-050 P

A. Marine Bearing

25 27

24

26

Fig 4.8.) Removal of Marine Bearing


Replacement Procedures SERVICE 1. Removal Tool Qty. Item No. 1. Remove bolts (and washers) from the flange Wrench 4 4 2. Pull the complete shaft assembly out of the IG tube.


3. Remove the pipe cap. Strap wrench 1 27 4. Push the marine bearing out from the inside of the IG

tube. Long rod 1 25

2. Assembly Tool Qty. Item No. 1. Replace the marine bearing at the bottom of the tube. Hammer 1 25 2. Put the pipe cap back onto the bearing. Hammer 1 27 3. Place the whole shaft assembly back into the IG. -- -- -- 4. Tighten the bolts. Wrench 4 4



III. Shaft Assembly

Fig 4.9.) Exploded Blade Assembly

No. Part Description Qty. Part No. 28 Female Blade L 19 1 210C-1307 P

29a,b Spring 2 210A-0076 P 30a,b Lock Nut #10-24 UNC 2 5248-300 P 31a,b Bushing x L 2 210A-0270 P 32a,b Mandrel x L 2 210A-0271 P 33a,b Blade Holder 2 210B-0638 P

34 Sleeve Bearing 0.253 x L 0.5 4 5925-000 P 35 Round HD Screw #10-24 UNC x 1 1 5252-813 P 36 End Pin 0.363 x L 0.97 2 210A-0269 P 37 Male Blade L 19 1 210C-1304 P 38 Hex Nut #10-24 UNC 1 5248-079 P 39 Rod 3/16 Round Rod 1 210B-0685 P

Note: The quantity (Qty.) is based on the assembly of a male blade. The assembly of a female blade

will be the same.


Replacement Procedures SERVICE Spare Part Kits

Vertical Accessory Kit 1695-0000 K No. Part Description Qty. Part No. 29 Spring 12 210A-0076 P 30 Lock Nut #10-24 UNC 12 5248-300 P 31 Bushing x L 12 210A-0270 P 32 Mandrel x L 12 210A-0271 P 34 Sleeve Bearing 0.253 x L 0.5 24 5925-000 P 35 Round HD Screw #10-24 UNC x 1 06 5252-813 P 36 End Pin 0.363 x L 0.97 12 210A-0269 P

Vertical Blade Kit 1695-0002 K No. Part Description Qty. Part No. 28 Female Blade L 19 3 210C-1307 P 37 Male Blade L 19 3 210C-1304 P

Vertical Rod Kit 1695-0002 K No. Part Description Qty. Part No. 38 Hex Nut #10-24 UNC 6 5248-079 P 39 Rod 3/16 6 210B-0685 P

A. Blade

Shaft Top Section

Shaft Middle Section

28

36

37

39

38

31

35

29

32

34

Fig 4.10.) Blade Assembly Shaft Top Section (Drive End)

The following procedures are the removal and assembly of one blade, male or female.



Fig 4.11.) Blade Assembly Top, Middle and Bottom Section

A. Removal Tool Qty. Item No.1. Remove bolts (and washers) from the flange Wrench 4 4 2. Pull the complete shaft assembly out of the IG

tube. Place it on a rack. -- -- --

3. Remove nuts. Wrench 2 30a,b 4. Remove rod. -- 1 39

B. Assembly Tool Qty. Item No.1. Make sure the new blade (taken from spare part

kit) is of the same kind as the damaged one. -- -- --

2. Install plastic endpin. Hammer 2 36 3. Drill holes in plastic endpins. Electrical driller,

drill bit 2 36

4. Install sleeve bearings through the drilled holes. Hammer 4 34 5a. Install screw, b. Plastic bushing and c. Nut.

Screwdriver 1 1 1

35 31a 30a

6. Set blade as shown in Fig 4.10. -- 1 37 7a. See Fig 4.11 for the orientation of the rod, and

install these in sequence: b. Plastic mandrel and c. Spring.

-- 1 1 1

39 32a 29a

8. Secure spring free end on plastic bushing. -- 2 29a 9a. Install plastic bushing, b. Nut on rod and c. Set spring free end on plastic bushing.

-- 1 1 1

31 30b 29b

Curve end on top

Top Section (Drive End)

Middle Section Bottom Section

Cut off Cut off

Curve endon bottomCurve end

on bottom

) (Non Drive End


deepchillTM Brine System User Manual

BS-90

Ice System


Brine System BS-90 Manual CONTENT

2007 Sunwell Technologies Inc. Brine System BS-90 User Manual i

Table of Content Section Page I. System Description ....................................................................................................................... 01 II. Brine Tank Drawings .................................................................................................................. 01-02 III. Salt Refill Procedures ....................................................................................................................... 03 IV. Brine Table .................................................................................................................. 04-05

Brine System BS-90

I. 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. 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 Qty. Part No.

01 Tank 24 x 48 Tank with cover 1 7699-069 P 02 Nipple 1 nipple x 3 (use half) PVC SCH80 1 7575-106 P 03 Elbow 1 elbow x 45 (sxs) PVC SCH80 1 7560-003 P 04 Piping assy Ref. Drawing # M448M017 1 05 Suction header Ref. Drawing # M448M018 1

06 Float switch header Ref. Drawing # M448M019 1

07 Screener assy Ref. Drawing # M448M020 1 08 Elbow 1 elbow x 90 (sxs) PVC SCH80 1 7560-002 P

09 Pipe 1 pipe x 2-1/2 approx. (cut 45 at one end) PVC SCH80 1 7696-104 P

10 Mounting plate Ref. Drawing # M448M023 1

11 Hex-bolt 3/8-16 UNC x 1-1/2 hex bolt SS316 2 5247-303 P

12 Flat washer 3/8 flat washer SS316 4 5246-040 P 13 Nylock nut 3/8-16 UNC nylock nut SS316 2 5248-379 P 14 Hex nut 3/8-16 UNC hex nut SS316 2 5248-075 P

Fig.1.1) BS-90 Brine Tank Component List

2007 Sunwell Technologies Inc. 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

Baume Degree Salometer Degree SG Salt in Brine (wt%) F C 0.0 0 1.000 0.0000 +32.0 00.3 1 1.002 0.2640 +31.8 -0.10.6 2 1.004 0.5279 +31.5 -0.30.9 3 1.006 0.7919 +31.3 -0.41.1 4 1.008 1.0558 +31.1 -0.51.3 5 1.010 1.3198 +30.8 -0.71.6 6 1.011 1.5837 +30.5 -0.81.9 7 1.013 1.8477 +30.2 -1.02.1 8 1.015 2.1116 +30.0 -1.12.4 9 1.017 2.3756 +29.6 -1.32.7 10 1.019 2.6395 +29.3 -1.53.0 11 1.021 2.9035 +29.1 -1.63.3 12 1.023 3.1674 +28.8 -1.83.5 13 1.025 3.4314 +28.5 -1.93.7 14 1.027 3.6953 +28.2 -2.14.0 15 1.029 3.9593 +27.9 -2.34.2 16 1.031 4.2232 +27.6 -2.44.5 17 1.032 4.4872 +27.3 -2.64.8 18 1.034 4.7511 +27.0 -2.85.0 19 1.036 5.0151 +26.7 -2.95.3 20 1.038 5.2790 +26.4 -3.15.6 21 1.040 5.5430 +26.1 -3.35.8 22 1.042 5.8069 +25.7 -3.56.1 23 1.044 6.0709 +25.4 -3.76.4 24 1.046 6.3348 +25.1 -3.86.7 25 1.048 6.5988 +24.7 -4.16.9 26 1.050 6.8627 +24.4 -4.27.2 27 1.052 7.1267 +24.0 -4.4

Freezing PointStrength of Brine


Brine System BS-90 IV.Brine Table (cont)

Baume Degree Salometer Degree SG Salt in Brine (wt%) F C 7.4 28 1.054 7.3906 +23.7 -4.67.7 29 1.056 7.6546 +23.3 -4.87.9 30 1.058 7.9185 +23.0 -5.08.2 31 1.060 8.1825 +22.6 -5.28.5 32 1.062 8.4464 +22.3 -5.48.7 33 1.064 8.7104 +22.0 -5.69.0 34 1.066 8.9743 +21.6 -5.89.2 35 1.068 9.2383 +21.3 -5.99.5 36 1.070 9.5022 +20.9 -6.29.7 37 1.072 9.7662 +20.5 -6.410.0 38 1.074 10.0301 +20.2 -6.610.2 39 1.076 10.2941 +19.8 -6.810.5 40 1.078 10.5580 +19.4 -7.010.7 41 1.080 10.8220 +19.1 -7.211.0 42 1.082 11.0859 +18.7 -7.411.2 43 1.084 11.3499 +18.3 -7.611.5 44 1.086 11.6138 +17.9 -7.811.7 45 1.088 11.8778 +17.5 -8.112.0 46 1.090 12.1417 +17.1 -8.312.2 47 1.092 12.4057 +16.7 -8.512.5 48 1.094 12.6696 +16.2 -8.812.7 49 1.096 12.9336 +15.8 -9.012.9 50 1.098 13.1975 +15.4 -9.213.2 51 1.100 13.4615 +15.0 -9.413.4 52 1.102 13.7254 +14.5 -9.713.7 53 1.104 13.9894 +14.1 -9.913.9 54 1.106 14.2533 +13.7 -10.214.1 55 1.108 14.5173 +13.3 -10.414.4 56 1.110 14.7812 +12.8 -10.714.6 57 1.112 15.0452 +12.3 -10.9

Strength of Brine Freezing Point


deepchillTM IG Troubleshooting

General Guideline

Ice System


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 Sunwell Technologies Inc.

2007 Sunwell Technologies Inc. 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

COM. OVERLOAD (Compressor overload)

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)

Loose power/control wiring Check and tighten all wirings.

Low line voltage Check and retify power supply.

COMPRESSOR HIGH-DIS. (High pressure cut-out)

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.


COMPRESSOR LOW-SUC. (Low pressure cut-out)

High condensing water flow or low condensing water temperature

Adjust condensing water flow accordingly.

Compressor suction valve is closed Open suction valve.



TEXT DISPLAY POSSIBLE CAUSE REMEDYCOMPRESSOR 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.

COM. OIL LUBE ALARM (Oil pressure cut-out)

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.

AGITATOR OVERLOAD (Agitator motor overload)

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.








AG CLR TRIP 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)

Flow rate is too low Check the flow rate through this IG.

CIR. PUMP OVERLOAD (Circulation pump overload)

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.

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).



TEXT DISPLAY POSSIBLE CAUSE REMEDYCOMPRESSOR LOW -SUC. (Low pressure cut-out)


Brine m ake-up rate is low Adjust brine m ake-up flow accordingly.



Check brine m ake-up salinity, increase salinity accordingly. Check shaft condition (blade, springs, rods).


Brine m ake-up pum ps suction strainer is plugged. Check and clean m esh screen.

COM. OIL LUBE ALARM (O il pressure cut-out)

Low oil level in com pressor crankcase DO NOT add oil. Contact Sunwell for further assistance.

Refrigerant charge is low Add R-404a, m axim um of 0.2 kg, then observe operating condition. Contact Sunwell for further assistance.

Loose com m unication wiring Check and tighten com m unication cable connections.


Defective O il Lube Control Check the oil lube control. Replace it if necessary.

AGITATOR OVERLOAD (Agitator m otor overload)

Low brine m ake-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 m otor specifications).

Defective current relay Check the current level relay. Replace it if necessary.

TEXT DISPLAY POSSIBLE CAUSE REMEDYCOMPRESSOR LOW-SUC. (Low pressure cut-out)


Brine make-up rate is low Adjust brine make-up flow accordingly.



Check brine make-up salinity, increase salinity accordingly. Check shaft condition (blade, springs, rods).



COM. OIL LUBE ALARM (Oil pressure cut-out)

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.






AG CLR TRIP 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)

Flow rate is too low Check the flow rate through this IG.

CIR. PUMP OVERLOAD (Circulation pump overload)

Low overload trip setting Check and correct trip setting (according to compressor service guide).




Line is blocked/closed Check all corresponding motorized valves are open. Check all MV wiring.Clean the pipes.

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).

TEXT DISPLAY POSSIBLE CAUSE REMEDYICE DEL PMP OVERLOAD (Delivery pump overload)

Low overload trip setting Check and correct trip setting (based on the compressor service guide).

motor if necessary.


Mechanical problem (e.g. something fall down from the top chute to delivery pump)

Open and check delivery pump.


HARVESTER OVERLOAD (Harvester motor overload)

Low overload trip setting Check and correct trip setting (based on the gear motor user manual).


Variable speed motor drive overload Switch OFF/ON harvester motor overload. Make sure the chute is not blocked by ice. Restart delivery.



STOR. TANK LOW WATER Storage tank is leaking Check and fix the leakage.

Level probe is frozen (possible in winter time) Make sure the heater on the level probe is "ON" and is heating the level probe.

Defective dual level relay (DLR) Check the DLR. Replace it if necessary.

SYSTEM LOW SALINITY! No salt inside the brine tanks Refill the tanks

Air was not taken from brine tanks Take air away from brine tanks.

Defective motor Check the motor's coils and current on each phase. Replace the



TEXT DISPLAY POSSIBLE CAUSE REMEDYICE 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 clo

m529 sunwell.manual

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