Installation, Operation, and Maintenance Manual - Chiller ......Installation, Operation, and...

Installation, Operation,and Maintenance Manual

T h e A r c t i c C h i l l e r G r o u p

Part #9800-0100Publication # PAC-001.02October, 2018ArctiChill • 71 Industrial Park RoadNewberry, South Carolina 29108

Manhattan ModularAir-Cooled Chiller

Installation, Operation, and Maintenance ManualManhattan ModularAir-Cooled Chiller

Publication PAC-001.02October, 2018

Company Confidential ©2018 The Arctic Chiller Group

ArctiChill Support ServicesQuestions regarding the proper installation or operation of this chiller or questions regarding the content of this technical manual should be directed to our trained, certified, factory technicians. ArctiChill technical experts are available directly during normal business hours (8:00 am to 5:00 pm Eastern Time), Monday through Friday.

For after-hours emergencies, the answering service will contact a factory technician who will return your call as quickly as possible.

• 24/7 Technical Support: 803-321-0779

• Customer Service: 803-321-1891

• General Toll Free: 800-849-7778

• International Calling: 001-1-803-321-1891

• email: [email protected]

Company Location and AddressUnited States71 Industrial Park RoadNewberry, South Carolina 29108

Canada2100 Steeles Avenue EastBrampton, Ontario L6T 1A7

Installation, Operation, and Maintenance Manual

Installation, Operation, and Maintenance Manual

Manhattan ModularAir-Cooled Chiller

Publication PAC-001.02October, 2018

Company Confidential ©2018 The Arctic Chiller Group

Unauthorized use or distribution of this copyrighted material herein is considered infringement and will be prosecuted as specified by Public Law 94-553, as amended.

Permission is granted for limited data rights to U.S. government entities and their authorized contractors and assignees the right to use, modify, reproduce, release, perform, display, or disclose these data contained in this publication only to the extent specified in AR 25-30, DA PAM 25-40, and applicable Federal Acquisition Regulations.

Publication DisclaimerArctiChill continues to make improvements to its products, services, and documentation. Changes may be made to product designs and specifications after the publication of this document. Contact ArctiChill for updated documentation and the latest design specifications. Statements and procedures outlined in the guide are not express warranties. This manual is produced for operators, maintainers, and contractors. Read all instructions carefully before attempting to operate, maintain, or troubleshoot the equipment described in this publication. Direct technical questions to the ArctiChill technical support contacts listed in this manual. This equipment operates with high voltage, high pressure fluids, and rotating components. Observe standard electrical safety protocols and all lockout/tagout procedures. Failure to follow these instructions can result in serious injury or death.

Installation, Operation, and Maintenance Manual vii

Table of Contents

Table of Contents

ArctiChill Support Services ............................................................................... ivCompany Location and Address ...........................................................................ivPublication Disclaimer...........................................................................................vi

General Safety Instructions.......................................................................... xiiiSafety of Operators and Maintainers ..................................................................xiii

Personal Protective Equipment........................................................xiiiIndicators, Cautions, and Warnings .................................................xivWarnings and Caution Statement ....................................................xivIntended Users.................................................................................xix

How to Use this Manual ......................................................................................xixChapter One: Chiller Description ..................................................... xxChapter Two: Rigging and Installation ............................................. xxChapter Three: Operating Procedures............................................. xxChapter Four: Maintenance Procedures.......................................... xxChapter Five: Troubleshooting......................................................... xxAppendices ...................................................................................... xx

Chapter 1: Chiller DescriptionChiller Scope................................................................................................... 1Chiller Capacities ............................................................................................ 1Chiller Performance Data................................................................................ 2Model Number and Coding ............................................................................. 2

Chiller Model and Serial Numbers .........................................................................4Technical Support ..................................................................................................4Operating Principles...............................................................................................5Model Coding Key..................................................................................................7

Logical Flow Diagrams.................................................................................... 8High Voltage Logical Flow .....................................................................................8Control Logical Flow ..............................................................................................9Refrigeration Logical Flow .....................................................................................9Water/Glycol Mixture Logical Flow.......................................................................11

Component Description ................................................................................ 11Copeland Compressor .........................................................................................12Evaporator ...........................................................................................................12

Table of Contents

viii Company Confidential ©2018 The Arctic Chiller Group

Expansion Valve.................................................................................................. 14Optional Tank-and-Pump Module........................................................................ 14Microprocessor Control System .......................................................................... 15

Master Microprocessor Controller ................................................... 15Slave Microprocessor Controller ..................................................... 15Remote Interface Panel ................................................................... 15Operator Control and Monitoring ..................................................... 16

Chiller Controls ............................................................................................. 16Power Distribution ............................................................................................... 16

Main Power Distribution................................................................... 17Panel Disconnect............................................................................. 18Module Electrical and Control Panel ............................................... 18

Electrical Controls ............................................................................................... 18Flow Switch ..................................................................................... 19Phase Monitor ................................................................................. 20

Refrigeration Controls ......................................................................................... 20Expansion Valve Settings................................................................ 20Sight Glass ...................................................................................... 21Low Pressure Bypass...................................................................... 21Low Pressure Pump Down (LPPD) Controls ................................... 21High and Low Ambient Controls ...................................................... 22Thermal Capacity ............................................................................ 22

Sequence of Operations ............................................................................... 22Constant Flow Sequence .................................................................................... 23Variable Flow Sequence: No Tank and Pump Module ........................................ 24

Chapter 2 Rigging and InstallingInspect and Report Damage......................................................................... 29

Inspection of Delivered Equipment .................................................... 30Warranty Issues .................................................................................................. 30

Long Term Storage Requirements................................................................ 30Factory Preparation............................................................................................. 31Customer Responsibilities................................................................................... 32

Handling of the Modules ............................................................................... 32Site Preparation and Clearances.................................................................. 33

Chiller Clearances ............................................................................................... 33Minimum Clearances....................................................................... 34

Installation, Operation, and Maintenance Manual ix

Table of Contents

Service Access ................................................................................ 35Rigging, Lifting, and Moving the Chiller ........................................................ 36Mounting Rails .............................................................................................. 37Install Piping and External Components ....................................................... 39Initial Flushing of Piping ................................................................................ 39

Fill with Water/Glycol Solution ............................................................ 40Connecting Module Couplings............................................................ 41

Connecting Module Power and Control Wires .............................................. 42Chiller Module Main Power ..................................................................................42Phase Monitor Installation....................................................................................42Power Interlock Switch.........................................................................................43

Single Point Connections ................................................................... 43Module Control Wiring .........................................................................................44

Preparation for Initial Startup ........................................................................ 44Initial Startup....................................................................................... 45

Request Initial Startup..........................................................................................46

Chapter 3 Operating ProceduresOperator Interface......................................................................................... 49

Chiller Power Panels............................................................................................49Panel-Mounted Disconnect Switch .................................................. 49Power Distribution Panels................................................................ 50Module Electrical and Control Panel................................................ 51

Electronic Control.................................................................................................52Slave and Master Controllers...............................................................................53Operating the Microprocessor..............................................................................53Microprocessor Functions....................................................................................54Password Protection ............................................................................................54Operator Control ..................................................................................................54How to Use the Remote Interface Panel..............................................................56

Quick Controller Tutorial..................................................................... 59Microprocessor Functions................................................................ 64

Connect the Remote Interface Panel ................................................. 64Long Distance Installation .................................................................. 66

Operator Tasks.............................................................................................. 68Normal Power Up ............................................................................... 69

Emergency Power Shutdown........................................................................ 70

Table of Contents

x Company Confidential ©2018 The Arctic Chiller Group

Monitor Water Quality ................................................................................... 71Maintain Glycol Level .......................................................................................... 72Prevent Freezing ................................................................................................. 73

Storage Provisions .......................................................................... 75

Chapter 4: Maintenance ProceduresMaintenance Strategy................................................................................... 77Power Disconnect Switch ............................................................................. 78Inspection and Maintenance Schedule......................................................... 79

Daily .................................................................................................................... 79Weekly ................................................................................................................ 81Monthly................................................................................................................ 81Quarterly ............................................................................................................. 84Annually .............................................................................................................. 85Pump and Tank Maintenance Tasks .................................................................. 87

Maintenance Procedures.............................................................................. 88Inspection Methods ............................................................................................. 88Critical Cleaning Tasks..................................................................................... 89

Strainer Cleaning Procedure.............................................................. 89Condenser Cleaning Procedure......................................................... 91Evaporator Cleaning Procedure......................................................... 93

Compressor Tasks .............................................................................................. 93Remove Compressor ......................................................................... 93Install Compressor ............................................................................. 94

Pump Tasks......................................................................................................... 96Remove Pump ................................................................................... 96Install Pump ....................................................................................... 98Replace Pump Seal ......................................................................... 100Replace Thermostat ......................................................................... 102

Chapter 5 Chiller TroubleshootingGeneral Approach to Fault Isolation ........................................................... 105Controller Diagnostic Codes....................................................................... 105Compressor Diagnostic Codes................................................................... 107

CoreSense Flash Codes ................................................................................... 107Flash Code Description..................................................................................... 107

Variable Frequency Drive Diagnostic Codes ...............................................110

Installation, Operation, and Maintenance Manual xi

Table of Contents

Diagnostic Displays............................................................................................110Fault Resetting...................................................................................................112

Flashing Red LED.......................................................................... 112Steady Red LED ............................................................................ 112

Phase Monitor Protection............................................................................ 112Symptoms and Solutions ............................................................................ 113

Compressor will not start ............................................................... 114Compressor will not run ................................................................. 115Compressor has excessive noise or vibration ............................... 115Compressor will not load or unload................................................ 116Compressor Loading/Unloading Cycles Too Short........................ 116Compressor loses oil ..................................................................... 116Low refrigeration suction pressure................................................. 117High refrigeration suction pressure ................................................ 118Low refrigerant discharge pressure ............................................... 118High refrigerant discharge pressure............................................... 119Low chilled water temperature ....................................................... 120High chilled water temperature ...................................................... 120Compressor thermal protector switch open .................................. 120No low voltage (24 VAC)................................................................ 121Pressure switch open..................................................................... 121Thermal expansion valve superheat too high ................................ 121Thermal expansion valve superheat too low.................................. 122Contactor/relay inoperative ............................................................ 122Freeze protection safety activated ................................................. 122

Appendix A: Acronyms and AbbreviationsAcronym List ............................................................................................... A-1Expansions ................................................................................................. A-6

Appendix B: Product WarrantyParts Warranty ............................................................................................ B-1Parts Failure Not Covered .......................................................................... B-1Policy for Independent Service Contractors................................................ B-1To Make a Warranty Claim.......................................................................... B-2Rates and Terms......................................................................................... B-2

Freight and Handling ................................................................................B-2Payment Terms ........................................................................................B-2

Table of Contents

xii Company Confidential ©2018 The Arctic Chiller Group

Appendix C: Tank and Pump ModuleTank and Pump Components ......................................................................C-1

Set the Pump Overload.....................................................................C-1Fill the Storage Tank .........................................................................C-2

Variable Flow Tank and Pump Module Sequence of Operations ................C-3

Appendix D: Request for Initial StartupManhattan Air-Cooled Chiller.......................................................................D-1Initial Start-up Agreement ............................................................................D-2

Appendix E: Variable Frequency Drive Troubleshooting ABB ACH-550 Fault Codes.........................................................................E-1

Installation, Operation, and Maintenance Manual xiii

General Safety Instructions

General Safety InstructionsThis equipment must be installed by qualified personnel in

accordance with all local and national codes. Chiller does not have a disconnect for high voltage isolation. Turn off power to chiller prior to opening any electrical and control panel. Failure to do so could lead to injury or death. An earth ground lug is provided on the cabinet exterior and in the electrical and control panel for proper grounding according to national electrical codes. The ground is necessary to ensure personnel safety and prevent electrical hazards around this unit.

This equipment is not to be used as an industrial water source for drinking water for humans or animals. This chiller is designed to operate with a 50/50 water/propylene glycol mixture. Operation with plain water will lead to corrosion of the evaporator, and not safeguard the chiller from freezing in ambient temperatures below 32 °F (0 °C). Operation with plain water may void the warranty on the chiller.

Safety of Operators and MaintainersThis equipment operates with high voltage, high pressure fluids, and

rotating components. Observe standard electrical safety protocols and all lockout/tagout procedures. Failure to follow these instructions can result in equipment damage and serious injury or death.

Personal Protective EquipmentAll procedures and processes described in this manual are to be

conducted in accordance with safety rules, directives, and policies of the local, state, and federal as well as the work rules and safety policies of individual companies and organizations under whose cognizance work is being performed. Specifically, these rules and policies should requires employees to wear flame resistant clothing that meets the performance requirements of ASTM F1506 when exposure to electric arc flash is possible. Lockout/tagout procedures must always be practiced and enforced.The term “lockout/tagout” refers to a safety procedure that ensures that dangerous machines and energy sources are properly shut off and not unexpectedly started up before the completion of maintenance work. These energy sources can include electrical, mechanical, hydraulic, pneumatic, chemical, radiation, and thermal hazards.

xiv Company Confidential ©2018 The Arctic Chiller Group

Indicators, Cautions, and WarningsTo assist users to quickly find and use important information, this

manual uses a specific set of symbols to identify certain parts of the manual content. The symbols shown in Table 1 identify the location of special types of messages encountered by the reader.

Warnings and Caution StatementThe following warnings and caution statements are used to indicate

equipment and procedures where the potential for harm exists unless operators and maintainers heed specific instructions contained in each statement.

Table 1: Special Messages Used in this Manual

Icon Type Purpose

WARNING

This message indicates a condition in which there is the potential for serious injury or death if specific hazards are ignored and the stated precautions are not followed.

CAUTION

This message indicates a condition in which there is the potential for damage to equipment if specific hazards are ignored and the stated precautions are not followed.

NOTEThis message provides specific information to draw the reader’s attention to unique situations requiring increased clarification, definition, or refining.

INSIGHTThis message provides optional information that is useful to the operator or maintainer but is not required for any specific process or procedure.

Installation, Operation, and Maintenance Manual xv


This equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void your warranty. Always use PPE and a functional voltmeter when conducting service on this equipment.

WARNINGHazardous Voltage and Electrical Capacitors! Failure to disconnect all power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure that electrical power cannot be accidentally energized. Always use PPE and a functional voltmeter when conducting service in this equipment.

WARNINGHazardous Voltage! Failure to de-energize before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure that electrical power cannot be accidentally energized. Always use PPE and a functional voltmeter when conducting service in this equipment.

WARNING

xvi Company Confidential ©2018 The Arctic Chiller Group

WARNINGThis Chiller Contains Hazardous Refrigerant! This equipment contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the refrigerant loop. See chiller nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in serious injury or death.

CAUTIONDo not install vibration isolators under individual modules.

CAUTIONAll rotalock valves must be properly back-seated. Failure to back-seated rotalock valves can cause compressor failure and void the chiller warranty. Verify that the control switches S1 and S2 on the chiller electrical and control panel are turned in the OFF position prior to applying power.

CAUTIONDo not use automotive antifreeze. Corrosion in the chiller can result in permanent damage to pump and internal cooling surfaces.

Installation, Operation, and Maintenance Manual xvii


CAUTIONThe compressor must not operate if there is no visible sign of oil in the compressor sump during operation. Catastrophic failure will result from operating the compressor with insufficient oil.

CAUTIONThis chiller uses an electronic controller containing one or more microprocessors susceptible to arcing or surges of electrical current. Any short-to-ground event involving a microprocessor or its communications wiring may damage sensitive electronic components beyond repair. De-energize the chiller using prescribed lockout/tagout procedures before performing maintenance or repairs. Never use wires or cables to attempt to “jump” components or bypass the manufacturer’s safety systems.

CAUTIONExtended operation with suction pressures below 80 psi is a clear sign of insufficient refrigerant charge, refrigeration obstruction, or valve closed. This can cause extensive damage to a compressor. Secure the circuit or module offline until the status can be examined in detail.

xviii Company Confidential ©2018 The Arctic Chiller Group

CAUTIONA bright yellow color can indicate excessive moisture in the chiller. (A white indicator in the sight glass does not necessarily indicate excessive moisture in the chiller.) This moisture can degrade the performance of the chiller and cause corrosion within the chiller components. Consider vacuum evacuation of the chiller.

CAUTIONWater/glycol mixture can be under considerable hydraulic pressure in the strainer housing. Escaping solution can thoroughly saturate equipment and personnel. Close isolation valves fully. Relieve pressure using a boiler valve. Use extreme care to slowly remove the end cap and release pressure gradually. Failure to relieve pressure gradually can result in unintended water damage to equipment.

CAUTIONDo not apply excessive force when fully opening an isolation valve. Doing so can cause the valve to bind in the fully open position and prevent later service isolation.

CAUTIONWash hands thoroughly prior to installing the new seal. Even a small piece of grit or dirt can damage the pump seal.

Installation, Operation, and Maintenance Manual xix


CAUTIONIf an external source, e.g. AUTO key, is selected for start command and it is active, the variable frequency drive may start immediately after fault reset.

CAUTIONNever “jumper out” a flow switch. This can damage equipment and defeat safety systems built into the equipment.

Intended UsersThis manual is intended to be used by chiller operators, maintainers,

and service technicians. It is task-organized to provide the user population with a complete description of the components and optional features of the chiller as well as a how-to guide to assist with maintenance and troubleshooting tasks.

Operator and maintenance personnel must be qualified to perform work on refrigeration systems and have a working knowledge of electrical high voltage systems, low voltage control circuits, and fluid system components and functions.

Pertinent chapters are liberally provided with notes, cautions, and warnings to preserve the equipment and guard the health and safety of the user population.

How to Use this ManualThis manual provides the user with necessary data to properly install,

operate, maintain, and troubleshoot the ArctiChill Manhattan Modular Air-Cooled Chiller.

This manual describes a typical air-cooled chiller with few, if any, optional components or devices attached. Operator and maintenance personnel must be qualified to perform work on refrigeration

xx Company Confidential ©2018 The Arctic Chiller Group

systems and have a working knowledge of high voltage systems, low voltage control circuits, and fluid system components and functions.

This document is organized into five chapters, with additional charts, tables, and drawings located in appendices in the back of the manual. Each chapter contains a specific category of information:

Chapter One: Chiller DescriptionThis chapter describes the chiller in detail, covering performance

data, control interfaces, operating principles, logical flow diagrams, component descriptions, sequence of operations, and model number decoding.

Chapter Two: Rigging and InstallationThis chapter explains the processes and requirements for lifting,

positioning, moving, and assembling the individual modules into an integrated unit and making the appropriate piping, refrigeration, electrical, and control connections. Important instructions for long-term storage are also provided.

Chapter Three: Operating ProceduresThis chapter describes the operator interface and controls; power

distribution panel; electrical and control panels; refrigeration controls; remote operator interface; normal power up, power down, and emergency shut down; water quality; freeze prevention; glycol levels; cleaning procedures; storage; and product warranty details.

Chapter Four: Maintenance ProceduresThis chapter describes the maintenance strategy; inspection and

maintenance schedules; maintenance tasks; critical cleaning tasks; compressor tasks, refrigeration tasks, pump tasks, and mechanical tasks.

Chapter Five: TroubleshootingThis chapter describes the general approach to fault isolation; remote

interface panel diagnostics; compressor diagnostic codes; symptoms and solutions; and troubleshooting tasks summary.

AppendicesEach appendix in this manual contains specific information on a

special topic of interest to all or part of the user population.

Installation, Operation, and Maintenance Manual xxi


Appendix A is a listing of all acronyms and abbreviations used in this manual and on the interface displays, and chiller signs, labels, and placards.

Appendix B describes and explains the ArctiChill product warranty.Appendix C describes the features and procedures for any optional

pump and tank module included as part of the chiller.Appendix D covers the form needed to request support for a new

chiller initial start-up.Appendix E explains the fault codes shown in the variable

frequency drives that control the chiller compressors.

xxii Company Confidential ©2018 The Arctic Chiller Group

End of Front Matter

Installation, Operation, and Maintenance Manual 1

CHAPTER 1 ChillerDescription

Chiller ScopeThis manual provides the user with necessary data to properly

operate, maintain, and troubleshoot the ArctiChill Manhattan Modular Air-Cooled Chiller. Operator and maintenance personnel must be qualified to perform work on refrigeration systems and have a working knowledge of high voltage systems, low voltage control circuits, and water/glycol mixture system components and functions.

Chiller CapacitiesThe Manhattan Chiller model is available in 10-, 12.5-, 15-, 20-, 25-,

30-, 40-, 50-, 60-, and 80-ton capacity modules. Up to 16 modules may connect together in a standard master/slave control system. The system consists of a master chiller module that contains the master microprocessor controller, the power distribution panel, one or more slave modules, an optional pump module with a glycol feed system, an optional free-cooling module, and an optional heat exchanger module or air separator module. It is important to connect modules in the correct sequence as detailed in “Handling of the Modules” on page 32.

Chiller Description

2 Company Confidential ©2018 The Arctic Chiller Group

The Manhattan Chiller uses independent refrigeration circuits in each module using scroll compressors. Models are available with either brazed-plate or shell-and-tube evaporators. The brazed-plate evaporator is typically made of SAE Grade 316 stainless steel and 99.9% copper brazing materials. Interconnecting headers are composed of carbon steel.

Water quality must be monitored and maintained by a water treatment professional familiar with the materials of construction and operation of the equipment. The chiller modules arrive fully charged with refrigerant. As required under Federal regulations, installation, initial start-up, and technical servicing should only be performed by fully qualified personnel.

This equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void your warranty. Always use PPE and a functional voltmeter when conducting service in this equipment.

Chiller Performance DataThis manual uses a typical 120-ton air-cooled chiller consisting of

four modules with brazed plate evaporators for example purposes. The model number and a chiller’s precise electrical and refrigerant data can be found on the chiller model nameplate. See “Chiller Model and Serial Numbers” on page 3.

Model Number and CodingWhen contacting ArctiChill for technical support, customer service,

or parts information, be prepared to provide the model number and serial number of the chiller modules in question. This information is located on the blue plastic chiller nameplate that is affixed to each module.

WARNING


Model Number and Coding

Chiller Model and Serial NumbersFor future reference, write the model number and serial number for

each module in the chiller in the spaces provided, in Table 2 on page 4. Refer to the official ArctiChill nameplate labeling for the precise serial number and model number for each module in the installed unit. Provide

Table 1 Typical Manhattan Air-Cooled Chiller Specification for Example Purposes

CHILLER SYSTEM (FOUR 30-TON AIR-COOLED CHILLER MODULES) MODEL # PACVMV0300D4-MMEvaporator Type brazed plate Condenser Type copper tube aluminum fin

Evaporator Flow 274 gpm

Evaporator Fluid 70/30 water/glycol

Entering Fluid Temperature 54 °F (12 °C) Ambient Design Temperature 95 °F (35 °C)

Leaving Fluid Temperature 44 °F (7 °C)

Evaporator Pressure Drop 5.8 psi

Maximum EvaporatorOperating Pressure

650 psi(refrigerant side) System Capacity 1,2274,000 btu/hr.

(106.2 tons)

Refrigerant R410A Connections 6 roll grooved

CHILLER MODULES (4)Compressors two per module Rated Load Amps 46 amps each

Horsepower 15 Total Full Load Amps 123 amps per module

Locked Rotor Amps 340 amps Electrical Power Supply 208/60/3

SYSTEM

Total Full Load Amps 492 amps Maximum Overcurrent Capacity 600 amps

Minimum Circuit Ampacity 506 amps Fans (2 ECM type) 5.7 amps each

DIMENSIONS

Each Chiller Module 38 W x 96 L x 89 Ha Overall Chiller System 162 W x 96 L x 89 Hb

aMaster module is 46 wide, including power distribution panel. bIncluding power distribution panel and end louvers.

WEIGHT

Each Chiller Module 2,500 lbs. Overall Chiller System 10,000 lbs.

Chiller Description


the ArctiChill Customer Service Department (803-321-1891) with the pertinent data when calling for information or parts.

Technical SupportQuestions regarding the proper installation or operation of this chiller

or questions regarding the content of this technical manual should be directed to our trained, certified, factory technicians. Factory technical

Table 2 Chiller Reference Data

Module Model Number Serial Number

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18



experts are available directly during normal business hours (8:00 am to 5:00 pm Eastern Time), Monday through Friday.

• 24/7 Technical Support: 803-321-0779

• Customer Service: 803-321-1891

• General Toll Free: 800-849-7778

• International Calling: 001-1-803-321-1891

• Electronic mail: [email protected]

For after-hours emergencies, the answering service will contacttechnical support who will return your call as quickly as possible.

Operating PrinciplesThe Manhattan Modular Air-Cooled Chiller is designed to operate

with a water/glycol mixture to prevent rust, scaling, and organic growth.The Manhattan Chiller provides 44 °F (7 °C) water under a heat load

with a return temperature of 54 °F (12 °C). The Manhattan Chiller typically uses an R410A, air-cooled mechanical refrigeration system.

The water/glycol mixture is cooled via a compact, brazed plate evaporator. An externally adjustable thermal expansion valve meters the proper flow of refrigerant to the evaporator where it evaporates and the heat in the system water/glycol mixture transfers to the refrigerant. The compressor then compresses the vapor to a higher pressure so that the condensing pressure of the refrigerant is at a higher temperature than the ambient air that is used to condense it. The condenser then condenses the vapor to a saturated liquid, and further cools it so that it reaches the expansion valve as a saturated liquid, to complete the basic cycle.

Chiller Description


Model Number: Critical information for contacting ArctiChill technical support. Reference to the actual chiller module serial number may also be beneficial. Each module has its own unique serial number.

Figure 1 Typical Manhattan Air-Cooled Chiller Nameplate



Model Coding KeyModel numbers assigned to ArctiChill systems provide a wealth of

information about the features for a chiller’s “as-built” configuration.

Figure 2 Unpacking the ArctiChill Model Number

Condenser Type:ACH = Air-Cooled condenser, Horizontal air flowACR = Air-Cooled Remote condenserACV = Air-Cooled condenser, Vertical air flowWCC = Water-Cooled Condenser

Refrigerant Circuits:D = Dual independent refrigerant circuitsR = Redundant refrigerant & electrical circuitsS = Single refrigerant circuitT = Tandem compressors in single circuit

Chiller Model:CP = Cold Plunge processDS1 = Digital Scroll (single)DS2 = Digital Scroll (dual)DW = Drinking Water & filtrationHP = Heat PumpHR = Heat RecoveryMM = Manhattan ModularPT = PolyThermSM = SuperMod

Chilled Water System:C = Condensing unitM = Single pass modular, no pumpP = Self-contained, recirculating

tank & pump

Cabinet Type:H = Horizontal low-profile cabinetU = Condensing unitV = Vertical upright cabinet

Capacity:0020 = Two ton0125 = 12.5 ton0200 = 20 ton0300 = 30 ton2000 = 200 ton

Voltage:1 = 208/230/60/12 = 460/60/13 = 208/230/60/34 = 460/60/35 = 575/60/36 = 220/50/17 = 380/50/38 = 115/60/1

Series:D = Dry cleaning seriesM = Medical & critical duty seriesP = Process and modular series

Configuration:[blank] = Constant speedVS1 = Variable speed (single)VS2 = Variable speed (dual)

Chiller Description


Logical Flow DiagramsThe following section presents the simplified logical flow block

diagrams for the principal systems in the Manhattan Modular Air-Cooled Chiller.

High Voltage Logical FlowManhattan Modular Air-Cooled Chiller models are available in a

range of voltage/amperage/phase configurations to meet the demands of a worldwide chiller market. The high voltage configuration for a chiller module is listed on each module’s name plate. The chiller is designed to operate with high voltage power supplied to the unit at all times. See Figure 3.

Figure 3 High Voltage Logical Flow


Logical Flow Diagrams

Control Logical FlowThe chiller uses low voltage for controller and sensor circuits. See

Figure 4.

Figure 4 Control Logical Flow

Refrigeration Logical FlowThe Manhattan Chiller uses two independent refrigeration circuits

per module using scroll compressors. See Figure 5 on page 10.

Chiller Description


Figure 5 Refrigeration Logical Flow


Component Description

The thermal capacity of the chiller modules is dependent on the leaving temperature of the chilled water maintaining a minimum flow of water through the evaporator.

Water/Glycol Mixture Logical FlowArctiChill recommends using a water/glycol mixture instead of an

all-water fluid. The water/glycol mixture is used within a closed system as shown in Figure 6.

Figure 6 Water/glycol Mixture Logical Flow

Component DescriptionEvery chiller requires four basic components; a compressor,

condenser, expansion valve, and evaporator. Each Manhattan Chiller module contains one or more of these primary refrigeration components.

Chiller Description


Copeland CompressorFor chillers larger than ten tons, the Copeland scroll compressor with

CoreSense technology is a state-of-the-art compressor with relay and overload monitoring capabilities designed to accommodate liquids (both oil and refrigerant) without causing compressor damage. CoreSense technology uses the Copeland compressor as a sensor to unlock advanced capabilities such as protection, diagnostics, communication, and verification. Technicians can make faster, more accurate decisions resulting in improved compressor performance and reliability. See Figure 7.

Figure 7 Copeland Scroll Compressor

EvaporatorThe brazed plate evaporator is constructed as corrugated channel

plates with filler material between each plate. The filler material forms a brazed joint at every contact point on the plates creating complex channels. This allows fluid to come into close proximity of the cold refrigerant, separated only by channel plates, thereby efficiently cooling the fluid to the required temperature. See Figure 8 on page 13.



Figure 8 Typical Brazed Plate Evaporator Configuration

Models with the brazed plate heat exchanger are typically made of SAE Grade 316 stainless steel and 99.9% copper brazing materials. Interconnecting headers are carbon steel.

NOTEA optional configuration with shell and tube evaporators having a carbon steel outer shell and copper tubing may be found in some chillers.

Water quality must be verified and maintained by a professional in water treatment and familiar with the materials of construction and operation of the equipment.

Insight: ValvesAn electronic valve is a butterfly valve used on an evaporator when the water/glycol mixture flow is variable or to operate an “N+1” chiller module configuration. (“N+1” is a configuration whereby a spare module is brought on line should an operating module fail. The spare module’s electronic valve opens, and the failed module’s valve closes thereby keeping the pressure drop and flow through each evaporator in the chiller system constant). Each valve has a 24 VAC power supply opening, closing, or modulating by a 0 to 10 VDC signal. A sensor in the water/glycol mixture header detects temperature or

Chiller Description


pressure via an electronic signal to the microprocessor that in turn controls the voltage to the valve actuator motor. The signal is either 0 or 10 volts.

Expansion ValveAn expansion valve is a metering device controlling the flow of

refrigerant to the evaporator based on evaporator superheat. See Figure 9 on page 14.

Figure 9 Expansion Valve

Figure 10 Master Controller

Optional Tank-and-Pump ModuleYour chiller may be equipped with an optional tank-and-pump

module. See “Tank and Pump Module” on page C-1 in Appendix C.



Microprocessor Control System Manhattan Chiller models employ a Carel pCO5+ all-digital data

control system to control and report key system settings and indicators.

Master Microprocessor ControllerMaster modules use a Carel pCO5+ large microprocessor controller.

Slave modules use a Carel pCO5+ medium microprocessor controller. The master microprocessor controller rotates the lead compressors every 168 system operating hours. This controller must have the optional BMS card installed to connect to a building management system. See Figure 10 on page 14.

Slave Microprocessor ControllerIn a normal configuration, a slave controller controls the single

module to which it is dedicated. The distributed master microprocessor controller system enables the chiller to operate in the event the master microprocessor controller fails; the system automatically fails-over to distributed master control where each slave controller operates its own module but lacks the ability to rotate the lead compressors every 168 system operating hours. See Figure 11.

Figure 11 Slave Controller

Remote Interface PanelThe remote interface panel is the primary means for controlling and

monitoring the system for the operator and maintainer. See Figure 12 on page 16.

Chiller Description


Figure 12 Remote Interface Panel

Operator Control and MonitoringEach system is provided with a remote interface panel that is used to

turn the chiller on and off, adjust set points, clear alarms, and perform detailed set-up of the microprocessor controllers.

Chiller ControlsThe operator uses three different types of controls and indicators to

monitor and maintain the desired operating parameters in the Manhattan Chiller. These controls and indicators are located in the power panels and the microprocessor controllers.

Power DistributionThere are two different electrical panels used in the Manhattan

Chiller. The main power distribution panel receives power from the building source and distributes it to the individual chiller modules. The module electrical and control panel receives power from the power


Chiller Controls

distribution panel and provides power to individual electrical components.

WARNINGThis equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void your warranty. Always use PPE and a functional voltmeter when conducting service in this equipment.

Main Power DistributionThe power distribution panel distributes electricity from the external

building power supply. It also houses breakers, phase monitor, and may include a door-mounted system disconnect switch. See Figure 13.

Figure 13 Power Distribution Panel

Chiller Description


Panel DisconnectSome Manhattan Chiller systems are optionally equipped with a

panel-mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller has power supplied directly to each individual module). The disconnect switch must be turned to the OFF position before the panel can be opened for service.

Module Electrical and Control PanelFrom the power distribution panel, power is fed to the individual

chiller modules and connects to each module’s electrical and control panel. See Figure 14.

Electrical ControlsThe Manhattan Chiller is provided with controls and indicators to

monitor the electrical activity and notify operators if problems arise.

Figure 14 Module Electrical and Control Panel


Chiller Controls

Flow SwitchA flow switch is wired into the low voltage control circuitry used to

detect the flow of liquid throughout the hydronic system. Flow switches are found on all evaporators with isolation valves. Flow switches close when flow is detected allowing compressors to start. If there is no flow, compressors cannot operate.

After every chiller power-on, all LEDs on the flow switch illuminate and go out again in sequence. The switch is ready for operation when an amber LED is visible on the switch display:

Figure 15 Flow Switch Display Indicators

• The number of green LEDs on the switch display indicates howstrong the current flow is through the switch. See Figure 15.

• The set point value is shown by an orange LED. The set point isadjusted at the factory. No further adjustment is required.

• If the set-point value is showing red and the lowest flow strengthLED is flashing green, the flow through the switch issignificantly below the set point range.

Chiller Description


• If the set-point value is showing orange and the highest flowstrength LED is flashing green, the flow through the switch issignificantly above the set point range.

In case of power failure or interruption all settings remain in their last known setting.

CAUTIONNever “jumper out” a flow switch. This can damage equipment and defeat safety systems built into the equipment.

Phase MonitorA compressor can fail if operated in reverse for more than a minute.

A phase monitor is used on three phase power systems to ensure that the electricity supplying the chiller is configured appropriately. A phase monitor prevents a motor from operating in reverse—if any of the three legs of power are landed incorrectly—and will shut the system down upon detection of a reversed phase condition.

Refrigeration ControlsControls on the refrigeration system are designed to provide safety

for the major components and for proper operation of the system.Pressure transducers convert pressure into an electronic signal that

the microprocessor displays in pounds per square inch (psi). Transducers vary in pressure ranges that depend on the type of refrigerant used. Pressure transducers are calibrated using the remote interface panel.

Temperature sensors transmit temperature data electronically to the microprocessor for display in either Fahrenheit (°F) or Celsius (°C). Temperature sensors are calibrated using the remote interface panel.

Expansion Valve SettingsSuperheat is factory-set for around 12 °F (-11 °C). Close the valve to

increase superheat. To accurately read superheat, install a temperature sensor at the evaporator outlet. The sensor bulb should be located at the 4


Chiller Controls

o’clock or 8 o’clock positions on the pipe for the most accurate pressure measurement.

Ensure that the closed cell insulation covers the thermal expansion valve sensing bulb. If insulation is missing, the bulb will tend to feed more refrigerant to satisfy the superheat setting.

Sight GlassWhen the sight glass shows a green indicator, no moisture is present.

When the sight glass shows a yellow indicator, there is moisture in the refrigerant line. Bubbles can be observed whenever chiller cycling causes the pressure to change up or down.

CAUTIONA bright yellow color can indicate excessive moisture in the system. (A white indicator in the sight glass does not necessarily indicate excessive moisture in the system.) This moisture can degrade the performance of the chiller and cause corrosion within the chiller components. Consider vacuum evacuation of the system.

Low Pressure BypassA control that uses a time delay that temporarily bypasses the low-

pressure switch for cold weather start up. Once the delay opens (times out) the normal controls are put back on line within the control circuit.

Low Pressure Pump Down (LPPD) ControlsAllows the system to start in low ambient conditions and prevents

flood-back to the compressor by pumping the liquid refrigerant out of the evaporator. The LPPD control consists of a pressure switch that is set at “cut in” and “cut out” pressures that depend on the type of refrigerant in the system and is based on pressure at which the refrigerant reaches the freezing point of the evaporator water/glycol mixture.

The set points are typically just below the freezing point. For R410A refrigerant and using water, the pressure is set at a 90 psi “cut out” (corresponding to 50 °F [10 °C]) and a 120 psi “cut in” (corresponding to

Chiller Description


40 °F [4.4 °C]) cut in. For any other water/glycol mixture, please contact ArctiChill technical support for proper set points.

Technical Support: 24/7 Technical Support: 803-321-0779.

High and Low Ambient ControlsCondenser coils must be properly oversized for high ambient

operation (or high elevation). Some chiller modules must be required to operate in low ambient temperatures to prevent refrigerant migration to the condensing coil. Without good condenser head pressure control, insufficient refrigerant is fed to the evaporator and will cause low suction pressure, evaporator freezing and will ultimately shut down the chiller. Flooded condenser head pressure control, fan variable frequency drive, and fan cycling are all used to allow varying degrees of low ambient operation.

Thermal CapacityThe thermal capacity of the chiller modules is dependent on the

leaving temperature of the chilled water/glycol mixture, maintaining a minimum flow of water through the evaporator and keeping debris out of the air-cooled condenser. In applications where it is desired to operate with a lower flow rate or higher temperature change, consult the ArctiChill 24/7 technical support for recommendations.

Insight: Contacting ArctiChill ExpertiseQuestions regarding the proper installation or operation of this chiller or questions regarding the content of this technical manual should be directed to our trained, certified, factory technicians. ArctiChill technical experts are available directly during normal business hours (8:00 am to 5:00 pm Eastern Time), Monday through Friday. For after-hours emergencies, the answering service will contact an ArctiChill technician who will return your call as quickly as possible.• 24/7 Technical Support 803-321-0779• Customer Service 803-321-1891• General Toll Free 800-849-7778• International Calling 001-1-803-321-1891• email [email protected]

Sequence of OperationsThis manual describes a typical air-cooled chiller system with few, if

any, optional components or devices attached. To cover the primary


Sequence of Operations

difference in construction and operation, two sequences of operation are included; one for a constant flow chiller system and the other for a variable flow chiller system.

Constant Flow Sequence1. The chiller operates with high voltage power supplied to the unit

at all times.2. When there is power on the system, the master microprocessor

controller selects a new lead module and rotates this lead once every 168 hours, or once a week.

3. The chiller system is enabled when the system ON/OFF switch onthe remote interface panel is energized, and the remote start/stop relay is enabled, either through a contact closure or via the BMS.

4. Once flow is established and the system demand (based onleaving water temperature) indicates that there is a requirement for cooling, the lead compressor of the lead module will energize provided all safeties on that circuit are satisfied.

5. As the system demand increases, the first compressor of the firstslave module will energize provided all safeties on that circuit are satisfied.

6. As the system demand increases, the leaving water temperaturefrom the chiller will slowly increase until the differential set point is reached (set point plus 4 °F [-16 °C]). When the differential is reached, a third compressor from the second slave module (or if there is only one slave module, the second compressor of the lead module) will be brought on-line.

7. As the demand continues to increase, and the temperature onceagain reaches the set point plus differential setting, a fourth compressor from the third slave module (or the second compressor of the first slave if there is only one slave) will be brought on line.

8. On a decrease in system demand such that the leaving watertemperature reaches the set point minus the differential (set point minus 1 °F [-17 °C]), a compressor will de-energize in the reverse of the sequence by which it came on.

9. This process occurs throughout the operating range of the chiller.

Chiller Description


10. The microprocessor will rotate to designate a new lead moduleonce a week to equalize the run time among the modules.

11. If power is removed and then returned to a chiller system (i.e.:power failure), the compressors will restart every five seconds for the next five minutes as needed. In a power return restart, once all the compressors have restarted every five seconds as needed within five minutes, any subsequent cycling of compressors will be every five minutes.

12. When a redundant master microprocessor controller is providedon a chiller module, the redundant master microprocessor will, without downtime and without any operational deficiency, perform the master microprocessor functions should it fail. All operational sequences will be uninterrupted and uninhibited should the master microprocessor fail.

Variable Flow Sequence: No Tank and Pump Module

1. The chiller is designed to operate with high voltage powersupplied to the unit at all times.

2. When there is power on the system, the master microprocessorselects the lead chiller module and rotates this lead once every 168 hours week. The lead module's electronic isolation valve will initially be provided with full power input driving the valve fully open.

3. The chiller system is enabled when the system ON/OFF switch onthe remote interface panel is energized, and the remote start/stop relay is enabled either through a contact closure or via the BMS.

4. The variable frequency drives (VFDs) for the customer-providedsystem pumps must monitor the system pressure differential to determine the pumps' speed. The electronic modulating valves on the modules open and close based on chiller system leaving fluid temperature. The system pump VFDs operate independently from the chiller modules; an increase in flow from the pumps corresponds to a higher system leaving fluid temperature and a demand for cooling. Electronic modulating valves open on a chiller module and its compressors turn on to satisfy the cooling demand. A decrease in flow, as determined by the system pressure differential, lowers the system leaving fluid temperature, decreases the demand for cooling and the chiller modules shut down and their electronic valves close.



5. The electronic isolation valve of the master lead chiller identifiedin step 2 is already energized. Therefore, the system pump must produce the minimum flow required by the lead chiller. A system bypass must be provided by the customer and installed external of the chiller to assure that the pump can provide the minimum flow required through the lead chiller. (A high-quality pressure-independent valve is recommended for this bypass to provide accurate bypass control regardless of the system pressure differential between the supply and return headers.)

6. Once this minimum flow is established and the system demand(based on leaving water/glycol temperature) indicates that there is a requirement for cooling, the lead compressor of the lead module will energize provided all safeties of that refrigeration circuit are satisfied.

7. Once there is a system load, the building management systemwill modulate the system bypass decreasing the bypass flow, as the flow rate through the fan coils increases. This control is provided by the customer external of the chiller but is presumed to be based on the temperature of the water back to the chiller or the pressure differential across the most remote fan coil unit if it has a three-way valve.

8. As the system demand continues to increase, the secondcompressor within that module will energize provided all safeties on that circuit are satisfied.

9. As the system demand continues to increase, the leaving water/glycol mixture temperature from the chiller system will slowly increase until the differential set point is reached. When the differential is reached, a second module is brought on-line. The pump VFD control must be set to ramp up quickly to provide adequate water flow to both operating modules and eliminate nuisance alarms such as low flow and low pressure if there is not sufficient flow to the operating modules.

10. As the flow and demand continue to increase, and thetemperature once again reaches the set point plus differential setting, the second compressor on the second module will energize. This operation continues with all subsequent chiller modules as needed based on system demand.

11. On a decrease in system demand (and flow) such that the leavingwater/glycol mixture temperature reaches the set point minus the differential, a compressor will de-energize. Once both operating compressors within an operating module have de-energized, the modulating valve will slowly close off flow to that module. It is critical

Chiller Description


that the corresponding pump variable frequency drive controller slowly ramp down the speed of the pump to the next operating point so as not to limit flow to the operating chillers as the valve time to close is approximately 150 seconds.

12. This process occurs throughout the operating range of the chillersystem. At all “in-between” stages of system capacity and demand balancing, the digital scroll compressor on the master module will modulate its capacity within the temperature control band limits to maintain the leaving water temperature control as tight as possible and to minimize the amount of compressor cycling.

13. Should the master microprocessor fail, the remaining moduleswill continue to operate in response to demand. The slave modules in the chiller system each have a “distributed master” microprocessor that allows the system to keep operating should there be a failure of the master microprocessor. The only function the distributed master cannot perform is the automatic rotation of modules as described in step 2.

14. When a redundant master microprocessor controller is providedon a slave chiller module, the redundant master microprocessor will, without downtime and without any operational deficiency, perform the master microprocessor functions should it fail. All above operational sequences are uninterrupted and uninhibited should the master microprocessor fail.

15. If power is removed and then returned to a chiller, thecompressors will restart every five seconds for the next five minutes as needed. In a power return restart, once all the compressors have restarted every five seconds as needed within five minutes, any subsequent cycling of compressors will occur every five minutes.

16. If power is removed from the chiller to take the chiller offline andthen restored later, compressors will restart every five seconds as needed if the chilled fluid temperature is warm enough to fall within the start set points of each compressor and warrant the need for cooling. If the fluid is cold and not within the temperature set point range, no compressor will start. If no compressor starts within five minutes, compressors will subsequently turn on every five minutes.

17. The quick starting of compressors occurs:

• After a power outage and the chiller comes back on line.



• When chiller is off using the ON/OFF button and it is pressed topower on.

• When the chiller is off via the remote START/STOP and is turned onby remote START/STOP

• When the chiller is off via the BMS integration and the BMSturns the chiller on.

Chiller Description


End of Chapter


CHAPTER 2 Rigging and Installing

Inspect and Report DamageUpon receipt, inventory the shipment against the ArctiChill bill of

lading to ensure all modules and components have been delivered. Inspect each package in the shipment for visible damage. Verify the

correct model number and that all skids and cartons have been delivered. Any damage must be reported to the motor carrier and ArctiChill within five days of receipt of the shipment.

Inspect all exterior components for concealed damage as soon as possible. Do not proceed with the installation of damaged equipment without prior approval of ArctiChill.

Do not refuse delivery of damaged goods without prior authorization. Unauthorized refusal of the shipment will result in a 20% restocking charge to the customer.

The ownership of the equipment is transferred to the consignee at point of shipment. Refusal of delivery may impede recovery of damages.

It is the consignee’s responsibility to accept delivery of damaged goods unless permission to refuse delivery has been granted by ArctiChill.

Rigging and Installing


Procedure: Inspection of Delivered EquipmentTo report damage incurred in transit, complete the following:

Step 1: Inspect each piece of equipment for visible damage before accepting delivery. Check for torn cartons, broken skids, bent metal and torn shrink wrap.

Step 2: Ensure the delivery driver notes any damage on the bill of lading and completes a Carrier Inspection Report. Failure to comply may result in difficulties in resolving any claims for damage.

Step 3: Inspect each piece of equipment for concealed damage before storage or as soon as possible after delivery.

Step 4: In the event of suspected concealed damage, ask the driver to wait until you inspect the equipment. Concealed damage must be reported within five days of receipt of equipment.

Step 5: If concealed damage is found, stop unpacking the shipment. Do not remove damaged material from the receiving location, take photos of the damage. The owner must provide reasonable evidence that the damage did not occur after delivery.

Step 6: Notify the carrier of the damage as soon as possible. Request an immediate joint inspection by the carrier and consignee. A determination of responsibility will be made and the carrier will authorize repairs in the event of admission of fault.

Step 7: Notify ArctiChill customer service department (803-321-1891) immediately. ArctiChill will coordinate repairs with the owner and carrier. Do not attempt to make repairs locally without permission.

Warranty IssuesArctiChill is not responsible for damages or for filing damage claims.

It is the customer’s responsibility to ensure that the necessary long term storage procedures have been completed and any deviations are reported to ArctiChill immediately.

Long Term Storage RequirementsAppropriate preparation and storage of ArctiChill chiller components

during extended periods of dormancy is essential to ensure the equipment


Long Term Storage Requirements

does not sustain damage or degradation due to inactivity and operates properly after installation.

The customer must notify ArctiChill during the sales process that the chiller system may be transported by ocean freight or placed in long-term storage under any of these conditions:

• The chiller will not be placed into operation for a periodexceeding six months after leaving the ArctiChill factory. That is,the initial start-up date will not occur within a six-monthmaximum dormancy window.

• The chiller will be shipped using ocean transit for all or part ofthe delivery process.

• Cold temperature storage conditions fall below -20 °F (-29 °C).

• Ambient temperature storage conditions exceed 150 °F (66 °C).

Factory PreparationUpon confirmation of an order requiring long-term storage or

protection against extreme environments, ArctiChill will inspect and protect vendor-supplied components before installation.

Prior to shipment, ArctiChill will prepare each chiller system for long-term storage in coastal or tropical environments by:

• Placing silica gel packs in all electrical panels and variable speeddrive panels to prevent corrosion of electrical contacts andmoisture from degrading sensitive controllers.

• Shrink-wrapping each chiller using polyethylene film to limitenvironmental exposure and protect the chillers from damageduring shipping.

• For multiple modular chiller system assemblies shipped on acommon skid, shrink wrap the entire skid rather than theindividual modules.

ArctiChill will document and photograph the status of the unit prior to shipment and carry out the instructions detailed in the factory order regarding in-shop preparation of units for long-term storage.



Customer ResponsibilitiesUpon receipt of a chiller system, the customer must conduct thorough

internal and external inspections, removing packaging material as needed for access to all components.

Visible damage must be noted on the signed and dated bill of lading. The customer may request a carrier inspection by telephone or in person, but any such request should be confirmed in writing. It is recommended that the customer request that the carrier inspect the damage within 72 hours of notification.

The customer must store the chiller system in a dry, non-corrosive, dust- and vibration-free environment due to the exposure sensitivities of the microprocessor controllers and to prevent electrical terminations from deteriorating from non-use. Conditions in storage locations should not fall below -20 °F (-29 °C) or exceed 150 °F (66 °C).

Components sealed in plastic shrink-wrap are not exempt from these storage requirement. Moisture can potentially collect inside the plastic film, resulting in corrosion of the cabinet and electronic components. Any chiller system packaging that is removed must be replaced with similar protective covering as soon as possible.

Failure to adhere to these long-term storage requirements may void the ArctiChill warranty. Any component that is damaged or inoperable due to improper storage may have its warranty voided.

Handling of the ModulesThe packaging from the factory permits lifting with a suitable crane.

Ensure straps are in good working condition and that they are rated for the weight of the machines. Spreader bars may be required for effective rigging and to avoid damage to the chiller modules.

The chiller modules arrive fully charged with refrigerant. As required under Federal regulations, installation, start-up and service should be performed by fully-qualified, factory-certified, personnel.


Site Preparation and Clearances

• All field wiring must be installed in accordance withlocal electrical and building codes.• All the terminals and connections must be tightened.Improper connection and fastenings can cause electricshock, short circuit, and fire.• Ensure that the rated voltage of the chillercorresponds to data on the nameplate before commencingwiring work according to the wiring diagrams.• The unit must be GROUNDED to prevent possiblehazards due to insulation failure.• Electrical wiring must not touch the refrigerantpiping, compressor, or pump.• Do not use fuses of different amperage than thatstated on the nameplate. Using wire etc. to replace a fusecan cause electric shock, short circuit, or fire.• Do not use joined and twisted wires for incomingpower supply.

Failure to follow these critical safety instructions can lead to serious injury or death.

Site Preparation and ClearancesChiller modules must be installed on a level surface that has been

checked by a qualified structural engineer to support the weight of the fluid-filled modules and the connective piping to and from the chiller. Installations must account for minimum service access clearances as may be practical or required by local building codes.

Chiller ClearancesOne of the most critical factors affecting the performance of air-

cooled chillers is air flow above and around the chiller modules. Walls, roofs, overhangs, and nearby mechanical heat sources can all degrade chiller performance. The further an air-cooled chiller is from such obstacles, the more efficiently it will operate.

WARNING



Minimum ClearancesThe unit must maintain generous clearance on all sides to provide for

adequate ambient air circulation. See Figure 16 on page 35.The air-cooled condensers are designed for outdoor installation and

must be mounted level on a roof or concrete slab that is strong enough to support the total equipment operating weight. Consult a professional structural engineer to determine safe mounting loads.

Unrestricted airflow must be provided to each condenser coil unit. Avoid air recirculation from other nearby equipment. Locate the condenser coils away from building air vents and heat sources such as exhaust fans.

The unit should be located far enough away from any wall or other obstruction to provide adequate clearance for ambient air intake and discharge:

There should be no obstruction above the chiller module to interfere with fan discharge of heated air. Even a partial overhang of an eave or awning can trap hot air and significantly degrade chiller performance.

Each chiller module must be as far away from any wall or barrier as space allows. Sufficient clearance must be maintained between the chiller modules and any walls or other objects that can interfere with the free flow of air to the condenser coils.

Screening fences must have 50% open surface area, with one foot of bottom clearance, and must not extend higher than the top of the module cabinet. Modules should be a minimum of three feet away from any fence. Failure to follow these minimum requirements may result in performance degradation.

Modules located in a sub-level or pit require special considerations to avoid air recirculation and heat buildup. The top of each cabinet must be level with, or higher than, the top of the pit. All sides of the chiller should be a minimum of three feet away from any side of the pit.

Do not attach ductwork to any fan or fan shroud.Refrigerant piping should be sufficiently flexible to prevent

transmission of noise and vibration into the building.If the desired location for the chiller is confined by walls, fences,

overhanging roof eaves, or is located in a pit (sub-level site), contact


Site Preparation and Clearances

ArctiChill technical support at 803-321-0779 to discuss potential impact on equipment performance.

The National Electric Code or local, state, and regional building codes may require greater clearance for the modular chiller than the figures listed in this publication. Always consult local regulatory agencies to ensure additional clearances are not required by building codes.

Service AccessSufficient clearance must be maintained between the module and any

nearby wall or impediment to provide sufficient room to open power distribution panel and electrical and control panel doors for routine maintenance and servicing. In general, 36 to 48 inches of space is required to allow panel doors to fully swing open, depending on the size of the module. Compressors, filter-strainers, and liquid line shutoff valves are accessible on each side or end of each chiller.

Figure 16 Recommended Chiller Clearances



Rigging, Lifting, and Moving the ChillerArctiChill Manhattan air-cooled chillers can be delivered to the

customer’s site as individual modules or as previously assembled single units, depending on customer requirements and preferences. Limitations on the methods and materials that can be used to rig, lift, or move a chiller or an individual module include:

• Maintain the module in an upright position at all times.

• Certain configurations of modules can be top-heavy. Movemodules slowly with consideration for each module’s center-of-gravity.

• Rig, lift, and move by strapping and lifting using a properlyconfigured floor jack or fork lift or by overhead means.

• Position lifting beams to prevent lifting straps from rubbing orcontacting module side panels or electrical boxes. (See Figure 17on page 37 and Figure 18 on page 38.)

• Do not use cables, chains, or any other type of metalizedstrapping to lift a module.

• Do not push a chiller module while directly in contact with thefloor using manual or mechanical means.


Mounting Rails

Figure 17 Recommended Chiller Rigging Assembled Unit

Mounting RailsThe chiller must be positioned on a firm, level surface. When

modules are installed onto structural steel rails, the rails must be level such that the modules are properly aligned. Mounting rails must be a minimum of 4 wide. Custom modules may have different requirements. Consult submittal drawings to confirm dimensions.



Figure 18 Recommended Chiller Rigging Assembled Unit (Side View)

All of the modules arrive with labels on the electrical and control panel. Review the installation drawings to determine which is the first, master, module. Typically the master module also has the power distribution panel attached to it. If part of the chiller, the tank and pump module must be installed last at the opposite end of the chiller modules. (The power distribution panel is typically installed on the tank and pump module when so equipped.)

While the compressors are installed with rubber-in-shear isolation pads, for additional vibration isolation, spring isolators may be installed under the structural steel mounting rails.

When installing modules directly onto a concrete pad, rubber-in-shear isolator pads may be installed under each module.


Install Piping and External Components

After setting each module, remove front or rear access panels to improve access to components when making connections.

Install Piping and External ComponentsProper support of piping and pipe hangers must consider the weight

of the piping as well as the water weight inside the pipes. A 60-mesh screen strainer must be installed in each water/liquid

system piping inlet for proper filtration and protection of the heat exchangers. Figure 19 provides a recommended installation of components.

Figure 19 Recommended Chiller Piping



Initial Flushing of PipingAfter installation of system piping and before connection to the

chiller system, it is important to clean and remove debris, weld slag, and other contamination deposited during fabrication of the piping system. Typical flushing includes hot water with mild detergent followed by a dilute phosphoric acid solution until all visible residue is removed.

Only cleaning liquids, acids, and detergents compatible with SAE Grade 316 stainless steel, copper, and carbon steel should be used. Consult a professional water treatment specialist when in doubt.

Flushing should take place across a filter/strainer with a maximum 30 Mesh screen and continue for a minimum of six hours with frequent removal of the screen to capture residue or until the strainer is clean.

After detergent and chemical cleaning, flush the water piping with fresh water for one hour to remove any remaining cleaning compounds.

Procedure: Fill with Water/Glycol SolutionIn most instances the installing contractor is responsible for charging

glycol into the chiller. If not charged, add glycol according to these instructions:

Step 1: Mix the concentrate of propylene glycol in a tank or drum for transfer into the chiller. Use Table 3, Glycol Performance Impact Factors on page 72 to assist in determining the appropriate glycol concentration for the chiller.

Step 2: Mix the glycol and water externally before filling the chiller to prevent clogging of the chiller piping with a heavy concentrate.

Step 3: Fill the chiller using the manual fill port on the cabinet. Fill so that the mixture reaches near the top. Stop every so often so the fill level can be monitored.

NOTEDo not use a glycol feeder pump to fill the chiller loop. It is not designed for continuous use and will fail.

Only after the above steps have been completed should the water piping be connected to the chiller system.


Initial Flushing of Piping

Insight: DowfrostDowfrost inhibited propylene glycol-based solution is listed as chemically acceptable by the US Department of Agriculture (USDA). The two ingredients in Dowfrost water/glycol mixture are generally recognized by the FDA as safe food additives under Parts 182 and 184 of the Food Additive Regulations.

Procedure: Connecting Module Couplings Install each module according to its position number indicated on its

electrical distribution cabinet. Install the master module first. Each slave module has the same installation procedure as the previous module.

Step 1: Remove the coupling that attaches the headers to the heat exchangers in order to position the header with the next module and attach the header coupling.

Step 2: Remove all four small couplings to allow the main headers to slide into the previous module.

Step 3: Position each subsequent module approximately 16 from the previous module when positioning the headers.

Step 4: Lubricate the main header coupling gasket with an approved lubricant and re-install onto the roll grooved header pipe. Push the gasket flush with the pipe end to avoid damage when installing the next module.

Step 5: Remove the coupling that attaches the main header to the heat exchanger.

Step 6: After positioning the module, slide the header and rotate it to avoid damage to the refrigeration piping.

Step 7: Note the refrigeration pipe above the header. Note the position of modules and headers extended.

Step 8: Position each of the four headers and attach the roll grooved couplings. Start by positioning the lubricated gasket so that the gasket fits inside the two grooves, one from each of the headers.

Step 9: Loosen one side of the metal coupling and remove the bolt from the other side to allow you to position it over the gasket.

Step 10: Install and tighten each of the four couplings. Begin with the inside headers, then the outside headers. Slide the module back to



the previous module and re-attach the header to the small coupling for the heat exchanger.

Step 11: Install the remaining modules using this procedure.

Connecting Module Power and Control WiresConnections are made at the master module, which typically contains

the power distribution panel (or on the tank and pump module, if so equipped).

Insight: Electrical HazardsRead before installing! This equipment must be installed by qualified personnel in accordance with all local and national codes. An earth ground lug is provided on the cabinet exterior for proper grounding according to national electrical codes. An earth ground is necessary to ensure personnel safety to prevent electrical hazards around this equipment. Read and follow all installation instructions for proper operation.

Labeled control and communication cables are coiled inside each module and are connected in series (daisy-chained) to the next module’s microprocessor controller at the J11 connector.

Chiller Module Main PowerModular systems feature single-point power connection from the

utility service to the power distribution panel on the master module as standard. Main power phases A, B, and C are connected to terminals A, B, and C respectively from left to right. Some systems have individual power supplied to each module in lieu of single point power.

Phase Monitor InstallationThe chiller is equipped with a phase monitor on the power

distribution panel. It communicates with the master microprocessor controller on the master module electrical and control panel via the ID10 terminal. Ensure that the wiring from the master microprocessor controller and terminal blocks to the phase monitor are connected and secure.


Connecting Module Power and Control Wires

The phase monitor continuously monitors each of the three phases. The microprocessor receives input from the phase monitor indicating whether the voltage is within acceptable values. The phase monitor is designed to protect against under-voltage, voltage imbalance, phase loss, and phase reversal.

Set voltage adjustment knob at the desired operating line voltage for the equipment. This adjustment automatically sets the under-voltage trip point. Check the phase monitor after initial startup. If it fails to energize, (the LED glows red or blinks) check the wiring of all three phases, voltage, and phase sequence. If phase sequence is incorrect, the LED flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further adjustment should be required.

Power Interlock SwitchSome Manhattan Chiller systems are optionally equipped with a

panel-mounted disconnect switch installed on the outside of the power distribution panel. The disconnect switch must be turned to the OFF position before the panel can be opened for service.

WARNINGThis equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void the warranty.

Procedure: Single Point ConnectionsFor systems with single point power connections, detach the power

cable on each module by cutting the wire tie installed for shipping.

Step 1: Uncoil the power cable and snake it through each module to reach the power distribution panel.

Step 2: Feed the taped end of the cable through the round opening on the extreme left of the power distribution panel.

Step 3: Remove the tape and connect and tighten the cable ends to the breaker corresponding to the module number being connected.



(For example, connect the cable for module #9 to the breaker labeled #9.)

Step 4: Connect the green ground lead to the ground lug at the base of the enclosure.

Step 5: Do not secure the ground wire until all of the ground wires are connected to the ground lug and then each can be tightened.

Step 6: After connection, secure all power cables with standard wire ties.

Module Control WiringThe master controller communicates with the slave controller in each

chiller module via a communication circuit. Each slave controller is daisy-chained back to the master controller via three-twisted-pair comm wire using each controller’s J11 port.

NOTEEnsure that the connection to each slave controller’s J11 port is made so that all slave controllers are connected to the master controller’s J11 port in series. The master controller cannot communicate with any slave controller that is not connected in this series.

Preparation for Initial StartupAfter the system is completely installed with all wires connected and

all piping securely coupled, the chiller can be prepared for initial startup.Ensure there is a sufficient cooling load available for proper testing of

the chiller system.

WARNINGThis equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void your warranty.


Preparation for Initial Startup

Procedure: Initial StartupStep 1: Close all drain valves and header purge valves.

Step 2: Fill the chiller with clean water/glycol mixture.

Step 3: Inspect all connections for leaks during the filling process.

Step 4: De-energize chiller using industry-standard lockout/tagout procedures. Verify main power is turned off at the power distribution panel.

Step 5: Inspect all electrical connections to ensure terminals are secure.

Step 6: Inspect all fuses and overload settings to ensure they conform to specifications.

Step 7: Inspect all refrigerant pressures for each module to ensure no refrigerant has been lost.

Step 8: Check that pressure switches and thermostats have correct “cut-in” and “cut-out” settings.

Step 9: Confirm the oil level is correct in each compressor.

NOTEIf ArctiChill pumps are provided, check that each pump’s overload setting matches the nameplate amperage of the pumps as described previously. “Bump” pump motors on to verify correct rotation.

CAUTIONThe compressor must not operate if there is no visible sign of oil in the compressor sump during operation. Catastrophic failure will result from operating the compressor with insufficient oil. See recommended inspection interval under “Monthly” on page 81.

Step 10: Connect phase monitor wiring, if required.

Step 11: Connect remote flow switch if the chiller is so equipped.



Step 12: Ensure refrigerant valves are open at the compressors.

Step 13: Confirm that pressure and temperature switches are in the closed position.

Step 14: Apply power to all modules in the chiller. (If a tank and pump module is included, there are switches inside the module control cabinet to start the pumps. Ensure that the pump rotation is correct.)

Step 15: Turn on the condenser water and evaporator pumps and ensure there is proper flow and the pressure drop across the system is as expected.

Step 16: Monitor and record all temperatures and refrigerant pressures.

Request Initial StartupInitial startup is an exacting, complex, procedure. Successful initial

startup is directly attributable to thorough preparation and completion of all essential tasks prior to the scheduled initial start-up date.

ArctiChill will not schedule a startup without a Request for Initial Startup form on file with the ArctiChill customer service department.

Submission of this form indicates all critical work described on the form has been completed. To prevent incurring additional startup charges, all items listed on the form must be completely functional and operating, with this form signed and returned to ArctiChill, at least 10 working days prior to scheduling an initial startup. (See Appendix D, “Request for Initial Start-Up.”)


Preparation for Initial Startup

Table 3 Initial Startup Readiness Checklist

Startup Readiness Dimension

Describe voltage service: Fused disconnect Non-fused disconnect • 50 cycle 60 cycle

Record rated power supply: __________volts_______ phase • Circuit breaker rating: _______

Record supply voltage on chiller nameplate: _________________

Record power supply voltage to ground: L-1= _______, L-2 = _______, L-3 = _______

Record voltage between each phase: L-1 to L-2 = ______, L-2 to L-3 = ______, L-1 to L-3 = ______

• Agrees with nameplate values? Voltages must be within 2%.

Check the box if all electrical connections inside the power distribution panel are tight.

Check the box if all electrical connections inside each module electrical and control panel are tight. Ensure all components inside each module are securely mounted and have not shifted during shipment.

Record the control voltage at TB-1-1 and TB-2-1: TB-1-1 = ________, TB-2-1= ________

Check the box if chiller system includes any remote panels (city water switchover, remote control panel, or customer supplied control devices). If so, voltage drops are likely to occur. Measure and record all control voltages: List devices: Voltage 1=_____________________, Voltage 2=_____________________, Voltage 3=___________________,__

Check the box if there are any field-supplied wiring junction boxes located between the chiller and any remote panels.

Check the box if there are any splices made in the field-supplied wiring junction boxes.

Check the box if there are any customer-supplied devices connected to the chiller wiring.

List devices: ______________________________________________________________________________________

Check the box if there are any ArctiChill remote devices connected to the chiller wiring.

Check the box if voltage drops are detected. Call ArctiChill technical support immediately: 803-321-0779.

Check the box if the appropriate water/glycol mixture has been added to the chiller.

Check the box if all chiller modules are installed with minimum clearances available from all sides.

Check the box if refrigeration gauges are indicating equal refrigerant pressures.

Check the box if chilled water lines from chiller to customer’s equipment are permanently connected.



Factory Certification: Training and certification is available from ArctiChill. Call Customer Service at 803-321-1891 for course schedule and availability.

As part of a continuous commitment to quality, initial startup of this chiller by a certified factory technician may be purchased from ArctiChill.

Check the box if chilled water lines have been flushed clean of mud, slag, and other construction debris.

Check the box if all chilled water line filters and strainers are clean.

Check the box if chilled water lines have been leak tested according to prestartup instructions.

Check the box if chiller reservoir (if included) is at operating level with correct water/glycol mixture.

Check the box if high voltage wiring is installed, tested, and functional.

Check the box if all water, refrigeration, and electrical connections between chiller modules are completed.

Check the box if all control wiring between modular chillers is installed, tested, and functional.

Check the box if control wiring is complete, including any additional remote interface panel or special-purpose wiring.

Check the box if all responsible installing contractors and sub-contractors have been notified to have representatives available on site to provide technical support for the initial start-up procedure.

Check the box if full load will be available for chiller on the initial start-up date.

Remote Interface Panel: Record version and date of software loaded into the remote interface panel:Version: ____________________________________ Date: ________________ Note: To view the software version, press water temperature button then press the up button. The version is in the lower left corner of the screen and the date is in lower right.

Table 3 Initial Startup Readiness Checklist (Continued)

Startup Readiness Dimension


CHAPTER 3 OperatingProcedures

Operator InterfaceAll Manhattan Modular Air-Cooled Chiller units, whether they are

composed of a single module or up to 16 modules, are automated systems that use a remote interface panel to monitor, report, and modify critical system functions.

Chiller Power PanelsThere are two different electrical panels used in the Manhattan

Chiller. The main power distribution panel receives power from the building source and distributes it to individual modules. The electrical and control panel receives power from the power distribution panel and provides power to the individual electrical components in that module.

Panel-Mounted Disconnect SwitchSome Manhattan Chiller systems are optionally equipped with a

panel-mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller has power supplied to each individual module). The disconnect switch must be turned to the OFF position before the panel can be opened for service. When the panel door is open, the power is disengaged.

Operating Procedures


Power Distribution PanelsThe power distribution panel distributes electricity from the external

building power supply. It also houses circuit breakers, a phase monitor, a master power disconnect switch. See Figure 20.

Figure 20 Power Distribution Panel

GroundLug

CircuitBreakers

DistributionBlock

PhaseMonitor


Operator Interface

Module Electrical and Control PanelEach module has its own electrical and control panel that distributes

electricity to individual components. It also has fuses and breakers, compressor switches, and the microprocessor controller. See Figure 21.

Figure 21 Module Electrical and Control Panel

K1 Contactor(Compressor 1)

DB DistributionBlock

T1, T2 24 VACTransformers

CompressorSwitches

CB-1 CircuitBreaker

(Compressor 1)

CarelpCO5+Controller

CB-2 CircuitBreaker

(Compressor 2) K2 Contactor(Compressor 2)

TB-1Terminal Block

TB-2Terminal Block

TB-4TerminalBlock



Electronic ControlManhattan Modular Air-Cooled Chiller models use Carel pCO5+

series microprocessor controllers to monitor and report critical operating parameters. The master module uses a large pCO5+ controller (Figure 22). Slave modules use a medium pCO5+ microprocessor (Figure 23).

Figure 22 Carel Large pCO5+ Master Controller

A master controller is used to control and coordinate the functioning of all the modules that make up the chiller unit. For units consisting of more than a single chiller, each module has its own controller. The master microprocessor controller must have an optional card installed to connect to a building management system.

Figure 23 Carel Medium pCO5+ Slave Controller


Operator Interface

Slave and Master ControllersThe distributed microprocessor control system enables all slave

modules to operate independently in the event that the master microprocessor controller fails. All chiller safeties including temperature set point, refrigerant pressures, and freeze protection are preserved. The distributed microprocessor control programming only lacks the ability to rotate the lead compressors which typically occurs every 168 compressor operating hours.

(See Figure 24 for a simplified example of a typical microprocessor controller network.)

In a normal configuration, a slave controller controls the single module to which it is dedicated.

The slave controller monitors key performance parameters for its module and sends real-time information to the master controller. The master controller monitors the performance of the chiller, activating and deactivating modules as needed to maintain the leaving water temperature for the chiller.

Figure 24 Typical Controller Network

Operating the MicroprocessorThe remote interface panel is ready to use when it is connected to the

master controller and chiller power is on. Upon initial startup, the status line will indicate that the chiller is off. Pressing the ON-OFF button on the remote interface panel turns the chiller on and the status line will indicate that it is powered on the LCD screen of the master module. Pressing this button effectively toggles the chiller on and off.



Microprocessor FunctionsFor practical purposes, all essential control information and operator

actions are read and responded to using the remote interface panel. The remote interface panel is connected to the master microprocessor controller and is the only way to access many master controller functions.

CAUTIONThis chiller uses an electronic controller containing one or more microprocessors susceptible to arcing or surges of electrical current. Any short-to-ground event involving a microprocessor or its communications wiring may damage sensitive electronic components beyond repair. De-energize the chiller using prescribed lockout/tagout procedures before performing maintenance or repairs. Never use wires or cables to attempt to “jump” components or bypass the manufacturer's safety systems.

Password Protection

24/7 Technical Support: 803-321-0779

There are two passwords. The Level One password, 0011, can be accessed and allows set point adjustment. The Level Two password is accessed only by ArctiChill technical personnel. Contact ArctiChill technical support regarding the possibility of any potential issues involving the Level Two password.

Operator ControlA remote interface panel is the primary means for the operator or

maintainer to monitor and modify a host of functions involving temperatures, pressures, set points, alarms, operating schedules, and elapsed operating hours. This remote interface panel can be located within proximity of the master microprocessor controller.

The remote interface panel accesses this data network by plugging a six-conductor (RJ-12) straight-through pinned cable into the jack on the back of the remote interface panel and connecting the other end of the cable into the J10 port in the top left portion of the master controller.


Operator Interface

In this manual, all functions, procedures, checklists, system information, and changes in system parameters (set points, alarms, master chiller control and so forth) are written assuming the operator is using the remote interface panel.

When connected to the master controller, the remote interface panel immediately displays current, real-time, information about the chiller as well as the status of critical parameters within each module of the chiller.

See “Quick Controller Tutorial” on page 59 for instructions on how to perform actions required to operate the remote interface panel. Table 1, Remote Interface Panel Buttons and Keys, on page 56 explains the buttons on the remote interface panel.

The chiller owner or operator has the option to locate another, remote, interface panel in a convenient and accessible location (a control room or on the interior wall of the equipment room) within 500 feet (152 meters) of the chiller’s master controller. (See Figure 25.) This additional interface panel is available from ArctiChill as an in-stock item.

Figure 25 Remote Interface Panel



How to Use the Remote Interface PanelThe remote interface panel is used to adjust set points, clear alarms,

and perform detailed setup of the microprocessor controllers.The remote interface panel displays information on its LCD screen

whenever specific combinations and sequences of keys and buttons are pressed by the operator. Four lines of data can be shown on each LCD screen. The bottom line on the LCD is the status line that will indicate whether the chiller is powered up or not. (See Figure 26.)

Figure 26 Remote Interface Panel LCD Screen

M A S T E R S T A T U SS y s t e m E n t e r : 0 6 4 ° FS y s t e m E n t e r : 0 4 7 ° FS Y S O N C M P S : 0 4

Line 1

Line 2

Line 3

Line 4

Line 4 = status line: Chiller is ON, with 4 compressors running.

Line 1 = screen name:This is the master status screen.

Table 1 Remote Interface Panel Buttons and Keys

Icon Name Activation function Visual result of activation

WATER TEMPS

Pressing this key displays chiller status or demand, identifies which compressors are currently energized, and the entering and leaving water temperature settings of the master controller.

SET POINTS

Pressing this key displays the chiller set points (based on the entering water temperature) and allows adjustment of a set point; the high and low temperature alarm set points can also be set.

REFRIG PRESSURE

Pressing this key displays the refrigeration pressure in each chiller module.

MASTER STATUS: 100%System Enter: 55°System Leave: 45°System Off

TemperatureSet PointsEntering> 45.0°FEWT Reset> 48.2°F

MASTER STATUS: 000%Low Press C1 000 PSIHigh Press C1 000 PSISystem Off


Operator Interface

PUMP PRESSURE

If the chiller includes a tank and pump module, pressing this key displays the pump discharge pressure.

CLOCK

Pressing this key displays the system actual time and allows the operator to energize or de-energize the chiller at specific hours for precise after-hours and weekend operational control.

ALARM LOG

Pressing this key displays the first of the previous 100 logged alarms including the time they occurred and the chiller temperature settings at the time of each alarm. Pressing the up arrow scrolls chronologically through each previous alarm in turn.

FLOW RATE

This optional controller feature is for a small-capacity chiller with a low flow rate (50 gpm maximum) to improve the accuracy of the flow reading. This is not used in Manhattan Chiller modules.

HAND-OFF-AUTO

This optional controller feature is for a chiller with redundant components so that individual compressors are controlled manually or automatically. Not used in Manhattan Chiller modules.

PROGRAM

Pressing this key displays the access panel for factory settings for the chiller's microprocessors. It is protected by a Level Two password to limit access to ArctiChill personnel only. This is typically not accessed for routine tasks.

INFO KEY

While viewing the master module screen, pressing this key displays the information for each compressor in the chiller modules, the run status of each compressor, and the accumulated running hours for each compressor.

Table 1 Remote Interface Panel Buttons and Keys (Continued)


MASTER STATUS: 000%Pump Suction 000psiPump Disc 000psiSystem Off

Set Date/TimeEnter Date: 01/01/24Enter Time: 10:17Enter Day: Tuesday

**ALARM**COMPRESSOR1OVERLOAD

Enter Password> 0000

Meter Run HoursCompressor 1Hours > 00016hrStarts > 00025



ON-OFF

While viewing the master module screen, pressing this button immediately de-energizes the chiller (“turns it off”). This action also overrides any instructions to the chiller delivered by the Building Management System. Pressing the button again restores power to the chiller.

ALARM

Pressing this button will display an alarm information screen for the current active module if there is a currently active alarm. The ALARM button will illuminate and an audible alarm will sound when an active alarm occurs. Pressing the ALARM button will silence the audible sound.

ENTER

Pressing this button when the NO MORE ALARMS screen is displayed on the LCD screen will clear this alarm if the problem has been resolved through operator action. If the ENTER button is pressed and the alarm does not clear, then the alarm has not been resolved and further action is required.

UP

Pressing the up button moves the LCD display UPWARD to the next alarm in a list of alarms or accumulated running hours for each compressor in the chiller. When it reaches the top item in the list, it cycles back to the bottom item in the list.

DOWN

Pressing the down button moves the LCD display DOWNWARD to the next alarm in a list of alarms or accumulated running hours for each compressor in the chiller. When it reaches the bottom item in the list, it automatically cycles back to the top item in the list.

Table 1 Remote Interface Panel Buttons and Keys (Continued)


**ALARM**COMPRESSOR1HIGH PRESSURE


Operator Interface

CAUTIONThe Carel remote interface panel interface must not be used in locations exposed to ambient weather conditions or subfreezing temperatures. Exposure to immersion in water or wet environments will drastically reduce its service life and subject the device to unpredictable performance and sudden failure. Operating the remote interface panel in such conditions voids the warranty. Use the device indoors or inside a NEMA Type 4 box.

Procedure: Quick Controller TutorialThese instructions are provided for first time users with little prior

experience with the Carel pCO5+ controller system. To complete this tutorial, use a remote interface panel connected to any slave controller J10 port, as described above.

Step 1: Navigate to the master status screen. From any other screen, follow the steps shown in Figure 27 to display the master status for the chiller.

Figure 27 Display Master Status Screen

Step 2: Display the slave #1 status screen as shown in Figure 28 on page 60.

Step 3: Cycle through all of the module status screens. For example, if this was a four-module chiller, the screens would cycle through master and three slaves, in turn, and return to the master.

Step 4: Display the slave #2 status screen as shown in Figure 29 on page 60.



Figure 28 Display Slave #1 Status

Step 5: While viewing the master controller screen, display entering and leaving temperature set points as shown in Figure 29.

Figure 29 Switch to Slave #2 Status

Step 6: Enter the Level One password to be able to change the temperature set point as shown in Figure 30.

Figure 30 Enter Password to Display Temperatures

Step 7: Inspect the data and time setting for each module as shown in Figure 31 on page 61.


Operator Interface

Figure 31 Inspect Chiller Date and Time

Step 8: Locate and display the temperature set point screen for each module. Follow the sequence shown in Figure 32.

Figure 32 Inspect Water Temperatures Set Points



Step 9: Locate and display the refrigeration temperature set point screen for each module. Follow the sequence shown in Figure 33.

Figure 33 Inspect Refrigeration Pressure Set Points

For the chiller to log alarms correctly, all modules should have the same date and time settings. Locate and change the date and time for each module. Follow the sequence shown in Figure 34 on page 63.

NOTEFor this action, the location of the screen cursor is showing by the blinking red block. Use the ENTER button to move the cursor from field to field to change the date and time values. To save each change after it is made, move the red blinking block to the top-leftmost corner and pressing the ENTER button again to move to the next field.


Operator Interface

Figure 34 Change Chiller Date and Time



Microprocessor FunctionsFor practical purposes, all essential control information and operator

actions can be read and responded to using the remote interface panel.

Procedure: Connect the Remote Interface PanelThe remote interface panel is designed to provide a remote diagnostic

display and allows the user to communicate with the microprocessor located within the chiller. The panel permits the operator to modify the temperature set points of the chiller, as well as make adjustments to the alarm set points. The panel displays the chiller status, refrigeration pressures, pump pressures (if chiller equipped), current alarms, logged alarms, and compressor and pump run hours.

The panel is equipped with an ON-OFF button that permits the user to shutdown the chiller remotely.

NOTEThe ON-OFF button must be illuminated by pressing the button to the ON position for the chiller to operate.

The remote interface panel is designed for panel or wall mounting. The is designed to be installed to a standard switch box. Wall mounting requires the use of the mounting plate provided with the unit and a standard electrical junction box for the passage of the cable. Fasten the bracket to the wall using the enclosed screws. Then, slide the rear of the panel downward onto the mounted bracket.

NOTEThe chamfered edge must be installed so that the longer edge of the bracket extends out from the wall. In this orientation, the vertical slotted hole is on the left, the horizontal slotted hole is on the right, and the notched groove is on the bottom. Installing the mounting plate in this orientation prevents the panel permits easier placement and removal of the panel from the wall.


Operator Interface

Step 1: Mount the junction box horizontally (sideways) to align with the mounting bracket. This will permit the six-conductor phone cable to be connected to the panel.

Figure 35 Chamfered Edge Pointed Out from Wall

Step 2: Prior to connecting the six-conductor power cable, verify that the cable has straight-through connections. If a tester is not available, visually compare the two RJ-12 connections. The depressor on one of connectors must face one side of the cable, and the depressor on the other connector must face the opposite side. This is distinguishable since most common six-conductor cables have a ribbed side and a flat side.

Step 3: Connect the RJ-12 connector to the panel. The RJ-12 connector on the opposite end of the cable attaches to the port labeled J10 on the master microprocessor.

Mounting Bracket

Junction BoxChamfered edge out

Wall

Vertical hole on left side

Mounting Bracket



CAUTIONThe power supply to the interface panel is polarity sensitive. Failure to properly orient the connectors will damage the panel and void the panel warranty! Always confirm that the two RJ-12 connectors align (“match up”) on the ribbed and flat sides.

Procedure: Long Distance InstallationIf the cable length from the microprocessor to the interface panel

exceeds 150, the interface panel must be connected using a 22 AWG (or larger) shielded three twisted pair cable. This wiring allows the remote interface panel to be installed up to 500 away from the master microprocessor controller. See Figure 36 on page 67.

Two “T-connectors” must be purchased separately when this installation option is required.

Step 1: One of the connectors may be installed to the junction box, while the other one is installed in the chiller electrical enclosure.

Step 2: This connector acts as a junction between the three twisted pair cable and the 6-conductor phone cable that connects the master microprocessor controller and the remote interface panel. See Figure 37 for connection details. The wiring scheme for connecting the 6-conductor phone cable is shown in Figure 37 on page 67 and Table 2, The 22 AWG Cable Connections, on page 68 .

Step 3: The remote interface panel receives its power from the master microprocessor controller. The cable can be plugged into the interface panel without turning off power to the microprocessor.


Operator Interface

Figure 36 Mounting the Remote Interface Panel at Distance

Figure 37 T-connector for Mounting Panel at Distance

500 feet maximum

T-Connector T-Connector

RemoteInterface

Panel

MasterController



CAUTIONPower fluctuations can damage the remote interface panel. Do not connect or disconnect without first waiting five seconds before powering up the remote interface panel again.

Operator TasksBefore operating the unit, ensure that all compressor refrigeration

service valves are fully back-seated counterclockwise.

CAUTIONAll rotalock valves must be properly back-seated. Failure to back-seated rotalock valves can cause compressor failure and void the chiller warranty. Verify that the control switches S1 and S2 on the chiller electrical and control panel are turned in the OFF position prior to applying power.

Table 2 The 22 AWG Cable Connections

Terminal Function Cable connection

0 ground shield

1 +VRL (30 VDC) first pair A

2 GND second pair A

3 Rx/Tx- third pair A

4 Rx/Tx+ third pair B

5 GND second pair B

6 +VRL (30 VDC) first pair B


Operator Tasks

Procedure: Normal Power UpThe following procedure is used for a startup resulting from

scheduled seasonal or programmed cold shut down of the chiller.

WARNINGHazardous Voltage and Electrical Capacitors! Failure to disconnect all power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure that electrical power cannot be accidentally energized. Always use PPE and a functional voltmeter when conducting service in this equipment.

NOTEThis start-up procedure is not to be used for the first-time initial startup for a newly installed chiller. See “Preparation for Initial Startup” on page 44 for instructions regarding that situation.

Step 1: De-energize chiller using standard lockout/tagout procedures.

Step 2: Using a known operational voltage meter, test and confirm chiller is de-energized before proceeding further.

Step 3: Inspect power distribution fuses and overload settings to verify they are correct.

Step 4: Inspect refrigerant pressures for each module using the remote interface panel.

Step 5: Verify that pressure switches and thermostats have the correct cut-in and cut-out settings using the remote interface panel.

Step 6: Verify that the oil level is correct in each compressor using the compressor sight glass.




Step 7: Verify that pressure and temperature switches are closed.

Step 8: Restore power to all modules.

Step 9: Verify chiller water flow to condenser and evaporator.

Step 10: Monitor and record temperature and refrigerant pressures registering on the remote interface panel.

Emergency Power ShutdownThe chiller does not include a disconnect to turn off the high voltage

to the modules. As per NFPA 70, The National Electrical Code, a disconnect must be installed within the line of sight of the electrical and control panel. Should an emergency condition arise, the disconnect must be opened to shut down all voltage to the chiller.

There are several ways to interrupt power to all or part of the chiller:

• Disconnect the primary power source from the building that feeds electricity to the chiller. This occurs in sudden emergencies (usually weather-related) or planned maintenance shut-downs.

• Press the panel disconnect switch on the exterior door of the chiller’s main power distribution panel, if so equipped.

• Move the circuit breaker switch to the OFF position (CB-1 and CB-2) on the power distribution panel. This cuts power to all of the chiller modules.

• Move the circuit breaker switch to the OFF position (CB-1 and CB-2) on a module’s electrical and control panel. This cuts power to the compressors in a single module. It does not cut power to electrical and control panel or other chiller modules.


Monitor Water Quality

• Press the ON-OFF button on the remote interface panel that is builtinto the power distribution panel door or more distant walllocation in the equipment room.

NOTEPressing the ON-OFF button on the remote interface panel does not de-energize the chiller or the high voltage current into each module’s electrical and control panel. This action sends a command to the controller in each module’s compressors to discontinue electrical current to that component.

Monitor Water QualityMaintaining water/glycol mixture quality and cleanliness is critical to

chiller health and maintainability. Strainers should be checked and cleaned on a regular basis. Water/glycol mixture samples should be taken and tested by a professional lab. The results will enable the accurate adjustment of quality thereby increasing the operational life of the chiller.

NOTEArctiChill will not validate the chiller warranty if the proper water/glycol mixture composition and quality is not maintained.

Protect the chiller from freezing, particularly if the chiller has a set point that is lower than the freezing point of the water/glycol mixture in the chiller. The chiller is designed to operate with a maximum propylene glycol concentration of 50%. See Table 3, Glycol Performance Impact Factors, on page 72 for the effects on the chiller when operating with other glycol concentrations.

This table shows the capacity reduction and the pressure drop that occurs when higher concentrations of glycol are used.



Maintain Glycol LevelWhen the chiller has a water set point that is below the freezing point

of the water/glycol in use, take precautions against freezing.The glycol concentration should be based on the lowest fluid design

temperature. Table 4, Freeze Protection Chart, on page 74 provides guidelines for adding propylene glycol.

A 10% to 50% solution of glycol should be added to prevent pipe corrosion regardless of the fluid temperature. Propylene glycol has corrosion inhibitors that protect piping and components from corrosion and buildup of rust and other deposits. ArctiChill recommends against using water/glycol solution in excess of 50% regardless of the ambient temperature conditions.

Table 3 Glycol Performance Impact Factors

Range Factor Glycol Concentration Percentages and Performance Impact

Propylene Glycol Concentration 30% 40% 50%

Lowest Ambient Temperature 10 °F (-12 °C) -4 °F(-10 °C) -20 °F (-29 °C)

Recommended Minimum Leaving Fluid Temperature

25 °F (-4 °C) 10 °F (-12 °C) -10 °F (-23 °C)

LeavingTemperature

CapacityReduction

Factor

Pressure Drop Factor

CapacityReduction

Factor


CapacityReduction

Factor


70 °F (21 °C) 0.96 1.27 0.93 1.43 0.91 1.63

60 °F (15.6 °C) 0.95 1.31 0.92 1.47 0.90 1.68

55 °F (13 °C) 0.95 1.31 0.92 1.50 0.89 1.73

50 °F (10 °C) 0.94 1.33 0.91 1.51 0.88 1.75



CAUTIONDo not use automotive antifreeze. Corrosion in the chiller can result in permanent damage to pump and internal cooling surfaces.

NOTEIf glycol-free solutions are mandated at the chiller site, special inhibitors are available for rust prevention, mineral deposit inhibition, and biological suppression. Adding these inhibitors to the water solution is strongly recommended.

Heaters, heat tracing cable, and closed cell insulation can be installed on any exposed “wet” chiller components and tank and pump modules for protection against freezing in low ambient temperature and low refrigerant pressure conditions. However, the best freeze prevention is using the appropriate concentration of glycol. ArctiChill does not warranty any component that fails due to freezing.

Prevent FreezingMany liquids expand in volume upon cooling. This expansion may

cause pipes and other enclosed systems containing a liquid to rupture or burst when exposed to low temperature conditions. Burst protection is needed to protect piping and other enclosed systems when they are inactive as they could rupture due to expansion during cold weather or low refrigerant pressure.

Table 4, Freeze Protection Chart, on page 74 shows freeze points and burst points of glycol-water solutions.



In order to maintain a high-quality glycol solution, the water used in the glycol mixture must have minimal impurities. Impurities in the water can increase metal corrosion, aggravate pitting of cast iron and steel, reduce the effectiveness of the corrosion inhibitors, and increase the depletion rate of the inhibitor package.

To assure inhibitor effectiveness, the levels of chlorides and sulfates in the water should not exceed 25 ppm each. The total hardness in terms of calcium carbonate should be less than 100 ppm. For best long-term results, de-ionized or distilled water is recommended. ArctiChill can provide concentrated solutions of Dowfrost, propylene glycol, or premixed solutions for use with the chiller.

CAUTIONDo not use automotive antifreeze. Corrosion in the chiller can result in permanent damage to internal cooling surfaces.

Insight: Propylene GlycolGlycol-based fluids provide such burst protection in water solutions due to their low freezing points. As a glycol-based fluid cools below the solution’s freezing point, ice crystals begin to form, and the remaining solution becomes more concentrated in glycol. This ice/water/glycol mixture results in a flowable slush, and remains fluid, even as the temperature continues to cool.

Table 4 Freeze Protection Chart

Water/Glycol Temperature

FreezeProtection

BurstProtection

20 °F (-7 °C) 18% glycol mixture 12% glycol mixture

10 °F (-12 °C) 29% glycol mixture 20% glycol mixture

0 °F (-17.8 °C) 36% glycol mixture 24% glycol mixture

-10 °F (-23 °C) 42% glycol mixture 28% glycol mixture

-20 °F (-29 °C) 46% glycol mixture 30% glycol mixture



The fluid volume increases as this slush forms and the temperature cools, flowing into available expansion volume in the chiller. If the concentration of glycol is sufficient, no damage to the chiller from fluid expansion should occur within the temperature range indicated in Figure 38, Water/Glycol Concentration Freezing Points (in degrees Fahrenheit), on page 76 . When liquids are cooled they eventually either crystallize like ice or become increasingly viscous until they fail to flow and set up like glass. The first type of behavior represents true freezing. The second is known as super-cooling. Glycols do not have sharp freezing points. Under normal conditions, propylene glycol sets to a glass-like solid, rather than freezing.

The addition of glycol to water yields a solution with a freezing point below that of water. This has led to the extensive use of glycol-water solutions as cooling media at temperatures appreciably below the freezing point of water. Instead of having sharp freezing points, glycol-water solutions become slushy during freezing. As the temperature falls, the slush becomes more and more viscous and finally fails to flow.

The precise concentration of glycol for a particular chiller is affected by several key factors such as ambient temperature extremes, entering and leaving water temperatures, and chiller size. A chiller’s optimum glycol concentration is modified by these considerations as reflected in Table 3, Glycol Performance Impact Factors, on page 72. These capacity correction factors are the “best informed estimates” for chillers with copper evaporators. The percentages may vary depending on the materials and alloys of the heat exchangers, total surface area, the amount of present or future fouling, and the brand of glycol used.

The calculations in this table are most accurate for Dowfrost (propylene glycol) and Dowtherm (ethylene glycol) branded products. Consult your local supplier or engineering contractor for more precise recommendations.

Storage ProvisionsThe chiller controls are designed for storage in ambient temperatures

from -20 °F (-29 °C) to 145 °F (63 °C) with relative humidity from 0% to 100%. The glycol should be removed from the chiller if the unit is to be stored for extended periods. Although fluids can be drained via the plug in the bottom of the evaporator, the inhibitors in an approved glycol solution will best protect the surfaces of the evaporator against oxidation if the glycol remains inside the chiller during storage.



Figure 38 Water/Glycol Concentration Freezing Points (in degrees Fahrenheit)


CHAPTER 4 Maintenance Procedures

Maintenance StrategyThe primary goal of preventive maintenance is to avoid the

consequences of failure of equipment. This may be by preventing the failure before it actually occurs which preventive maintenance helps to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. In addition, operators can record equipment operating conditions, temperatures, and pressures so they know to replace or repair worn parts before they cause chiller failure. The ideal maintenance program predicts and prevents unnecessary and costly repairs and chiller down time. ArctiChill chillers are designed for ease of access with a premium placed on locating key components to facilitate visual inspection and hands-on verification.

One approach to chiller maintenance envisions three levels of maintenance effort reflecting frequent, periodic, and scheduled maintenance tasks, with each level building on the previous level. A daily or weekly “health check” involves habitual visual and manual inspections of the components of the chiller so that anomalies become evident when they occur. Weekly or monthly periodic maintenance involves cleaning specific components and inspecting glycol and lubrication fluids. Finally, since all components will eventually wear out, a prudent maintenance

Maintenance Procedures


strategy will anticipate and schedule replacement or rebuilding of critical components before they fail and require emergency response to keep chillers operational. (See Figure 39.)

Maintenance for HVAC equipment and facilities can include a “preventive maintenance checklist” which includes small checks which can significantly extend service life. Other considerations such as weather and equipment age are taken into account; maintenance and equipment replacement is often performed before the hottest time of the year.

Figure 39 An Approach to Chiller Maintenance

Power Disconnect SwitchSome Manhattan Chiller units are optionally equipped with a panel-

mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller has power supplied to each individual module). The disconnect switch must be turned to the OFF position before the panel can be opened for service. When the panel door is open, power can be reconnected by turning the handle located on the inside of the panel to the ON position.


Inspection and Maintenance Schedule

CAUTIONThis chiller uses an electronic controller containing one or more microprocessors susceptible to arcing or surges of electrical current. Any short-to-ground event involving a microprocessor or its communications wiring may damage sensitive electronic components beyond repair. De-energize the chiller using prescribed lockout/tagout procedures before performing maintenance or repairs. Never use wires or cables to attempt to “jump” components or bypass the manufacturer's safety systems.

Insight: Federal Clean Air ActResponsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be properly certified. The Federal Clean Air Act prescribes procedures for handling, reclaiming, recovering, and recycling of refrigerants and the equipment that must be used in maintenance procedures involving potential leakage of HVAC refrigerants. State and local governments may have additional requirements that must be followed to responsibly handle HVAC refrigerants.

Inspection and Maintenance ScheduleProactive measures should be taken to prevent potential problems

with the chillers. These include maintaining a operational log and conducting weekly, quarterly, and annual inspections of the chiller. See Table 5, Recommended Chiller Service Intervals, on page 80.

DailyA daily visual inspection can reveal obvious problems. Keep notes of

the chiller performance:

• Log pressures and temperatures.

• Visually inspect of the unit.



Table 5 Recommended Chiller Service Intervals

Task Frequency

Visually inspect the chiller Daily

Log pressure and temperatures Daily

Inspect remote interface panel for alarm history Weekly

Clean strainers on the inlet water pipe Monthly

Check the compressor oil level sight glass Monthly

Confirm the glycol concentration Monthly

Confirm the refrigeration pressures Monthly

Check the refrigeration liquid line sight glass Monthly

Inspect refrigerant pressures and temperature set points Quarterly

Inspect superheat (10 °F to 12 °F [-12 °C to -11 °C]) and sub-cooling temperatures (10 °F to 15 °F [-12 °C to -9.4 °C]) Quarterly

Inspect the evaporator entering and leaving evaporator temperature Quarterly

Collect water/glycol mixture sample for analysis Quarterly

Inspect crankcase heaters Quarterly

Inspect piping for signs of leaks Quarterly

Inspect refrigerant piping for oil or refrigerant leaks Quarterly

Observe refrigeration operating pressures Quarterly

Confirm motor amperage draw and voltage Quarterly

Confirm chiller superheat and sub-cooling Quarterly

Check for worn or burned contactors Quarterly

Inspect all electrical connections and fuses Annually

Inspect each compressor for refrigerant pressures, overheating, oil leaks Annually

Inspect compressor terminals for pitting, corrosion, and loose connections Annually

Inspect compressor oil level Annually

Confirm and record compressor amperage draw and voltage Annually

Compare water/glycol flow against design specifications Annually

Tighten compressor rotalock nuts Annually



WeeklyWeekly inspection is a continuation and elaboration of daily best

practice:

• Inspect remote interface panel for alarm status and additions tothe alarm history. (Do not clear alarms as this is a very importantperformance record if troubleshooting problems occur.)

• Listen for excessive vibrations or motor noise. This usuallysignals a loose brace or section of piping.

• Measure all refrigerant static pressure on any idle circuits. recordany significant changes or reductions in pressure.

• Clean strainers weekly during initial weeks after initial start upuntil water quality has been reliably established. Thereafter,inspect and clean strainers at least monthly.

MonthlyThe monthly maintenance inspection examines many items that

generally require frequent attention. This routine event identifies small problems early before they can become big problems requiring serious repair and refurbishment:

1. Remove the strainer on the inlet water pipe to the chiller andverify that it is clean and free of debris.

2. The 60 Mesh screen is made of SAE Grade 304 stainless steeland is cleaned by back-washing with high water velocity. If fine particles cannot be removed with the water stream, use a mild detergent and a non-abrasive brush to remove them.

3. Check the compressor oil level sight glass. The oil should alwaysbe clear and watery. Any milky or “slow rolling” effect indicates that liquid refrigerant is making its way back into the compressor and will cause premature compressor failure.




4. When the compressor is not operating, the oil level should be atleast at the bottom of the sight glass, up to two-thirds full. When the compressor is operating, the oil level will normally be at the bottom of the sight glass, or even below, but it must be visible.


5. Low oil sight glass conditions could signify an underchargedchiller that lacks proper refrigerant velocity to return oil to the compressor sump. Eventually, dry compressor starts could occur causing premature compressor failure. This may indicate that some oil has been lost from a previous refrigerant leak repair. The compressor data label indicates the correct oil type and quantity with which it should be filled.



NOTEA flashlight may be required to see the oil churning in the sump of the compressor. Adjusting the line of sight may be necessary to visually inspect the oil in the compressor sump during operation. At a minimum, the oil must be seen churning in the compressor sump. It should be clear.


6. Check the glycol concentration using a refractometer.7. Check the refrigeration pressures. For R410A refrigerant, low

pressure refrigeration gauge should read 120 to 160 psi and high pressure refrigeration gauge should read 300 to 450 psi.

CAUTIONExtended operation with suction pressures below 80 psi is a clear sign of insufficient refrigerant charge, refrigeration obstruction, or valve closed. This can cause extensive damage to a compressor. Secure the circuit or module offline until the status can be examined in detail.

8. Check the refrigeration liquid line sight glass for persistentbubbles (“flashing”).



NOTEBubbles in the sight glass do not necessarily indicate loss or lack of refrigerant charge. Bubbles (commonly know as “flashing”) will occur whenever the condenser fans cycle until the expansion valve settles out the refrigerant flow. Occasional bubbles also form when the condenser head pressure control valve bypasses hot gas around the condenser coil in low ambient operation. If the refrigeration pressures are in the normal range, the unit is most likely adequately charged. “Flashing” could also indicate excessive superheat adjustment of the thermal expansion valve.


QuarterlyThe quarterly maintenance inspection is a comprehensive event that

examines all aspects of the chiller to identify early problems before they can damage a chiller and require major repair or refurbishment:

1. Inspect refrigerant pressures and temperature set points.2. Inspect chiller superheat and sub-cooling. System superheat

should be 10 °F to 12 °F (-12 °C to -11 °C). System sub-cooling should be 10+ °F (12+ °C) depending on the ambient conditions.

3. Inspect the approach delta T - entering evaporator water/glycolmixture temperature and leaving evaporator water/glycol mixture temperature.



4. Inspect strainers. Ensure bypass valve is properly adjusted to a minimum of 25% open position.

5. Collect chilled water/glycol mixture sample for professional analysis. Check for cleanliness. Drain and refill with clean solution if excessive sludge or dirt is present. Flush the chiller prior to refilling.

6. Inspect water/glycol mixture levels. Add glycol as required.7. Inspect crankcase heaters for proper operation.8. Inspect the water piping for signs of leaks at joints and fittings.9. Inspect refrigerant piping circuit for signs of oil or refrigerant

leakage. Conduct “sniffer test” to find refrigerant leaks. Inspect all pressure switch bellows.

10. Tighten all refrigeration piping connections (e.g. rotalocks, Schrader valves, and ball valves).

11. Install a manifold and gauge set to observe chiller’s refrigeration operating pressures.

• Verify that the pressure controls (low pressure and high pressure switches) are “cutting in” and “cutting out” at the appropriate pressures.

• Verify refrigerant charge by recording the superheat and sub-cooling temperatures.

• Observe head pressure for signs of improper condensing from clogged strainers or a modulating expansion valve issue.

12. Check compressor motor amperage draws and voltage supplies and maintain a record of those values. Verify that they are within the name plate rating. Also, check for voltage imbalance. The chiller’s phase monitor will open if the voltage imbalance exceeds 4%.

13. Check for excessive wear or burned contacts on motor starters. Replace contacts if in doubt.

AnnuallyThe annual chiller maintenance inspection is critical to the long-term

performance of the chiller. Whether a chiller has a service life of 15 years or 30 years is almost entirely dependent upon how consistently and how diligently the annual maintenance inspection is performed. The annual event is a comprehensive inspection that examines all aspect of the chiller



to identify small problems before they can become major issues that damage a chiller and require significant repair or refurbishment.

1. Inspect all electrical connections for damage and ensureterminals are tight. Inspect all contactors for pitting and corrosion and replace as necessary.

WARNINGHazardous Voltage! Failure to de-energize before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure that power cannot be accidentally energized. Always use PPE and a functional voltmeter when conducting service in this equipment.

2. Inspect fuses to ensure they are undamaged and functioning.3. Energize each compressor and check refrigerant pressures, signs

of overheating, and oil leaks. Check chiller for leaks with a halogen leak detector. Inspect packing nuts on rotalock valves, threaded connections of rotalock valves, flared fittings on refrigeration gauges and pressure switches, and access ports on Schrader valves.

WARNINGThis Chiller Contains Hazardous Refrigerant! This equipment contains oil and refrigerant under high pressure. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or additives could result in serious injury or death. Recover refrigerant to relieve pressure before opening the system. See Chiller nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

4. De-energize each compressor and inspect terminals for pitting,corrosion, and loose connections.



5. Inspect that the oil level is visible in each compressor and notdiscolored or bubbled. Annual oil samples should be taken to be analyzed for destructive acids, corrosive materials, or metal deposits.

6. Inspect and record the compressor amperage draws and voltage.7. Record water/glycol mixture flow to ensure it meets design

specifications.8. Tighten rotalock nuts at the compressors. The recommended

torque is 80 lbf for 2 and larger and 60 lbf for rotalock nuts smaller than 2.

9. Inspect all control capillary tubing to ensure that the lines areseparated and not vibrating against one another or the frame or housing.

10. Ensure all refrigeration lines are properly supported to preventvibration from causing premature failure of copper piping.

11. Inspect all insulation on piping and control sensors. Repair andreplace as necessary.

12. Inspect entire plumbing system for leaks.13. Review logged alarms and look for repetitive trends. The chiller

can retain the previous 100 alarms with time and date of occurrence.14. If equipped on low-temperature units, inspect crankcase heaters

to verify proper operation.15. Sample refrigerant to analyze for moisture or acid.16. Inspect operating pressures and temperatures and ensure the

chiller has a full refrigerant charge.

Pump and Tank Maintenance Tasks For chillers equipped with a tank and pump module, additional

maintenance steps are required at least every six months:1. Ensure that the pump, motor, and the immediate area are clear of

dirt, debris, leaves, animal nests, and so forth.2. Ensure pump mountings are secure and fasteners are tight to

prevent pipe movement and eventual failure.3. Inspect pump for proper rotation.4. Check pump for leaks and excessive noise while in operation.



5. Lubricate pumps as recommended by the manufacturer. Refer tothe pump manufacturer’s operating and maintenance manual for lubricating instructions, if any are required.

6. Test and record the motor amp draw under full load.7. Test the pump overload protection device. Adjust if necessary.

Maintenance ProceduresThe maintenance tasks described herein present the basic, minimal,

steps required to successfully complete a task. Local policies and protocols may require more elaborate procedures with additional checks and inspections. Freely substitute in those cases where local procedures are more elaborate and complete than the procedures listed in this manual.

Inspection MethodsAppropriate inspection for modern chillers can be described as

“hands on.” Where possible and appropriate, visual inspection should include touching the component or apparatus being inspection. The sense of touch provides additional feedback regarding temperature, texture, tightness, and dryness that “eyes only” inspection cannot match. Habitually touching each item to be inspected also ensures that items are not subconsciously skipped during the inspection process. For a summary of tasks, see Table 5, Recommended Chiller Service Intervals, on page 80.




Critical Cleaning TasksMonitor temperature change and pressure drops across the evaporator

and condenser circuit to determine the frequency for strainer cleaning. Monitor water quality in the chiller’s closed system to determine the optimum frequency for evaporator cleaning.

Temperature change and pressure drop across the evaporator circuit should be monitored to determine the frequency needed for strainer cleaning. On multiple module chillers, ArctiChill provides service isolation valves on each evaporator to isolate each strainer for cleaning without disrupting the operation of any remaining modules in the chiller.

Procedure: Strainer Cleaning ProcedureStrainers at each evaporator are critical for maintaining water/glycol

mixture cleanliness and preventing excessive fouling. Service valves on the evaporator (and often, if a tank and pump module is provided, on the pumps’suction lines) isolate each strainer for cleaning without interrupting the operation of other modules in the chiller.

Step 1: De-energize power to the module containing the strainer by moving both toggle switches S-1 and S-2 on the power distribution panel to the OFF position.

Step 2: Close the two service isolation valves between the header and the evaporator.

NOTEIf this is a variable flow chiller, the outlet may be equipped with an electronic valve that must be manually locked in the closed position.

Step 3: Remove the insulation to expose the roll grooved blind end cap (or service cap and gasket on a Y-diffuser strainer) on the end of the strainer housing. (Capture water/glycol mixture by positioning a container under the housing as the cap is removed. Dispose of water/glycol mixture according to local protocols.)



CAUTIONWater/glycol mixture can be under considerable hydraulic pressure in the strainer housing. Escaping solution can thoroughly saturate equipment and personnel. Close isolation valves fully. Relieve pressure using a boiler valve. Use extreme care to slowly remove the end cap and release pressure gradually. Failure to relieve pressure gradually can result in unintended water damage to equipment.

Step 4: For a Y-diffuser strainer, inspect the gasket and service cap for abrasions, tears, excessive dirt, or deterioration. Replace gasket if necessary.

Step 5: Open the two service valves. Ensure the water/glycol make-up system is operational to replenish the water/glycol mixture lost during the cleaning process. Any air that is introduced into the chiller is purged by an expansion tank or air separator.

Step 6: Remove the strainer from the housing.

Figure 40 Chiller Strainer Types

Step 7: Clean the strainer inside and out using a soft natural bristle brush and tap water.



Step 8: Clean the interior of the end cap (or service cap), and the gasket using a soft natural bristle brush and tap water. Apply a light coating of lubrication to the gasket.

Step 9: Re-install the strainer in the housing. Replace the end cap and hand-tighten securely.

Step 10: Lubricate the gasket on roll grooved connection and Y-type composite gaskets. Secure the cap with two bolts.

Step 11: Isolate each evaporator using the isolation valves and drain water/glycol mixtures to the roof or floor drains, as appropriate.

Step 12: Open the service isolation valves between the header and the evaporator.

Step 13: Ensure the water/glycol make-up system is operational to replenish the water/glycol mixture lost during the cleaning process.

Step 14: Energize power to the module containing the strainer by moving both toggle switches S-1 and S-2 on the power distribution panel to the OFF position.

Procedure: Condenser Cleaning ProcedureFouling of condenser will result in a gradual decline in performance

of the chiller and is particularly significant during high ambient operation:

Step 1: Turn off and “lock out” the power to the chiller module or remote condenser.

WARNINGHazardous Voltage! Failure to de-energize before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing. Follow proper lockout/tagout procedures to ensure that electrical power cannot be accidentally energized. Always use a known good electrical voltage tester to ensure electric power is off.

Step 2: Remove fan grills to improve access to condenser coils.



NOTEIf chiller is equipped with EC-type fan motors, remove the C-side V baffle end cap, instead.

Step 3: Use a garden hose with spray nozzle or a long spray wand with a 90° turn spray head. (Using a pressure washer is not recommended).

CAUTIONHigh pressure water from a power washer can damage and distort the cooling fins on the coil. Using a pressure washer on condenser coils is not recommended. Damaged fins can adversely affect chiller efficiency.

Step 4: Clean coils by spraying water in the opposite direction of the air flow, from top of the coil to the bottom. Spray in a consistent pattern to work the dirt and debris from the top to the lower part of the coil.

Step 5: For extremely dirty coils, chemical soaking may be required to loosen debris build-up. Apply chemicals with a hand-held pump sprayer following a similar pattern used in the water cleaning.

Step 6: Let the chemical mixture soak in the evaporator for a short period of time to loosen sediment and scale build up. ArctiChill recommends using one of the following products:

• Nu-Calgon Nu-Brite A/C Condenser Coil Cleaner withdegreaser; 4:1 dilution; pH 12.7-14; requires rinsing afterapplication.

• Nu-Calgon Evap Foam No Rinse A/C Evaporator Coil Cleanerwith degreaser; ready-to-use; pH 12.3, foaming action: requiresrinsing after application.

• Simple Green A/C Condenser & Evaporator Coil Cleaner withdegreaser; 4:1 dilution; pH 10.2-11.3; self-rinsing.



Step 7: After chemical cleaning, all surfaces must be flushed thoroughly with clean water to remove residual chemicals. Trace chemical residue may result in premature aluminum fin breakdown and deterioration requiring coil replacement.

Step 8: Securely reinstall fan grills (or V baffle end cap).

Step 9: Turn power back on individual unit.

Step 10: Ensure that each unit’s panels are clean and clear of debris.

Procedure: Evaporator Cleaning ProcedureFouling of evaporators will result in a gradual decline in performance

of the chiller.

Step 1: Isolate each evaporator using the isolation valves and drain the water/glycol mixture to the roof or floor drains.

Step 2: Back flush using the city water supply forced to a drain.

Step 3: A brazed-plate evaporator is cleaned by back washing which is forcing a cleansing water/glycol mixture backwards through it at higher than normal pressures.

Step 4: Flushing should take place across a maximum 30 Mesh screen filter/strainer with frequent screen cleaning to remove the debris from the chiller. Flushing should continue until the screen is clean. After detergent and chemical cleaning, flush the piping for a minimum of one hour with fresh water to remove any remaining cleaning compounds.

Step 5: Back flush using the city water supply forced to a drain.

Compressor TasksThe Manhattan Chiller has been designed for ease of maintenance

access. When properly positioned within a machine room or space, Copeland compressors can be quickly removed for repair or replacement. (See “Site Preparation and Clearances” on page 33.)

Procedure: Remove CompressorVerify that power is disconnected from the chiller.



WARNINGThis equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void the warranty.

Step 1: Close the suction and discharge rotalock valves. Firmly front-seat both rotalock valves clockwise.

NOTEDo not over-tighten as valve can become difficult to loosen if over-tightened.

Step 2: Recover the refrigerant from the high and low sides of the compressor using a suitable vacuum recovery machine and clean recovery cylinder.

Step 3: Detach the refrigeration lines from the compressor suction and discharge stubs. Reconnect rotalock valves.

Step 4: Evacuate the compressor using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range would be ideal).

Step 5: Open the compressor electrical cover.

Step 6: Remove the conduit connector nut, nut ring, and wiring from the compressor terminals.

Step 7: Using an adjustable wrench, remove the rotalock nuts from the compressor.

Step 8: Remove the four compressor mounting bolts from frame using two 1/2 sockets, or a socket and a wrench. (Install the nuts underneath the frame.)

Step 9: Remove the compressor from the module.

Procedure: Install CompressorVerify that power is disconnected from the chiller.




Step 1: Position the compressor into the chiller and attach it to the frame with the four mounting bolts, washers, and nuts. Tighten nuts with 1/2 socket and wrench.

Step 2: Install the rotalock nuts on the compressor suction and discharge connections. Tighten with an adjustable wrench.

Step 3: Evacuate the compressor shell using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range would be ideal).

Step 4: Install the refrigeration lines from the compressor suction and discharge stubs.

Step 5: Remove the compressor electrical cover.

Step 6: Install the conduit connector nut, nut ring, and wiring to the compressor terminals.

Step 7: Attach wires as follows:

• Yellow wires labeled “0” attach to terminals M1, M2 and T2 of thecompressor overload.

• Blue wire #19 on compressor #1 attaches to terminal T1 on thecompressor.

• Blue wire #20 on compressor #2 attaches to overload.

• Power wire #1 attaches to the upper left terminal.

• Power wire #2 attaches to the upper right terminal.

• Power wire #3 attaches to the lower middle terminal.

• Green ground wire attaches to the ground terminal.



• (If wire numbers do not correspond exactly, consult thedocumentation that was shipped with the chiller for the specificwire numbers for that unit.)

Step 8: Replace the electrical and control panel cover.

Step 9: Open both rotalock valves until fully back-seated counterclockwise.

CAUTIONDo not apply excessive force when fully opening an isolation valve. Doing so can cause the valve to bind in the fully open position and prevent later service isolation.

Step 10: Tighten valve packing nuts and threaded connections with an appropriately-sized wrench. Use a spud (narrow) wrench for compressor rotalock connections. Inspect all connections for refrigerant leaks.

Step 11: Replace valve cover caps.

Step 12: Restore power to the module containing the compressor by moving both toggle switches S-1 and S-2 on the power distribution panel to the ON position.

Step 13: Observe the newly installed compressor to verify that all connections have been seated and tightened correctly.

Pump TasksThe following section applies to those chillers equipped with a tank

and pump module.

Procedure: Remove PumpPrior to servicing the pump or pump motor, verify that the power to

the chiller is disconnected.

Step 1: De-energize power to the module containing the pump by moving both toggle switches S-1 and S-2 on the power distribution panel to the OFF position




Step 2: Close the ball valves on the suction and discharge sides of the pump.

Step 3: Using adjustable wrenches or pipe wrenches, slowly loosen the connections on the suction and discharge piping.

NOTEAlways use a second, counter, wrench, when performing plumbing tasks to firmly hold the fittings or joint while loosening the tightening the opposite side.

NOTEA small quantity of water/glycol mixture is lost during this operation. Propylene glycol does not pose an environmental hazard, however.

Step 4: Remove the ring nut on the strain relief connector from the motor housing using an adjustable wrench inside the electrical enclosure. Remove the wiring from the box.

Step 5: Remove the cover from the electrical box on the side of the pump motor.

Step 6: Mark and clip the wires that attach the line power to the motor wires and unscrew the ground wire from the ground lug.



Step 7: Loosen the four bolts that attach the pump base to the frame with a 1/2 wrench.

Step 8: Remove the pump from the chiller.

Step 9: Disconnect the piping stubs from the suction and discharge connections.

Procedure: Install PumpPrior to servicing the pump or pump motor, verify that the power to

the chiller is disconnected.

Step 1: De-energize power to the module containing the pump by moving both toggle switches S-1 and S-2 on the power distribution panel to the OFF position.


Step 2: Apply a minimal amount of thread sealant, such as Rectorseal Tru-Blu with Teflon or equivalent, to the threads of the suction and discharge pipe adapters and install the adapters onto the new pump.

Step 3: Loosely install the four mounting bolts onto the mounting nuts on the chiller frame.

Step 4: Align the pump suction and discharge unions onto the piping connections and hand tighten.



NOTEThe pump suction pipe stub must be positioned 90 degrees to the right of the pump to mate up to the union on the pump suction piping.

Step 5: Fasten the mounting bolts to the frame using a 1/2 wrench or socket.

Step 6: Tighten the suction and discharge unions using large adjustable wrenches or pipe wrenches. To minimize the torque on the piping, apply an equal and opposite force to the pipe fitting with an additional adjustable wrench or pipe wrench.

NOTEAlways use a second, counter, wrench, when performing plumbing tasks to firmly hold the fittings or joint while loosening the tightening the opposite side.

Step 7: Position the conduit into the knockout of the electrical box cover.

Step 8: Fasten the conduit to the box with the ring nut.

Step 9: Replace the cover onto the electrical box on the side of the pump motor. Ensure gasket is in place prior to replacing cover.

Step 10: Reconnect the nut on the strain relief connector from the motor housing using an adjustable wrench.

Step 11: Open the ball valves on the suction and discharge sides of the pump.

Step 12: Restore power to the module containing the pump by moving both toggle switches S-1 and S-2 on the power distribution panel to the ON position.

Step 13: Observe the newly installed pump to verify that all connections have been seated and tightened correctly.



Procedure: Replace Pump SealPrior to servicing the pump, verify that the power to the chiller is

disconnected.

Step 1: De-energize power to the module containing the pump by moving both toggle switches S-1 and S-2 on the power distribution panel to the OFF position.


Step 2: Close the ball valves on the suction and discharge sides of the pump.

NOTEIt is not necessary to remove the pump housing from the piping to change the pump seal.

Step 3: Using adjustable wrenches or pipe wrenches, loosen the connections on the suction and discharge piping.

NOTEA small quantity of water/glycol solution is lost during this operation. Propylene glycol does not pose an environmental hazard, however.

Step 4: Remove the ring nut on the strain relief connector from the motor housing using an adjustable wrench inside the electrical enclosure. Remove the wiring from the box.



Step 5: Remove the cover from the electrical box on the side of the pump motor.

Step 6: Clip the wires that attach the line power to the motor wires and unscrew the ground wire from the ground lug.

Step 7: Remove the ring nut from the strain relief connector inside the electrical enclosure and remove the wiring from the box.

Step 8: Detach the pump motor adapter from the pump casing by removing the four bolts that are located between the two components using a 9/16 wrench.

NOTEA small quantity of water/glycol solution will be lost during this operation. Propylene glycol does not pose an environmental hazard, however.

Step 9: Loosen the four bolts that attach the pump base to the frame with a 1/2 wrench.

Step 10: Remove the pump from the chiller.

Step 11: Remove the pump impeller from the shaft by loosening the pump retainer bolt.

Step 12: Remove the seal retainer, spring, and shaft sleeve from the motor shaft.

Step 13: Remove the seal from the pump adapter opening.

Step 14: Position the new pump seal into the opening of the pump adapter.

CAUTIONWash hands thoroughly prior to installing the new seal. Even a small piece of grit or dirt can damage the pump seal.

Step 15: Place the shaft sleeve, spring, and seal retainer onto the shaft.



Step 16: Position the pump impeller and secure into place with the impeller retainer bolt.

Step 17: Position the pump inside the chiller and attach it to the pump casing using the four bolts previously removed.

Step 18: Attach the mounting bolts to the frame using a 1/2 wrench or socket.

Step 19: Push the conduit and wires into the knockout on the electrical box cover.

Step 20: Attach the conduit to the box with the ring nut. Use a standard screwdriver to secure the nut.

Step 21: Strip the 14-gauge wires that were cut when removing the old motor. Attach the wires:

• Attach wires T-1 and T-7 to the red wire lead.

• Attach wires T-2 and T-8 to the white wire lead.

• Attach wires T-3 and T-9 to the black wire lead.

• (If wire numbers do not correspond exactly, consult the documentation that was shipped with the chiller for the specific wire numbers for that unit.)

Step 22: Secure the leads with crimp-type bell caps.

Step 23: Attach the electrical box cover to the housing.

Step 24: Restore power to the module containing the pump by moving both toggle switches S-1 and S-2 on the power distribution panel to the ON position.

Step 25: Observe the newly installed pump to verify that all connections have been seated and tightened correctly.

Procedure: Replace ThermostatPrior to servicing the thermostat, verify that the power to the chiller is

disconnected.

Step 1: Remove the four screws of the thermostat cover using a Phillips screwdriver.



WARNINGThis equipment operates with high voltage. Failure to observe standard electrical procedures can result in serious injury or death. Failure to adhere to these instructions may affect your safety and void your warranty.

Step 2: Remove the sensor wires, control power leads, and wires from the contact terminals.

Step 3: Remove the two screws that attach the control to the electrical and control panel backboard.

Step 4: Remove the old thermostat from the chiller.

Step 5: Position the new thermostat in position. Attach thermostat to the electrical and control panel backboard using the two pan head screws:

• Attach the black and white sensor wires to the bottom twoterminals on TB-3 (inside the power distribution panel).

• Attach control power wire #17 to thermostat #1.

• Attach control power wire #16 to thermostat #2 to 24 VAC of TB-1 (inside the power distribution panel).

• Attach the yellow common wire #0 to LN on TB-1.

• Attach wire #35 and #36 of thermostat #1 to the LC and LNDcontacts (wires #40 and 41 of thermostat #2).

• (If wire numbers do not correspond exactly, consult thedocumentation that was shipped with the chiller for the specificwire numbers for that unit.)

Step 6: Replace the thermostat cover on the controller using the four screws and a Phillips screwdriver.

Step 7: Restore power to the module by moving both toggle switches S-1 and S-2 on the power distribution panel to the ON position.



End of Chapter


CHAPTER 5 Chiller Troubleshooting

General Approach to Fault IsolationArctiChill manufactures chillers with embedded fault detection and

diagnostics in each module’s controller that offers continuous dedicated monitoring to record and report faults as they occur in real time allowing repairs to be performed in a timely manner.

Various faults occurring in a building’s HVAC system can lead to unnecessary energy consumption and poor thermal comfort for a building’s occupants. Fault detection and isolation plays a significant role in monitoring, maintaining, and repairing chillers to improve operator safety and minimize operating costs.

Fault detection is recognizing that a problem has occurred, even if the root cause is not yet known. Fault isolation is the process of reducing potential causes to determine the most likely source of chiller failure.

Controller Diagnostic CodesThe following table assists in explaining the alarm codes that appear

in the remote interface panel in the event of an alarm. The alarm history is accessed by pressing the alarm log key. See “Remote Interface Panel Diagnostic Code Key” on page 106.

Chiller Troubleshooting


Table 6 Remote Interface Panel Diagnostic Code Key

Code Diagnostic Significance

**ALARM**EEPROM FAILURE Microprocessor hardware or software failure.

**ALARM**LEAVING WATERHIGH TEMPERATURE

Loop temperature has risen above the high temperature alarm point found under set point buffer parameters.

**ALARM**LEAVING WATERLOW TEMPERATURE

Loop temperature has risen below the high temperature alarm point found under set point buffer parameters.

**ALARM**COMPRESSOR 1HIGH PRESSURE

ID2, ID4: discharge refrigerant pressures have risen to the cut out point. That is, 630 psi on air-cooled R410A chillers.

**ALARM**COMPRESSOR 1LOW PRESSURE

ID3, ID5: suction pressure has reached the low pressure cut out point.

**ALARM**COMPRESSOR 1OVERLOAD

ID11, ID5: compressor over-current relay has opened.

**ALARM**WRONG PHASE

ID10: under- or over-current; out of phase; loss of power

**ALARM**SENSOR FAILURE

B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8, B-3:temperature or pressure sensor failure alarm.

**ALARM**COMMUNICATIONSERRORTO A SLAVE UNIT

A controller in the chiller network is off line or is no longer “seen” by the master microprocessor controller.

**ALARM**PUMP SWITCHOVER

Lead pump has failed to close flow switch or has become “open” during operation.

**ALARM**PRIMARY/SECONDARYPUMP FAILURE

Both primary and secondary pumps have failed to close flow switches.


Compressor Diagnostic Codes

Compressor Diagnostic CodesCopeland compressors used in ArctiChill chillers are highly

automated with digital capability to record and report a range of operating parameters and critical events. This technology can be employed to assist in troubleshooting compressor faults and potential corrective action.

CoreSense Flash CodesThe CoreSense technology in the Copeland compressor will

communicate an abnormal system condition through a unique flash code: ALERT LED (Yellow): The ALERT LED will flash a number of times

consecutively, pause and then repeat the process. The number of consecutive flashes, defined as the flash code, correlates to a specific anomaly or abnormal condition.

TRIP/LOCK LED (Red): indicates either a TRIP or LOCK condition.

• TRIP is indicated by a solid illumination of the LED. This meansthe compressor is not running and demand is present at themodule.

• LOCK is indicated by a flashing LED correlating to a lockcondition in which the module will prevent the compressor fromstarting.

Flash Code DescriptionCopeland compressors will report a range of flash codes when

specific critical events occur. See “Compressor Fault Code Summary” on page 109.

**ALARM**TANK LEVEL

Tank level switch has “closed.”(Only signals alarm when 24 VAC is “made.”)

**ALARM**WRONG PHASEPUMP CONTROLLER

Pump is in wrong power phase; loss of power, or over or under.

Table 6 Remote Interface Panel Diagnostic Code Key

Code Diagnostic Significance



CODE 1 – Long Run Time: The module will flash yellow one time when the compressor operates for longer than 18 continuous hours. This is an alert code only and the module will not lockout the compressor for this condition. (This code is inactive for heat pumps.)

CODE 2 – Compressor (Pressure) Trips: The module will flash yellow two times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting longer than 7 minutes. When four consecutive or ten total code 2 events are recorded, the module will lockout the compressor and flash red two times.

CODE 3 – Pressure Switch Cycling: The module will flash yellow three times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting between 35 seconds to 7 minutes. When four consecutive or ten total CODE 3 events are recorded, the module will lockout the compressor and flash red three times.

CODE 4 – Locked Rotor Trip: The module will flash yellow four times when the compressor trips within 12 seconds of operation and does not reset and start within 35 seconds. When ten consecutive CODE 4 events are recorded the module will lockout the compressor and flash red four times.

CODE 5 – Compressor (Moderate Run) Trip: The module will flash yellow five times when the compressor has operated between 15 minutes and 18 hours, followed by a compressor trip lasting longer than 7 minutes. When four consecutive or ten total CODE 5 events are recorded, the module will lockout the compressor and flash red five times.

CODE 6 – Open Start Circuit: The module will lockout the compressor and flash red six times if the module detects a demand signal in the Y terminal and current in the R winding of the compressor, but no current is detected in the S winding of the compressor for 2 seconds.

CODE 7 – Open Run Circuit: The module will lockout the compressor and flash red seven times if the module detects a demand signal in the Y terminal and current in the S winding of the compressor, but no current is detected in the R winding of the compressor for 2 seconds.

CODE 8 – Welded Contactor: The module will flash yellow eight times if it has detected line currents in the S and R windings and demand is absent for 15 seconds.

CODE 9 – Low Voltage: The module will flash nine times if the module supply voltage drops below 17 VAC for 2 seconds. The module will


Compressor Diagnostic Codes

prevent the compressor from starting until adequate voltage is established.

CODE 10 – Over-Current Protection: When the current at the PROT terminal is greater than 2A for 40 milliseconds, the module will flash a CODE 10. The red LED will flash 10 times with the yellow LED remaining off. This event will cause a lockout of the compressor and indicates that the module is mis-wired or the contactor coil is shorted to ground.

Table 7 Compressor Fault Code SummaryAlertCode

AlertCondition

LockoutLevel

Lockout Indication

Normal RunSolid Green Normal operation, no alarm status. N/A N/A

CODE 1Yellow Flash 1

Long run time. Compressor is running for more than 18 hours at full load. (CODE 1 is disabled in heat pump mode.) N/A N/A


Compressor pressure trip. Compressor runs for 12 seconds to 15 minutes followed by a compressor trip condition lasting longer than 7 minutes.

4x consecutive, 10x total

Red:Flash 2


Pressure switch cycling. Compressor runs for 12 seconds to 15 minutes followed by a compressor trip lasting 35 seconds to 7 minutes.

4x consecutive, 10 total

Red:Flash 3


Locked rotor. Compressor trips within a compressor run time of 12 seconds and does not start within 35 seconds. 10x consecutive Red:

Flash 4


Compressor moderate run trip. Compressor runs for 15 minutes to 18 hours followed by a compressor trip lasting longer than 7 minutes.

4x consecutive, 10x total

Red:Flash 5

CODE 6Red Flash 6

Open start circuit. Module has detected Y or Y1, and current in the R winding of the compressor and no current in the S winding of the compressor for 2 seconds.

1 occurrence Red:Flash 6

CODE7Red Flash 7

Open run circuit. Module has detected Y or Y1, and current in the S winding of the compressor and no current in the R winding of the compressor for 2 seconds.

1 occurrence Red:Flash 7


Welded contactor. Module has detected line currents in R and S windings, and Y or Y1 is at 0 VAC for 15 seconds. N/A N/A

CODE9Yellow Flash 9

Low voltage. Module has detected a 24 VAC supply voltage below 17 VAC ±1 VAC for 2 seconds. N/A N/A

CODE10Red Flash 10

Over current protection. PROT terminal has above a 2A input for more than 40 milliseconds. 1 occurrence Red:

Flash 10



Variable Frequency Drive Diagnostic CodesThe ABB ACH-550 Variable Frequency Drive (VFD) provides

proven reliability and flexibility in an intelligent variable frequency drive dedicated to saving energy, producing quality air, and alleviating environmental concerns. The ACH-550 programmable drive controls fans, compressors, and pump motors precisely for an energy efficient HVAC environment. The drive is physically located near a module’s electrical and control panel.

A comprehensive user’s manual for this drive is packed with the documentation package shipped with every chiller. This manual describes in detail the programming options and fault codes for the ABB ACH-550.

Diagnostic DisplaysThe ACH550 VFD detects error situations and reports them using:

• Green and red LEDs displayed on the body of the drive

• Fault Word and Alarm Word parameter bits (parameters 0305 TO0309).

Figure 41: ABB ACH550 Variable Frequency Drive

The form of the display depends on the severity of the error. Specify the severity for many errors by directing the drive to:


Variable Frequency Drive Diagnostic Codes

• Ignore the error situation

• Report the situation as an alarm

• Report the situation as a fault.

The drive signals that it has detected a severe error, or fault, by:

• Enabling the red LED on the drive (LED is either steady orflashing)

• Showing the steady red status LED on the control panel (ifattached to the drive)

• Setting an appropriate bit in a Fault Word parameter (0305 to0307)

• Overriding the control panel display with the display of a faultcode

• Stopping the motor (if it is on).

The fault code on the control panel display is temporary. Pressing themenu, enter, up, or down key removes the fault message. The message reappears after a few seconds if the control panel is not touched and the fault is still active. A synopsis of these codes is reprinted in Appendix D, “Variable Frequency Drive Troubleshooting” in this manual.

For less severe errors, called alarms, the diagnostic display is advisory. For these situations, the drive is simply reporting that it had detected something “unusual.” In these situations, the drive:

• Flashes the green LED on the drive

• Flashes the green status LED on the control panel (if attached tothe drive)

• Sets an appropriate bit in an Alarm Word parameter (0308 or0309)

• Overrides the control panel display with the display of an alarmcode or name.

Alarm messages disappear from the control panel display after a few seconds. The message returns periodically as long as that alarm condition exists.



Fault ResettingThe ACH550 can be configured to automatically reset certain faults.

Refer to parameter Group 31: AUTOMATIC RESET.

CAUTIONIf an external source, e.g. AUTO key, is selected for start command and it is active, the variable frequency drive may start immediately after fault reset.

Flashing Red LEDTo reset the drive for faults indicated by a flashing red LED:

• Turn off the power to the drive for 5 minutes

• After five minutes, turn the power to the drive back on.

Steady Red LEDTo reset the drive for faults indicated by a red LED (on, not flashing),

correct the problem and do one of the following:

• From the control panel: press RESET

• Turn the power off for 5 minutes

• After five minutes, turn the power to the drive back on.

Depending on the value of 1604 FAULT RESET SEL the following couldalso be used to reset the drive:

• Digital input

• Serial communication.

When the fault has been corrected, the motor can be started.

Phase Monitor ProtectionIf the chiller fails to power up, eliminate electrical phase issues by

inspecting the phase monitor device located in the power distribution panel.


Symptoms and Solutions

When all voltages are acceptable and the phase sequence is correct the output relay is energized and the LED glows green. Under-voltages and unbalanced voltages must be sensed for a continuous trip delay period before the relay de-energizes. Reset is automatic upon correction of the fault condition. The output relay will not energize if a fault condition is sensed as power is applied. The LED flashes red during the trip delay, then glows red when the output de-energizes. The LED flashes green/red if phase reversal is sensed.

If the phase monitor fails to energize (the LED glows red) check wiring of all three phases, voltage, and phase sequence. If phase sequence is incorrect, the LED flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further adjustment should be required.

Symptoms and SolutionsThis section lists the most common troubleshooting symptoms and

the closest potential solution for each. The “References” column will list a reference within this manual, if applicable. This is not an exhaustive listing of all potential causes or resolutions, but represents the best direction in which to initiate a solution.

Table 8 LED Phase Monitor Diagnostic Codes

LED Display Indication

Glowing green: All voltages are acceptable and phase sequence is correct.

Flashing red: Trip delay prior to de-energizing.Glowing red: Output has been de-energized upon fault detection.

Flashing red and green: Phase reversal is detected.

No power to phase monitor.



NOTEAn anti-short cycle timer is included in the master microprocessor controller to prevent the compressors from starting until the delay has elapsed. The microprocessor also provides minimum compressor run timers. Take these fixed timer parameters into consideration when conducting a fault isolation process.

1. Compressor will not start

Possible Causes Potential Solutions

Compressor switches S1 or S2 off Activate S1 or S2 switch

Temperature control not in demand Set point has been reached

Pressure switch open due to low water flow Condenser side loss of flow; open switch

Pressure switch defective Replace S1 or S2 switch

Low pressure switch open Low pressure event has occurred

High pressure switch open High pressure event has occurred

Compressor overload opened Allow motor to cool and reset; High amp load/floodback

No power to module Check breakers and fuses; energize from module electrical and control panel.

Phase monitor open or tripped Over/under 4% to 8%; loss of leg.



2. Symptom: Compressor will not run


Compressor will not run Assure all breakers and switches are on.

Main switch open or circuit breakers open.

Check circuits and motor winding for shorts or grounds.

Fuse is blown. Replace fuse or reset breakers after fault is corrected.

Investigate for possible overloading.

Overloads are auto-reset. Monitor to assure the overload does not re-occur.

Thermal overload breaker tripped or fuses blown. Repair or replace.

Defective contactor or coil. Determine type and cause. Correct fault before resetting safety.

System shut down by safety devices. Repair or replace coil.

Liquid line solenoid will not open.

Check motor for open circuit, short circuit, or motor burnout.

Motor electrical trouble. Tighten all terminal screws.

3. Symptom: Compressor has excessive noise or vibration


Flooding of refrigerant into crankcase. Check setting of expansion valve.

Improper discharge piping support. Relocate, add, or remove supports.

Improper or worn compressor supports. Replace supports.

Worn compressor Replace or rebuild compressor.



4. Symptom: Compressor will not load or unload


Defective capacity control. Repair or replace module.

Unloader mechanism defective. Replace unloader.

Faulty thermostat gauge or broken capillary tube. Replace thermostat assembly.

Stages not properly set for application.

Reset thermostat setting for operating requirements.

5. Symptom: Compressor Loading/Unloading Cycles Too Short


Temperature differential set too low (4 °F [-15.6 °C] minimum)

Ramp/set temperature set point

Erratic water thermostat device. Replace thermostat assembly.

Insufficient evaporator water flow. Adjust flow rate or remove flow.

6. Symptom: Compressor loses oil


Low refrigerant charge. Check for leaks and repair. Add refrigerant to proper charge.

Gas velocity in risers too low. Check riser sizes against compressor gas flow.

Oil trapped in line. Check pitch of lines and refrigerant velocities.

Excessive compression ring blow by. Replace or rebuild compressor.



7. Symptom: Low refrigeration suction pressure


Lack of refrigerant Check for leaks. Repair and add charge.

Evaporator dirty Clean chemically.

Clogged suction line or suction gas strainers Clean strainers.

Condensing temperature too low Check condensing temperature regulation system.

Low water temperature Lower set point; check design specification

Compressor will not unload Replace solenoid or controller

Low discharge pressure Refrigerant charge; replace compressor

Expansion valve malfunctioning Reset for proper superheat. Replace if necessary

Mis-adjusted or defective TXV Adjust or replace valve

Receiver service valve closed Turn counterclockwise completely. Do not fully backseat when FCS is involved

Compressor service valves closed Dangerous! Turn counterclockwise completely

Loss of charge in thermostatic bulb Replace TEV or power head

Clogged liquid line filter-drier Replace cartridges

Excessive glycol concentration Drain, refill (deionized water), retest

Liquid line solenoid restricted or faulty Replace solenoid valve or coil

Insufficient chilled water Adjust flow rate across evaporator

Restricted water/glycol line Clean strainers; check manual and electronic valves



Water/glycol mixture contaminated

Intensive cleanup effort needed to identify source of contamination; external filter may be required

Evaporator tubing clogged or fouled Reverse flush with appropriate chemical solutions

8. Symptom: High refrigeration suction pressure


Expansion valve opened too far

Re-adjust to 10° to 12°(scroll) or 13° to 16°(digital scroll)

Excessive refrigerant charge Creates high pressure alarms; bleed excess

High water temperature Low refrigerant charge; failing compressor; check design specifications

9. Symptom: Low refrigerant discharge pressure


Suction shut off valve partially closed Open valve

Insufficient refrigerant in chiller Check for leaks. Repair and add R410A as needed

Compressor operating unloaded

See failure of compressor to unload or load up below

Condenser too large Check condenser rating tables

Low ambient conditions Check condenser rating tables

Low suction pressure See low pressure below

7. Symptom: Low refrigeration suction pressure (Continued)




Condenser pressure regulating valve not properly adjusted

Refer to OEM manufacturer manual for default settings; check equipment room ambient temperature

Fan cycling controls not properly set

Reset cut-in, cut-out settings to conform to design specifications

10. Symptom: High refrigerant discharge pressure


System overcharged with refrigerant Remove excess refrigerant

Dirty tube and fin surface Clean with compressed air or water spray, use fin comb if fins are bent

Non-condensables in chiller Purge non-condensables.

Fan cycling controls not properly set Reset fan cycle setting; replace motor controller fuse

Condensing fans not operating Reset fan cycle setting; replace motor controller fuse

Restricted bypass line Check valves obstructed; flush line; blow out line with dry nitrogen gas

Discharge shut off valve partially closed Open valve

Condenser is undersized Check condenser rating tables with operating parameters

High ambient conditions exist Check condenser rating tables with operating parameters

9. Symptom: Low refrigerant discharge pressure




11. Symptom: Low chilled water temperature


Temperature controllers set too low

Reset temperature controllers to correct design specifications

Water velocity through evaporator too low

Clean strainer; check pump, VFD, and differential pressure settings

Temperature controllers malfunctioning Replace temperature sensor

12. Symptom: High chilled water temperature


Refrigeration circuits not cooling Reset operating pressures

Load higher than capacity of chiller Refer to chiller design specifications

Loss of refrigeration charge Pressure test refrigeration system

Fouled evaporator Reverse flush evaporator; check strainer for debris

Obstructed flow through evaporator

Reverse flush evaporator; check strainer for debris; check VFD, pump, valves

13. Symptom: Compressor thermal protector switch open


Operating beyond design conditions

Allocate chiller for use within operating capacity. Add equipment

Discharge valve partially shut Open valve

Blown valve plate gasket Replace gasket



14. Symptom: No low voltage (24 VAC)


Control circuit fuse open Check fuse prong contact points; replace fuse

Phase monitor opened or tripped Check for correct voltages

Transformer T1 defective Replace transformer T1, T2, T3

No primary voltage on T1 Check breakers, fuses; check power supply specifications

15. Symptom: Pressure switch open


Insufficient water flow Check strainer for debris; clean strainer

Switch defective Clogged high and low capillary tubes

16. Symptom: Thermal expansion valve superheat too high


Water/glycol temperature too warm Low refrigerant level; recharge chiller

Obstructed filter dryer Replace dryer core

Low refrigerant charge Recharge refrigerant as per data plate

Improperly adjusted superheat valve setting Reset valve settings to factory specifications

Equalization line pinched or obstructed Repair or replace equalization line



17. Symptom: Thermal expansion valve superheat too low


Sensing bulb not properly located

Check if secured to pipe or insulated; check sensor position on pipe at 4-8-10-2 clock positions

Defective thermostatic element Replace power head

Valve adjusted too far open Re-adjust to 10° to 12°(scroll) or 13° to 16°(digital scroll)

18. Symptom: Contactor/relay inoperative


Coil shorted or open Replace coil

Mechanical parts broken or jammed Replace assembly

Contacts pitted or burned Replace contactors

No 24 VAC to coil Replace secondary fuse to T2 transformer

19. Symptom: Freeze protection safety activated


Thermostat set too low. Reset above freezing temperature at evaporate or discharge

Low water flow. Remove restrictions. Increase HP

Low suction pressure. See “low suction pressure”

Installation, Operation, and Maintenance Manual A-1

Acronym List

APPENDIX A Acronymsand Abbreviations

All acronyms and abbreviations used in this manual, on the chiller controllers, and on module indicators and gauges are listed in the following tables.

Acronym List All acronyms and abbreviations in this publication are listed in the

following table, with their full spellings and expansions.

Table A-1 Acronyms and Abbreviations

Item Expansion

410A R410A

ACWS Automatic City Water Switchover

AHRI Air-Conditioning, Heating and Refrigeration Institute

AL alarm

Alrms alarms

Anlg Analog

AO1 analog output one

Bd board

btu British thermal unit

C Celsius

C1 Circuit 1

C2 Circuit 2

CB Circuit Breaker

CE Conformance European

ckt circuit

Acronyms and Abbreviations

A-2 Company Confidential ©2018 The Arctic Chiller Group

CL cool

Cntrl Controller

Comps Compressors

COND condenser

CSA Canadian Standards Association

DB Dry Bulb

DB Distribution Block

DifFr Differential Pressure

Dly Delay

DP Differential Pressure

DTC Danfoss Turbocor Compressors Inc.

ECM Electrically Commutated Motor

EER Energy Efficiency Rating

EMC Electromagnetic Compatibility

EMI Electromagnetic Interference

EPC Extended Performance Compressor

EvapFl Evaporator Flow

EVC Electronic [expansion] Valve Controller

EXP1 Expansion Board 1

EXV Electronic [expansion] Valve

F Fahrenheit

FLA Full Load Amperes

FLC Full Load Current

FREECOOL Free Cooling

Table A-1 Acronyms and Abbreviations (Continued)

Item Expansion


Acronym List

FRI Friday

gpm gallons per minute

GUI Graphical User Interface

HFC Hydrofluorocarbon

HG Hot Gas

Hotgas1 Hot Gas 1

HP horsepower

HPS High Pressure Switch

HT heat

HVAC Heating, Ventilation, and Air-Conditioning

ID Inside Diameter

Ident Identification

IEEE Institute of Electrical and Electronic Engineers

IGBT Insulated Gate Bipolar Transistor

IGV Inlet Guide Vane

INFO Information

Int Integration

IP Industry Pack

Iso Isolation

LA Low Ambient

lbf foot pounds

LBV Load Balance Valve

LED Light-Emitting Diode

LIFO Last In First Out


Item Expansion



LLS Liquid Line Solenoid

LP Low Pressure

LPPD Low Pressure Pump Down

LPS Low Pressure Switch

LRA Locked Rotor Ampere-s

m minute

Max Maximum

Min Minimum

MON Monday

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

NTC Negative Temperature Coefficient

OA Outside Ambient

OAT Outside ambient Air Temperature

OD Outside Diameter

ORD Open on Rise Differential pressure

ORI Open on Rise Inlet pressure

P Process

PD Pressure Differential

PE Protective Earth

PLC Programmable Logic Controller

PMD Panel Mounted Disconnect

POE Polyolester Oil

ppm parts per million


Item Expansion


Acronym List

Pres pressure

psi pounds per square inch

PumpDown Pump Down

PumpMod Pump Module

PWM Pulse Width Modulation

Pwrup Stg Up Power Up Stage Up

REFRIG Refrigeration

RemOff Remote Off

RMA Returned Merchandise Authorization

Rot Rotation

RP Redundant Pump

rpm revolutions per minute

s second

S1, S2 Switch #1, Switch #2

SAT Saturday

SDT Saturated Discharge Temperature

SP Set Point

SSS Solid State Starter

SST Saturated Suction Temperature

StartPt Stating Point

SUN Sunday

Sys System

Temp Temperature

TEMPS Temperatures


Item Expansion



ExpansionsAll acronyms and abbreviations listed in Table A-1, Acronyms and

Abbreviations, on page A-1 are listed below, with their full spellings and expansions.

THU Thursday

TT Twin Turbine

TUE Tuesday

TXV Thermal Expansion Valve

U1, U2 binary 1, binary 2

UL Underwriters Laboratories

UV Ultraviolet

VAC Volts, Alternating Current

VDC Volts, Direct Current

VFD Variable Frequency Drive

WED Wednesday

Y1, Y2 analog output: y1 = condenser, y2 = evaporator

Y4 analog output


Item Expansion


Expansions

Table A-2 Expanded Terms

Expansion Acronym

Air-Conditioning, Heating and Refrigeration Institute AHRI

alarm AL

alarms Alrms

Analog Anlg

analog output Y4

analog output one AO1

analog output: y1 = condenser, y2 = evaporator Y1, Y2

Automatic City Water Switching ACWS

binary 1, binary 2 U1, U2

board Bd

British thermal unit btu

Canadian Standards Association CSA

Celsius C

circuit ckt

Circuit 1 C1

Circuit 2 C2

Circuit Breaker CB

Compressors Comps

condenser COND

Conformance European CE

Controller Cntrl

cool CL

Danfoss Turbocor Compressors Inc. DTC



Delay Dly

Differential Pressure DifFr

Differential Pressure DP

Distribution Block DB

Dry Bulb DB

Electrically Commutated Motor ECM

Electromagnetic Compatibility EMC

Electromagnetic Interference EMI

Electronic [expansion] Valve EXV

Electronic [expansion] Valve Controller EVC

Energy Efficiency Rating EER

Evaporator Flow EvapFl

Expansion Board 1 EXP1

Extended Performance Compressor EPC

Fahrenheit F

foot pounds lbf

Free Cooling FREECOOL

Friday FRI

Full Load Amperes FLA

Full Load Current FLC

gallons per minute gpm

Graphical User Interface GUI

heat HT

Heating, Ventilation, and Air-Conditioning HVAC

Table A-2 Expanded Terms (Continued)

Expansion Acronym


Expansions

High Pressure Switch HPS

horsepower HP

Hot Gas HG

Hot Gas 1 Hotgas1

Hydrofluorocarbon HFC

Identification Ident

Industry Pack IP

Information INFO

Inlet Guide Vane IGV

Inside Diameter ID

Institute of Electrical and Electronic Engineers IEEE

Insulated Gate Bipolar Transistor IGBT

Integration Int

Isolation Iso

Last In First Out LIFO

Light-Emitting Diode LED

Liquid Line Solenoid LLS

Load Balance Valve LBV

Locked Rotor Ampere-s LRA

Low Ambient LA

Low Pressure LP

Low Pressure Pump Down LPPD

Low Pressure Switch LPS

Maximum Max


Expansion Acronym



Minimum Min

minute m

Monday MON

National Electrical Manufacturers Association NEMA

National Fire Protection Association NFPA

Negative Temperature Coefficient NTC

Open on Rise Differential pressure ORD

Open on Rise Inlet pressure ORI

Outside Ambient OA

Outside ambient Air Temperature OAT

Outside Diameter OD

Panel Mounted Disconnect PMD

parts per million ppm

Polyolester Oil POE

pounds per square inch psi

Power Up Stage Up Pwrup Stg Up

pressure Pres

Pressure Differential PD

Process P

Programmable Logic Controller PLC

Protective Earth PE

Pulse Width Modulation PWM

Pump Down PumpDown

Pump Module PumpMod


Expansion Acronym


Expansions

R410A 410A

Redundant Pump RP

Refrigeration REFRIG

Remote Off RemOff

Returned Merchandise Authorization RMA

revolutions per minute rpm

Rotation Rot

Saturated Discharge Temperature SDT

Saturated Suction Temperature SST

Saturday SAT

second s

Set Point SP

Solid State Starter SSS

Stating Point StartPt

Sunday SUN

Switch #1, Switch #2 S1, S2

System Sys

Temperature Temp

Temperatures TEMPS

Thermal Expansion Valve TXV

Thursday THU

Tuesday TUE

Twin Turbine TT

Ultraviolet UV


Expansion Acronym



Underwriters Laboratories UL

Variable Frequency Drive VFD

Volts, Alternating Current VAC

Volts, Direct Current VDC

Wednesday WED


Expansion Acronym

Installation, Operation, and Maintenance Manual B-1

Parts Warranty

APPENDIX B ProductWarranty

All parts are guaranteed to be free of defects in material and workmanship for 12 months from date of start-up or 13 months from the date of shipment, whichever occurs first.

Parts Warranty Hermetic compressors are guaranteed to be free of defects in material

and workmanship for 60 months from date of original purchase. An optional five-year chiller warranty may be purchased for an additional minimal fee. A decision to repair or replace a part resides solely with ArctiChill. ArctiChill will not reimburse the customer if a part or component is purchased through another vendor. All warranty claims must be processed through ArctiChill.

Parts Failure Not CoveredTo be covered, a part or component failure must be a result of

manufacturing defect, not normal wear and tear. Parts that fail due to causes external to the chiller, such as improper installation, electrical supply problems, leaking or broken pipes, poor water quality, failure to maintain clean filters, or contractor or owner negligence are not covered by this warranty. Glycol, the labor to add glycol to the chiller, and damage resulting from improper freeze protection are not covered by this warranty.

Policy for Independent Service ContractorsArctiChill will hire independent service contractors to provide service

for equipment under warranty at our discretion. ArctiChill may or may not hire a service contractor to perform service, start-ups, or repairs that is owned by, associated with, or influenced by the sales representative, to avoid conflicts of interest, and disputes over quality of services or other issues. ArctiChill is most interested in avoiding such issues and conflicts from adversely affecting its relationship with the sales representative.

Product Warranty

B-2 Company Confidential ©2018 The Arctic Chiller Group

To Make a Warranty ClaimAll warranty claims must be processed through ArctiChill and all

parts returned for credit must have a Return Merchandise Authorization (RMA).number. To make a warranty claim, contact the technical support department at 803-321-0779 from 8:00 a.m. until 5:00 p.m. (Eastern Time), Monday through Friday. ArctiChill will issue a RMA number. The RMA number must be clearly marked on the outside packaging or else the package will be refused.

Rates and TermsThe terms and rates for the services of the contractor must be

established before issuing a purchase order for any service. The various rates charged for travel, service calls, overtime, and any other separate rate charge must be on file and approved as reasonable. The contractor’s workmanship guarantee and policy for repeat calls for the same problems must be recorded. ArctiChill is not inclined to be favorable toward a contractor who is not thorough the first time.

Freight and HandlingThe customer is responsible for freight and handling charges to

ArctiChill along with the outbound freight and handling charges. Parts shipped to ArctiChill freight-collect will be refused. Warranty components are shipped to the customer freight collect.

Payment TermsParts are sent open account only if the recipient or dealer is on open

account status with ArctiChill for equipment purchases. ArctiChill accepts checks, VISA, Discover, or MasterCard.

Installation, Operation, and Maintenance Manual C-1

Tank and Pump Components

APPENDIX C Tank andPump Module

Tank and Pump ComponentsA tank and pump module typically contains dual lead/lag pumps and

an expansion tank. If the chiller fluid is glycol, there will be a glycol feeder consisting of a vented reservoir and charging pump. The charging pump maintains the system pressure at 21 psi by sensing the pump suction pressure.

A sealed stainless steel storage tank can also be provided in lieu of an expansion tank. With a pressurized tank there is no requirement for an additional expansion tank as it uses trapped air in the fluid system to allow system expansion. An air separator is not recommended in a fluid system with a pressurized tank because without the trapped air, the system expansion characteristics of the tank could not be exploited. The sealed tank also contains a vacuum vent to protect the tank from imploding.

Dual lead/lag pumps, each with 100% pumping capacity, are provided in each tank and pump module. If the lead pump fails to operate, the lag pump activates and an alarm signal is generated on the microprocessor controller indicating primary pump failure. Under normal system operation, each pump rotates as the lead pump every 168 hours of system operation. Pump motors can be equipped with variable frequency drives (VFDs) for variable flow operation. For the system to operate with variable flow, each heat recovery chiller module must have electronic modulating valves.

Switches inside the pump module control panel start each pump. Ensure that the each pump rotates clockwise and the pressure drop across the system is as expected.

Tank and Pump Module

C-2 Company Confidential ©2018 The Arctic Chiller Group

Figure C-1 Typical Tank and Pump Module Layout


Tank and Pump Components

Figure C-2 Typical Tank and Pump Module Electrical and Control Panel

Procedure: Fill the Storage TankThe tank and pump module may contain a pressurized storage tank.

The tank is pressurized during operation and maintains pressure when the chiller is turned off. The tank also has a vacuum vent to prevent the tank imploding.

Step 1: Turn off the pump using the two switches on the electrical and control panel.

Step 2: Bleed any air pressure in the tank by pressing the vacuum vent valve on the top of the tank. The storage tank has a float-type tank level switch; if the level falls below a factory-set point, an alarm will activate.

Step 3: Open the tank fill port valve and fill the tank.

TB-2Terminal Block

T3 24 VACTransformer

CB-2 CircuitBreaker

(Pump 2)

CB-1 CircuitBreaker

(Pump 1)

DB DistributionBlock

CarelpCO5+Controller

TB-1Terminal Block





CAUTIONIf the chiller uses glycol, do not permanently connect the water fill port to a water supply as plain water entry into the chiller could dilute the glycol concentration and lead to system failure due to freezing.

Step 4: Ensure that both the front fill port and service valve remain closed during operation.

Step 5: The pressure relief valve is set to 100 psi to prevent over-pressurizing the tank.

Variable Flow Tank and Pump Module Sequence of Operations

1. The chiller is designed to operate with high voltage powersupplied to the unit at all times. This will provide power to the compressor crankcase heaters, and minimize liquid refrigerant from migrating to the compressor sumps.

2. As long as there is power on the chiller, the mastermicroprocessor selects the master module and rotates this lead once every 168 hours week. The lead module's electronic isolation valve will initially be provided with full power input driving the valve fully open.

3. The chiller is enabled when the on/off switch on the built-in (orremote) interface panel is energized, and the remote start/stop relay is enabled (either through a contact closure or through the building management system.)

4. The variable frequency drives for the chiller pumps monitors theopening and closing of the electronic valves which are controlled based on leaving water temperature. The variable frequency drives allow the pumps to deliver the required flow through each operating evaporator. The pump speed varies proportionally to the number of modules that are operating (electronic valves open) in the chiller.

5. Since the electronic isolation valve of the master module isalready energized, the pump must produce the minimum flow required by the master module. A system bypass with valve must be provided by the


Variable Flow Tank and Pump Module Sequence of Operations

customer and installed externally from the chiller at the most remote fan coil or device to ensure that the pump can provide the minimum flow required through the master module if the return flow to chillers could be completely restricted with all fan coils or devices isolated. (A high quality pressure-independent valve is recommended for this bypass so as to provide accurate bypass control regardless of system pressure differential between supply and return headers.)

6. When this minimum flow is established and the system demand(based on leaving fluid temperature) indicates that there is a requirement for cooling, the lead compressor of the lead module will energize provided all safeties of that refrigeration circuit are satisfied.

7. When there is a system load, the BMS will modulate the systembypass decreasing the bypass flow, as the flow rate through the fan coils increase. This control is provided by the customer external of the chiller, and is presumed to be based on the pressure differential across the most remote fan coil or user.

8. As the system demand continues to increase, the secondcompressor within that module will energize provided all safeties on that circuit are satisfied.

9. As the system demand continues to increase, the leaving fluidtemperature from the chiller will slowly increase until the differential set point is reached. When the differential is reached, a second module will be brought on-line. Instead of opening the valve fully in this chiller module, which will cause a substantial drop in flow in the previously operating module and create a low leaving water temperature condition, both valves will modulate in both modules to maintain a constant leaving fluid temperature.

10. As the flow and demand continue to increase, and thetemperature once again reaches the set point plus differential setting, the second compressor on the second module will energize.

11. With a decrease in system demand (and flow) such that theleaving water temperature reaches the set point minus the differential, a compressor will de-energize, and the modulating valves will once again balance the flow between the operating modules.

12. This process occurs throughout the operating range of the chiller.At “in-between” stages of chiller capacity and demand balancing, the modulating valves maintain a constant leaving fluid temperature across all operating modules.



13. The microprocessor will rotate to a new master module eachweek to equalize the running time among the modules.

14. When a redundant master microprocessor controller is providedon a chiller module, the redundant master microprocessor will, without downtime and without any operational deficiency, perform the Master microprocessor functions should it fail. All operational sequences shall be uninterrupted and uninhibited should the master microprocessor fail.

Installation, Operation, and Maintenance Manual D-1

Manhattan Air-cooled Chiller

APPENDIX D Request forInitial Startup

Manhattan Air-cooled ChillerAs part of a continuous commitment to quality, initial startup of this chiller by a factory-certified

technician may be purchased from ArctiChill. No initial startup will be scheduled without a Request for Initial Startup form completed and on file with the ArctiChill customer service department. Submitting this form indicates that all critical work described on the form has been completed. To prevent additional charges for aborted startups, the following items must be completely functional and operating and this form signed and returned to ArctiChill at least 10 working days prior to the scheduled initial startup date.

Chiller Initial Start-up Data

Model Number: Master Module Serial Number:

Primary Contact Name: Primary Contact Phone:

Primary Contact FAX: Primary Contact Mobile:

Name of Chiller Site:

Physical Location of Chiller:

Requested Date for Initial Start-up:

Requested Time for Initial Start-up:

Mandatory Initial Startup Requirements

Mandatory Tasks Date Completed

Initialed Complete

All chiller modules are installed with minimum clearances available from all sides.

Refrigeration gauges are indicating equal pressures.

Chilled water lines from chiller to customer’s equipment are permanently connected.

Chilled water lines have been flushed clean of mud, slag, and other construction debris.

All chilled water line filters and strainers are clean.

Chilled water lines have been leak tested according to prestart instructions.

Request for Initial Startup

D-2 Company Confidential ©2018 The Arctic Chiller Group

Initial Start-up AgreementBy signing this form, you agree the chiller is ready for initial startup. It is understood that, if the

chiller is not ready for initial startup due to site problems, the initial startup will be aborted at the discretion of the designated start-up technician. Payment for an aborted startup will be forfeited. Rescheduled initial startups are subject to any additional costs that may have been incurred by the technician. An approved purchase order or payment in advance will be required to reschedule an aborted initial startup.

Name (Printed): ____________________________________ Date: ________________________

Signature: ___________________________ Company __________________________________

Chiller reservoir (if included) is at operating level with correct water/glycol mixture.

High voltage wiring is installed, tested, and functional.

All water, refrigeration, electrical, and control connections between chiller modules are completed.

All control wiring between modular chillers is installed, tested, and functional.

Control wiring is complete, including any remote interface panel or special-purpose module wiring.

Automatic City Water Switchover (if included) is installed, flushed, and leak-tested.

Condenser, if applicable, is installed, piped, wired, and leak-tested.

All responsible installing contractors and sub-contractors are notified to have representatives available on site to provide technical support for the initial start-up procedure.

Full load shall be available for chiller on the initial start-up date.

Mandatory Initial Startup Requirements (Continued)

Mandatory Tasks Date Completed

Initialed Complete

Installation, Operation, and Maintenance Manual E-1

ABB ACH-550 Fault Codes

APPENDIX D Variable Frequency Drive Troubleshooting

ABB ACH-550 Fault CodesThe following table lists the faults by code number and describes each. The fault name is the long

form shown on the control panel display when the fault occurs. The fault names shown in the fault logger mode and the fault names for parameter 0401 LAST FAULT may be shorter.

Alarm Codes

LED Display Recommended Corrective Action

1 OVERCURRENT

Output current is excessive. Check for and correct:• Excessive motor load• Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and 2205ACCELER TIME 2)• Faulty motor, motor cables or connections.

2 DC OVERVOLT

Intermediate circuit DC voltage is excessive. Check for and correct:• Static or transient over-voltages in the input power supply• Insufficient deceleration time (parameters 2203 DECELER TIME 1 and 2206DECELER TIME 2)• Undersized brake chopper (if present).

3 DEV OVERTEMP

Drive heat sink is overheated. Temperature is at or above limit.- R1…R4: 239 °F (115 °C)- R5/R6: 257 °F (125 °C)Check for and correct:• Fan failure• Obstructions in the air flow• Dirt or dust coating on the heat sink• Excessive ambient temperature• Excessive motor load.

4 SHORT CIRCFault current. Check for and correct:• A short-circuit in the motor cables or motor• Supply disturbances.

5 RESERVED Not used.

Variable Frequency Drive Troubleshooting

E-2 Company Confidential ©2018 The Arctic Chiller Group

6 DC UNDERVOLT

Intermediate circuit DC voltage is not sufficient. Check for and correct:• Missing phase in the input power supply• Blown fuse• Under-voltage in mains.

7 AI1 LOSS

Analog input 1 loss. Analog input value is less than AI1 FAULT LIMIT (3021). Check for and correct:• Source and connection for analog input• Parameter settings for AI1 FAULT LIMIT (3021) and 3001 AI<MIN FUNCTION.

8 AI2 LOSS

Analog input 2 loss. Analog input value is less than AI2 FAULT LIMIT (3022). Check for and correct:• Source and connection for analog input• Parameter settings for AI2 FAULT LIMIT (3022) and 3001 AI<MIN FUNCTION.

9 MOT OVERTEMP

Motor is too hot, as estimated by the drive.• Check for overloaded motor• Adjust the parameters used for the estimate (3005…3009)• Check the temperature sensors and Group 35: MOTOR TEMP MEAS parameters.

10 PANEL LOSS

Panel communication is lost and either:• Drive is in local control mode (the control panel displays HAND), or• Drive is in remote control mode (AUTO) and is parameterized to accept start/stop, direction or reference from the control panel.To correct, check:• Communication lines and connections• Parameter 3002 PANEL COMM ERR• Parameters in Group 10: START/STOP/DIR• Parameters in Group 11: REFERENCE SELECT (if drive operation is AUTO).

11 ID RUN FAIL The motor ID run was not completed successfully. Check for and correct motor connections.

12 MOTOR STALL

Motor or process stall. Motor is operating in the stall region. Check for and correct:• Excessive load• Insufficient motor power• Parameters 3010…3012.


14 EXT FAULT 1 Digital input defined to report the first external fault is active. See parameter 3003 EXTERNAL FAULT 1.

Alarm Codes




15 EXT FAULT 2 Digital input defined to report the second external fault is active. See parameter 3004 EXTERNAL FAULT 2.

16 EARTH FAULT

The load on the input power system is out of balance.• Check for/correct faults in the motor or motor cable• Verify that motor cable does not exceed max. specified length• Decrease the detection level for earth fault with parameter 3028 EARTH FAULT LVL. Note: Disabling ground (earth fault) may void the warranty.

17 OBSOLETE Not used.

18 THERM FAIL Internal fault. The thermistor measuring the internal temperature of the drive is open or shorted. Contact your local ABB representative.

19 OPEX LINK Internal fault. A communication-related problem has been detected between the control and main circuit boards. Contact your local ABB representative.

20 OPEX PWR Internal fault. Exceptionally low voltage detected on the main circuit board. Contact your local ABB representative.

21 CURR MEAS Internal fault. Current measurement is out of range. Contact your local ABB representative.

22 SUPPLY PHASERipple voltage in the DC link is too high. Check for and correct:• Missing mains phase• Blown fuse.


24 OVERSPEED

Motor speed is greater than 120% of the larger (in magnitude) of 2001 MINIMUM SPEED or 2002 MAXIMUM SPEED. Check for and correct:• Parameter settings for 2001 and 2002• Adequacy of motor braking torque• Applicability of torque control• Brake chopper and resistor.


26 DRIVE ID Internal fault. Configuration block drive ID is not valid. Contact your local ABB representative.

27 CONFIG FILE Internal configuration file has an error. Contact your local ABB representative.

Alarm Codes




28 SERIAL 1 ERR

Fieldbus communication has timed out. Check for and correct • Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME)• Communication settings (Group 51: EXT COMM MODULE or Group 53: EFB PROTOCOL as appropriate)• Poor connections or noise on line.

29 EFB CON FILE Error in reading the configuration file for the fieldbus adapter.

30 FORCE TRIP Fault trip forced by the fieldbus. See the fieldbus user’s manual.

31 EFB 1Fault code reserved for the EFB protocol application. The meaning is protocol dependent.32 EFB 2

33 EFB 3

34 MOTOR PHASE

Fault in the motor circuit. One of the motor phases is lost. Check for and correct:• Motor fault• Motor cable fault• Thermal relay fault (if used)• Internal fault.

35 OUTP WIRING

Incorrect input power and motor cable connection (i.e., input power cable is connected to drive motor connection). The fault can be erroneously declared if the drive is faulty or the input power is a delta grounded system and the motor cable capacitance is large. This fault can be disabled by using parameter 3023 WIRING FAULT. • Check input power connections. • Check grounding.

36 INCOMPATIBLE SW Loaded software is not compatible with the current drive type. Contact your local ABB representative.

37 CB OVERTEMP

Drive control board is overheated. Fault trip limit is 190 °F (88 °C). Check for and correct:• Excessive ambient temperature• Fan failure• Obstructions in the air flow.Not for drives with an OMIO control board.

38 USER LOAD CURVECondition defined by parameter 3701 USER LOAD C MODE has been valid longer than the time defined by 3703 USER LOAD C TIME.

Alarm Codes




101…

199SYSTEM ERROR Error internal to the drive. Contact your local ABB representative and report the error

number.

201…

299SYSTEM ERROR Error in the system. Contact your local ABB representative and report the error

number.

1000 PAR HZRPM

Parameter values are inconsistent. Check for any of the following:• 2001 MINIMUM SPEED > 2002 MAXIMUM SPEED• 2007 MINIMUM FREQ > 2008 MAXIMUM FREQ• 2001 MINIMUM SPEED / 9908 MOTOR NOM SPEED is outside the range 128…128• 2002 MAXIMUM SPEED / 9908 MOTOR NOM SPEED is outside the range 128…128• 2007 MINIMUM FREQ / 9907 MOTOR NOM FREQ is outside the range 128…128• 2008 MAXIMUM FREQ / 9907 MOTOR NOM FREQ is outside the range 128…128.

1001 PAR PFA REF NEGParameter values are inconsistent. Check for 2007 MINIMUM FREQ is negative, when 8123 PFA ENABLE is active.


1003 PAR AI SCALEParameter values are inconsistent. Check for any of the following:• 1301 MINIMUM AI1 > 1302 MAXIMUM AI1• 1304 MINIMUM AI2 > 1305 MAXIMUM AI2.

1004 PAR AO SCALEParameter values are inconsistent. Check for any of the following:• 1504 MINIMUM AO1 > 1505 MAXIMUM AO1• 1510 MINIMUM AO2 > 1511 MAXIMUM AO2.

1005 PAR PCU 2

Parameter values for power control are inconsistent: Improper motor nominal kVA or motor nominal power. Check for 1.1 < (9906 MOTOR NOM CURR · 9905 MOTOR NOM VOLT · 1.73 / PN) < 2.6, where: PN = 1000 · 9909 MOTOR NOM POWER (if units are kW) or PN = 746 · 9909 MOTOR NOM POWER (if units are hp).

1006 PAR EXT ROParameter values are inconsistent. Check for the following:• Extension relay module not connected and• 1410…1412 RELAY OUTPUTS 4…6 have non-zero values.

1007 PAR FIELDBUS MISSING

Parameter values are inconsistent. Check for and correct the parameter is set for fieldbus control (e.g. 1001 EXT1 COMMANDS = 10 (COMM)), but 9802 COMM PROT SEL = 0.

Alarm Codes




1008 PAR PFA MODEParameter values are inconsistent –9904 MOTOR CTRL MODE must be = 3 (SCALAR:FREQ) when 8123 PFA ENABLE is activated.

1009 PAR PCU 1

Parameter values for power control are inconsistent: Improper motor nominal frequency or speed. Check for the following:• 1 < (60 · 9907 MOTOR NOM FREQ / 9908 MOTOR NOM SPEED) < 16• 0.8 < 9908 MOTOR NOM SPEED / (120 · 9907 MOTOR NOM FREQ / Motor poles) < 0.992.

1010 PAR PFA & OVERRIDE

Override mode is enabled and PFA is activated at the same time. This cannot be done because PFA interlocks cannot be observed in the override mode.

1011 PAR OVERRIDE

Parameter values are inconsistent. All override mode parameters do not have correct values when override mode is enabled (parameter 1705 OVERRIDE ENABLE). Check for any of the following:• parameter 1701 OVERRIDE SEL, override activation signal• parameter 1702 OVERRIDE FREQ and 1703 OVERRIDE SPEED both zero.

1012 PAR PFA IO 1IO configuration is not complete – not enough relays are parameterized for PFA. Or, a conflict exists between group 14, parameter 8117 NR OF AUX MOT and parameter 8118 AUTOCHNG INTERV.

1013 PAR PFA IO 2 IO configuration is not complete – the actual number of PFA motors (parameter 8127 MOTORS) does not match the PFA motors in Group 14 and parameter 8118 AUTOCHNG INTERV.

1014 PAR PFA IO 3 IO configuration is not complete – the drive is unable to allocate a digital input (interlock) for each PFA motor (parameters 8120 INTERLOCKS and 8127 MOTORS).


Alarm Codes




1016 PAR USER LOAD C

Parameter values for the user load curve are inconsistent. Check that the following conditions are met:• 3704 LOAD FREQ 1 < 3707 LOAD FREQ 2 < 3710 LOAD FREQ 3 < 3713 LOAD FREQ 4 < 3716 LOAD FREQ 5• 3705 LOAD TORQ LOW 1 < 3706 LOAD TORQ HIGH 1• 3708 LOAD TORQ LOW 2 < 3709 LOAD TORQ HIGH 2• 3711 LOAD TORQ LOW 3 < 3712 LOAD TORQ HIGH 3• 3714 LOAD TORQ LOW 4 < 3715 LOAD TORQ HIGH 4• 3717 LOAD TORQ LOW 5 < 3718 LOAD TORQ HIGH 5.

-

UNKNOWN DRIVE TYPE: ACH550 SUPPORTED DRIVES: x

Wrong type of panel, i.e. panel that supports drive X but not the ACH550, has been connected to the ACH550.

Alarm Codes




End of Appendix

Part #9800-0100Publication # PAC-001.02October, 2018ArctiChill • 71 Industrial Park RoadNewberry, South Carolina 29108

Date post:	01-Mar-2021
Category:	Documents
Upload:	others
View:	40 times
Download:	3 times

Installation, Operation, and Maintenance Manual - Chiller ......Installation, Operation, and...

Documents