Installation, Operation, and Maintenance Manual: The Arctic Chiller Group
Installation, Operation, and Maintenance Manual: The Arctic Chiller Group
Installation, Operation, and Maintenance Manual: The Arctic Chiller Group
Manhattan Modular
Model PWCCMV0300D3-MM Shown Water-Cooled Chiller
Part #9800-0050
Publication # PWC-001.00
August, 2018
• email: chiller@arctichill.com
Canada
2100 Steeles Avenue East
Brampton, Ontario L6T 1A7
Evaporator........................................................................................................... 13
Expansion Valve.................................................................................................. 14
Microprocessor Control System .......................................................................... 15
Master Microprocessor Controller .................................................. 15
Slave Microprocessor Controller ..................................................... 15
Built-in Interface Panel .................................................................... 16
Operator Control and Monitoring ..................................................... 17
Chiller Controls ............................................................................................. 17
Power Distribution ............................................................................................... 17
Main Power Distribution................................................................... 17
Panel Disconnect ............................................................................ 17
Module Electrical and Control Panel .............................................. 19
Electrical Controls ............................................................................................... 19
Flow Switch ..................................................................................... 19
Phase Monitor ................................................................................ 20
Refrigeration Controls ......................................................................................... 20
Expansion Valve Settings ................................................................ 20
Sight Glass ...................................................................................... 21
Low Pressure Bypass ...................................................................... 21
Thermal Capacity ............................................................................ 21
Sequence of Operations............................................................................... 22
Constant Flow Sequence .................................................................................... 22
Variable Flow Sequence ..................................................................................... 23
Technical Support............................................................................ 69
WARNING
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.
WARNING
Hazardous 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.
WARNING
Hazardous 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
This 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.
CAUTION
Unless the chiller is being installed on a concrete pad, do
not install vibration isolators under individual modules.
CAUTION
All 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.
CAUTION
Do not use automotive antifreeze. Corrosion in the chiller
can result in permanent damage to pump and internal
cooling surfaces.
CAUTION
The 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.
CAUTION
This 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.
CAUTION
Extended 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.
CAUTION
A 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.
CAUTION
Water/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.
CAUTION
Do 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.
CAUTION
Wash hands thoroughly prior to installing the new seal.
Even a small piece of grit or dirt can damage the pump
seal.
CAUTION
If 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.
CAUTION
Never “jumpered out” a flow switch. This can damage
equipment and defeat safety systems built into the
equipment.
Intended Users
This 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.
It is assumed that operator and maintenance personnel are 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.
Chiller Scope
This manual provides the user with necessary data to properly
operate, maintain, and troubleshoot the ArctiChill Manhattan Modular
Water-Cooled Chiller. It assumes that operator and maintenance
personnel are 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 Capacities
The Manhattan Chiller model is available in 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 30.
WARNING
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.
WEIGHT
Each Chiller Module 2,100 lbs. Overall Chiller System 8,400 lbs.
10
11
12
13
14
15
16
17
18
Technical Support
Questions 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
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
• Electronic mail: chiller@arctichill.com
Operating Principles
The Manhattan Modular Water-Cooled Chiller is designed to operate
with a water/inhibitor solution to prevent rust, scaling, and organic
growth.
The Manhattan Chiller provides 44 °F (7 °C) water under a maximum
heat load of 3,007,000 btu/hr in ambient temperatures ranging from 10 °F
(-12 °C) to 110 °F (43 °C) with a maximum return temperature of 54 °F
(12 °C). The Manhattan Chiller typically uses an R410A, water-cooled
mechanical refrigeration system.
The water/inhibitor solution 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/inhibitor solution 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
condenser fluid 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.
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.
Component Description
Every 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.
Copeland Compressor
For chillers larger than about 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.
Condenser
The condenser is a key chiller component that receives refrigerant in
the form of gas from the compressor and changes it to liquid thereby
transferring heat to water that absorbs the heat dissipated by a cooling
tower or ground source well system. See Figure 8 on page 13.
Evaporator
The brazed plate heat exchanger that is the evaporator is constructed
as a plate package of 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
at to come into close proximity, separated only by channel plates that
enable heat from one fluid to be transferred to the other with very high
efficiency, but without gaskets and frame parts. See Figure 9.
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.
NOTE
A optional configuration with shell and tube evaporators
having a carbon steel or stainless steel outer shell and
copper tubing may be found in some chillers.
Expansion Valve
An expansion valve is a metering device controlling the flow of
refrigerant to the evaporator based on evaporator superheat. See Figure
10.
Insight: Valves
An 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 modulation by a 0
to 10 VDC signal. A sensor in the water/glycol mixture header detects temperature or
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.
Chiller Controls
The operator uses three different types of controls and indicators to
monitor and maintain the desired operating parameters in the Manhattan
Chiller chiller. These controls and indicators are located in the power
panels and the microprocessor controllers.
Power Distribution
There 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 modules. The module
electrical and control panel receives power from the power distribution
panel and provides power to individual electrical components.
WARNING
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.
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.
Electrical Controls
The Manhattan Chiller is provided with a robust set of controls and
indicators to monitor the electrical activity and notify operators if
problems arise.
Flow Switch
A flow switch is wired into the low voltage control circuitry used to
detect the flow of liquid throughout the closed loop piping system. The
differential pressure switch detects water/glycol mixture flow through a
pressure differential in the discharge line. 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.
CAUTION
Never “jumper out” a flow switch. This can damage
equipment and defeat safety systems built into the
equipment.
Phase Monitor
A 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 Controls
Controls 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 built-in 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 built-in interface panel.
Expansion Valve Settings
Superheat 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
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 Glass
When 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.
CAUTION
A 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.
Sequence of Operations
This manual describes a notional water-cooled chiller system with
few, if any, optional components or devices attached. To cover the
primary 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.
slave module, the second compressor of the lead module) will be brought
on-line.
8. As the demand continues to increase, and the temperature once
again 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.
9. On a decrease in system demand such that the leaving water
temperature 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.
10. This process occurs throughout the operating range of the chiller.
11. The microprocessor will rotate to designate a new lead module
once a week to equalize the run time among the modules.
12. A three-way condenser water-regulating valve can be provided to
maintain chiller head pressure when the condenser water temperature is
below 65 °F (18 °C). The regulating valve bypasses cold water from the
condensers to the condenser water return line while allowing sufficient
water to the condensers to maintain head pressure.
13. Alternatively, for a water-cooled chiller with a two-way
condenser water-regulating valve, the valve modulates to allow sufficient
water to the condensers to maintain head pressure when the condenser
water temperature falls below 65 °F (18 °C).
will de-energize, and the secondary pump will activate. An alarm signal is
generated providing an indication of primary pump failure on the
microprocessor controller.
5. The variable frequency drive (VFD) for the chiller pumps are
provided and installed by ArctiChill. The control signal for each VFD is
provided from the microprocessor in the tank and pump module. The
pump speed is synchronized with the number of chillers that are operating
on the system.
6. The electronic isolation valve of the master lead chiller identified
in 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.)
7. 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.
8. Once there is a system load, the building management system will
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.
9. As the system demand continues to increase, the second
compressor within that module will energize provided all safeties on that
circuit are satisfied.
10. 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.
11. As the flow and demand continue to increase, and the temperature
once again reaches the set point plus differential setting, the second
Warranty Issues
ArctiChill 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.
Factory Preparation
Upon 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 speed
drive panels to prevent corrosion of electrical contacts and
moisture from degrading sensitive controllers.
• Shrink-wrapping each chiller using polyethylene film to limit
environmental exposure and protect the chillers from damage
during shipping.
• For multiple modular chiller system assemblies shipped on a
common skid, shrink wrap the entire skid rather than the
individual 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 Responsibilities
Upon 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.
WARNING
• All field wiring must be installed in accordance with
local electrical and building codes.
• All the terminals and connections must be tightened.
Improper connection and fastenings can cause electric
shock, short circuit, and fire.
• Ensure that the rated voltage of the chiller
corresponds to data on the nameplate before commencing
wiring work according to the wiring diagrams.
• The unit must be GROUNDED to prevent possible
hazards due to insulation failure.
• Electrical wiring must not touch the refrigerant
piping, compressor, or pump.
• Do not use fuses of different amperage than that
stated on the nameplate. Using wire etc. to replace a fuse
can cause electric shock, short circuit, or fire.
• Do not use joined and twisted wires for incoming
power supply.
Chiller Clearances
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.
Minimum Clearances
The unit must maintain a minimum of 36 clearance on all sides. See
Figure 16 “Recommended Chiller Clearances.”
Service Access
Compressors, filter-strainers, and liquid line shutoff valves are
accessible on each side or end of the unit.
Mounting Rails
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 and separated such that the modules can be
bolted to the rails on 100 centers. Custom modules may have different
requirements. Consult submittal drawings to confirm dimensions.
After setting and lubricating the mounting rails, begin installing the
modules. 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 main
power distribution panel attached to it.
While the compressors are installed with rubber-in-shear isolation
pads for additional vibration isolation, spring isolators must be installed
under the structural steel mounting rails.
CAUTION
Unless the chiller is being installed on a concrete pad, do
not install vibration isolators under individual modules.
Such a configuration may cause the headers to leak due
to eccentric alignment of the header connections.
NOTE
Do 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.
Insight: Dowfrost
Dowfrost 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.
WARNING
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 the warranty.
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.
NOTE
Ensure 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.
WARNING
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.
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.
NOTE
If 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.
CAUTION
The 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 75.
Factory Certification:
Training and certification is As part of a continuous commitment to quality, initial startup of this
available from ArctiChill. Call chiller by a certified factory technician may be purchased from
Customer Service at 803- ArctiChill.
321-1891 for course schedule
and availability.
Record rated power supply: __________volts_______ phase • Circuit breaker rating: _______
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.
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.
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.
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, electrical, and control 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 remote interface panel or special-purpose module 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.
Built-in Interface Panel: Record version and date of software loaded into the built-in interface panel:
Version: ____________________________________ Date: ________________
o
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.
Operator Interface
All Manhattan Modular Water-Cooled Chiller units, whether they are
composed of a single module or up to 16 modules, are automated systems
that use a built-in interface panel to monitor, report, and modify critical
system functions.
Circuit
Breakers
Distribution
Block
Phase
Monitor
Ground
Lug
DB Distribution
CB-1 Circuit Block
Breaker
(Compressor 1)
K1 Contactor
(Compressor 1)
CB-2 Circuit
Breaker
(Compressor 2) K2 Contactor
(Compressor 2)
T1, T2 24 VAC
Transformers
Carel
pCO5+
Compressor Controller
Switches
TB-1 TB-4
Terminal Block Terminal
Block
TB-2
Terminal Block
Electronic Control
Manhattan Modular Water-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
23). Slave modules use a medium pCO5+ microprocessor (Figure 24).
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.
that it is powered on the LCD screen of the master module. Pressing this
button effectively toggles the chiller on and off.
Microprocessor Functions
For practical purposes, all essential control information and operator
actions are read and responded to using the built-in interface panel. The
built-in interface panel is connected to the master microprocessor
controller and is the only way to access many master controller functions.
CAUTION
This 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: There are two passwords. The Level One password, 0011, can be
803-321-0779 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 Control
A built-in 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 built-in interface panel is typically located
on the exterior door of the power distribution panel.
Line 1
Line 1 = screen name:
MASTER STATUS This is the master status screen.
Line 2
System Enter: 064°F
Line 3 System Enter: 047°F Line 4 = status line: Chiller is ON,
SYS ON CMPS: 04 with 4 compressors running.
Line 4
MASTER STATUS:
REFRIG Pressing this key displays the refrigeration pressure Low Press C1 000 PSI
PRESSURE in each chiller module. High Press C1 000 PSI
System Off
If the chiller includes a tank and pump module, MASTER STATUS: 000%
PUMP
pressing this key displays the pump discharge Pump Disc 000psi
PRESSURE
pressure. System Off
End of Sequence:
Step 1: Navigate to the master status screen. From any other screen, This symbol indicates end of
follow the steps shown in Figure 27 to display the master status sequence:
for the chiller.
each module, master and three slaves, in turn and return to the
master as shown in Figure 28.
Step 5: While viewing the master controller screen, display entering and
leaving temperature set points as shown in Figure 30.
Step 6: Enter the Level One password to be able to see the temperature
set point as shown in Figure 31.
NOTE
For 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.
Step 9: 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.
Operator Tasks
Before operating the unit, ensure that all compressor refrigeration
service valves are fully back-seated counterclockwise.
CAUTION
All 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.
WARNING
Hazardous 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.
NOTE
This 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 40 for
instructions regarding that situation.
CAUTION
The 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 75.
• Press the ON-OFF button on the built-in interface panel that is built
into the power distribution panel door or more distant wall
location in the equipment room.
NOTE
Pressing the ON-OFF button on the built-in 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.
NOTE
ArctiChill 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 5, Glycol Performance Impact
Factors 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.
Propylene Glycol
Concentration
30% 40% 50%
Lowest Ambient
Temperature
10 °F (-12 °C) -4 °F(-10 °C) -20 °F (-29 °C)
Recommended
Minimum Leaving 25 °F (-4 °C) 10 °F (-12 °C) -10 °F (-23 °C)
Fluid Temperature
CAUTION
Do not use automotive antifreeze. Corrosion in the chiller
can result in permanent damage to pump and internal
cooling surfaces.
NOTE
If 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 Freezing
Many 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.
Freeze points and burst points of glycol-water solutions are shown in
Table 6, Freeze Protection Chart, on page 67.
In order to maintain a high quality glycol solution, the water used in
the glycol mixture must have very few 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.
CAUTION
Do not use automotive antifreeze. Corrosion in the chiller
can result in permanent damage to internal cooling
surfaces.
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 35, Water/Glycol Concentration Freezing Points (in degrees
Fahrenheit), on page 68. 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.
Technical Support
Questions 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
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
• Electronic mail: chiller@arctichill.com
Maintenance Strategy
The 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
CAUTION
This 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.
Daily
A daily visual inspection can reveal obvious problems. Keep notes of
the chiller performance:
• Log pressures and temperatures.
• Visually inspect of the unit.
Weekly
Weekly inspection is a continuation and elaboration of daily best
practice:
• Inspect built-in interface panel for alarm status and additions to
the alarm history. (Do not clear alarms as this is a very important
performance record if troubleshooting problems occur.)
• Listen for excessive vibrations or motor noise. This usually
signals a loose brace or section of piping.
• Measure all refrigerant static pressure on any idle circuits. record
any significant changes or reductions in pressure.
• Clean strainers weekly during initial weeks after initial start up
until water quality has been reliably established. Thereafter,
inspect and clean strainers at least monthly.
Monthly
The 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 and
verify that it is clean and free of debris.
2. The 60 Mesh screen is made of SAE Grade 304 stainless steel
and 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 always
be 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.
CAUTION
A 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.
CAUTION
The 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 75.
NOTE
A 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
CAUTION
The 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 75.
CAUTION
Extended 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.
NOTE
Bubbles 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.
CAUTION
A 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.
Quarterly
The 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/glycol
mixture temperature and leaving evaporator water/glycol mixture
temperature.
Annually
The 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 ensure
terminals are tight. Inspect all contactors for pitting and corrosion and
replace as necessary.
WARNING
Hazardous 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.
WARNING
This Chiller Contains Hazardous Refrigerant! This
equipment contains oil and refrigerant under high
pressure. 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. Failure to follow
proper procedures or the use of non-approved
refrigerants, refrigerant substitutes, or additives could
result in serious injury or death.
5. Inspect that the oil level is visible in each compressor and not
discolored 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 are
separated and not vibrating against one another or the frame or housing.
10. Ensure all refrigeration lines are properly supported to prevent
vibration from causing premature failure of copper piping.
11. Inspect all insulation on piping and control sensors. Repair and
replace 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.
Maintenance Tasks
The 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 Methods
Appropriate inspection for modern chillers can be described as
“hands on.” Where possible and appropriate, visual inspection should
WARNING
Hazardous 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.
Step 2: Close the two service isolation valves between the header and the
evaporator.
NOTE
If 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 rolled groove 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.)
CAUTION
Water/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.
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 rolled groove 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.
Compressor Tasks
Manhattan Chiller chillers have 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 31.)
WARNING
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 the warranty.
Step 1: Close the suction and discharge rotalock valves. Firmly front-seat
both rotalock valves clockwise.
NOTE
Do 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.
WARNING
Hazardous 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.
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 the
compressor overload.
• Blue wire #19 on compressor #1 attaches to terminal T1 on the
compressor.
• 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 the
documentation that was shipped with the chiller for the specific
wire numbers for that unit.)
Step 8: Replace the electrical and control panel cover.
Step 9: Open both rotalock valves until fully back-seated
counterclockwise.
CAUTION
Do 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 Tasks
The following section applies to those chillers equipped with a tank
and pump module.
WARNING
Hazardous 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.
NOTE
Always use a second, counter, wrench, when performing
plumbing tasks to firmly hold the fittings or joint while
loosening the tightening the opposite side.
NOTE
A 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.
WARNING
Hazardous 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.
NOTE
The 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.
NOTE
Always 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.
WARNING
Hazardous 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.
NOTE
It is not necessary to remove the pump housing from the
piping to change the pump seal.
NOTE
A 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.
NOTE
A 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.
CAUTION
Wash 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.
**ALARM**
Microprocessor hardware or software failure.
EEPROM FAILURE
**ALARM**
ID11, ID5: compressor over-current relay has
COMPRESSOR 1
OVERLOAD opened.
**ALARM** B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8, B-3:
SENSOR FAILURE temperature or pressure sensor failure alarm.
**ALARM**
A controller in the chiller network is off line or is no
COMMUNICATIONS
longer “seen” by the master microprocessor
ERROR
TO A SLAVE UNIT controller.
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
Diagnostic Displays
The 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 TO
0309).
The form of the display depends on the severity of the error. Specify
the severity for many errors by directing the drive to:
Fault Resetting
The ACH550 can be configured to automatically reset certain faults.
Refer to parameter Group 31: AUTOMATIC RESET.
CAUTION
If 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.
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.
NOTE
An 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.
Main switch open or circuit Check circuits and motor winding for shorts or
breakers open. grounds.
Gas velocity in risers too low. Check riser sizes against compressor gas flow.
Expansion valve
Reset for proper superheat. Replace if necessary
malfunctioning
Restricted water/glycol line Clean strainers; check manual and electronic valves
Insufficient refrigerant in chiller Check for leaks. Repair and add R410A as needed
Compressor operating
See failure of compressor to unload or load up below
unloaded
Fan cycling controls not Reset cut-in, cut-out settings to conform to design
properly set specifications
Water velocity through Clean strainer; check pump, VFD, and differential
evaporator too low pressure settings
Temperature controllers
Replace temperature sensor
malfunctioning
Obstructed flow through Reverse flush evaporator; check strainer for debris;
evaporator check VFD, pump, valves
Technical Support
Questions 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
Acronym List
All acronyms and abbreviations in this publication are listed in the
following table, with their full spellings and expansions.
410A R410A
AL alarm
Alrms alarms
Anlg Analog
Bd board
C Celsius
C1 Circuit 1
C2 Circuit 2
CB Circuit Breaker
CE Conformance European
ckt circuit
CL cool
Cntrl Controller
Comps Compressors
COND condenser
DB Dry Bulb
DB Distribution Block
Dly Delay
DP Differential Pressure
F Fahrenheit
FRI Friday
HFC Hydrofluorocarbon
HG Hot Gas
HP horsepower
HT heat
ID Inside Diameter
Ident Identification
INFO Information
Int Integration
IP Industry Pack
Iso Isolation
LA Low Ambient
LP Low Pressure
m minute
Max Maximum
Min Minimum
MON Monday
OA Outside Ambient
OD Outside Diameter
P Process
PD Pressure Differential
PE Protective Earth
Pres pressure
REFRIG Refrigeration
Rot Rotation
RP Redundant Pump
s second
SAT Saturday
SP Set Point
SUN Sunday
Sys System
Temp Temperature
TEMPS Temperatures
THU Thursday
TT Twin Turbine
TUE Tuesday
UL Underwriters Laboratories
UV Ultraviolet
WED Wednesday
Y4 analog output
Expansions
All acronyms and abbreviations listed in Table A-1, Acronyms and
Abbreviations, on page A-1 are listed below, with their full spellings and
expansions.
alarm AL
alarms Alrms
Analog Anlg
analog output Y4
board Bd
Celsius C
circuit ckt
Circuit 1 C1
Circuit 2 C2
Circuit Breaker CB
Compressors Comps
condenser COND
Conformance European CE
Controller Cntrl
cool CL
Delay Dly
Differential Pressure DP
Distribution Block DB
Dry Bulb DB
Fahrenheit F
Friday FRI
heat HT
horsepower HP
Hot Gas HG
Hydrofluorocarbon HFC
Identification Ident
Industry Pack IP
Information INFO
Inside Diameter ID
Integration Int
Isolation Iso
Low Ambient LA
Low Pressure LP
Maximum Max
Minimum Min
minute m
Monday MON
Outside Ambient OA
Outside Diameter OD
pressure Pres
Pressure Differential PD
Process P
Protective Earth PE
R410A 410A
Redundant Pump RP
Refrigeration REFRIG
Rotation Rot
Saturday SAT
second s
Set Point SP
Sunday SUN
System Sys
Temperature Temp
Temperatures TEMPS
Thursday THU
Tuesday TUE
Twin Turbine TT
Ultraviolet UV
Underwriters Laboratories UL
Wednesday WED
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.
Payment Terms
Parts 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.
All chiller modules are installed with minimum clearances available from all sides.
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.
Chilled water lines have been leak tested according to prestart instructions.
Chiller reservoir (if included) is at operating level with correct water/glycol mixture.
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.
Full load shall be available for chiller on the initial start-up date.
Analog input 1 loss. Analog input value is less than AI1 FAULT LIMIT (3021). Check
for and correct:
7 AI1 LOSS
• Source and connection for analog input
• Parameter settings for AI1 FAULT LIMIT (3021) and 3001 AI<MIN FUNCTION.
Analog input 2 loss. Analog input value is less than AI2 FAULT LIMIT (3022). Check
for and correct:
8 AI2 LOSS
• Source and connection for analog input
• Parameter settings for AI2 FAULT LIMIT (3022) and 3001 AI<MIN FUNCTION.
The motor ID run was not completed successfully. Check for and correct motor
11 ID RUN FAIL
connections.
Motor or process stall. Motor is operating in the stall region. Check for and correct:
• Excessive load
12 MOTOR STALL
• Insufficient motor power
• Parameters 3010…3012.
Digital input defined to report the first external fault is active. See parameter 3003
14 EXT FAULT 1
EXTERNAL FAULT 1.
Digital input defined to report the second external fault is active. See parameter
15 EXT FAULT 2
3004 EXTERNAL FAULT 2.
The load on the input power system is out of balance.
• Check for/correct faults in the motor or motor cable
16 EARTH FAULT • 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.
Internal fault. The thermistor measuring the internal temperature of the drive is open
18 THERM FAIL
or shorted. Contact your local ABB representative.
Internal fault. Exceptionally low voltage detected on the main circuit board. Contact
20 OPEX PWR
your local ABB representative.
Internal fault. Current measurement is out of range. Contact your local ABB
21 CURR MEAS
representative.
Ripple voltage in the DC link is too high. Check for and correct:
22 SUPPLY PHASE • Missing mains phase
• Blown fuse.
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
24 OVERSPEED
• Adequacy of motor braking torque
• Applicability of torque control
• Brake chopper and resistor.
Internal fault. Configuration block drive ID is not valid. Contact your local ABB
26 DRIVE ID
representative.
27 CONFIG FILE Internal configuration file has an error. Contact your local ABB representative.
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 1
Fault code reserved for the EFB protocol application. The meaning is protocol
32 EFB 2
dependent.
33 EFB 3
Fault in the motor circuit. One of the motor phases is lost. Check for and correct:
• Motor fault
34 MOTOR PHASE • Motor cable fault
• Thermal relay fault (if used)
• Internal fault.
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
35 OUTP WIRING capacitance is large. This fault can be disabled by using parameter 3023 WIRING
FAULT.
• Check input power connections.
• Check grounding.
Loaded software is not compatible with the current drive type. Contact your local
36 INCOMPATIBLE SW
ABB representative.
Drive control board is overheated. Fault trip limit is 190 °F (88 °C). Check for and
correct:
• Excessive ambient temperature
37 CB OVERTEMP
• Fan failure
• Obstructions in the air flow.
Not for drives with an OMIO control board.
Condition defined by parameter 3701 USER LOAD C MODE has been valid longer
38 USER LOAD CURVE
than the time defined by 3703 USER LOAD C TIME.
101
Error internal to the drive. Contact your local ABB representative and report the error
… SYSTEM ERROR
number.
199
201
Error in the system. Contact your local ABB representative and report the error
… SYSTEM ERROR
number.
299
Parameter values are inconsistent. Check for any of the following:
• 2001 MINIMUM SPEED > 2002 MAXIMUM SPEED
• 2007 MINIMUM FREQ > 2008 MAXIMUM FREQ
1000 PAR HZRPM • 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.
Parameter values are inconsistent. Check for 2007 MINIMUM FREQ is negative,
1001 PAR PFA REF NEG
when 8123 PFA ENABLE is active.
Parameter values are inconsistent. Check for and correct the parameter is set for
PAR FIELDBUS
1007 fieldbus control (e.g. 1001 EXT1 COMMANDS = 10 (COMM)), but 9802 COMM PROT
MISSING
SEL = 0.
Parameter values for power control are inconsistent: Improper motor nominal
frequency or speed. Check for the following:
1009 PAR PCU 1 • 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.
PAR PFA & Override mode is enabled and PFA is activated at the same time. This cannot be
1010
OVERRIDE done because PFA interlocks cannot be observed in the override mode.
Parameter values are inconsistent. All override mode parameters do not have
correct values when override mode is enabled (parameter 1705 OVERRIDE
1011 PAR 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.
IO configuration is not complete – not enough relays are parameterized for PFA. Or,
1012 PAR PFA IO 1 a conflict exists between group 14, parameter 8117 NR OF AUX MOT and parameter
8118 AUTOCHNG INTERV.
IO configuration is not complete – the actual number of PFA motors (parameter
1013 PAR PFA IO 2 8127 MOTORS) does not match the PFA motors in Group 14 and parameter 8118
AUTOCHNG INTERV.
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
1016 PAR USER LOAD C • 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 Wrong type of panel, i.e. panel that supports drive X but not the ACH550, has been
-
SUPPORTED connected to the ACH550.
DRIVES: x
Operator Control
Some Manhattan Chiller chillers have the built-in interface panel
manufactured into the door of the main power distribution panel where its
display is monitored without need to open the panel door. An additional,
remote, interface panel can be located in a control room or on the interior
wall of the equipment room.
CAUTION
The 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.
If the chiller includes a tank and pump module, MASTER STATUS: 000%
PUMP Pump Suction 000psi
pressing this key displays the pump discharge Pump Disc 000psi
PRESSURE
pressure. System Off
CAUTION
The 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.
Step 1: Navigate to the master status screen. From any other screen,
follow the steps shown in Figure E-4 to display the master status
for the chiller.
Step 5: While viewing the master controller screen, display entering and
leaving temperature set points as shown in Figure E-7.
Step 7: Inspect the data and time setting for each module as shown in
Figure E-8.
Step 8: Locate and display the temperature set point screen for each
module. Follow the sequence shown in Figure E-9.
Step 9: Locate and display the refrigeration temperature set point screen
for each module. Follow the sequence shown in Figure E-10.
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 E-11.
NOTE
For 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.
Microprocessor Functions
For practical purposes, all essential control information and operator
actions can be read and responded to using the remote interface panel.
NOTE
The ON-OFF button must be illuminated by pressing the
button to the ON position in order for the chiller to
operate.
NOTE
The 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.
bracket
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.
CAUTION
The 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.
T-Connector T-Connector
Master
Controller
Remote
Interface
Panel
0 ground shield
CAUTION
Power 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.