Installation, Operation, and Maintenance Manual: The Arctic Chiller Group

Installation, Operation,
and Maintenance Manual
Manhattan Modular
Model PWCCMV0300D3-MM Shown Water-Cooled Chiller
Part #9800-0050
Publication # PWC-001.00
August, 2018
The Arctic Chiller Group

Installation, Operation, and Maintenance Manual
Manhattan Modular
Water-Cooled Chiller
Publication PWC-001.00
August, 2018
ArctiChill Support Services
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. 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: chiller@arctichill.com
Company Location and Address

United States
71 Industrial Park Road
Newberry, South Carolina 29108
Canada
2100 Steeles Avenue East
Brampton, Ontario L6T 1A7
Company Confidential ©2018 The Arctic Chiller Group

Manhattan Modular
Water-Cooled Chiller
Publication PWC-001.00
August, 2018

Publication Disclaimer
ArctiChill 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.
Company Confidential ©2018 The Arctic Chiller Group

Table of Contents
ArctiChill Support Services ...................................................................................iv
Company Locations ..............................................................................................iv
Publication Disclaimer...........................................................................................vi
General Safety Instructions.......................................................................... xiii
Safety of Operators and Maintainers ..................................................................xiii
Personal Protective Equipment ....................................................... xiii
Indicators, Cautions, and Warnings ................................................xiv
Warnings and Caution Statement ...................................................xiv
Intended Users ................................................................................xix
How to Use this Manual ......................................................................................xix
Chapter One: Chiller Description ..................................................... xx
Chapter Two: Rigging and Installation ............................................. xx
Chapter Three: Operating Procedures............................................. xx
Chapter Four: Maintenance Procedures.......................................... xx
Chapter Five: Troubleshooting......................................................... xx
Appendices ...................................................................................... xx
Chapter 1: Chiller Description

Chiller Scope................................................................................................... 1
Chiller Capacities ............................................................................................ 1
Chiller Performance Data................................................................................ 2
Model Number and Coding ............................................................................. 2
Chiller Model and Serial Numbers .........................................................................4
Technical Support ..................................................................................................5
Operating Principles...............................................................................................5
Model Coding Key..................................................................................................7
Logical Flow Diagrams.................................................................................... 8
High Voltage Logical Flow .....................................................................................8
Control Logical Flow ..............................................................................................9
Refrigeration Logical Flow ...................................................................................10
Water/Glycol Mixture Logical Flow....................................................................... 11
Component Description ................................................................................ 12
Copeland Compressor .........................................................................................12
Condenser ...........................................................................................................12
Installation, Operation, and Maintenance Manual vii

Table of Contents
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
Chapter 2 Rigging and Installing

Inspect and Report Damage......................................................................... 27
Inspection of Delivered Equipment ........................................................ 28
Warranty Issues .................................................................................................. 28
Long Term Storage Requirements................................................................ 28
Factory Preparation............................................................................................. 29
Customer Responsibilities................................................................................... 30
Handling of the Modules............................................................................... 30
Site Preparation and Clearances.................................................................. 31
Chiller Clearances............................................................................................... 31
Minimum Clearances ...................................................................... 32
Service Access ............................................................................... 32
Rigging, Lifting, and Moving the Chiller ........................................................ 32
viii Company Confidential ©2018 The Arctic Chiller Group

Table of Contents
Mounting Rails .............................................................................................. 33

Install Piping and External Components ....................................................... 35
Initial Flushing of Piping ................................................................................ 35
Fill with Water/Glycol Solution ............................................................... 36
Connecting Module Couplings ............................................................... 37
Connecting Module Power and Control Wires .............................................. 38
Chiller Module Main Power ..................................................................................38
Phase Monitor Installation....................................................................................38
Power Interlock Switch.........................................................................................39
Single Point Connections ....................................................................... 39
Module Control Wiring .........................................................................................40
Preparation for Initial Startup ........................................................................ 40
Initial Startup .......................................................................................... 40
Request Initial Startup..........................................................................................42
Chapter 3 Operating Procedures

Operator Interface......................................................................................... 45
Chiller Power Panels............................................................................................45
Panel-Mounted Disconnect Switch .................................................. 45
Power Distribution Panels................................................................ 46
Module Electrical and Control Panel................................................ 47
Electronic Control.................................................................................................48
Slave and Master Controllers...............................................................................48
Operating the Microprocessor..............................................................................49
Microprocessor Functions....................................................................................50
Password Protection ............................................................................................50
Operator Control ..................................................................................................50
How to Use the Built-in Interface Panel ...............................................................51
Quick Controller Tutorial......................................................................... 55
Operator Tasks.............................................................................................. 59
Normal Power Up ................................................................................... 60
Emergency Power Shutdown........................................................................ 62
Monitor Water Quality ................................................................................... 63
Maintain Glycol Level...........................................................................................64
Prevent Freezing..................................................................................................65
Storage Provisions........................................................................... 67
Installation, Operation, and Maintenance Manual ix

Table of Contents
Technical Support............................................................................ 69
Chapter 4: Maintenance Procedures

Maintenance Strategy................................................................................... 71
Power Disconnect Switch ............................................................................. 72
Inspection and Maintenance Schedule......................................................... 73
Daily .................................................................................................................... 73
Weekly ................................................................................................................ 75
Monthly................................................................................................................ 75
Quarterly ............................................................................................................. 78
Annually .............................................................................................................. 79
Maintenance Tasks ....................................................................................... 81
Inspection Methods ............................................................................................. 81
Critical Cleaning Tasks........................................................................................ 82
Strainer Cleaning Procedure ................................................................. 82
Evaporator Cleaning Procedure............................................................. 85
Compressor Tasks .............................................................................................. 85
Remove Compressor ............................................................................. 85
Install Compressor ................................................................................. 86
Pump Tasks......................................................................................................... 88
Remove Pump ....................................................................................... 88
Install Pump ........................................................................................... 90
Replace Pump Seal ............................................................................... 91
Chapter 5 Chiller Troubleshooting

General Approach to Fault Isolation ............................................................. 95
Controller Diagnostic Codes......................................................................... 95
Compressor Diagnostic Codes..................................................................... 97
CoreSense Flash Codes ..................................................................................... 97
Flash Code Description....................................................................................... 97
Variable Frequency Drive Diagnostic Codes .............................................. 100
Diagnostic Displays........................................................................................... 100
Fault Resetting .................................................................................................. 102
Flashing Red LED ......................................................................... 102
Steady Red LED ............................................................................ 102
Phase Monitor Protection ........................................................................... 102
Symptoms and Solutions............................................................................ 103
x Company Confidential ©2018 The Arctic Chiller Group

Table of Contents
Compressor will not start .............................................................. 104

Compressor will not run ................................................................ 105
Compressor has excessive noise or vibration ............................... 105
Compressor will not load or unload................................................ 106
Compressor Loading/Unloading Cycles Too Short........................ 106
Compressor loses oil .................................................................... 106
Low refrigeration suction pressure ................................................ 107
High refrigeration suction pressure ............................................... 108
Low refrigerant discharge pressure .............................................. 108
High refrigerant discharge pressure .............................................. 109
Low chilled water temperature ...................................................... 110
High chilled water temperature ..................................................... 110
Compressor thermal protector switch open .................................. 110
No low voltage (24 VAC)................................................................ 111
Pressure switch open..................................................................... 111
Thermal expansion valve superheat too high ................................ 111
Thermal expansion valve superheat too low.................................. 112
Contactor/relay inoperative ............................................................ 112
Freeze protection safety activated ................................................. 112
Technical Support .............................................................................................. 112
Appendix A: Acronyms and Abbreviations
Acronym List ............................................................................................... A-1
Expansions ................................................................................................. A-6
Appendix B: Product Warranty
Parts Warranty ............................................................................................ B-1
Parts Failure Not Covered .......................................................................... B-1
Policy for Independent Service Contractors................................................ B-1
To Make a Warranty Claim.......................................................................... B-2
Rates and Terms......................................................................................... B-2
Freight and Handling ................................................................................B-2
Payment Terms ........................................................................................B-2
Appendix C: Request for Initial Startup
Manhattan Water-Cooled Chiller................................................................ C-1
Initial Start-up Agreement ............................................................................... 2
Appendix D: Variable Frequency Drive Troubleshooting
ABB ACH-550 Fault Codes ........................................................................ D-1
Installation, Operation, and Maintenance Manual xi

Table of Contents
Appendix E: Remote Interface Panel

Remote Location ......................................................................................... E-1
Operator Control.......................................................................................... E-1
Remote Microprocessor Control System.....................................................E-3
How to Use the Remote Interface Panel .................................................... E-5
Quick Controller Tutorial ....................................................................... E-6
Operating the Microprocessor ................................................................. E-11
Microprocessor Functions ....................................................................... E-11
Connect the Remote Interface Panel ..................................................E-11
Long Distance Installation ................................................................... E-14
xii Company Confidential ©2018 The Arctic Chiller Group

General Safety Instructions

This 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 Maintainers

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 equipment damage and serious injury or death.
Personal Protective Equipment
All 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.
Installation, Operation, and Maintenance Manual xiii

Indicators, Cautions, and Warnings
To 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.
Table 1: Special Messages Used in this Manual

Icon Type Purpose
This message indicates a condition in

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

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

information that is useful to the operator
INSIGHT
or maintainer but is not required for any
specific process or procedure.
Warnings and Caution Statement

The 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.
xiv Company Confidential ©2018 The Arctic Chiller Group

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
equipment.
Installation, Operation, and Maintenance Manual xv

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.
xvi Company Confidential ©2018 The Arctic Chiller Group

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.
Installation, Operation, and Maintenance Manual xvii

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.
xviii Company Confidential ©2018 The Arctic Chiller Group

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.
How to Use this Manual

This manual provides the user with necessary data to properly install,
operate, maintain, and troubleshoot the ArctiChill Manhattan Modular
Water-Cooled Chiller.
This manual describes a typical water-cooled chiller with few, if any,
optional components or devices attached. It is assumed that the operator
and maintenance personnel are qualified to perform work on refrigeration
Installation, Operation, and Maintenance Manual xix

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 Description
This 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 Installation
This 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 Procedures
This chapter describes the operator interface and controls; power
distribution panel; electrical and control panels; refrigeration controls;
built-in 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 Procedures
This 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: Troubleshooting
This chapter describes the general approach to fault isolation; built-in
interface panel diagnostics; compressor diagnostic codes; symptoms and
solutions; and troubleshooting tasks summary.
Appendices
Each appendix in this manual contains specific information on a
special topic of interest to all or part of the user population.
xx Company Confidential ©2018 The Arctic Chiller Group

Appendix A is a listing of all acronyms and abbreviations used in

this manual and on the interface displays, and chiller signs, labels, and
placarding.
Appendix B describes and explains the ArctiChill product warranty.
Appendix C covers the form needed to request support for a new
chiller initial start-up.
Appendix D explains the fault codes shown in the variable
frequency drives that control the chiller compressors.
Appendix E contains full explanations and tutorials for the optional
remote interface panel that can be connected to control the chiller from up
to 500 feet (152 meters) away from the master controller.
Installation, Operation, and Maintenance Manual xxi

xxii Company Confidential ©2018 The Arctic Chiller Group
CHAPTER 1 Chiller
Description
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.
Installation, Operation, and Maintenance Manual 1

Chiller Description
The Manhattan Chiller uses independent refrigeration circuits in

each module using scroll or semi-hermetic compressors. Models are
available with either brazed-plate or shell-and-tube evaporators. The
brazed-plate heat exchanger 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.
WARNING
when conducting service in this equipment.
Chiller Performance Data

For illustrative purposes, this manual uses a notional 120-ton water-
cooled chiller consisting of four modules with brazed plate evaporators
and condensers for example purposes. The model number and a chiller’s
precise configuration can be found on the chiller model nameplate. See
“Chiller Model and Serial Numbers” on page 4.
Model Number and Coding

When 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.
2 Company Confidential ©2018 The Arctic Chiller Group

Table 1 Notional Manhattan Modular Chiller Specification for Example Purposes

CHILLER SYSTEM (FOUR 30-TON WATER-COOLED CHILLER MODULES)
Evaporator Type brazed plate Condenser Type brazed plate
Evaporator Flow 300 gpm Condenser Flow 260 gpm
Evaporator Fluid water Condenser Fluid water
Entering Fluid Temperature 54 °F (12 °C) Entering Fluid Temperature 85 °F (29 °C)
Leaving Fluid Temperature 44 °F (7 °C) Leaving Fluid Temperature 95 °F (37.3 °C)
Evaporator Pressure Drop 4.4 psi Condenser Pressure Drop 3.1 psi
1,503,500 btu/hr. Maximum 650 psi
System Capacity
(120 tons) Operating Pressure (refrigerant side)
Refrigerant R410A Connections 6 roll groove
CHILLER MODULES (4)
Compressors two per module Rated Load Amps 48.4 amps each
Horsepower 15 Total Full Load Amps 96.8 amps per module
Locked Rotor Amps 340 amps Electrical Power Supply 208/60/3
SYSTEM
Maximum Overcurrent
Total Full Load Amps 387amps 500 amps
Capacity
Minimum Circuit Ampacity 394 amps
DIMENSIONS
Each Chiller Module 24 W x 66 L x 76 Ha Overall Chiller System 104 W x 66 L x 76 Hb
aMaster module is 32 wide, including power distribution panel. bIncluding power distribution panel.
WEIGHT
Each Chiller Module 2,100 lbs. Overall Chiller System 8,400 lbs.

Chiller Description
Chiller Model and Serial Numbers

For future reference, write the model number and serial number for
each module in the chiller in the spaces provided, in Table 2, Chiller
Reference Data. Refer to the official ArctiChill nameplate placarding for
the precise serial number and model number for each module in the
installed unit. Provide the ArctiChill Customer Service Department (803-
321-1891) with the pertinent data when calling for information or parts.
Table 2 Chiller Reference Data

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

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 Water-Cooled Chiller Nameplate

Model Coding Key

Model numbers assigned to ArctiChill systems provide a wealth of
information about the features for a chiller’s “as-built” configuration.
Pump: Power Supply: Extension:

M = Single pass modular, no pump 1 = 208/230/60/1 [blank] = Constant Speed
P = Self-contained, recirculating 2 = 460/60/1 -3HX = PolyTherm
tank & pump 3 = 208/230/60/3 -CP = Cold Plunge
4 = 460/60/3 -DS1 = Digital Scroll (single)
5 = 575/60/3 -DS2 = Digital Scroll (dual)
6 = 220/50/1 -DW = Drinking Water
Series: 7 = 380/50/3 -HP = Heat Pump
Profile:
D = Commercial High 8 = 115/60/1 -HR = Heat Recovery
H = Horizontal low-profile
Temperature 9 = All other -MM = Manhattan Modular
cabinet
M = Medical & High Tech V = Vertical upright -MMA = Manhattan Modular Advanced
P = Process Chiller cabinet -VS1 = Variable Speed (single)
-VS2 = Variable Speed (dual)
Configuration: Tonnage: Form: Type:

ACH = Air-Cooled condenser, 0005 = Half ton D = Dual independent circuits MM = Manhattan Modular
Horizontal air discharge 0020 = Two ton R = Redundant refrigeration MMA = Manhattan Modular
ACR = Air-Cooled Remote condenser 0300 = 30 ton & electrical Advanced
ACU = Air-Cooled condenser, W-coil 2000 = 200 ton S = Single refrigeration circuit
ACV = Air-Cooled condenser, T = Tandem compressors,
Vertical air discharge single refrigeration circuit
ACW = Air-Cooled
WCC = Water-Cooled Condenser
Figure 2 Unpacking the ArctiChill Model Number

Chiller Description
Logical Flow Diagrams

The following section presents the simplified logical flow block
diagrams for the principal systems in the Manhattan Modular Water-
Cooled Chiller.
High Voltage Logical Flow

Manhattan Modular Water-Cooled Chiller is 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

Control Logical Flow

The chiller uses low voltage for controller and sensor circuits. See
Figure 4.
Figure 4 Control Logical Flow

Chiller Description
Refrigeration Logical Flow

The Manhattan Chiller uses independent refrigeration circuits per
module using scroll compressors. See Figure 5.
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.
Figure 5 Refrigeration Logical Flow

Water/Glycol Mixture Logical Flow

ArctiChill 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

Chiller Description
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.
Figure 7 Copeland Scroll Compressor
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.

Figure 8 Typical Condenser Configuration
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.
Figure 9 Typical Evaporator Configuration

Chiller Description
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.
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.
Expansion Valve
An expansion valve is a metering device controlling the flow of
refrigerant to the evaporator based on evaporator superheat. See Figure
10.
Figure 10 Expansion Valve
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.
Microprocessor Control System

Manhattan Chiller models employ a Carel pCO5+ all-digital data
control system to control and report key system settings and indicators.
Figure 11 Master Controller
Master Microprocessor Controller

Master modules use a Carel pCO5+ large microprocessor controller.
Slave modules use a Carel pCO5+ medium microprocessor controller.
The master microprocessor controller must have the optional BMS card
installed to connect to a building management system. See Figure 11.
Slave Microprocessor Controller
In 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. All safeties including refrigerant pressures and freeze protection
are preserved. The distributed master mode lacks the ability to rotate the
lead compressors which occurs every 168 system operating hours. See
Figure 12.

Chiller Description
Figure 12 Slave Controller
Built-in Interface Panel

The built-in interface panel is the primary means for controlling and
monitoring the system for the operator and maintainer. See Figure 13.
Figure 13 Built-in Interface Panel

Chiller Controls
Operator Control and Monitoring

Each system is provided with a built-in 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 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
when conducting service in this equipment.
Main Power Distribution

The power distribution panel distributes electricity from the external
building power supply. It also houses breakers, phase monitor, and a built-
in interface panel (and, potentially, an optional door-mounted master
power interrupter switch). See Figure 14 on page 18.
Panel Disconnect
Some Manhattan Chiller systems are optionally equipped with a
panel-mounted disconnect switch installed on the outside of the power

Chiller Description
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.
Figure 14 Main Power Distribution Panel

Chiller Controls
Module Electrical and Control Panel

From the power distribution panel, power is fed to the individual
modules in the chiller and connects to each module’s electrical and
control panel. See Figure 15.
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.
Figure 15 Module Electrical Panel
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.

Chiller Description
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.

Chiller Controls
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
the system. (A white indicator in the sight glass does not
necessarily indicate excessive moisture in the system.)
Consider vacuum evacuation of the system.
Low Pressure Bypass

Logic that uses a time delay that temporarily bypasses the low-
pressure switch for compressor start up. Once the delay times out the
normal controls are put back on line within the control circuit.
Thermal Capacity
The 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 Expertise

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. 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

Chiller Description
• International Calling 001-1-803-321-1891

• email chiller@arctichill.com
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.
Constant Flow Sequence

1. The chiller operates with high voltage power supplied to the unit at
all times.
2. 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 on the
built-in interface panel is energized, and the remote start/stop relay is
enabled, either through a contact closure or via the BMS.
4. For systems with a tank and pump module, when the chiller is
enabled, the lead chiller pump energizes. If the flow switch in the tank
and pump module closes within the delay period, the primary pump
continues to operate. Should the primary pump fail to start or to close the
flow switch within the time delay period, this pump will be shut down,
and the secondary pump activates. An alarm signal sounds on the
microprocessor controller indicating primary pump failure.
5. Once flow is established and the system demand (based on leaving
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.
6. As the system demand increases, the first compressor of the first
slave module will energize provided all safeties on that circuit are
satisfied.
7. As the system demand increases, the leaving water temperature
from 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.
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).
Variable Flow Sequence

1. The chiller is designed to operate with high voltage power supplied
to the unit at all times.
2. As long as there is power on the system, the electronic valve in the
master module will open to allow flow through the entire chiller system.
3. The chiller system is enabled when the system ON-OFF switch on the
built-in interface panel is energized, and the remote start/stop relay is
enabled either through a contact closure or via the BMS.
4. When the system is enabled, the chiller pump (if provided by
ArctiChill) will energize. If the differential pressure switch within the
tank and pump module closes within the time delay period, the primary
pump continues to operate. Should the primary pump fail to start or close
the differential pressure switch within the time delay period, this pump

Chiller Description
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

compressor on the second module will energize. This operation continues

with all subsequent chiller modules as needed based on system demand.
12. On a decrease in system demand (and flow) such that the leaving
water/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
that the corresponding pump variable frequency driver 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.
13. This process occurs throughout the operating range of the chiller
system. 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.
14. Should the master microprocessor fail, the balance of the modules
will continue to operate in response to demand. If the chiller system is
provided with a redundant master microprocessor on a slave chiller
module, all functions of the master microprocessor are transferred to the
redundant master microprocessor should the master microprocessor fail.
15. The microprocessor control system in each chiller module will
close the electronic isolation valve within that chiller module if there are
alarms on both refrigeration circuits within that module to prevent flow
from flowing through a non-active module which causes an increase in
the system flow and an unnecessary increase in the number of chiller
modules to maintain the system set point.

CHAPTER 2 Rigging and
Installing
Inspect and Report Damage

Upon 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 Equipment

To 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 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.
Long Term Storage Requirements

Appropriate 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 period
exceeding six months after leaving the ArctiChill factory. That is,
the initial start-up date will not occur within a six-month
maximum dormancy window.
• The chiller will be shipped using ocean transit for all or part of
the delivery process.
• Cold temperature storage conditions fall below -20 °F (-29 °C).
• Ambient temperature storage conditions exceed 150 °F (66 °C).
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.
Handling of the Modules

The 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
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.
Failure to follow these critical safety instructions can

lead to serious injury or death.
Site Preparation and Clearances

Chiller 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 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.
Figure 16 Recommended Chiller Clearances
Rigging, Lifting, and Moving the Chiller

ArctiChill Manhattan Water-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.

Mounting Rails
• Certain configurations of modules can be top-heavy. Move

modules slowly with consideration for each module’s center-of-
gravity.
• Rig, lift, and move by strapping and lifting using a properly
configured floor jack or fork lift or by overhead means.
• Position lifting beams to prevent lifting straps from rubbing or
contacting module side panels or electrical boxes. (See Figure 17,
below, and Figure 18 on page 34.)
• Do not use cables, chains, or any other type of metalized
strapping to lift a module.
• Do not push a chiller module while directly in contact with the
floor using manual or mechanical means.
Figure 17 Recommended Chiller Rigging Assembled 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.
Figure 18 Recommended Chiller Rigging Assembled Unit (Side

View)
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.

Install Piping and External Components
When installing modules onto a concrete pad, rubber-in-shear isolator

pads may be installed under each module.
After setting each module, remove front or rear access panels to
improve access to components when making connections.
Install Piping and External Components

Proper 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 Piping

After 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 Solution

In 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 5, Glycol Performance Impact
Factors on page 64 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.
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.

Initial Flushing of Piping
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 2 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 rolled groove header pipe. Push
the gasket flush with the pipe end to avoid damage when
installing the next module.
Step 5: Remove the 2 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 rolled groove
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 Wires

Connections are made at the master module, which typically contains
the power distribution panel.
Insight: Electrical Hazards

Read 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.
This unit is equipped with a flow switch. The chiller will not run
unless the pump is circulating water through the system.
Chiller Module Main Power

Modular 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 Installation

The chiller is equipped with a PLM phase monitor on the power
distribution panel. It communicates with the master microprocessor
controller on the master module electrical and control panel via a J11
connection. Ensure that the wiring from the master microprocessor
controller and terminal blocks to the phase monitor are connected and
secure.
The PLM series is a three-phase voltage monitor that continuously
monitors each of the three phases. It monitors both delta and wye systems
and no connection to neutral is required. The microprocessor controller
circuit design protects against under-voltage, voltage imbalance, phase

Connecting Module Power and Control Wires
loss, and phase reversal. Protection is assured when regenerated voltages

are present.
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) 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 Switch

distribution panel. The disconnect switch must be turned to the OFF
position before the panel can be opened for service.
WARNING
instructions may affect your safety and void the warranty.
Procedure: Single Point Connections

For 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 Wiring

The master controller communicates with the slave controller in each
chiller module via a communication circuit. Each slave controller
connects with the master controller in series via three-twisted-pair comm
wire connected to each controller’s J11 port.
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.
Preparation for Initial Startup

After 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.
WARNING
warranty.
Procedure: Initial Startup

Step 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.
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
compressor with insufficient oil. See recommended
inspection interval under “Monthly” on page 75.
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.

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 Startup

Initial 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 C, “Request for
Initial Start-Up.”)
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.

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 _________
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.

Table 3 Initial Startup Readiness Checklist (Continued)
 Startup Readiness Dimension
 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.

CHAPTER 3 Operating
Procedures
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.
Chiller Power Panels

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 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 Switch
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 Panels

The power distribution panel distributes electricity from the external
building power supply. It also houses circuit breakers, a phase monitor,
and a door-mounted built-in interface panel and, optionally, a master
power disconnect switch. See Figure 20.
Circuit
Breakers
Distribution
Block
Phase
Monitor
Ground
Lug
Figure 20 Power Distribution Panel

Operator Interface
Module Electrical and Control Panel

Each 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.
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
Figure 21 Module Electrical and Control Panel

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.
Figure 22 Typical Controller Network
Slave and Master Controllers

The 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 22 for a simplified example of a typical microprocessor
controller network.)

Operator Interface
Figure 23 Carel Large pCO5+ Master Controller
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 Carel Medium pCO5+ Slave Controller
Operating the Microprocessor

The built-in 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
built-in 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 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
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.

Operator Interface
To access, monitor, or modify certain specific chiller operating

parameters and settings, the built-in interface panel must be connected to
the master microprocessor controller located in the master module. The
built-in 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 built-in interface panel and connecting the other end of the cable
into the J10 port in the top left portion of the master controller.
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
built-in interface panel.
When connected to the master controller, the built-in 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 55 for instructions on how to
perform actions required to operate the built-in interface panel. Table 4,
Built-in Interface Panel Buttons and Keys explains the buttons on the
built-in 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 26.) This “remote-type”
interface panel is available from ArctiChill as an in-stock item.
How to Use the Built-in Interface Panel

The built-in interface panel is used to adjust set points, clear alarms,
and perform detailed setup of the microprocessor controllers.
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
Figure 25 Built-in Interface Panel LCD Screen

The built-in 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 25.)
Figure 26 Remote Interface Panel
Basic operator tasks are described in the following sequence of

illustrations that comprise a controller tutorial.

Operator Interface
Table 4 Built-in Interface Panel Buttons and Keys
Icon Name Activation function Visual result of activation
Pressing this key displays chiller status or demand,

MASTER STATUS: 100%
WATER identifies which compressors are currently energized, System Enter: 55°
TEMPS and the entering and leaving water temperature System Leave: 45°
System Off
settings of the master controller.
Pressing this key displays the chiller set points Temperature

(based on the entering water temperature) and allows Set Points
SET POINTS Leaving> 45.0°F
adjustment of a set point; the high and low
temperature alarm set points can also be set.
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
Pressing this key displays the system actual time and

Set Date/Time
allows the operator to energize or de-energize the Enter Date: 01/01/24
CLOCK
chiller at specific hours for precise after-hours and Enter Time: 10:17
Enter Day: Tuesday
weekend operational control.
Pressing this key displays the first of the previous 100

logged alarms including the time they occurred and 23:02 4/03/29
001-C2 HighPres
ALARM LOG the chiller temperature settings at the time of each L1:999 L2:999 E:074
alarm. Pressing the up arrow scrolls chronologically H1:999 H2:999 L:074
through each previous alarm in turn.
This optional controller feature is for a small-capacity

chiller with a low flow rate (50 gpm maximum) to
FLOW RATE
improve the accuracy of the flow reading. This is not
used in Manhattan Chiller modules.

Table 4 Built-in Interface Panel Buttons and Keys (Continued)
This optional controller feature is for a chiller with

redundant components so that individual
HAND-OFF-
compressors are controlled manually or
AUTO
automatically. Not used in Manhattan Chiller
modules.
Pressing this key displays the access panel for

factory settings for the chiller's microprocessors. It is Enter Password> 0000
PROGRAM protected by a Level Two password to limit access to
ArctiChill personnel only. This is typically not
accessed for routine tasks.
While viewing the master module screen, pressing
this key displays the information for each compressor Meter Run Hours
Compressor 1
INFO KEY in the chiller modules, the run status of each Hours > 00016hr
compressor, and the accumulated running hours for Starts > 00025
each compressor.

this button immediately de-energizes the chiller
(“turns it off”). This action also overrides any
ON-OFF
instructions to the chiller delivered by the Building
Management System. Pressing the button again
restores power to the chiller.
Pressing this button will display an alarm information

screen for the current active module if there is a
**MASTER ALARM**
currently active alarm. The ALARM button will COMPRESSOR1
ALARM
illuminate and an audible alarm will sound when an HIGH PRESSURE
active alarm occurs. Pressing the ALARM button will

silence the audible sound.
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 *NO MORE ALARMS*
ENTER Key ALARM to EXIT
operator action. If the ENTER button is pressed and Key ENTER to CLEAR
the alarm does not clear, then the alarm has not been
resolved and further action is required.

Operator Interface
Table 4 Built-in Interface Panel Buttons and Keys (Continued)
Pressing the up button moves the LCD display

UPWARD to the next alarm in a list of alarms or
UP 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.
Pressing the down button moves the LCD display

DOWNWARD to the next alarm in a list of alarms or
DOWN 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.
Procedure: Quick Controller Tutorial

These instructions are provided for first time users of the built-in
interface panel. This material will increase facility in using the controller
for those operators and maintainers with little prior experience with the
Carel controller system.
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.
Interface display tip:

Pressing the alarm log and
flow rate buttons together at
the same time will scroll
through each module in turn,
as shown in Figure 28. Then,
pressing the water temp
button reveals the home
Figure 27 Display Master Status Screen screen of the module
currently being viewed.
Step 2: Display the slave #1 status screen as shown in Figure 29.
Step 3: Cycle through all of the module status screens. For example, if
this is a four-module chiller, the screens would cycle through

each module, master and three slaves, in turn and return to the
master as shown in Figure 28.
Figure 28 Cycling Through Module Screens
Step 4: Display the slave #2 status screen as shown in Figure 29.
Figure 29 Display Slave Module #1 and #2 Temperatures
Step 5: While viewing the master controller screen, display entering and
leaving temperature set points as shown in Figure 30.

Operator Interface
Figure 30 Display Temperature Set Points for Each Module
Step 6: Enter the Level One password to be able to see the temperature
set point as shown in Figure 31.
Figure 31 Enter Password to Display Temperature Set Points

Master Status Screen Tip:

Working from the Master Step 7: Locate and display the refrigeration pressure set point screen for
Status screen has a major each module. Follow the sequence shown in Figure 32.
benefit of providing quick
Step 8: Locate and display the date and time for each module. Follow the
access to water temperature
sequence shown in Figure 33.
and refrigeration pressure
status screens for all of the
chiller modules by simply
pressing the down arrow
button for each one.
Figure 32 Inspect Refrigeration Pressure
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.

Operator Tasks
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.
Figure 33 Inspect Chiller Date and Time
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.

Figure 34 Change Chiller Date and Time
Procedure: Normal Power Up

The following procedure is used for a startup resulting from
scheduled seasonal or programmed cold shut down of the chiller.

Operator Tasks
WARNING
Hazardous Voltage and Electrical Capacitors! Failure to
disconnect all power and discharge capacitors before
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.
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 built-in
interface panel.
Step 5: Verify that pressure switches and thermostats have the correct
cut-in and cut-out settings using the built-in interface panel.
Step 6: Verify that the oil level is correct in each compressor using the
compressor sight glass.

CAUTION
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 built-in interface panel.
Emergency Power Shutdown

The 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 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.

Maintaining 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.
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.

Maintain Glycol Level

When 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 6, Freeze Protection Chart, on page 67 provides
guidelines for adding propylene glycol.
Table 5 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 25 °F (-4 °C) 10 °F (-12 °C) -10 °F (-23 °C)
Fluid Temperature
Capacity Capacity Capacity

Leaving Pressure Pressure Pressure
Reduction Reduction Reduction
Temperature Drop Factor Drop Factor Drop Factor
Factor Factor 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
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.

CAUTION
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.

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.
CAUTION
can result in permanent damage to internal cooling
surfaces.
Insight: Propylene Glycol

Glycol-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.
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.

Table 6 Freeze Protection Chart

Water/Glycol Freeze Burst
Temperature Protection Protection
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 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 5, Glycol Performance Impact Factors, on page 64. 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 Provisions
The 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 35 Water/Glycol Concentration Freezing Points (in degrees Fahrenheit)

Technical Support
• Electronic mail: chiller@arctichill.com

CHAPTER 4 Maintenance
Procedures
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

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 36.)
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 36 An Approach to Chiller Maintenance
Power Disconnect Switch

Some Manhattan Chiller units are optionally equipped with a panel-
mounted disconnect switch installed on the outside of the power
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
CAUTION
components or bypass the manufacturer's safety systems.
Insight: Federal Clean Air Act

Responsible 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.

Proactive 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 7, Recommended Chiller Service Intervals, on page 74.
Daily
A daily visual inspection can reveal obvious problems. Keep notes of
the chiller performance:
• Log pressures and temperatures.
• Visually inspect of the unit.

Table 7 Recommended Chiller Service Intervals

Task Frequency
Visually inspect the chiller Daily
Log pressure and temperatures Daily
Inspect built-in 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
Quarterly
°F [-12 °C to -9.4 °C])
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

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
4. When the compressor is not operating, the oil level should be at

least 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.
CAUTION
5. Low oil sight glass conditions could signify an undercharged

chiller 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.
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
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.
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.
8. Check the refrigeration liquid line sight glass for persistent

bubbles (“flashing”).

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
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.

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

corrosion, and loose connections.

Maintenance Tasks
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

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 7, Recommended Chiller Service Intervals, on
page 74.
WARNING
Critical Cleaning Tasks

Monitor 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 Procedure

Strainers at each evaporator are critical for maintaining water/glycol
mixture cleanliness and preventing excessive fouling. Service valves on
the evaporator 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.

Maintenance Tasks
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.

Figure 37 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 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.

Maintenance Tasks
Procedure: Evaporator Cleaning Procedure

Fouling 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 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.)
Procedure: Remove Compressor

Verify that power is disconnected from the chiller.
WARNING
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.
Procedure: Install Compressor

Verify that power is disconnected from the chiller.
WARNING

Maintenance Tasks
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.
Procedure: Remove Pump

Prior to servicing the pump or pump motor, verify that the power to
the chiller is disconnected.
WARNING

Maintenance Tasks
Step 1: De-energize power to the module containing the pump by moving

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.
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.

Procedure: Install Pump

Prior to servicing the pump or pump motor, verify that the power to
the chiller is disconnected.
WARNING

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.
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

Maintenance Tasks
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
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 Seal

Prior to servicing the pump, verify that the power to the chiller is
disconnected.
WARNING


Step 2: Close the ball valves on the suction and discharge sides of the
pump.
NOTE
It 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.
NOTE
A small quantity of water/glycol solution is lost during
this operation. Propylene glycol does not pose an
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.

Maintenance Tasks
NOTE
A small quantity of water/glycol solution will be lost
during this operation. Propylene glycol does not pose an
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
to the ON position.
Step 25: Observe the newly installed pump to verify that all connections
have been seated and tightened correctly.

CHAPTER 5 Chiller
Troubleshooting
General Approach to Fault Isolation

ArctiChill 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 Codes

The 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 96.

Chiller Troubleshooting
Table 8 Remote Interface Panel Diagnostic Code Key

Code Diagnostic Significance
**ALARM**
Microprocessor hardware or software failure.
EEPROM FAILURE
**ALARM** Loop temperature has risen above the high

LEAVING WATER temperature alarm point found under set point
HIGH TEMPERATURE buffer parameters.
**ALARM** Loop temperature has risen below the high

LEAVING WATER temperature alarm point found under set point
LOW TEMPERATURE buffer parameters.
**ALARM** ID2, ID4: discharge refrigerant pressures have

COMPRESSOR 1 risen to the cut out point. That is, 630 psi on water-
HIGH PRESSURE cooled R410A chillers.
**ALARM**
ID3, ID5: suction pressure has reached the low
COMPRESSOR 1
LOW PRESSURE pressure cut out point.
**ALARM**
ID11, ID5: compressor over-current relay has
COMPRESSOR 1
OVERLOAD opened.
**ALARM** ID10: under- or over-current; out of phase; loss of

WRONG PHASE power
**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.
**ALARM** Lead pump has failed to close flow switch or has

PUMP SWITCHOVER become “open” during operation.
**ALARM**
Both primary and secondary pumps have failed to
PRIMARY/SECONDARY
PUMP FAILURE
close flow switches.

Compressor Diagnostic Codes
Table 8 Remote Interface Panel Diagnostic Code Key

Code Diagnostic Significance
**ALARM** Tank level switch has “closed.”(Only signals alarm

TANK LEVEL when 24 VAC is “made.”)
**ALARM**
Pump is in wrong power phase; loss of power, or
WRONG PHASE
PUMP CONTROLLER
over or under.

Copeland 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 Codes

The 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 means
the compressor is not running and demand is present at the
module.
• LOCK is indicated by a flashing LED correlating to a lock
condition in which the module will prevent the compressor from
starting.
Flash Code Description

Copeland compressors will report a range of flash codes when
specific critical events occur. See “Compressor Fault Code Summary” on
page 99.

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

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 9 Compressor Fault Code Summary

Alert Alert Lockout Lockout
Code Condition Level Indication
Normal Run
Normal operation, no alarm status. N/A N/A
Solid Green
CODE 1 Long run time. Compressor is running for more than 18
N/A N/A
Yellow Flash 1 hours at full load. (CODE 1 is disabled in heat pump mode.)
Compressor pressure trip. Compressor runs for 12 seconds
CODE 2 4x consecutive, Red:
to 15 minutes followed by a compressor trip condition lasting
Yellow Flash 2 10x total Flash 2
longer than 7 minutes.
Pressure switch cycling. Compressor runs for 12 seconds to
15 minutes followed by a compressor trip lasting 35 seconds
Yellow Flash 3 10 total Flash 3
to 7 minutes.
CODE 4 Locked rotor. Compressor trips within a compressor run time Red:
10x consecutive
Yellow Flash 4 of 12 seconds and does not start within 35 seconds. Flash 4
Compressor moderate run trip. Compressor runs for 15
minutes to 18 hours followed by a compressor trip lasting
Yellow Flash 5 10x total Flash 5
longer than 7 minutes.
Open start circuit. Module has detected Y or Y1, and current
CODE 6 Red:
in the R winding of the compressor and no current in the S 1 occurrence
Red Flash 6 Flash 6
winding of the compressor for 2 seconds.
Open run circuit. Module has detected Y or Y1, and current
CODE7 Red:
in the S winding of the compressor and no current in the R 1 occurrence
Red Flash 7 Flash 7
winding of the compressor for 2 seconds.
CODE 8 Welded contactor. Module has detected line currents in R
N/A N/A
Yellow Flash 8 and S windings, and Y or Y1 is at 0 VAC for 15 seconds.
CODE9 Low voltage. Module has detected a 24 VAC supply voltage
N/A N/A
Yellow Flash 9 below 17 VAC ±1 VAC for 2 seconds.
CODE10 Over current protection. PROT terminal has above a 2A Red:
1 occurrence
Red Flash 10 input for more than 40 milliseconds. Flash 10

Variable Frequency Drive Diagnostic Codes

The 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 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).
Figure 38: 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 or
flashing)
• Showing the steady red status LED on the control panel (if
attached to the drive)
• Setting an appropriate bit in a Fault Word parameter (0305 to
0307)
• Overriding the control panel display with the display of a fault
code
• Stopping the motor (if it is on).
The fault code on the control panel display is temporary. Pressing the
menu, 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,
“ABB ACH-550 Fault Codes” 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 to
the drive)
• Sets an appropriate bit in an Alarm Word parameter (0308 or
0309)
• Overrides the control panel display with the display of an alarm
code 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 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.
Flashing Red LED

To 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 LED
To 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 could
also be used to reset the drive:
• Digital input
• Serial communication.
When the fault has been corrected, the motor can be started.
Phase Monitor Protection

If 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.
Table 10 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.
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.

This 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.

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.
1. Compressor will not start

Possible Causes Potential Solutions
Compressor switches S1 or S2
Activate S1 or S2 switch
off
Temperature control not in

Set point has been reached
demand
Pressure switch open due to low

Condenser side loss of flow; open switch
water flow
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
Allow motor to cool and reset; High amp load/

Compressor overload opened
floodback
Check breakers and fuses; energize from module

No power to 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 Check circuits and motor winding for shorts or
breakers open. grounds.
Fuse is blown. Replace fuse or reset breakers after fault is corrected.
Investigate for possible Overloads are auto-reset. Monitor to assure the

overloading. overload does not re-occur.
Thermal overload breaker

Repair or replace.
tripped or fuses blown.
Determine type and cause. Correct fault before

Defective contactor or coil.
resetting safety.
System shut down by safety

Repair or replace coil.
devices.
Check motor for open circuit, short circuit, or motor
Liquid line solenoid will not open.
burnout.
Motor electrical trouble. Tighten all terminal screws.
3. Symptom: Compressor has excessive noise or vibration

Flooding of refrigerant into
Check setting of expansion valve.
crankcase.
Improper discharge piping

Relocate, add, or remove supports.
support.
Improper or worn compressor

Replace supports.
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

Replace thermostat assembly.
broken capillary tube.
Stages not properly set for

Reset thermostat setting for operating requirements.
application.
5. Symptom: Compressor Loading/Unloading Cycles Too Short

Temperature differential set too
Ramp/set temperature set point
low (4 °F [-15.6 °C] minimum)
Erratic water thermostat

Replace thermostat assembly.
device.
Insufficient evaporator water

Adjust flow rate or remove flow.
flow.
6. Symptom: Compressor loses oil

Check for leaks and repair. Add refrigerant to proper
Low refrigerant charge.
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

Replace or rebuild compressor.
blow by.

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

Clean strainers.
gas strainers
Condensing temperature too

Check condensing temperature regulation system.
low
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
Reset for proper superheat. Replace if necessary
malfunctioning
Mis-adjusted or defective TXV Adjust or replace valve
Turn counterclockwise completely. Do not fully

Receiver service valve closed
backseat when FCS is involved
Compressor service valves

Dangerous! Turn counterclockwise completely
closed
Loss of charge in thermostatic

Replace TEV or power head
bulb
Clogged liquid line filter-drier Replace cartridges
Excessive glycol concentration Drain, refill (deionized water), retest
Liquid line solenoid restricted

Replace solenoid valve or coil
or faulty
Insufficient chilled water Adjust flow rate across evaporator
Restricted water/glycol line Clean strainers; check manual and electronic valves

7. Symptom: Low refrigeration suction pressure (Continued)

Water/glycol mixture Intensive cleanup effort needed to identify source of
contaminated contamination; external filter may be required
Evaporator tubing clogged or

Reverse flush with appropriate chemical solutions
fouled
8. Symptom: High refrigeration suction pressure

Expansion valve opened too Re-adjust to 10° to 12°(scroll) or 13° to 16°(digital
far scroll)
Excessive refrigerant charge Creates high pressure alarms; bleed excess
Low refrigerant charge; failing compressor; check

High water temperature
design specifications
9. Symptom: Low refrigerant discharge pressure

Suction shut off valve partially
Open valve
closed
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
Condenser too large Check condenser rating tables
Low ambient conditions Check condenser rating tables
Low suction pressure See low pressure below

9. Symptom: Low refrigerant discharge pressure

Condenser pressure
Refer to OEM manufacturer manual for default
regulating valve not properly
settings; check equipment room ambient temperature
adjusted
Fan cycling controls not Reset cut-in, cut-out settings to conform to design
properly set specifications
10. Symptom: High refrigerant discharge pressure

System overcharged with

Remove excess refrigerant
refrigerant
Clean with compressed air or water spray, use fin

Dirty tube and fin surface
comb if fins are bent
Non-condensables in chiller Purge non-condensables.
Fan cycling controls not

Reset fan cycle setting; replace motor controller fuse
properly set
Condensing fans not

Reset fan cycle setting; replace motor controller fuse
operating
Check valves obstructed; flush line; blow out line with

Restricted bypass line
dry nitrogen gas
Discharge shut off valve

Open valve
partially closed
Check condenser rating tables with operating
Condenser is undersized
parameters
Check condenser rating tables with operating

High ambient conditions exist
parameters

11. Symptom: Low chilled water temperature

Temperature controllers set Reset temperature controllers to correct design
too low specifications
Water velocity through Clean strainer; check pump, VFD, and differential
evaporator too low pressure settings
Temperature controllers
Replace temperature sensor
malfunctioning
12. Symptom: High chilled water temperature

Refrigeration circuits not
Reset operating pressures
cooling
Load higher than capacity of

Refer to chiller design specifications
chiller
Loss of refrigeration charge Pressure test refrigeration system
Fouled evaporator Reverse flush evaporator; check strainer for debris
Obstructed flow through Reverse flush evaporator; check strainer for debris;
evaporator check VFD, pump, valves
13. Symptom: Compressor thermal protector switch open

Operating beyond design Allocate chiller for use within operating capacity. Add
conditions 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

Check for correct voltages
tripped
Transformer T1 defective Replace transformer T1, T2, T3
Check breakers, fuses; check power supply

No primary voltage on T1
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
Low refrigerant level; recharge chiller
warm
Obstructed filter dryer Replace dryer core
Low refrigerant charge Recharge refrigerant as per data plate
Improperly adjusted superheat

Reset valve settings to factory specifications
valve setting
Equalization line pinched or

Repair or replace equalization line
obstructed

17. Symptom: Thermal expansion valve superheat too low

Sensing bulb not properly Check if secured to pipe or insulated; check sensor
located position on pipe at 4-8-10-2 clock positions
Defective thermostatic element Replace power head
Re-adjust to 10° to 12°(scroll) or 13° to 16°(digital

Valve adjusted too far open
scroll)
18. Symptom: Contactor/relay inoperative

Coil shorted or open Replace coil
Mechanical parts broken or

Replace assembly
jammed
Contacts pitted or burned Replace contactors
No 24 VAC to coil Replace secondary fuse to T2 transformer
19. Symptom: Freeze protection safety activated

Reset above freezing temperature at evaporate or
Thermostat set too low.
discharge
Low water flow. Remove restrictions. Increase HP
Low suction pressure. See “low suction pressure”
Technical Support


Electronic mail: chiller@arctichill.com

APPENDIX A Acronyms
and 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 Switching
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
Installation, Operation, and Maintenance Manual A-1

Acronyms and Abbreviations
Table A-1 Acronyms and Abbreviations (Continued)

Item Expansion
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
A-2 Company Confidential ©2018 The Arctic Chiller Group

Acronym List

Item Expansion
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

Acronym List

Item Expansion
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
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
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.
Table A-2 Expanded Terms

Expansion Acronym
Air-Conditioning, Heating and Refrigeration Institute AHRI
alarm AL
alarms Alrms
Analog Anlg

Expansions
Table A-2 Expanded Terms (Continued)

Expansion Acronym
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


Expansion Acronym
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
High Pressure Switch HPS
horsepower HP
Hot Gas HG
Hot Gas 1 Hotgas1
Hydrofluorocarbon HFC

Expansions

Expansion Acronym
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
Minimum Min
minute m
Monday MON
National Electrical Manufacturers Association NEMA
National Fire Protection Association NFPA


Expansion Acronym
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
R410A 410A
Redundant Pump RP
Refrigeration REFRIG
Remote Off RemOff
Returned Merchandise Authorization RMA

Expansions

Expansion Acronym
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
Underwriters Laboratories UL
Variable Frequency Drive VFD
Volts, Alternating Current VAC
Volts, Direct Current VDC
Wednesday WED

APPENDIX B Product
Warranty
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 Covered

To 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 Contractors

ArctiChill 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.
Installation, Operation, and Maintenance Manual B-1

Product Warranty
To Make a Warranty Claim

All 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 customer service
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 Terms

The 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 Handling

The 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 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.
B-2 Company Confidential ©2018 The Arctic Chiller Group

APPENDIX C Request for
Initial Startup
Manhattan Water-Cooled Chiller
As 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 ArctiChillcustomer 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
Chiller Model Number: Chiller 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 Initialed
Completed 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.
Installation, Operation, and Maintenance Manual C-1

Request for Initial Startup
Mandatory Initial Startup Requirements (Continued)

Mandatory Tasks Date Initialed
Completed Complete
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.
Initial Start-up Agreement

By 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 __________________________________
C-2 Company Confidential ©2018 The Arctic Chiller Group

APPENDIX D Variable Frequency Drive
Troubleshooting
ABB ACH-550 Fault Codes

The 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 LED Display Recommended Corrective Action

Codes
Output current is excessive. Check for and correct:

• Excessive motor load
1 OVERCURRENT • Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and 2205
ACCELER TIME 2)
• Faulty motor, motor cables or connections.
Intermediate circuit DC voltage is excessive. Check for and correct:

• Static or transient over-voltages in the input power supply
2 DC OVERVOLT • Insufficient deceleration time (parameters 2203 DECELER TIME 1 and 2206
DECELER TIME 2)
• Undersized brake chopper (if present).
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:
3 DEV OVERTEMP • Fan failure
• Obstructions in the air flow
• Dirt or dust coating on the heat sink
• Excessive ambient temperature
• Excessive motor load.
Fault current. Check for and correct:

4 SHORT CIRC • A short-circuit in the motor cables or motor
• Supply disturbances.
5 RESERVED Not used.
Installation, Operation, and Maintenance Manual D-1

Variable Frequency Drive Troubleshooting

Codes
Intermediate circuit DC voltage is not sufficient. Check for and correct:

• Missing phase in the input power supply
6 DC UNDERVOLT
• Blown fuse
• Under-voltage in mains.
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.
Motor is too hot, as estimated by the drive.

• Check for overloaded motor
9 MOT OVERTEMP
• Adjust the parameters used for the estimate (3005…3009)
• Check the temperature sensors and Group 35: MOTOR TEMP MEAS parameters.
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.
10 PANEL LOSS 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).
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.
D-2 Company Confidential ©2018 The Arctic Chiller Group


Codes
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.
17 OBSOLETE Not used.
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. A communication-related problem has been detected between the

19 OPEX LINK
control and main circuit boards. 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.


Codes
Fieldbus communication has timed out. Check for and correct

• Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME)
28 SERIAL 1 ERR • 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 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.


Codes
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.

1003 PAR AI SCALE • 1301 MINIMUM AI1 > 1302 MAXIMUM AI1
• 1304 MINIMUM AI2 > 1305 MAXIMUM AI2.
1004 PAR AO SCALE • 1504 MINIMUM AO1 > 1505 MAXIMUM AO1
• 1510 MINIMUM AO2 > 1511 MAXIMUM AO2.
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
1005 PAR PCU 2
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).
Parameter values are inconsistent. Check for the following:

1006 PAR EXT RO • Extension relay module not connected and
• 1410…1412 RELAY OUTPUTS 4…6 have non-zero values.
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.


Codes
Parameter values are inconsistent –9904 MOTOR CTRL MODE must be = 3

1008 PAR PFA MODE
(SCALAR:FREQ) when 8123 PFA ENABLE is activated.
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.
IO configuration is not complete – the drive is unable to allocate a digital input

1014 PAR PFA IO 3
(interlock) for each PFA motor (parameters 8120 INTERLOCKS and 8127 MOTORS).


Codes
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
• 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

APPENDIX E Remote Interface
Panel
Remote Location
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.
The remote interface panel has the same functionality for controlling
and monitoring the chiller as the built-in interface. See Figure E-1.
This “remote-type” interface panel is available from ArctiChill as an
in-stock item. See “Technical Support” on page E-5 for specific contact
information to learn about purchasing details.
Figure E-1 Remote Interface Panel (Closed)
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.
Installation, Operation, and Maintenance Manual E-1

Remote Interface Panel
The remote interface panel allows the operator or maintainer to

monitor and modify a host of functions involving temperatures, pressures,
set points, alarms, operating schedules, and elapsed operating hours.
Figure E-2 Remote Interface Panel Showing Interior
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.
E-2 Company Confidential ©2018 The Arctic Chiller Group

Remote Microprocessor Control System

To access, monitor, or modify certain specific chiller operating
parameters and settings, a remote interface panel must be connected to a
slave controller located in a module’s electrical and control panel. The
remote interface panel is connected to this data network by plugging a
normal telephone extension cord into the jack on the back of the remote
interface panel and connecting the other end of the cord into the J10
telephone port in the top left portion of a slave controller.
When connected to the controller network, 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.
This is the same as the data shown in the built-in interface panel.
See “Quick Controller Tutorial” on page E-6 for instructions on how
to perform actions required to operate the remote interface panel. Table E-
1, Remote Interface Panel Buttons and Keys explains the buttons on the
remote interface panel.
Table E-1 Remote Interface Panel Buttons and Keys
Pressing this key displays chiller status or demand,

MASTER STATUS: 100%
WATER identifies which compressors are currently energized, System Enter: 55°
TEMPS and the entering and leaving water temperature System Leave: 45°
System Off
settings of the master controller.
Pressing this key displays the chiller set points Temperature

(based on the entering water temperature) and allows Set Points
SET POINTS Entering> 45.0°F
adjustment of a set point; the high and low EWT Reset> 48.2°F
temperature alarm set points can also be set.
MASTER STATUS: 000%

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

Table E-1 Remote Interface Panel Buttons and Keys (Continued)
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
Pressing this key displays the system actual time and

Set Date/Time
allows the operator to energize or de-energize the Enter Date: 01/01/24
CLOCK
chiller at specific hours for precise after-hours and Enter Time: 10:17
Enter Day: Tuesday
weekend operational control.
Pressing this key displays the first of the previous 100

logged alarms including the time they occurred and **ALARM**
COMPRESSOR1
ALARM LOG the chiller temperature settings at the time of each OVERLOAD
alarm. Pressing the up arrow scrolls chronologically
through each previous alarm in turn.
This optional controller feature is for a small-capacity

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

redundant components so that individual
HAND-OFF-
compressors are controlled manually or
AUTO
automatically. Not used in Manhattan Chiller
modules.
Pressing this key displays the access panel for

factory settings for the chiller's microprocessors. It is Enter Password> 0000
PROGRAM protected by a Level Two password to limit access to
ArctiChill personnel only. This is typically not
accessed for routine tasks.

this key displays the information for each compressor Meter Run Hours
Compressor 1
INFO KEY in the chiller modules, the run status of each Hours > 00016hr
compressor, and the accumulated running hours for Starts > 00025
each compressor.

Table E-1 Remote Interface Panel Buttons and Keys (Continued)

this button immediately de-energizes the chiller
(“turns it off”). This action also overrides any
ON-OFF
instructions to the chiller delivered by the Building
Management System. Pressing the button again
restores power to the chiller.
Pressing this button will display an alarm information
screen for the current active module if there is a
**ALARM**
currently active alarm. The ALARM button will COMPRESSOR1
ALARM
illuminate and an audible alarm will sound when an HIGH PRESSURE
active alarm occurs. Pressing the ALARM button will

silence the audible sound.
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
ENTER
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.
Pressing the up button moves the LCD display

UPWARD to the next alarm in a list of alarms or
UP 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.
Pressing the down button moves the LCD display

DOWNWARD to the next alarm in a list of alarms or
DOWN 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.
How to Use the Remote Interface Panel

The remote interface panel is used to adjust set points, clear alarms,
and perform detailed setup of the microprocessor controllers.

Line 1 = screen name:

This is the master status screen.
Line 1
MASTER STATUS
Line 2
System Enter: 064°F
Line 3 System Enter: 047°F
SYS ON CMPS: 04
Line 4
Line 4 = status line:
chiller is ON, with 4 compressors running.
Figure E-3 Remote Interface Panel LCD Screen
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 E-3.)
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.
Basic operator tasks are described in the following sequence of

illustrations that comprise a controller tutorial.
Procedure: Quick Controller Tutorial

These 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 E-4 to display the master status
for the chiller.
Figure E-4 Display Master Status Screen
Step 2: Display the slave #1 status screen as shown in Figure E-5.

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 E-6.
Figure E-5 Display Slave #1 Status
Step 5: While viewing the master controller screen, display entering and
leaving temperature set points as shown in Figure E-7.
Figure E-6 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 E-7.
Figure E-7 Enter Password to Display Temperatures
Step 7: Inspect the data and time setting for each module as shown in
Figure E-8.
Figure E-8 Inspect Chiller Date and Time

Figure E-9 Inspect Water Temperatures Set Points
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.
Figure E-10 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 E-11.
Figure E-11 Change Chiller Date and Time

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.
Operating the Microprocessor

The remote interface panel is ready to use when the remote interface
panel is connected to the any slave controller and the chiller power is
turned on. Upon startup, the status line will indicate that the chiller is off.
Pressing the ON-OFF button on the remote interface panel turns on the
modules and the status line indicates that the chiller is on. Pressing this
button toggles the chiller on and off.
Microprocessor Functions
For 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 Panel

The 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.

NOTE
The ON-OFF button must be illuminated by pressing the
button to the ON position in order for the chiller to
operate.
The remote interface panel is designed for panel or wall mounting.

The mounting plate provided with the unit is designed to be installed to a
standard switch box. Wall mounting requires the use of the special
mounting bracket included with the panel 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.
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.
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
Junction box Chamfered edge out from wall
Vertical hole on the left
Mounting bracket (included)
Figure E-12 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.

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.
Procedure: Long Distance Installation

If 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 E-13.
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 E-14 for connection details. The wiring scheme for
connecting the 6-conductor phone cable is shown in Table E-2,
22 AWG Cable Connections, on page 16.
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.

500 feet maximum
T-Connector T-Connector
Master
Controller
Remote
Interface
Panel
Figure E-13 Mounting the Remote Interface Panel at Distance
Figure E-14 T-connector for Mounting Panel at Distance

Table E-2 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
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.

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Installation, Operation,

and Maintenance Manual

The Arctic Chiller Group

For after-hours emergencies, the answering service will contact a factory

• 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

Company Location and Address

Company Confidential ©2018 The Arctic Chiller Group

Installation, Operation, and Maintenance Manual

Company Confidential ©2018 The Arctic Chiller Group

Chapter 1: Chiller Description

Installation, Operation, and Maintenance Manual vii

Chapter 2 Rigging and Installing

viii Company Confidential ©2018 The Arctic Chiller Group

Mounting Rails .............................................................................................. 33

Chapter 3 Operating Procedures

Installation, Operation, and Maintenance Manual ix

Chapter 4: Maintenance Procedures

Chapter 5 Chiller Troubleshooting

x Company Confidential ©2018 The Arctic Chiller Group

Compressor will not start .............................................................. 104

Installation, Operation, and Maintenance Manual xi

Appendix E: Remote Interface Panel

xii Company Confidential ©2018 The Arctic Chiller Group

General Safety Instructions

Safety of Operators and Maintainers

Installation, Operation, and Maintenance Manual xiii

Table 1: Special Messages Used in this Manual

This message indicates a condition in

This message provides specific

This message provides optional

Warnings and Caution Statement

xiv Company Confidential ©2018 The Arctic Chiller Group

Installation, Operation, and Maintenance Manual xv

xvi Company Confidential ©2018 The Arctic Chiller Group

Installation, Operation, and Maintenance Manual xvii

xviii Company Confidential ©2018 The Arctic Chiller Group

How to Use this Manual

Installation, Operation, and Maintenance Manual xix

systems and have a working knowledge of high voltage systems, low

xx Company Confidential ©2018 The Arctic Chiller Group

Appendix A is a listing of all acronyms and abbreviations used in

Installation, Operation, and Maintenance Manual xxi

Installation, Operation, and Maintenance Manual 1

The Manhattan Chiller uses independent refrigeration circuits in

Chiller Performance Data

Model Number and Coding

2 Company Confidential ©2018 The Arctic Chiller Group

Table 1 Notional Manhattan Modular Chiller Specification for Example Purposes

Installation, Operation, and Maintenance Manual 3

Chiller Model and Serial Numbers

Table 2 Chiller Reference Data

4 Company Confidential ©2018 The Arctic Chiller Group

Installation, Operation, and Maintenance Manual 5

Figure 1 Typical Manhattan Water-Cooled Chiller Nameplate

6 Company Confidential ©2018 The Arctic Chiller Group

Model Coding Key

Pump: Power Supply: Extension:

Configuration: Tonnage: Form: Type:

Figure 2 Unpacking the ArctiChill Model Number

Installation, Operation, and Maintenance Manual 7