Installation, Operation, and Maintenance Manual

1 installation , Operation, and Maintenance ManualThe Arctic Chiller GroupPart #9800-0100 Publication # , 2018 ArctiChill 71 Industrial Park RoadNewberry, South Carolina 29108 Manhattan ModularAir-Cooled ChillerInstallation, Operation, and Maintenance ManualManhattan ModularAir-Cooled ChillerPublication , 2018 Company Confidential 2018 The Arctic Chiller GroupArctiChill Support ServicesQuestions regarding the proper installation or operation of this chiller or questions regarding the content of this technical Manual should be directed to our trained, certified, factory technicians. ArctiChill technical experts are available directly during normal business hours (8:00 am to 5:00 pm Eastern Time), Monday through after-hours emergencies, the answering service will contact a factory technician who will return your call as quickly as possible.

2 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: Location and AddressUnited States71 Industrial Park RoadNewberry, South Carolina 29108 Canada2100 Steeles Avenue EastBrampton, Ontario L6T 1A7 installation , Operation, and Maintenance ManualInstallation, Operation, and Maintenance ManualManhattan ModularAir-Cooled ChillerPublication , 2018 Company Confidential 2018 The Arctic Chiller GroupUnauthorized use or distribution of this copyrighted material herein is considered infringement and will be prosecuted as specified by Public Law 94-553, as is granted for limited data rights to government entities and their authorized contractors and assignees the right to use, modify, reproduce, release, perform, display.

3 Or disclose these data contained in this publication only to the extent specified in AR 25-30, DA PAM 25-40, and applicable Federal Acquisition DisclaimerArctiChill continues to make improvements to its products, services, and documentation. Changes may be made to product designs and specifications after the publication of this document. Contact ArctiChill for updated documentation and the latest design specifications. Statements and procedures outlined in the guide are not express warranties. This Manual is produced for operators, maintainers, and contractors. Read all instructions carefully before attempting to operate, maintain, or troubleshoot the equipment described in this publication. Direct technical questions to the ArctiChill technical support contacts listed in this Manual .

4 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 , Operation, and Maintenance ManualviiTable of ContentsTable of ContentsArctiChill Support Services .. ivCompany Location and Safety of Operators and Protective , Cautions, and and Caution to Use this One: Chiller xxChapter Two: Rigging and xxChapter Three: Operating xxChapter Four: Maintenance xxChapter Five: xxChapter 1: Chiller DescriptionChiller Performance Number and Model and Serial Numbers ..4 Technical Coding Flow Voltage Logical Logical Logical Mixture Logical 11 Component 11 Copeland of ContentsviiiCompany Confidential 2018 The Arctic Chiller GroupExpansion 14 Optional Tank-and-Pump 14 Microprocessor Control 15 Master Microprocessor Controller.

5 15 Slave Microprocessor Controller .. 15 Remote Interface 15 Operator Control and 16 Chiller 16 Power 16 Main Power 17 Panel 18 Module Electrical and Control Panel .. 18 Electrical 18 Flow Switch .. 19 Phase Monitor .. 20 Refrigeration 20 Expansion Valve 20 Sight 21 Low Pressure 21 Low Pressure Pump Down (LPPD) 21 High and Low Ambient 22 Thermal Capacity .. 22 Sequence of 22 Constant Flow 23 Variable Flow Sequence: No Tank and Pump 24 Chapter 2 Rigging and InstallingInspect and Report 29 Inspection of Delivered Equipment .. 30 Warranty 30 Long Term Storage 31 Customer 32 Handling of the 32 Site Preparation and 33 Chiller 33 Minimum 34 installation , Operation, and Maintenance ManualixTable of ContentsService Access.

6 35 Rigging, Lifting, and Moving the Piping and External Flushing of with Water/Glycol Module Module Power and Control Module Main Monitor Interlock Point Connections ..43 Module Control for Initial Initial 3 Operating ProceduresOperator Power Disconnect Distribution Electrical and Control and Master the to Use the Remote Interface Controller the Remote Interface Panel ..64 Long Distance installation ..66 Operator Power Power of ContentsxCompany Confidential 2018 The Arctic Chiller GroupMonitor Water 71 Maintain Glycol 72 Prevent 73 Storage Provisions .. 75 Chapter 4: Maintenance ProceduresMaintenance 77 Power Disconnect 78 Inspection and Maintenance 85 Pump and Tank Maintenance Tasks.

7 87 Maintenance 88 Inspection 88 Critical Cleaning 89 Strainer Cleaning 89 Condenser Cleaning 91 Evaporator Cleaning 93 Compressor 93 Remove 93 Install 94 Pump 96 Remove Pump .. 96 Install Pump .. 98 Replace Pump Seal .. 100 Replace 102 Chapter 5 Chiller TroubleshootingGeneral Approach to Fault 105 Controller Diagnostic 105 Compressor Diagnostic 107 CoreSense Flash Codes .. 107 Flash Code Description .. 107 Variable Frequency Drive Diagnostic , Operation, and Maintenance ManualxiTable of ContentsDiagnostic 110 Fault 112 Flashing Red Red Monitor 112 Symptoms and 113 Compressor will not start ..114 Compressor will not has excessive noise or vibration ..115 Compressor will not load or Loading/Unloading Cycles Too loses oil.

8 116 Low refrigeration suction refrigeration suction refrigerant discharge pressure ..118 High refrigerant discharge chilled water chilled water thermal protector switch 120No low voltage (24 VAC)..121 Pressure switch expansion valve superheat too expansion valve superheat too protection safety A: Acronyms and AbbreviationsAcronym A-1 Expansions .. A-6 Appendix B: Product WarrantyParts B-1 Parts Failure Not Covered .. B-1 Policy for Independent Service B-1To Make a Warranty B-2 Rates and B-2 Freight and of ContentsxiiCompany Confidential 2018 The Arctic Chiller GroupAppendix C: Tank and Pump ModuleTank and Pump the Pump the Storage Flow Tank and Pump Module Sequence of operations .

9 C-3 Appendix D: Request for Initial StartupManhattan Air-Cooled Start-up E: Variable Frequency Drive Troubleshooting ABB ACH-550 Fault , Operation, and Maintenance ManualxiiiGeneral Safety InstructionsGeneral Safety InstructionsThis equipment must be installed by qualified personnel in accordance with all local and national codes. Chiller does not have a disconnect for high voltage isolation. Turn off power to chiller prior to opening any electrical and control panel. Failure to do so could lead to injury or death. An earth ground lug is provided on the cabinet exterior and in the electrical and control panel for proper grounding according to national electrical codes. The ground is necessary to ensure personnel safety and prevent electrical hazards around this equipment is not to be used as an industrial water source for drinking water for humans or animals.

10 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 of Operators and MaintainersThis equipment operates with high voltage, high pressure fluids, and rotating components. Observe standard electrical safety protocols and all lockout/tagout procedures. Failure to follow these instructions can result in equipment damage and serious injury or Protective EquipmentAll procedures and processes described in this Manual are to be conducted in accordance with safety rules, directives, and policies of the local, state, and federal as well as the work rules and safety policies of individual companies and organizations under whose cognizance work is being performed.