Sterling 882.93092.00 Marine Instruments User Manual

GP Series Portable Chillers

Part Number: 882.93092.00

Bulletin Number: SC2-620.2

Effective: 1/12/2010

Write Down Your Serial Numbers Here For Future Reference:

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We are committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual are subject to change without notice.

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© Copyright 2010

All rights reserved.

Shipping Information

Unpacking and Inspection

You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the

Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the agent’s report. A certified copy of our invoice is available upon request. The original Bill of

Lading is attached to our original invoice. If the shipment was prepaid, write us for a receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the packing list. In addition to the equipment itself, you should have:

Bill of lading

Packing list

Operating and Installation packet

Electrical schematic and panel layout drawings

Component instruction manuals (if applicable)

Re-inspect the container and packing material to see if you missed any smaller items during unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and service department

immediately at (262) 641-8610. Have the order number and item number available.

Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department.

GP Series Portable Chillers ii

Table of Contents

CHAPTER 1: SAFETY................................................................ 5

1-1 How to Use This Manual ............................................................................................. 5

Safety Symbols Used in this Manual .....................................................................5

1-2 Warnings and Precautions .......................................................................................... 6

1-3 Responsibility .............................................................................................................. 6

CHAPTER 2: FUNCTIONAL DESCRIPTION ............................. 7

2-1 Models Covered in This Manual.................................................................................. 7

2-2 General Description..................................................................................................... 7

Chilled Water Circuit..............................................................................................7

Refrigeration Circuit...............................................................................................7

2-3 Standard Features....................................................................................................... 8

Mechanical Features .............................................................................................8

Electrical Features.................................................................................................8

Refrigeration Features...........................................................................................9

Controller Features................................................................................................9

Other Features ......................................................................................................9

2-4 Safety Devices and Interlocks ..................................................................................... 9

Crankcase Heater .................................................................................................9

High Pressure Cutout ..........................................................................................10

Low Pressure Cutout (no switch but done through the transducer) ....................10

Flow Switch .........................................................................................................10

Remote Start/Stop Interlock ................................................................................10

2-5 Optional Features...................................................................................................... 10

CHAPTER 3: INSTALLATION.................................................. 13

3-1 Uncrating ................................................................................................................... 13

3-2 Electrical Connections............................................................................................... 13

3-3 Process Water Connections ....................................................................................... 14

3-4 Bypass Valve Considerations.................................................................................... 14

3-5 Galvanic Corrosion Considerations........................................................................... 14

3-6 Water Treatment Considerations .............................................................................. 14

3-7 Condenser Considerations........................................................................................ 15

Water-Cooled Chiller Condensers.......................................................................15

Air-Cooled Chiller Condensers ............................................................................15

3-8 Checking Motor Direction .......................................................................................... 23

Three-Phase Compressors .................................................................................23

Water Pumps.......................................................................................................23

Condenser Fan....................................................................................................23

3-9 Water Reservoir ........................................................................................................ 24

3-10 Automatic Water Make-Up Option............................................................................. 26

3-11 Initial Start-Up............................................................................................................ 26

3-12 Finishing Setup: Setting Up Passwords .................................................................... 26

CHAPTER 4: OPERATION....................................................... 29

GP Series Portable Chillers iii

4-1 Panel Buttons, Indicator Lights, and Switches .......................................................... 29

Microprocessor Controller ...................................................................................29

4-2 Initial Start-up ............................................................................................................ 30

4-3 Status Screens .......................................................................................................... 31

4-4 Access Levels ........................................................................................................... 33

4-5 Controller Setpoints................................................................................................... 34

4-6 Alarms ....................................................................................................................... 35

4-7 Optional Communications ......................................................................................... 35

CHAPTER 5: MAINTENANCE ................................................. 38

5-1 Lubrication................................................................................................................. 38

5-2 Filter Cleaning ........................................................................................................... 38

5-3 Maintaining the Condenser ....................................................................................... 38

Air- and Remote Air-Cooled Chillers ...................................................................38

Water-Cooled Chillers .........................................................................................38

5-4 Maintaining the Evaporator ....................................................................................... 39

5-5 Evaporator Process Piping Y-Strainer....................................................................... 39

5-6 Preventative Maintenance Service............................................................................ 39

CHAPTER 6: TROUBLESHOOTING ....................................... 40

CHAPTER 7: APPENDIX.......................................................... 42

7-1 Returned Material Policy ........................................................................................... 42

Credit Returns .....................................................................................................42

7-2 Technical Assistance................................................................................................. 43

Parts Department ................................................................................................43

Service Department.............................................................................................43

Sales Department................................................................................................43

Contract Department ...........................................................................................43

7-3 Specifications ............................................................................................................ 44

Air-Cooled Portable Chillers ................................................................................44

Water-Cooled Portable Chillers ...........................................................................46

7-4 Pump Curves, Flow, and Pressure Considerations................................................... 54

60 Hertz Pump Curves ........................................................................................54

7-5 Electrical Schematic .................................................... Error! Bookmark not defined.

GP Series Portable Chillers iv

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and optional features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of the equipment. We can also provide the assistance of a factory-trained technician to help train your operator(s) for a nominal charge. This section includes instructions, checks, and adjustments that should be followed before commencing with operation of the equipment.

These instructions are intended to supplement standard shop procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in addition to information for operating the equipment safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your equipment provides excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems.

Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, and parts lists. A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.

Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation or practice which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation or practice which, if not avoided, may result in minor or moderate injury or in property damage.

GP Series Portable Chillers Chapter 1: Safety 5 of 73

1-2 Warnings and Precautions

Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.

To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:

9 Follow all SAFETY CODES.

9 Wear SAFETY GLASSES and WORK GLOVES.

9 Disconnect and/or lock out power before servicing or maintaining the equipment.

9 Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.

9 Operate this equipment within design specifications.

9 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

9 Make sure the equipment and components are properly GROUNDED before you switch on power.

9 When welding or brazing in or around this equipment, make sure

VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed.

9 Refrigeration systems can develop refrigerant pressures in excess of 500 psi

(3,447.5 kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION

SYSTEM. This must be performed by a qualified service technician only.

9 Do not restore power until you remove all tools, test equipment, etc., and the equipment and related components are fully reassembled.

9 Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.

All warning and danger signs must be observed and obeyed. All actual or potential danger areas must be reported to your immediate supervisor.

GP Series Portable Chillers Chapter 1: Safety 6 of 73

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for air-, water-and remote air-cooled portable chillers. Model numbers are listed on the serial tag. Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service.

Our portable chiller models are designated by approximate output in kW of cooling (20, 30,

40, 50, etc) and the cooling method used: -A for air-cooled, -W for water-cooled, and –R for remote-air cooled.

Our portable chillers are reliable, accurate, and easy to use process cooling units. They are available in air-, water-, and remote air-cooled designs in a range of sizes from 5 to 60 tons.

All are self-contained, fully portable and shipped ready to use. (Remote air-cooled chillers require field installation by qualified technicians.)

Standard range of operation is 20ºF to 80ºF (-7ºC to 27ºC) for applications using a water/glycol mix and 45ºF to 80ºF (7º to 27ºC) for water only applications.

A factory installed crankcase pressure regulating valve option is available for processes requiring a leaving water temperature over 80ºF (27ºC).

Chilled Water Circuit

Cooling water “To Process” and “From Process” connections are made at the female NPT couplings provided outside the unit. Warm coolant (water and glycol mixture) returns from the process and goes into the reservoir tank. The coolant is then pumped through the evaporator where it is cooled. The coolant flows to the process and returns to repeat the cycle.

A (manual) pressure actuated process water bypass valve located between the supply line and reservoir tank (single pump models only) allows minimal flow through the unit during the intermittent fluctuating flow conditions. It is not intended to provide continuous full bypass flow.

This minimal flow allows the temperature sensor to signal the controller to shut down the compressor because of the drop in process water temperature. Typically the flow switch shuts down the chiller in this low flow condition. This valve allows enough flow for the chiller to function when the flow is shut off to process.

Refrigeration Circuit

Air-, water-, and remote air-cooled refrigerant condensing differ only in the way the compressed gas is condensed to a liquid.

Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes through a shut-off valve into a filter/dryer that removes moisture and other contaminants. A refrigerant sight glass is provided. The refrigerant then passes through the thermal expansion valve, which allows the refrigerant to expand (boil off) and cool (remove the heat from) the fluid inside of the evaporator. The refrigerant gas flows through the suction line back into the compressor.

GP Series Portable Chillers Chapter 2: Functional Description 7 of 73

The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser. There it gives up its heat as it condenses to a liquid in the condenser.

An electronic hot gas bypass valve is used to control cooling capacity during intermittent or partial load conditions. This feature contributes substantially to chiller longevity by eliminating excessive cycling of the compressor and providing close temperature control.

Mechanical Features

Compressor. Hermetic scroll compressors.

Evaporator. Stainless steel copper brazed plate evaporators.

Air-Cooled Condenser. Aluminum fin/ tube with washable filters, package unit only (option

on remotes). Variable speed fan control standard for GPAC70 thru 210.

Water-Cooled Condenser. Tube-in-tube condensers (5-15 ton), Shell-and-tube condensers

(20-60 ton). All come with electronic cooling water regulating valves. 1 in. NPT valves for

GPWC20 & 30; 1.25 in. NPT valves for GPWC40; 1.50 in. NPT valves for GPWC50, 2 in

NPT valves for GPWC70 & 90, 2.5 in NPT valves for GPWC105, 3 in NPT valves for

GPWC140 & 175, and 4 in NPT valves for GPWC210.

Remote Air-Cooled Condenser. Aluminum fin/tube with low ambient control down to –

20ºF (-29ºC) via a variable-speed primary fan.

Reservoir. 5 hp and 7.5 hp models use a 20 gallon polyethylene tank. 10 hp and 15 hp models use a 40 gallon polyethylene tank.

Piping. Non-ferrous piping

Pump. ODP motors (TEFC Optional)—horizontally mounted stamped stainless steel construction.

Other Mechanical Features

• Low process water thermal flow switch

• NEMA-rated fan motor(s) on air-cooled models

• Galvanized structural steel frame, painted cabinetry, with 4” (locking) swivel casters

• Internal process water bypass valve for system protection only

• Fully insulated refrigeration and process water piping

• 20 mesh Y strainer on process water piping into the evaporator

• Tank level indication

• Pump pressure indication

Electrical Features

• Fully accessible NEMA 12-style electrical control enclosure

• Single-point power and ground connection

• Non-fused disconnect switch, lockable

• Branch circuit fusing


• 208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt

Refrigeration Features

• HFC-410a refrigerant

• Electronic hot gas bypass capacity control

• High refrigerant pressure cutout switches

• Suction and discharge pressure transducers.

• High pressure spring actuated relief valve

• Multiple refrigeration access ports

• Liquid line shut-off ball valves

• Filter-dryer

• Sight glass

• Externally equalized thermal expansion valve

• Liquid line solenoid

• Compressor crankcase heater

Controller Features

• Off-the-shelf microprocessor-based PID controller with To Process, From Process and

Set Point readout

• Time delay for proof of water flow/pressure (models w/pump only)

• Low refrigerant pressure time delay for low ambient start-up on remote air-cooled and air-cooled chillers with the variable-speed fan option.

• 8 line x 20 character display with status, alarm, and service screens

Other Features

• One year labor warranty and one year compressor warranty

• Two year parts warranty

• Two year limited controller warranty

Caution! Protect the system from freezing with glycol 20ºF below the leaving water temperature set point. Condensation may form inside the pump tank and dilute the mixture, therefore the freezing point should be verified periodically. See

Figure 6 on page 18 for the correct mixture.

Crankcase Heater

All of the chillers are equipped with a compressor crankcase heater. It is wired through the control transformer that operates continuously whenever power is applied to the chiller.


Caution! Energize the crankcase heater for at least 24 hours before initial startup to drive dissolved refrigerant from the compressor oil. Failure to do so will damage the compressor.

High Pressure Cutout

This electro-mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 575 psi..

Note:

The high-pressure cutout is a manual reset device typically mounted on the compressor discharge line inside the mechanical cabinet. Call a refrigeration service technician to analyze the problem and reset the control.

Low Pressure Cutout (no switch but done through the transducer)

There are two pressure transducers in the refrigeration piping – one on the suction line before the compressor and one on the discharge line after the compressor. Within the program there are four settings that warn and fault based on these two pressure transducers. The low suction warning is set for 110 psig (758 kPa), and the compressor will fault at 100 psig (689 kPa).

The low discharge warning is set for 200 psig (1,379 kPa), and the compressor will fault at

180 psig (1,241 kPa). To prevent nuisance tripping there are delays built in to the program.

Note: Call a refrigeration service technician to analyze the problem to prevent recurring low pressure faults.

Flow Switch

The thermal dispersion flow switch cutout device, mounted in the process piping, shuts down the chiller if it senses that the water/glycol flow rate through the evaporator has dropped below an acceptable level. The flow switch opens the control circuit and shuts down the pumps and the chiller.

Remote Start/Stop Interlock

An additional contact is provided to allow the remote starting or stopping of the chiller. To use this feature, remove the jumper between terminals 1 and 23, and supply a switch or dry contact interlock connected in series between these two terminals. Refer to the schematic inside the control enclosure door.

Options marked with “*” indicate options that can be factory installed or retrofitted in the field.

Automatic Water Make-Up*. Not available on chillers less reservoir tank. Includes an electric water solenoid valve, a level sensing pressure switch mounted in the reservoir tank, and the necessary internal piping to connect the chiller to a make-up water source. See

Appendix for typical piping diagrams.

Caution! Customer piping must provide backflow protection and venting of tank to atmosphere to prevent over-pressurization of the reservoir tank (not needed for

open tank). See Error! Reference source not found. on page Error! Bookmark not defined..


Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank.

This option includes a 50 micron filter, flow meter, ball valve for throttling water flow, and the necessary piping to provide constant filtering of the process water at about one gallon per minute (1 gpm/3.8lpm).

General Fault Indicator Audible/Visual Alarm*. This option includes a 100 dB audible alarm horn/ visual alarm strobe and silence button with provisions for customer wiring indication interlock. The alarm signals anytime that a fault is recognized during the operation of the chiller.

Communications Options. RS-485 serial Modbus communications.

High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan discharge. High-pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork.

They can be retrofitted without sheet metal modification, but will require changing out fan blades, and in some cases, fan motors and electrical components.

Variable Speed Fan – GPAC20-50. Reduces the speed of the fan based on entering air temperature and system load, allowing the chiller to operate in ambient temperatures below

60ºF (15.5ºC). This option will also reduce fan noise in ambient temperatures below 95ºF

(35ºC).

Stainless Steel Reservoir. Manufactured from 304 stainless steel.

Mounting Features.

• Mounting rails with feet

Optional Operating Voltages. 208-230/3/60, 460/3/60, 575/3/60, and 400/3/50 volt available

UL Labeled Electrical Subpanel. This option provides for the subpanel to be listed with

Underwriters Laboratory, with UL-related benefits and features.

Optional Pumps. Pump options are available for greater pressure and flow rates. A recirculation pump is required whenever process water flow is less than 1.2 gpm per ton or greater than 4.8 gpm per ton. See Figure 1 on page 12 for optional pump amperages.

NEMA 4 Electrical Enclosure. Provides for NEMA 4-level electrical enclosure protection.


Figure 1: Optional Pump Amperages

Voltage Construction

460/3/60 SS

HP

1

Full Load Amps

1.7

1.5 2.3

2 4.0

3

5

4.2

8.2

7.5 10.3

10 12.0

15 20.0

30 32.0


Chapter 3: Installation

3-1 Uncrating

All models are shipped mounted on a skid, enclosed in a plastic wrapper, and open-crated on all four sides and top.

1. Pry the crating away from the skid.

2. Use a pry bar to remove the blocks securing the unit to the skid.

3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks. Lift slowly and only high enough to clear the skid. Use a pry bar if necessary to carefully remove the skid from the unit.

4. Lower slowly. The unit should land on its casters or rails and can then be moved into position.

5. Retain the crating material for reshipping the chiller in case hidden shipping damage is found.

Supply electricity of the voltage, phase, and cycle listed on the serial tag. Total running amps are also found in the specification tables on pages in the Appendix.

Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to the National Electrical Code recommendations. Note the outline drawings for egress into the cabinet. Make sure all electrical connections are tight.

Important!

Refer to your local electrical requirements for proper feeder conductor and supply disconnecting sizing. For instance, in the United States refer to

National Electric Code (NEC) Article 430-24 through 430-26, Table

310.15(B)(2)(a)

GP Series Portable Chillers Chapter 3: Installation 13 of 73

3-3 Process Water Connections

All of our portable chillers have two chilled water connections. The chilled water supply, labeled “To Process” is the outlet for the chilled water leading to the process being cooled.

The chilled water return, labeled “From Process” is the inlet leading from the process back into the chiller to be cooled and re-circulated.

All external chilled water connections should be run full size to the process. Flow and pressure information is available in the Appendix. The largest possible openings and passages should be provided for the flow of chilled water through platens, dies, molds, or other pieces of equipment.

Note: Be sure to reduce external pressure drop as much as possible by generously sizing piping and tooling water passageways.

Our portable chillers have an internal manual bypass valve. If the flow is stopped to the process while the chiller is running, the factory-set bypass valve allows a small amount of water to flow through the chiller. This action allows the chiller to keep functioning while the flow is stopped to process. The bypass valve is not intended to provide continuous full bypass flow.

Caution! Do not attempt to adjust or otherwise tamper with the internal bypass. Your warranty will be voided.

3-5 Galvanic Corrosion Considerations

The materials used in the water circuit piping of these chillers are non-ferrous and react electro-chemically with ferrous metallic materials. Some water has dissolved minerals that greatly accelerate the reaction between dissimilar metals.

PVC or non-ferrous piping is recommended to reduce galvanic action. If iron piping must be used, use dielectric unions at the chiller, and water treatment is required.

Water treatment is an integral part of the system. In some locations, water may cause large deposits of scale, erosion, algae, and/or corrosion.

Note:

The use of poor quality water may result in inefficient operation, heat exchanger damage, and pump seal damage. Consult a qualified water treatment specialist to determine whether treatment is needed.


Water-Cooled Chiller Condensers

Water-cooled portable chillers can use city water or tower water as a cooling medium. Make sure that all external piping and connections supplying and discharging water to and from the condenser are full size.

You will make two connections to the water-cooled condenser:

Condenser Water In. The condenser water supply, labeled “Condenser Water In”, is located at the rear of the chiller. It is the inlet for city or tower water.

Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum pressure of 25 psi.

Caution! The electronic water-regulating valves pressure setpoint is set at the factory.

Only a qualified refrigeration technician should adjust the pressure setting.

Please contact our service group at 800-423-3183 to schedule an appointment.

Normal HFC-410a refrigerant condensing pressure is 342 psi (2,360 kPa), with 85ºF (27ºC) water at 25 psi entering condenser water pressure

Condenser Water Out. Condenser water return, labeled “Condenser Water Out”, is located at the rear of the chiller. It is the outlet for water after it has passed through the condenser.

It is connected to the tower water return line or to a sewer or other approved discharge receiver. A water-regulating valve is a standard feature in the condenser water out line.

Air-Cooled Chiller Condensers

Air-cooled chillers use the surrounding air to cool the condenser. Install the chiller in an area where there is free passage of air for condensing and provisions for removal of heated air from the area. Do not locate air-cooled chillers in locations where steam, hot air, or fume exhausts can be drawn into the chiller.

Caution! Clean air-cooled condensers and filters frequently. Failure to do so results in reduced capacity, increased operating costs, and possible failure of the equipment. Cleaning instructions can be found in the Maintenance chapter of this manual

Normal maximum refrigerant condensing pressure with 95ºF (35ºC) air entering the condenser is 420 psi (2896 kPa).

Condensing Air Temperature. Our air-cooled portable chillers are designed to operate at a minimum condenser entering air temperature of approximately 60ºF (15.5ºC). Operation of the equipment at a lower condenser entering air temperature can cause the chiller to malfunction. For entering air temperatures below 60ºF (15.5°C), an optional fan motor speed control is available. We recommend maintaining a minimum 60ºF (15.5°C) ambient temperature.

Remote Air-Cooled Chiller Condensers

Remote air-cooled portable chillers are shipped with nitrogen holding charge and a full charge of oil (excluding the amount needed for field piping). The remote air condenser is shipped with a dry nitrogen charge. Verify that the holding charge has not been lost prior to


installation. If there is no pressure, leak test the unit and repair before installing the interconnecting refrigerant piping. Read this entire section before installation.

Note: Piping should be type “L” or type “K” refrigerant grade copper tubing only.

Proper sizing and installation has a significant effect on system performance, reliability, and safety.

Interconnecting Refrigerant Piping. The chiller and condenser refrigerant lines are terminated with a cap and brazed closed. Use a tube cutter to remove caps.

Caution! Do not use a saw to remove the end caps because this will allow copper chips to contaminate the system.

A certified refrigeration contractor need only to install the interconnecting refrigerant piping between the chiller and the outdoor air-cooled condenser. This piping must be properly sized, type “L” or type “K” refrigerant grade tubing, high temperature brazed, Install a customer supplied 650 psi approved refrigerant relief valve in the discharge line at the condenser, following all codes.

When brazing copper joints, flow dry nitrogen through the system to prevent carbon/scale formation, which causes contamination. Isolate the refrigerant lines from the building, preventing transfer of line vibration to the structure. Do not secure the lines rigidly.

Leak check and evacuate the system down to 400 microns. A decay of 50 microns after one hour is acceptable.

Warning! To prevent injury or death due to explosion and/or inhalation of phosgene gas, purge system thoroughly while brazing refrigerant piping connections. Use a pressure regulator in the line between the unit and the high-pressure nitrogen cylinder to avoid over-pressurization and possible explosion.

System Configuration. The system can be configured in any of the arrangements shown on page 59 of the Appendix. The configuration and distance between the chiller and the condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are limitations that must be adhered to for reliable and optimal operation.

• Leaving water temperature affects discharge line size. Be sure to inform the installing contractor of the leaving water temperature range in which the chiller will be operating

• The total distance between the chiller and condenser must not exceed 200 feet or 300 equivalent pipe feet

• Discharge line risers cannot exceed an elevation difference greater than 100 feet without a 2% efficiency decrease.

• Refer to page 59 of the Appendix for the location of traps.

• Refrigeration lines must not be crossed, i.e., chiller liquid lines are to be piped to condenser liquid lines.

Sizing Refrigerant Lines. To determine field installed liquid and discharge line sizes, first establish the equivalent length of pipe for each line, valve, and elbow. Chiller capacity and leaving water temperature range is also required. See Figure 2 on page 18 for lengths of refrigerant valves and fittings.

Liquid Line Sizing. The liquid line should be sized as small as possible while maintaining acceptable pressure drop to minimize the refrigerant charge. Liquid line risers must not exceed 15 feet from the base of the air-cooled condenser. Horizontal runs do not require a pitch. Insulation is not required unless the line is installed in a high ambient area, i.e., boiler


room. Install a liquid line-charging valve to facilitate refrigerant charging. See Figure 3 on page 18 for sizing information. See Figure 5 on page 22 for charge determination.

Discharge Line Sizing. For horizontal runs, the discharge line should be pitched downward, in the direction of flow, at a rate of 1/2” for every 10 feet. This will allow oil to flow towards the condenser. Discharge line sizing is based on the velocity required for sufficient oil return back to the compressor. See


Figure 4 on page 21 for discharge line sizing.

Figure 2: Equivalent Length in Feet for Valves and Fittings

Line Size

OD (inches)

Angle

Valve

Short

Radius EL

Long

Radius EL

3/8 24 4 2.8

1/2 24 4.7 3.2

5/8 25 5.7 3.9

3/4 25 6.5 4.5

7/8 28 7.8 5.3

1-1/8 29 2.7 1.9

1-3/8 33 3.2 2.2

1-5/8 34 3.8 2.6

2-1/8 39 5.2 3.4

2-5/8 44 6.5 4.2

Figure 3: Liquid Line Sizing

5 TON CIRCUIT 7.5 TON CIRCUIT

Liquid Line Size (OD") Liquid Line Size (OD")

Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 1/2 1/2 1/2 1/2

50 1/2 1/2 1/2 1/2

Total Equiv.

Length (Ft)

25

50

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

5/8 5/8 5/8 5/8

5/8 5/8 5/8 5/8

75 1/2 1/2 1/2 1/2

100 1/2 1/2 1/2 5/8

125 1/2 1/2 1/2 5/8

150 1/2 1/2 5/8 5/8

175 1/2 5/8 5/8 5/8

75 5/8 5/8 5/8 5/8

100 5/8 5/8 5/8 5/8

125 5/8 5/8 5/8 5/8

150 5/8 5/8 5/8 5/8

175 5/8 5/8 5/8 3/4

200 1/2 5/8 5/8 5/8

225 1/2 5/8 5/8 5/8

250 5/8 5/8 5/8 5/8

275 5/8 5/8 5/8 5/8

300 5/8 5/8 5/8 5/8

200 5/8 5/8 5/8 3/4

225 5/8 5/8 5/8 3/4

250 5/8 5/8 3/4 3/4

275 5/8 5/8 3/4 3/4

300 5/8 5/8 3/4 3/4


10 TON CIRCUIT 15 TON CIRCUIT

Liquid Line Size (OD") Liquid Line Size (OD")

Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 5/8 5/8 5/8 3/4 25 7/8 7/8 7/8 7/8

50 5/8 5/8 3/4 3/4 50 7/8 7/8 7/8 7/8

75 5/8 5/8 3/4 3/4 75 7/8 7/8 7/8 7/8

20 TON CIRCUIT

Total Equiv.

Length (Ft)

Horizontal or

Downflow

Liquid Line Size (OD")

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 TON CIRCUIT

Total Equiv.

Length (Ft)

Horizontal or

Downflow


Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft


30 TON CIRCUIT


Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 1-1/8 1-1/8 1-1/8 1-1/8

50 1-1/8 1-1/8 1-1/8 1-1/8

75 1-1/8 1-1/8 1-1/8 1-1/8

100 1-1/8 1-1/8 1-1/8 1-1/8

125 1-1/8 1-1/8 1-1/8 1-1/8

150 1-1/8 1-1/8 1-1/8 1-1/8

175 1-1/8 1-1/8 1-1/8 1-1/8

200 1-1/8 1-1/8 1-1/8 1-1/8

225 1-1/8 1-1/8 1-1/8 1-1/8

250 1-1/8 1-1/8 1-1/8 1-1/8

275 1-1/8 1-1/8 1-1/8 1-1/8

300 1-1/8 1-1/8 1-1/8 1-3/8

50 TON CIRCUIT


Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 1-3/8 1-3/8 1-3/8 1-3/8

50 1-3/8 1-3/8 1-3/8 1-3/8

75 1-3/8 1-3/8 1-3/8 1-3/8

100 1-3/8 1-3/8 1-3/8 1-3/8

125 1-3/8 1-3/8 1-3/8 1-3/8

150 1-3/8 1-3/8 1-3/8 1-3/8

175 1-3/8 1-3/8 1-3/8 1-3/8

200 1-3/8 1-3/8 1-3/8 1-3/8

225 1-3/8 1-3/8 1-3/8 1-3/8

250 1-3/8 1-3/8 1-3/8 1-3/8

275 1-3/8 1-3/8 1-3/8 1-3/8

300 1-3/8 1-3/8 1-3/8 1-3/8

40 TON CIRCUIT


Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 1-1/8 1-1/8 1-1/8 1-1/8

50 1-1/8 1-1/8 1-1/8 1-1/8

75 1-1/8 1-1/8 1-1/8 1-1/8

100 1-1/8 1-1/8 1-1/8 1-1/8

125 1-1/8 1-1/8 1-1/8 1-1/8

150 1-1/8 1-1/8 1-1/8 1-1/8

175 1-1/8 1-1/8 1-1/8 1-3/8

200 1-1/8 1-1/8 1-1/8 1-3/8

225 1-1/8 1-1/8 1-1/8 1-3/8

250 1-1/8 1-1/8 1-3/8 1-3/8

275 1-1/8 1-1/8 1-3/8 1-3/8

300 1-1/8 1-1/8 1-3/8 1-3/8

60 TON CIRCUIT


Total Equiv.

Length (Ft)

Horizontal or

Downflow

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

25 1-3/8 1-3/8 1-3/8 1-3/8

50 1-3/8 1-3/8 1-3/8 1-3/8

75 1-3/8 1-3/8 1-3/8 1-3/8

100 1-3/8 1-3/8 1-3/8 1-3/8

125 1-3/8 1-3/8 1-3/8 1-3/8

150 1-3/8 1-3/8 1-3/8 1-3/8

175 1-3/8 1-3/8 1-3/8 1-3/8

200 1-3/8 1-3/8 1-3/8 1-5/8

225 1-3/8 1-3/8 1-3/8 1-5/8

250 1-3/8 1-3/8 1-3/8 1-5/8

275 1-3/8 1-3/8 1-5/8 1-5/8

300 1-3/8 1-3/8 1-5/8 1-5/8


Figure 4: Discharge Line Sizing

Circuit

Tons

5

7.5

10

15

20

25

30

40

50

60

Circuit

Tons

Horizontal or Downflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

25 50 75 100 125 150 175 200 225 250 275 300

5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8

7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8

7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8

7/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8

1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8

1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8

1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8

1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8

1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8

Upflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

25 50 75 100 125 150 175 200 225 250 275 300

5

7.5

10

15

A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8

B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4

A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2

B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-7/8 B-7/8 B-7/8 B-7/8 B-7/8

7/8 7/8 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2

B-7/8 B-7/8 B-7/8 B-7/8 B-7/8 B-7/8 B-7/8 B-7/8

B-1-1/8 B-1-1/8

7/8 7/8 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2 A-5/8 A-5/8

20

25

30

40

50

60

1-1/8 1-1/8 1-1/8 1-1/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4

B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8

1-1/8 1-1/8 1-1/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4

B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-1/8 B-1-3/8 B-1-3/8 B-1-3/8

1-1/8 1-3/8 1-3/8 1-3/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4

1-3/8 1-3/8 1-3/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4

B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8

1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4


Refrigerant Charge Determination. The approximate amount of refrigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the chiller and the amount of charge based on discharge and liquid line sizes and lengths. Add these three numbers together to find the final operating charge. The final operating charge must be verified by running the system and checking the liquid line sight glass.

Figure 5: Refrigerant Charge Determination

Line Size

OD (inches)

Discharge Line

LBS of R-410a

3/8 0.3

Liquid Line

LBS of R-410a

3.2

1/2 0.6

5/8 1.0

6.0

9.6

3/4 1.5 14.4

7/8 2.1 20.0

1-1/8 3.7 34.1

1-3/8 5.6 52.0

1-5/8 7.9 73.6

2-1/8 13.7 128.0

2-5/8 21.2 197.4

3-1/8 30.2 281.7

3-5/8 40.9 381.1

4-1/8 53.1 495.4

Note: The amounts listed in Figure 5 are based on 100 feet of pipe. Actual amounts will be in direct proportion to the actual length of the piping.

Oil Charge Determination. The remote air-cooled portable chillers are factory charged with the amount of oil required without field-installed piping. Additional oil required is dependent on the amount of additional refrigerant added.

Calculate the amount of additional oil required by using the following formula:

Pints of oil (Copeland Ultra 22cc) = lbs of R-410a added for field installed piping / 100.


3-8 Checking Motor Direction

All of our portable chillers have their motor rotations properly phased at the factory. If compressors, pumps, or fans are running in reverse rotation, disconnect and lock out the power source and reverse any two power leads into the chiller disconnect switch.

Caution! Do not switch leads at the motors, motor starters, or contactors.

Three-Phase Compressors

Scroll compressors are directionally-dependent and compress in one rotational direction.

Reversing rotation direction results in an elevated sound level and a substantially-reduced current draw.

Water Pumps

Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure gauge. Pump rotation should be clockwise when viewed from the motor end. For chillers with optional pumps, check the appropriate pump curve in the Appendix.

Caution! Do not run pump dry. Doing so will result in seal damage.

Condenser Fan

Air should be drawn through the condenser and discharged vertically from the chiller.


All portable chillers shipped during the fall, winter, or spring, or those units that are shipped from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping components prone to retaining water from freezing. During startup and when additional solution is required, refer to the ethylene glycol and propylene glycol curves in Figure 6 on page 20 Add a pre-mixed solution of industrial quality (not automotive) ethylene glycol or propylene glycol and water to provide freeze protection to a temperature 20ºF (11ºC) below the normal chiller operating temperature set point.

Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel, stainless steel, and bronze) in the system from corrosion. If you intend to use straight water, we strongly advise a minimum leaving water temperature of 45 ºF ( 7 ºC) or contact the service department.

The following glycol products are available:

Part Number Description

A0541358 Ethylene glycol, 5 gallons (18.9 liters)

Caution! Do not connect make-up water directly to the chilled water reservoir unless you have an approved automatic water make-up system installed.

Caution! Do not pressurize tank. Supply and return connections must be trapped and vented to allow vertical risers to drain into tank. Do not overfill system. Allow enough free space in tank for vertical piping to drain.

If your application has chilled water or process piping above the chiller, trap and vent the supply and return lines to allow vertical piping to drain into tank.

Note: In applications where the process or process piping is above the reservoir, take steps to prevent over pressurization of the reservoir. This condition can occur on system shutdown when the water in the system drains into the reservoir. To prevent this, a vacuum breaker should be installed at the high point of the “To

Process” and “From Process” lines.


Figure 6: Ethylene Glycol and Propylene Glycol Curves

Pe rce n t G lyc o l Cu rves fo r F ree ze P ro tec tion

40.0

30.0

20.0

10.0

Eth ylene G ly col

P rop ylene G lyc ol

0.0

-10.0

-20.0

-30.0

-40.0

-50.0

-60.0

0.0

Note:

10.0

20.0

30.0

% Gl ycol by Vol um e

40.0

50.0

60.0

Example: 45°F set point minus 20°F = 25°F.

From Figure 28, 25°F equates to 10% by volume of glycol required.

The standard pumps used in the GPAC Serice chillers are not recommended to be used with fluid below 0°F (-18°C). Please consult factory for the proper pump.


3-10 Automatic Water Make-Up Option

The chiller may be connected to an automatic make-up system if the optional package (pipe fittings, solenoid valve and 1/2” NPT city water make-up connection) is factory installed.

If the automatic make-up system is connected to a city water system, make provisions to prevent backflow contamination. Install an approved backflow preventer in accordance with local codes.

Caution! Adding straight city water into a glycol/water mixture dilutes the solution and eventually leads to system freeze-up. Damage from freeze-up is not covered by the warranty.

To prevent system freeze-up in automatic make-up applications, we recommend using either a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for more information about these configurations.

3-11 Initial Start-Up

• Check the shipping papers against the serial tag to be sure chiller size, type and voltage is correct for the process that will be controlled. Portable chillers are built with a voltage specific compressor and cannot be re-wired for an alternate voltage.

• Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using. The voltage at the main power connection must read within plus or minus ten percent (±10%) of the voltage listed on the serial tag.

Electrical connections must conform to all applicable codes.

• Complete chilled water To Process and From Process connections.

• Be sure the reservoir tank and chilled water circuit piping are filled a water/glycol mixture. The water/glycol mixture should provide for freeze protection to at least 20°F

(11ºC) below the leaving water temperature you want. Should the display show a tank level less than 0 after the tank is filled, check the clear tube leading from the tank to the tank level pressure switch for a blockage.

• The air-cooled condenser should have an adequate supply of 60º to 115ºF (16º to 46ºC) air for proper operation.

• The tower or city water condenser cooling in and out connections should be completed and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi pressure, for proper operation.

• Connect the main 3 phase incoming power to the unit making certain that line one (1)

L1 is connected to the A phase, line two (2) L2 is connected to the B phase, and line three (3) L3 is connected to the C phase. Check for proper rotation direction of fan(s) and pump(s).

The crankcase heater is automatically energized when the main power is applied. It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil.

3-12 Finishing Setup: Setting Up Passwords

You can establish passwords for two levels of security: operators and supervisors. The controller comes from the factory with neither password set. This allows every user access to all functions.


Operator Password. If you define a password for operators, then a password will be required to carry out any function (other than reviewing the status screens). Entering the operator’s password will give the user access to the setpoints for leaving temperature, high temperature warning, high temperature fault.

Supervisor Password. If you define a password for supervisors (or setup personnel) then most settings can be changed only after entering the password. The password will be required to display the extended setpoints for operating parameters and alarms. Section 4-6 shows a table of setpoints and the restrictions between Operator and Supervisor.

To set password protections:

1. Press the button to access the menu screen.

2. Press the or to highlight SETPOINTS, and press .

3. Press the or until the following screen appears for the Operator Password or the following screen for the Supervisor Password

4. Press to accept the screen, and then press until the Operator or Supervisor

Password line is highlighted.

5. Press or to increment or decrement the number. The password can be between

0 and 9999.


6. Press to accept the Password and move to the next line.

7. For either Operator or Supervisor password the time that the password will allow the controller to be active can be set by the Operator or Supervisor Password Time. With the

PW Time value highlighted, press or to increment or decrement the time. The password time for either setup can be from 0 to 99 minutes.


Chapter 4: Operation

4-1 Panel Buttons, Indicator Lights, and Switches

Microprocessor Controller

The standard chillers use a microprocessor-based PID controller. The Carel PCO controller along with the Carel PGD1 Interface is a modular, self-contained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustment to the internal controls is necessary. The standard operation range is 20ºF to 80ºF (-7ºC to 27ºC).

Figure 7 - Controller Display

Button Button Description

Menu Button

Detailed description

Used to access the menus structure of the PGD interface

On/Off Button

Used to turn the entire chiller On or Off. The button is backlit and will turn amber when the chiller is On.

Back Button

Used to back up from a menu and return to the main status screen

Up Arrow Button

Used to increment a data field or scroll up within a menu structure.

Enter Button

Used to accept a data field value or to select a menu item.

Down Arrow Button

Used to decrement a data field or scroll down within a menu structure.

GP Series Portable Chillers Chapter 4: Operation 29 of 73

1. Verify the initial start-up checklist from Chapter 3, Section 3-11.

2. With the main supply power switch in the ON position, the screen will display the version of the software for a period of 5 seconds, and then display the main status screen.

Figure 8 - Main Status Screen

3. Set the Leaving Fluid temperature by depressing the button to display the menu.

Figure 9 - Menu Screen

4. Depress the or button to highlight SETPOINTS and press . If passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear.

GP Series Portable Chillers

Enter the established Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number. Once all of the numbers have been entered depress the to accept the password. The following screen will

Chapter 4: Operation 30 of 73

appear.

Figure 10 - Operator Setpoints Screen

5. Depress to move the cursor to the Leaving Temp line. Use the or

button to increment or decrement the value. Depress to accept the value and move the cursor down one line.

6. Depress the button twice to return to the main status screen.

7. Depress the to start the chiller.

8. Check pump rotation

9. Check the pump amp draw and pump pressure. Make sure that the amp draw reading is within the running load and service factor amps.

10. Operate the chiller, looking for any leaks and listening for unusual noises or vibrations that could indicate improper operation.

Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of operation, the compressor internal protector trips.

The controller has eight (8) preconfigured status screens. The main status screen (shown in

Figure 11) shows the main operating points of the chiller: Entering and Leaving fluid temperatures; Leaving fluid setpoint, pump discharge pressure, tank fluid level (depth), and percentage of hot-gas bypass output.

Figure 11 - Main Status Screen

Depressing cycles through the following screens (shown below) – Analog I/O, Digital

I/O, and Test. The Analog and Digital I/O screens provide status of all of the inputs and


outputs for the controller. The Test aides in troubleshooting the chiller when it is not functioning properly by displaying the basic information that a service person will need to know to determine the problem.


The controller is setup to allow access to three distinct password groups: operator, supervisor, and service. Operator access allows the user to modify the Leaving Water Temp, Hi Temp

Warning, and Hi Temp Fault setpoints. Supervisor access allows the supervisor to modify the above plus

Selecting any of the menus in the Menu Screen will display the Password Screen.


Variable Description

Leaving Temp Temperature of fluid out to process

Hi Temp Warning

Hi Temp Fault

Compressor On

Differential

Compressor Off

Differential

Pump Stop Delay

Low Temperature

Warning

Setpoint for alarm to warn when leaving fluid temperature is too high

Setpoint to shut down pump and compressor based on leaving fluid temperature

Temperature Difference between Leaving Fluid

Temperature and Setpoint to turn on the compressor

Temperature Difference between Leaving Fluid

Temperature and Setpoint to turn off the compressor

Delay time in seconds between fault and stopping the pump

Temperature to activate Low Temperature Warning alarm

Low Temperature Fault Temperature to activate Low Temperature Fault alarm

Water Make-up On

Water Make-up Off

Water Make-up Time

Low Level Warning

The tank level to turn on optional water make-up valve; based on size of tank

The tank level to turn off optional water make-up valve; based on size of tank.

The time in seconds that controller will allow for filling the tank

Tank level that will activate Low Level Warning alarm

Low Level Fault

High Level Warning

Tank level that will activate Low Level Warning fault

Tank level that will activate High Level Warning alarm

High Level Fault

High Temperature

Delay

Alarm Silence Time

Operator Password

Time

Supervisor Password

Time

Tank level that will activate High Level Warning fault

Delay time in minutes between fault and stopping the compressor and pump

Time in minutes to silence alarm (with optional audible alarm). After time alarm will reactivate.

Time in minutes for operator password to be active

Time in minutes for supervisor password to be active

Access Level

Operator Supervisor x x x x x x

x

x

x

x x

x

x

x x x x x

x

x x x

1. Set the Leaving Fluid temperature by depressing the button to display the menu.

Figure 12 - Menu Screen


2. Depress the or button to highlight SETPOINTS and press . If passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear.

Enter the Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number. Once all of the numbers have been entered depress the to accept the password. The following screen will appear.

Figure 13 - Operator Setpoints Screen

3. Depress to move the cursor to the Leaving Temp line. Use the or

button to increment or decrement the value. Depress to accept the value and move the cursor down one line.

4. Adjust the Hi Temp Warning and Hi Temp Fault in the same manner.

5. Depress the button twice to return to the main status screen.

4-6 Alarms

The controller is setup with multiple alarms, most of them configurable using the Supervisor password. Section 4-5 Controller Setpoints gives a list of alarms that the controller is setup to display. The alarms are broken up into two categories – warnings and faults. The warning notifies the user that the parameter has been exceeded and the chiller is allowed to keep operating, but should be monitored to determine the cause of the warning. The fault notifies the user that the parameter has been exceeded and the chiller and pump has been shut down to protect the system.

The communications function allows you to monitor and set the parameters by a program prepared and running on a host computer connected to the controller.


When using the communications function, you must add on the unit for RS-485 Modbus communications. The communications function allows you to read/write parameters, do operating instructions, and select the setting level.



Chapter 5: Maintenance

5-1 Lubrication

Grease all fan motors, and pump motors that do not have permanently sealed bearings. Be sure to use an all-purpose industrial grease with a temperature reference of 185˚ F (85˚ C).

Remove the grease relief plug (motors only) before adding grease, add grease until a small amount pours out, and replace the plug when finished.

Caution! Failure to remove the grease relief plug will result in dislodging the bearing grease seal, eventually causing bearing failure.

Refrigeration compressors are hermetically sealed and no lubrication is required.

Air filter cleaning is important to keep your air-cooled portable chiller operating at peak efficiency and capacity. Clean the filters whenever they appear dirty, or at regularly scheduled intervals.

1. Turn the chiller off.

2. Slide the filter rod to release it from the frame at the top and bottom.

3. Wash down the filter with clean water (preferably with a garden hose), directing the flow of water opposite the direction of airflow. If dirt is heavy, use a mild detergent and rinse well. Allow the filter to dry completely before replacing it on the chiller.

Note:

Keep a spare air filter set on hand. Install and use it while cleaning).

Caution! Do not use compressed air to blow off a dirty filter. It will not clean very well, and the filter could be damaged. Never run the chiller without properly installed filters.

5-3 Maintaining the Condenser

Dirty condenser heat exchange surfaces reduce system capacity and efficiency.

Air- and Remote Air-Cooled Chillers

Brush or vacuum light dirt accumulations off the aluminum condenser fins. Avoid bending or damaging them. Heavy dirt accumulations on the fins may require professional cleaning.

Water-Cooled Chillers

Proper water treatment will greatly reduce cleaning intervals.

Coaxial Condensers ( 5-15 tons )

. Remove dirt and slime in the condenser tube water side by reverse-circulating with a mild detergent and water solution. Remove mineral deposits by reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the water side of the condenser. Follow the directions on the container.

Shell & Tube Condensers (20-60 tons)

. Remove dirt and slime in the condenser tube water side by cleaning with a nylon tube brush. Remove mineral deposits by reverse circulating

Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the tube water side of the condenser. Follow the directions on the container.

The refrigerant side is sealed and requires no routine maintenance.

GP Series Portable Chillers Chapter 5: Maintenance 38 of 73

Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you are monitoring the refrigeration circuit for excessive pressure with gauges.

Only a trained technician should use this method.

5-4 Maintaining the Evaporator

Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt and slime in the evaporator by reverse-circulating with a mild detergent and water solution.

Remove mineral deposits by reverse-circulating Liquid Citric Acid De-Scaling Solution (Part

No. A0536607). Follow the directions on the container.

5-5 Evaporator Process Piping Y-Strainer

The process piping Y-strainer requires periodic cleaning of its screen to insure the proper flow through the evaporator. To clean the strainer screen, remove the access plug and retaining cap, and pull out the screen.

Wipe, brush, or vacuum out any dirt left in the strainer body. Clean the screen and replace it in the strainer taking care to fit it squarely into the machined seat provided.

Caution! Do not forget to re-install the screen after cleaning it. Operating the chiller with no strainer screen can potentially plug the evaporator with dirt. The warranty does not cover chiller failures from a dirty evaporator.

5-6 Preventative Maintenance Service

Follow a systematic preventive maintenance program to help avoid costly down time. Call the Service Department to arrange a schedule of inspections. This service can be tailored to fit your maintenance requirements. These inspections include, but are not limited to:

• Checking refrigerant suction and discharge pressures

• Checking safety and operating conditions

• Checking voltage and amperage of all motors

• Checking all electrical connections

• Checking quantity of refrigerant

• Checking compressor oil level on units with tandem compressors

• Checking lubrication of motor and pump bearings

• Checking circulating pump operation

• Checking flow through heat exchangers

• Checking compressor efficiency

• Checking noise levels

GP Series Portable Chillers Chapter 5: Maintenance 39 of 73

Chapter 6: Troubleshooting

Problem

Unit does not run.

Pump runs; compressor does not.

Possible cause

No power.

Wrong voltage supplied to unit.

Defective display.

Control circuit fuse blown.

Defective control transformer.

Piping flow switch circuit open.

Pump motor off on overload.

Leaving fluid setpoint set higher than temperature of liquid in system.

Compressor internal overload or fuses are open.

Compressor contactor holding coil open.

Defective compressor auxiliary contact.

Solution

Check main disconnect, fuses, wiring, and power lead to unit.

Voltage must be within plus or minus

10% of nameplate rating.

Replace.

Replace control circuit fuse.

Check transformer.

Check for a short circuit.

Replace.

Add water or water/glycol solution as required.

Reset and test.

Lower the leaving fluid temperature below the leaving temperature you desire.

Allow time to cool and reset, then check for high/low volt-age. It must be within plus or minus 10% of the nameplate rating.

Check for open fuses and loose compressor electrical connections.

Repair or replace.

Repair or replace.

Broken wire in the compressor control circuit.

Locate and repair.

Plugged Y-strainer

Pump runs, compressor cycles at short intervals.

Hot gas not coming on

Water temperature is too high.

Low water flow

Water/glycol mixture inadequate for process.

Improperly set leaving fluid temperature, warning, or fault set point

Refrigerant charge is low.

Clean

Check hot gas analog output value through status screen. Contact Service if output value remains at 0% throughout compressor cycle.

Install bypass between to-and-from process line

Make sure that the water/glycol mixture protection is right for the process.

Adjust.

Call service to find and repair the leak, then have refrigerant added.

GP Series Portable Chillers Chapter 6: Troubleshooting 40 of 73

Problem

Pump process pressure low (refer to curves for normal pressure for various pumps).

Possible cause

Pump running in reverse.

Check for foreign matter.

Pump process pressure is too high. Restricted water flow.

Restricted condenser air flow.

Unit runs continuously, but not enough cooling power .

Unit low on refrigerant.

Compressor not operating efficiently.

Unit under-sized for application.

Solution

Verify rotation; if running in reverse rotation, reverse any two main power leads. Re-verify for correct pump rotation.

Clean the system strainer.

Check for partially closed valves etc.

Make sure that all lines are properly sized.

Clean filters.

Clean condenser.

Check the refrigerant charge by viewing sight glass on liquid line upstream of the expansion valve.

Call service.

Call sales rep.

GP Series Portable Chillers Chapter 6: Troubleshooting 41 of 73

Chapter 7: Appendix

7-1 Returned Material Policy

Credit Returns

Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

All returned Material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking charge.

All returns are to be shipped prepaid.

The invoice number and date or purchase order number and date must be supplied.

No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new and unused condition, suitable for resale.

Warranty Returns

Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

All returns are to be shipped prepaid.

The invoice number and date or purchase number and date must be supplied.

After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if the item is found to be defective in materials or workmanship. Purchased components are covered under their specific warranty terms.

GP Series Portable Chillers Chapter 7: Appendix 42 of 73

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 423-3183 or call [262] 641-8610

Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most products.

Sales Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales

Department for the name of the sales representative nearest you.

Contract Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.


7-3 Specifications

Air-Cooled Portable Chillers

Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.

G-PAC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

COOLANT FLOW

UNIT PRESSURE DROP

4.65 TONS ALTITUDE

50 °F COMPRESSOR POWER

95 °F EER

4936

11.31

WATTS

BTU/WATT



COMPRESSOR

COOLANT PUMP

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

11

7

20-80

60-115

GPM

PSID

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1 METER

OPERATING PARAMETERS

°F COOLANT FLOW

SPECIFICATIONS

EVAPORATOR FILTER SCROLL

STAINLESS STEEL

CENTRIFUGAL

COOLANT CIRCUIT

86

20 MESH

NON-FERROUS

HOT GAS BYPASS

3 LBS R-410A ALUMINUM

24 INCH

AXIAL

1/2 HP OAO, 1140 RPM

REFRIGERANT

FRAME

PANELS dBA dBA

GPM

POWDER COATED STEEL

690 LBS

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

G-PAC-30

120

10.7

VDC ELECTRICAL ENCLOSURE

AMPS CONTROL




COOLANT

COOLANT FLOW

UNIT PRESSURE DROP

7.30 TONS ALTITUDE


95 °F EER



COMPRESSOR

COOLANT PUMP

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

NEMA 12

MICROPROCESSOR

7579

11.56

WATTS

BTU/WATT

18

7

20-80

60-115

GPM SOUND POWER LEVEL

PSID SOUND PRESSURE LEVEL @ 1 METER


°F COOLANT FLOW

SPECIFICATIONS

EVAPORATOR FILTER SCROLL

STAINLESS STEEL

CENTRIFUGAL

COOLANT CIRCUIT

92

20 MESH

NON-FERROUS

HOT GAS BYPASS

4 LBS R-410A ALUMINUM

24 INCH

AXIAL

1 HP OAO, 1140 RPM

REFRIGERANT

FRAME

PANELS dBA dBA

GPM

POWDER COATED STEEL

870 LBS

CONTROL CIRCUIT


120

16.4


AMPS CONTROL

NEMA 12

MICROPROCESSOR


G-PAC-40




COOLANT

COOLANT FLOW

UNIT PRESSURE DROP

9.91 TONS ALTITUDE


95 °F EER

24

7

GPM

PSID

SOUND POWER LEVEL




COMPRESSOR

COOLANT PUMP

20-80

60-115


°F COOLANT FLOW

SCROLL

STAINLESS STEEL

CENTRIFUGAL

SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

ALUMINUM

32 INCH

AXIAL

1 HP OAO, 1140 RPM

REFRIGERANT

FRAME

PANELS

10070

11.81

87

WATTS

BTU/WATT dBA dBA

GPM

20 MESH

NON-FERROUS

HOT GAS BYPASS

6 LBS R-410A

POWDER COATED STEEL

1090 LBS

CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE


G-PAC-50

20 AMPS CONTROL




COOLANT

COOLANT FLOW

UNIT PRESSURE DROP

15.19 TONS ALTITUDE


95 °F EER

36

7

GPM

PSID

SOUND POWER LEVEL


NEMA 12

MICROPROCESSOR

14882

12.25

93

WATTS

BTU/WATT dBA dBA



COMPRESSOR

COOLANT PUMP

20-80


°F COOLANT FLOW

60-115

SCROLL

STAINLESS STEEL

CENTRIFUGAL

SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

GPM

20 MESH

NON-FERROUS

HOT GAS BYPASS

8 LBS R-410A CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

ALUMINUM

32 INCH

AXIAL

2 HP OAO, 1140 RPM

REFRIGERANT

FRAME

PANELS POWDER COATED STEEL

1290 LBS

CONTROL CIRCUIT


120

30

VDC

AMPS

ELECTRICAL ENCLOSURE

CONTROL

NEMA 12

MICROPROCESSOR


GPAC-70

COOLING CAPACITY



COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

GPAC-90


COOLANT

COOLANT FLOW

UNIT PRESSURE DROP


COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT


WATER


20.16

50

95

48

7

TONS

°F

°F

GPM

PSID

ALTITUDE

COMPRESSOR POWER

EER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

20-80

60-115


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(2) 24 INCH AXIAL

(2) 1/2 HP OAO, 1140 RPM

70 GALLON POLYETHYLENE

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120

(2) @ 17.9 AMPS EACH

VAC

20-80


CONTROL

WATER


25.47 TONS ALTITUDE


95 °F EER

61 GPM

CONDENSER AIR FLOW

SOUND POWER LEVEL

7 PSID SOUND PRESS LEVEL @ 1 METER


°F COOLANT FLOW

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(2) 32 INCH AXIAL

(2) 2 HP OAO, 1140 RPM


SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120


VAC ELECTRICAL ENCLOSURE

CONTROL

20 MESH

NON-FERROUS

HOT GAS BYPASS

12 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2580 LBS

NEMA 12

MICROPROCESSOR

SEA LEVEL

20048

12.07

16916

89

WATTS

BTU/WATT

CFM dBA dBA

24-96

4.03

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

12 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2180 LBS

NEMA 12

MICROPROCESSOR

25504 WATTS

25374

95

CFM dBA dBA

30-120 GPM


GPAC-105

COOLING CAPACITY



COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT


40 TON (GPAC-140)

COOLING CAPACITY



COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT


WATER


30.21

50

95

72

7

TONS

°F

°F

GPM

PSID

ALTITUDE

COMPRESSOR POWER

EER

CONDENSER AIR FLOW

SOUND POWER LEVEL


20-80

60-115


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(2) 32 INCH AXIAL

(2) 2 HP OAO, 1140 RPM


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL

WATER


40 TONS ALTITUDE

50

95

96

7

°F

°F

GPM

PSID

COMPRESSOR POWER

EER

CONDENSER AIR FLOW

SOUND POWER LEVEL


20-80

60-115


°F

°F

COOLANT FLOW

MINIMUM LOAD

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(3) 32 INCH AXIAL

(3) 2 HP OAO, 1140 RPM


SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL

SEA LEVEL

29731

12.19

25374

95

WATTS

BTU/WATT

CFM dBA dBA

36-144

6.04

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

16 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2580 LBS

NEMA 12

MICROPROCESSOR

SEA LEVEL

38153

12.58

38061

98

WATTS

BTU/WATT

CFM dBA dBA

48-192

8.00

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

18 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

3870 LBS

NEMA 12

MICROPROCESSOR


GPAC-175

COOLING CAPACITY



COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT


GPAC-210

COOLING CAPACITY



COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

CONTROL CIRCUIT


WATER


49.41

50

95

118

7

TONS

°F

°F

GPM

PSID

ALTITUDE

COMPRESSOR POWER

EER

CONDENSER AIR FLOW

SOUND POWER LEVEL


20-80

60-115


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(3) 32 INCH AXIAL

(3) 2 HP OAO, 1140 RPM


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL

WATER


63.95

50

95

TONS

°F

ALTITUDE

COMPRESSOR POWER

°F

GPM

EER

CONDENSER AIR FLOW

SOUND POWER LEVEL 153

7 PSID SOUND PRESS LEVEL @ 1 METER

20-80

60-115


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

ALUMINUM

(4) 32 INCH AXIAL

(4) 2 HP OAO, 1140 RPM


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL

SEA LEVEL

48693

12.18

38061

98

WATTS

BTU/WATT

CFM dBA dBA

60-240

9.88

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

24 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

3870 LBS

NEMA 12

MICROPROCESSOR

SEA LEVEL

63589

12.07

50748

99

WATTS

BTU/WATT

CFM dBA dBA

72-288

12.79

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

32 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

5160 LBS

NEMA 12

MICROPROCESSOR


Water-Cooled Portable Chillers

Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton

(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60

Hz capacity flow rate must be maintained.

G-PWC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)

5.12 TONS ALTITUDE

50 °F COMPRESSOR POWER 4064 WATTS COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER

TEMPERATURE

85 °F EER

COOLANT FLOW

UNIT PRESSURE DROP

13

7

GPM

PSID

SOUND POWER LEVEL


COOLANT FLOW dBA dBA

15 GPM COOLANT SUPPLY TEMPERATURE


TEMPERATURE

20-80 °F

SPECIFICATIONS

COMPRESSOR

COOLANT PUMP

SCROLL

STAINLESS STEEL

CENTRIFUGAL

CONDENSER TUBE IN TUBE

EVAPORATOR FILTER 20 MESH

COOLANT CIRCUIT

REFRIGERANT

NON-FERROUS

HOT GAS BYPASS

3 LBS R-410A

PANELS

RESERVOIR

CONTROL CIRCUIT


120

10.7


AMPS CONTROL

POWDER COATED STEEL

690 LBS

NEMA 12

MICROPROCESSOR

G-PWC-30



TEMPERATURE

COOLANT

COOLANT FLOW

UNIT PRESSURE DROP


7.98 TONS ALTITUDE


85 °F EER

20

7

20-80

GPM

PSID

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1

METER


°F COOLANT FLOW

6416

22.5

WATTS

GPM COOLANT SUPPLY TEMPERATURE


TEMPERATURE dBA dBA

COMPRESSOR

COOLANT PUMP

CONDENSER

SCROLL

STAINLESS STEEL

CENTRIFUGAL

SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

TUBE IN TUBE REFRIGERANT

20 MESH

NON-FERROUS

HOT GAS BYPASS

4 LBS R-410A

PANELS

RESERVOIR

CONTROL CIRCUIT


120

16.4


AMPS CONTROL

POWDER COATED STEEL

870 LBS

NEMA 12

MICROPROCESSOR


G-PWC-40



TEMPERATURE

COOLANT

COOLANT FLOW

UNIT PRESSURE DROP



TEMPERATURE

COMPRESSOR

COOLANT PUMP

CONDENSER

RESERVOIR

CONTROL CIRCUIT


G-PWC-50

COOLING CAPACITY



TEMPERATURE

COOLANT FLOW

UNIT PRESSURE DROP


10.94 TONS ALTITUDE


85 °F EER

27

7

20-80

GPM

PSID

SOUND POWER LEVEL


METER


°F COOLANT FLOW

SCROLL

STAINLESS STEEL

CENTRIFUGAL

SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT


PANELS

120

20

VDC

AMPS


CONTROL


16.66

50

TONS

°F

ALTITUDE

COMPRESSOR POWER

85 °F EER

40

7

20-80

GPM

PSID

SOUND POWER LEVEL


METER


°F COOLANT FLOW COOLANT SUPPLY TEMPERATURE


TEMPERATURE

COMPRESSOR

COOLANT PUMP

SCROLL

STAINLESS STEEL

CENTRIFUGAL

SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT


PANELS

CONDENSER

RESERVOIR

CONTROL CIRCUIT


120

30

VDC

AMPS


CONTROL

8450 WATTS

30 dBA dBA

GPM

20 MESH

NON-FERROUS

HOT GAS BYPASS

6 LBS R-410A

POWDER COATED STEEL

1090 LBS

NEMA 12

MICROPROCESSOR

12778

SEA LEVEL

WATTS

45 dBA dBA

GPM

20 MESH

NON-FERROUS

HOT GAS BYPASS

8 LBS R-410A

POWDER COATED STEEL

1290 LBS

NEMA 12

MICROPROCESSOR


GPWC-70

COOLING CAPACITY


CONDENSER INLET WATER TEMP

COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT


GPWC-90

COOLING CAPACITY



COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT



22.68

50

85

TONS

°F

°F

ALTITUDE

COMPRESSOR POWER

EER

54

7

GPM

PSID

SOUND POWER LEVEL


20-80

50-90


°F

°F

COOLANT FLOW

MINIMUM LOAD

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


SPECIFICATIONS

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL


28.43

50

85

TONS

°F

°F

ALTITUDE

COMPRESSOR POWER

EER

68

7

20-80

50-90

GPM

PSID

°F

°F

SOUND POWER LEVEL



COOLANT FLOW

MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

24/120



CONTROL

SEA LEVEL

16970

16.04

WATTS

BTU/WATT

74 dBA dBA

24-96

4.54

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

12 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2180 LBS

NEMA 12

MICROPROCESSOR

SEA LEVEL

21716

15.71

WATTS

BTU/WATT

74 dBA dBA

30-120

5.69

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

12 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2580 LBS

NEMA 12

MICROPROCESSOR


GPWC-105

COOLING CAPACITY



COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT


GPWC-140

COOLING CAPACITY



COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT



33.64

50

85

80

7

TONS

°F

°F

GPM

PSID

ALTITUDE

COMPRESSOR POWER

EER 15.83 BTU/WATT

WATER GPM

SOUND POWER LEVEL


SEA LEVEL

25508

76

WATTS dBA dBA

20-80

50-90


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

36-144

6.73

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

16 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

2580 LBS

24/120



CONTROL

NEMA 12

MICROPROCESSOR


43.35

50

85

TONS

°F

°F

ALTITUDE

COMPRESSOR POWER

SEA LEVEL

32685 WATTS

EER 15.92 BTU/WATT

WATER GPM

SOUND POWER LEVEL 79 dBA 104

7

GPM

PSID SOUND PRESS LEVEL @ 1 METER dBA

20-80

50-90


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

20 MESH

48-192

8.67

NON-FERROUS

HOT GAS BYPASS

18 LBS R-410A

GALVANIZED STEEL

GPM

TONS

POWDER COATED STEEL

3870 LBS

24/120



CONTROL

NEMA 12

MICROPROCESSOR


GPWC-175

COOLING CAPACITY



COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT


GPWC-210

COOLING CAPACITY



COOLANT FLOW

UNIT PRESSURE DROP



COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

RESERVOIR

CONTROL CIRCUIT



54.46

50

85

130

7

TONS

°F

°F

GPM

PSID

ALTITUDE

COMPRESSOR POWER

EER 15.70 BTU/WATT

WATER GPM

SOUND POWER LEVEL


SEA LEVEL

41633

82

WATTS dBA dBA

20-80

50-90


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

60-240

10.89

GPM

TONS

20 MESH

NON-FERROUS

HOT GAS BYPASS

24 LBS R-410A

GALVANIZED STEEL

POWDER COATED STEEL

3870 LBS

24/120



CONTROL

NEMA 12

MICROPROCESSOR


70.63

50

85

TONS

°F

°F

ALTITUDE

COMPRESSOR POWER

SEA LEVEL

54315 WATTS

EER 15.60 BTU/WATT

WATER GPM

SOUND POWER LEVEL 81 dBA 169

7

GPM

PSID SOUND PRESS LEVEL @ 1 METER dBA

20-80

50-90


°F COOLANT FLOW

°F MINIMUM LOAD

SPECIFICATIONS

SCROLL

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE


EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

FRAME

PANELS

WEIGHT (OPERATING)

20 MESH

72-288

14.13

NON-FERROUS

HOT GAS BYPASS

32 LBS R-410A

GALVANIZED STEEL

GPM

TONS

POWDER COATED STEEL

5160 LBS

24/120



CONTROL

NEMA 12

MICROPROCESSOR


7-4 Pump Curves, Flow, and Pressure Considerations

60 Hertz Pump Curves

ACS CHILLER PUMPS

5-15 ALL 60 Hz

300

September 8, 2009

120

250

200

100

10 HP 3U 32-200-1100D3G

5 HP 2CDU 200/506

80

3 HP 2CDU 70/306

150

60

100

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

40

50

20

0

0 10 20 30 40

Capacity [Gal/min]

50

HP Model

1.5

CDU 70/315D3G

2 CDU 70/520D3G

3 CDU 120/530D3G

3 2CDU 70/306

5 2CDU 200/506

10 3U 32-200-1100D3G

GP 20 GP 30 GP 40 GP 50

STD

OPT

OPT

OPT

STD

OPT

OPT

STD

OPT

OPT

OPT

STD

OPT

OPT

60 70 80

0



300

70-210 ALL 60 Hz

September 8, 2009

120

250

200

5 HP 2CDU 200/506

150

100

10 HP 3U 32-200-1100D3G

15 HP 3U 40-200B150D3G

100

80

30 HP 3UB 65-200300D3G

5 HP 3U 32-160B50D3G

5 HP CDU200/550D3G

10 HP 3U 40-160-1100D3G

7.5 HP 3U 40-160-75D3G

5 HP 3U 40-125B-50D3G

60

40

50

20

300

0 0

0 60 120 180

Capacity [Gal/min]

240

HP

5

5

5

5

7.5

10

15

30

Model

CDU 200/550D3G

3U 32-160B50D3G

3U 40-125B50D3G

2CDU 200/506D3G

3U 40-160-75D3G

3U 32-200-1100D3G

3U 40-200B150D3G

3UB 65-200300D3G

GP70 GP90 GP105 GP 140 GP175 GP210

STD STD STD

OPT OPT OPT STD STD

STD

OPT

OPT

OPT

OPT

OPT

OPT

OPT OPT OPT

OPT

OPT

OPT

OPT


50 Hertz Pump Curves

ACS CHILL ER PUMPS

70

5-15 ALL 50 Hz

September 8, 2009

20

10

40

30

60

50

6

10 HP 3U 32-200-1100D3G

5

3 HP 2CDU 70/306

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

5 HP 2CDU 200/506

4

3

2

1

0

0 50 100 150

Capacity [liter/min]

200

HP Model

1.5

CDU 70/315D3G

2 CDU 70/520D3G

3 CDU 120/530D3G

3 2CDU 70/306

5 2CDU 200/506

10 3U 32-200-1100D3G

GP 20 GP 30 GP 40 GP 50

STD

STD ST D

OPT OPT OPT STD

OPT

OPT OPT OPT

OPT

OPT

OPT

250

GP Series Portable Chillers Chapter 7: Appendix

300

0

56 of 73


70

60

50

40

30

20

10

0

0

20-50 ALL 50 Hz

3 HP 2CDU 70/306

5 HP 2CDU 200/506

4

3

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

September 8, 2009

6

10 HP 3U 32-200-1100D3G

5

2

1

50 100 150

Capacity [liter/min]

200

HP Model

1.5

CDU 70/315D3G

2 CDU 70/520D3G

3 CDU 120/530D3G

3 2CDU 70/306

5 2CDU 200/506

10 3U 32-200-1100D3G

GP 20 GP 30 GP 40 GP 50

STD

OPT

OPT

OPT

STD

OPT

OPT

STD

OPT

OPT

OPT

STD

OPT

OPT

250 300

0


Pure Water at >40°F

GPXC-20 GPXC-30 GPXC-40 GPXC-50

GPXC-210

Calculating Chiller Nominal Flow and Pressure to Process

• Flow rate: Obtain the flow reading from the appropriate pump curve.

• Pressure: Obtain a corresponding pressure reading from the pump curve you selected, then subtract the one-pump pressure drop listed in the above table using the appropriate chiller hp and flow rate.


7-5 Remote Air-Cooled Chiller Configurations


7-6 Typical Ductwork for Air-Cooled Chillers

Model

60 Hz Discharge 50 Hz Discharge air

Fan air volume volume m

3

/min CFM m

3

/min

GPAC-20 0.5 0.4 4230

GPAC-30 1.0 0.7 6343

120 3525 100

180 5286 150

GPAC-40 1.0 0.7 8458

GPAC-50 2.0 1.5 12687

GPAC-70 (2) 1.0 (2) 0.7

GPAC-90 (2) 2.0 (2) 1.4

GPAC-105

GPAC-140

(2) 2.0

(3) 2.0

(2) 1.4

(3) 1.4

16916

25374

240 7048 200

479

718

25374 718

38061 1077

14097

21145

21145

31718

399

598

598

898

GPAC-175 (3) 2.0 (3) 1.4

GPAC-210 (4) 2.0 (4) 1.4

38061 1077

50748 1436

31718

42290

898

1197

When locating your air-cooled portable chiller and designing its ductwork, note any potential high temperature conditions when discharging into your building and any negative pressures with the building when discharging air outside.

Notes:

• Customer use of ductwork requires the high pressure fan option. • Allow 30” (77 cm) minimum clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility

•

Size the ductwork for maximum capacity

• Support ductwork from the building structure, not off of the


chiller

• Back draft damper to outside must be closed at all times when fan/blower is not operating •

Chillers with dual fans/blower must have a back draft damper on the cycling fan/blower to prevent recirculation of hot discharge air

• Chillers are designed to operate at a condensing entering air temperature of 60ºF (16ºC) minimum without optional Variable Frequency Drive

• Maximum total static pressure drop external to the chiller must not exceed 0.30” WG (75 Pa)














Sterling 882.93092.00 Marine Instruments User Manual

GP Series Portable Chillers

Shipping Information

Table of Contents

Chapter 1: Safety

1-1 How to Use This Manual

1-2 Warnings and Precautions

1-3 Responsibility

Chapter 2: Functional Description

2-1 Models Covered in This Manual

Chapter 3: Installation

3-1 Uncrating

Important!

3-3 Process Water Connections

3-5 Galvanic Corrosion Considerations

3-8 Checking Motor Direction

3-10 Automatic Water Make-Up Option

3-11 Initial Start-Up

3-12 Finishing Setup: Setting Up Passwords

Chapter 4: Operation

4-1 Panel Buttons, Indicator Lights, and Switches

4-6 Alarms

Chapter 5: Maintenance

5-1 Lubrication

5-3 Maintaining the Condenser

5-4 Maintaining the Evaporator

5-5 Evaporator Process Piping Y-Strainer

5-6 Preventative Maintenance Service

Chapter 6: Troubleshooting

Chapter 7: Appendix

7-1 Returned Material Policy

7-3 Specifications

7-4 Pump Curves, Flow, and Pressure Considerations

7-5 Remote Air-Cooled Chiller Configurations

7-6 Typical Ductwork for Air-Cooled Chillers

Related manuals

Table of contents

Sterling 882.93092.00 Marine Instruments User Manual

GP Series Portable Chillers

Shipping Information

Table of Contents

Chapter 1: Safety

1-1 How to Use This Manual

1-2 Warnings and Precautions

1-3 Responsibility

Chapter 2: Functional Description

2-1 Models Covered in This Manual

Chapter 3: Installation

3-1 Uncrating

Important!

3-3 Process Water Connections

3-5 Galvanic Corrosion Considerations

3-8 Checking Motor Direction

3-10 Automatic Water Make-Up Option

3-11 Initial Start-Up

3-12 Finishing Setup: Setting Up Passwords

Chapter 4: Operation

4-1 Panel Buttons, Indicator Lights, and Switches

4-6 Alarms

Chapter 5: Maintenance

5-1 Lubrication

5-3 Maintaining the Condenser

5-4 Maintaining the Evaporator

5-5 Evaporator Process Piping Y-Strainer

5-6 Preventative Maintenance Service

Chapter 6: Troubleshooting

Chapter 7: Appendix

7-1 Returned Material Policy

7-3 Specifications

7-4 Pump Curves, Flow, and Pressure Considerations

7-5 Remote Air-Cooled Chiller Configurations

7-6 Typical Ductwork for Air-Cooled Chillers

Related manuals

Sterling

GP Series

Sterling

Refrigerator 882.93092.00

Sterling

Refrigerator 882.93092.01

Sterling

GP Series

Sterling

Refrigerator A0554831

HP (Hewlett-Packard)

A0554832

AEC

A0551794 RS Series

Thermal Care

Accuchiller NQ Series

Thermal Care

TSE

Table of contents