Sterling Refrigerator 882.93092.01 User manual

R4
10
a
GP Series Portable Chillers
Part Number: 882.93092.01
Bulletin Number: SC2-620.4
Effective: 10/10/2011
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.
ECN No. ____________
© Copyright 2012
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 1-2 1-3 How to Use This Manual .............................................................................................. 5 Safety Symbols Used in this Manual ..................................................................... 5 Warnings and Precautions ........................................................................................... 6 Responsibility ............................................................................................................... 6 CHAPTER 2: FUNCTIONAL DESCRIPTION ............................. 7 2-1 2-2 2-3 2-4 2-5 Models Covered in This Manual .................................................................................. 7 General Description ..................................................................................................... 7 Typical Applications............................................................................................... 7 System Limitations ................................................................................................ 7 Chilled Water Circuit.............................................................................................. 8 Refrigeration Circuit............................................................................................... 9 Standard Features ..................................................................................................... 10 Mechanical Features ........................................................................................... 10 Electrical Features............................................................................................... 11 Refrigeration Features......................................................................................... 11 Controller Features.............................................................................................. 12 Other Features .................................................................................................... 12 Safety Devices and Interlocks .................................................................................... 12 Crankcase Heater ............................................................................................... 12 High Pressure Cutout .......................................................................................... 13 Low Pressure Cutout (no switch but done through the transducer) .................... 13 Flow Switch ......................................................................................................... 14 Remote Start/Stop Interlock ................................................................................ 14 Optional Features ...................................................................................................... 14 CHAPTER 3: INSTALLATION.................................................. 16 3-1 3-2 3-3 3-4 3-5 3-6 3-7 Uncrating .................................................................................................................... 16 Electrical Connections ............................................................................................... 16 Process Water Connections ...................................................................................... 17 Bypass Valve Considerations .................................................................................... 17 Galvanic Corrosion Considerations ........................................................................... 18 Water Treatment Considerations ............................................................................... 18 Condenser Considerations ........................................................................................ 18 Water-Cooled Chiller Condensers ....................................................................... 18 Air-Cooled Chiller Condensers ............................................................................ 19 Remote Air-Cooled Chiller Condensers .............................................................. 20 3-8 Checking Motor Direction ........................................................................................... 27 Three-Phase Compressors ................................................................................. 27 Water Pumps....................................................................................................... 27 Condenser Fan.................................................................................................... 27 3-9 Water Reservoir ......................................................................................................... 28 3-10 Automatic Water Make-Up Option ............................................................................. 31 3-11 Initial Start-Up ............................................................................................................ 31 3-12 Finishing Setup: Setting Up Passwords ..................................................................... 33 CHAPTER 4: OPERATION ....................................................... 35 4-1 4-2 4-3 Panel Buttons, Indicator Lights, and Switches ........................................................... 35 Microprocessor Controller ................................................................................... 35 Initial Start-up ............................................................................................................. 36 Status Screens ........................................................................................................... 37 GP Series Portable Chillers
iii
4-4 4-5 4-6 4-7 4-8 Access Levels ............................................................................................................ 41 Controller Setpoints.................................................................................................... 41 Configuration Settings ................................................................................................ 45 Alarms ........................................................................................................................ 47 Optional Communications .......................................................................................... 47 5-1 5-2 5-3 Lubrication ................................................................................................................. 48 Filter Cleaning ............................................................................................................ 48 Maintaining the Condenser ........................................................................................ 48 Air- and Remote Air-Cooled Chillers ................................................................... 48 Water-Cooled Chillers ......................................................................................... 48 Maintaining the Evaporator ........................................................................................ 49 Evaporator Process Piping Y-Strainer ....................................................................... 49 Preventative Maintenance Service ............................................................................ 49 CHAPTER 5: MAINTENANCE ................................................. 48 5-4 5-5 5-6 CHAPTER 6: TROUBLESHOOTING ....................................... 50 6-1 Identifying the Cause of a Problem ............................................................................ 50 Non-Controller Related Issues ............................................................................ 55 CHAPTER 7: APPENDIX .......................................................... 58 7-1 7-2 7-3 7-4 7-5 7-6 7-7 Returned Material Policy ............................................................................................ 58 Credit Returns ..................................................................................................... 58 Technical Assistance ................................................................................................. 58 Parts Department ................................................................................................ 58 Service Department............................................................................................. 59 Sales Department................................................................................................ 59 Contract Department ........................................................................................... 59 Specifications ............................................................................................................. 60 Air-Cooled Portable Chillers ................................................................................ 60 Water-Cooled Portable Chillers ........................................................................... 65 Pump Curves, Flow, and Pressure Considerations ................................................... 70 60 Hertz Pump Curves ........................................................................................ 70 50 Hertz Pump Curves ........................................................................................ 72 Remote Air-Cooled Chiller Configurations ................................................................. 75 Typical Ductwork for Air-Cooled Chillers ................................................................... 77 Piping Diagrams ......................................................................................................... 79 GP Series Portable Chillers
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Chapter 1:
1-1
Safety
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.
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Chapter 1: Safety
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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:
ü Follow all SAFETY CODES.
ü Wear SAFETY GLASSES and WORK GLOVES.
ü Disconnect and/or lock out power before servicing or maintaining the equipment.
ü Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
ü Operate this equipment within design specifications.
ü OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
ü Make sure the equipment and components are properly GROUNDED before you
switch on power.
ü 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.
ü 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.
ü Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
ü Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
1-3
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.
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.
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Chapter 1: Safety
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Chapter 2:
2-1
2-2
Functional Description
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, through 210) and the cooling method used: -A for air-cooled, -W for water-cooled,
and –R for remote-air cooled.
General Description
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 20 kW
through 210 kW (5 through 60 tons of refrigeration). All are self-contained, fully portable and
shipped ready to use. (Remote air-cooled chillers require field installation by qualified
technicians.) In the standard configuration the chiller basically consists of a pump, tank,
compressor, condenser, evaporator, and a control platform. All of these components, plus the
other integral components to maintain the leaving fluid temperature, are described throughout
this Chapter as well as Chapters 3 and 4.
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.
Typical Applications
This series of portable chillers can be used in any application that needs a constant source of
cool process water. Typical applications include, but are not limited to, the following:
Injection molding
Blow molding
Extrusion
Thermoforming
Machine tool
Metal plating
Thermal spray
After-coolers (air compressors, dryers, etc.)
Laser
Printing (offset, gravure, digita)
System Limitations
These packaged chillers should be chosen using the following criteria:
Process heat load – Choose the size of the chiller so that rated capacity is no greater than
10% more than the process heat load.
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Process Fluid Temperature – The standard range for the leaving fluid temperature for this
series of packaged chillers is 20°F to 80°F (-6.7°C to 26.7°C). When the process requires
fluid temperatures below 45°F (27.2°C) it is imperative that the process fluid is a mix of an
industrial grade ethylene or propylene glycol and water to the proper percentage (by volume)
to protect the system. See Chapter 3 for a further discussion regarding the use of glycol
within the system for these applications.
WARNING! - ACS Group does not warrant the freeze up of the evaporator
under any circumstances.
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 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 flow switch to make when
the process flow is stopped. If the flow switch is not made the controller shuts down the
compressor to prevent freezing up the evaporator.
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Chapter 2: Functional Description
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Refrigeration Circuit
Air-, water-, and remote air-cooled refrigerant condensing differ only in the way the
compressed gas is condensed to a liquid. Shown below is a water cooled version.
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.
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. After the
filter/dryer the refrigerant passes through a solenoid
valve to prevent liquid migration when the
compressor is off. A refrigerant sight glass is
provided to view the flow of liquid refrigerant, and
to view if the system is free of moisture. 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.
From the evaporator the refrigerant gas flows
through the suction line back into the compressor.
A modulating 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.
System Control
Putting this all together, the controller maintains the desired leaving fluid temperature using
multiple inputs to determine if, when and for how long the compressor(s) are on, and if,
when, the percent open and for how long the modeling hot gas bypass valve is on.
Once the unit’s power is enabled and the controller is turned on (see Chapter 4 for more
details on the operation of the controller) it verifies there is sufficient fluid level in the tank (if
present). If there is not enough fluid in the tank the controller will warn the user, or fill the
tank with water from a connected source if equipped with the optional automatic water
makeup valve. See Chapter 3 for more information regarding the initial setup and startup of
the unit.
Once the tank level is satisfied and the start button is pressed, the process pump turns on and
provides flow to the process. The controller verifies the flow through the electronic flow
switch. If the flow is not established within 10 seconds the controller will alarm and disable
the refrigeration circuit. Upon flow verification the controller uses the leaving fluid
temperature and the setpoint temperature to determine the operation of the compressor(s).
When the leaving fluid temperature is greater than the setpoint plus the “compressor on
GP Series Portable Chillers
Chapter 2: Functional Description
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differential” value the controller will enable the compressor; if equipped with two
compressors the controller will enable the one with the least amount of hours. The second
compressor will be enabled if the leaving fluid temperature remains above the setpoint plus
the “compressor on differential” value for more than 60 seconds.
The hot gas valve is designed to trim the load of one compressor and will modulate in order
to meet the desired leaving fluid setpoint via a PID algorithm. After the compressor starts,
the hot gas valve is allowed to modulate. The compressor will shut off if the leaving fluid
temperature drops below the “compressor off differential” and the hot gas valve is at 100%
for the “compressor off delay” time. The hot gas will reset to 0% when the compressor is off.
There is a “compressor anticyle” timer that will delay the time between compressor starts to
prevent short cycling of the compressor. This is a start to start timer set at 5 minutes. For
example, if the compressor has been running for 5 minutes and shuts off, then the compressor
can start immediately if the demand is there. If it has only been running for 2 minutes, then it
would not be able to start again for 3 minutes.
For a unit with two compressors, the second compressor or lag compressor starts when the
lead compressor is on, the hot gas is at 0%, and the leaving fluid temperature is above the
setpoint plus the “compressor on differential”. There is also an adjustable “lag compressor on
delay” timer. Before starting either compressor, the compressor with the least amount of
runtime hours is considered the lead compressor and the first to start. When both
compressors are running, the compressor with the most hours is considered the lead
compressor and is the first to stop. The lead compressor will shut off if the leaving fluid
temperature drops below the “compressor off differential” and the hot gas valve is at 100%
for the “lead compressor off delay” time. The compressor anti-cycle timers are active with
the two compressor units.
There will be two PID controls running simultaneously for determining the position of the hot
gas valve. One PID output will be based on leaving fluid temperature and the other based on
a minimum saturated suction temperature for freeze protection. The hot gas valve position
will be determined by which output is greater. If it is controlling to the saturated suction
temperature to prevent freezing, a warning will display on the screen that the hot gas is in this
mode. Once the control goes back to setpoint control, the warning will disappear. The
saturated suction temperature is calculated from the suction pressure and the type of
refrigerant.
2-3
The discharge pressure is controlled using an analog output signal to drive a fan for aircooled units or a water regulating valve for water-cooled units. The output signal is
determined from a PID algorithm using a discharge pressure transducer as the process
variable. The VFD or water regulating valve is controlled from the analog output to an
adjustable discharge pressure setpoint. The analog output starts at the initial “discharge
pressure start” % for a given time delay (discharge pressure hold). After the time delay, it
will control to the discharge pressure setpoint via the PID control. There is also a setting to
control the discharge pressure to the most efficient value.
Standard Features
Mechanical Features
Compressor – Hermetic scroll compressors.
Evaporator – Stainless steel copper brazed plate evaporators.
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Chapter 2: Functional Description
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Air-Cooled Condenser – Aluminum fin/ tube with washable filters, packaged units only.
Variable speed fan control standard for all remote air cooled condensers and GPAC70
through 210. Optional on GPAC20 through 50.
Water-Cooled Condenser – Tube-in-tube condensers (GPWC20 – GPWC50), Shell-andtube condensers (GPWC70 – GPWC210). All come with electronic cooling water regulating
valves.
Remote Air-Cooled Condenser– Aluminum fin/tube with low ambient control down to
–20ºF (-29ºC) via variable-speed fan(s).
Reservoir – GP20 and GP30 models use a 20 gallon (75 liter) polyethylene tank, GP40 and
GP50 models use a 40 gallon (150 liter) polyethylene tank, GP70 thru GP105 models use a
70 gallon (265 liter) polyethylene tank, GP140 thru GP210 models use a 140 gallon (530
liter) polyethylene tank. 304SS is available as an option for all sizes.
Piping – Non-ferrous chilled water 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, polyester powder coat painted cabinetry
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 via operator interface
Pump pressure indication via operator interface
Electrical Features
Fully accessible NEMA 4/12-style electrical control enclosure
Single-point power and ground connection
Non-fused disconnect switch, lockable
Branch circuit protection
208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt
Refrigeration Features
HFC-410a refrigerant
Electronic modulating hot gas bypass capacity control
High refrigerant pressure cutout switch (manual reset)
Suction and discharge pressure transducers.
High refrigerant pressure spring actuated relief valve
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Chapter 2: Functional Description
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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 22 character display with status, alarm, and service screens
Display has magnetic back and can be mounted anywhere.
Other Features
One year labor warranty and one year compressor warranty
Two year parts warranty
2-4
Three year limited controller warranty
Safety Devices and Interlocks
Caution! Protect the system from freezing with inhibited industrial grade 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, and
the compressors are off.
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. If unit is mounted outdoors, power to the unit (and
the main power switch) must remain on 24 hours per day, 7 days per week to
prevent liquid migration to the compressor.
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Chapter 2: Functional Description
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High Pressure Cutout
This electro-mechanical cutout device opens the compressor control circuit if the refrigeration
system compressor discharge pressure exceeds 575 psig.
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.
High pressure cutout
Typical GPAC-20
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
pressure warning and fault are calculated based on the Freeze Point value entered into the
controller. 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.
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Chapter 2: Functional Description
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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
pump 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 install a switch or dry contact interlock connected in series between terminals
4 and 23. Refer to the electrical schematic supplied in the control enclosure. Once the wiring
is complete the controller will need to be reconfigured in the supervisor settings.
2-5
Optional Features
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. This option
includes an electric water solenoid valve, and the necessary internal piping to connect the
chiller to a make-up water source. The controller uses the standard tank level pressure
transducer to determine when to fill the tank. 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 Section 7-7 for flow schematics.
Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank.
This option includes a 50 micron filter, flow indicator, 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*. This option provides the capability for the unit’s controller to
communicate with an external device using a variety of serial communication protocols.
Currently the unit can communicate over RS-485 Modbus RTU, BACNet, LONWorks,
Ethernet Modbus.
High Pressure Fans. Provides either 0.3” WC (75 Pa) or 1.0”WC (250 Pa) of external static
pressure on fan discharge. High-pressure fans are necessary and must be included in chiller
installations where exiting air exhausts through ductwork.
The 0.3” WC (75 Pa) static fan can be retrofitted without sheet metal modification, but will
require changing out fan housing, fan blades, fan motors and electrical components.
Variable Speed Fan – GPAC20-50. Reduces the speed of the fan based on refrigerant
pressure and system load, allowing the chiller to operate in ambient temperatures below 75ºF
(24ºC). This option will also reduce fan noise in lower ambient temperatures and low loads.
GP Series Portable Chillers
Chapter 2: Functional Description
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Stainless Steel Reservoir. Manufactured from 304 stainless steel.
Mounting Features.
Mounting rails with feet – GP20-GP105 indoor units. Standard on GP140-GP210 and all
outdoor packaged units.
Optional Operating Voltages. 208-230/3/60, 460/3/60, 575/3/60, and 400/3/50 volt
available
UL/cUL Labeled Electrical Subpanel. This option provides for the subpanel to be listed
with Underwriters Laboratory, with UL-related benefits and features. Sub-panels marked by
the UL/cUL sticker are accepted within Canada.
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 below for optional pump amperages.
Figure 1: Optional Pump Amperages
Voltage
Construction
HP (kW)
460/3/60
SS
1 (0.8)
1.7
1.5 (1.1)
2.3
2 (1.5)
4.0
3 (2.2)
4.2
5 (3.7)
8.2
GP Series Portable Chillers
Full Load Amps
7.5 (5.6)
10.3
10 (7.5)
12.0
15 (11)
20.0
30 (22)
32.0
Chapter 2: Functional Description
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Chapter 3:
3-1
Installation
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.
3-2
Electrical Connections
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. 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)
Note:
For all chillers manufactured with Variable Frequency Drives the
voltage may vary up to 10% from the converter nominal voltage.
However, the phase-to-phase input voltage imbalance must not
exceed 3%. If the input voltage does have an imbalance from phase
to phase greater than 3% then a line reactor must be installed to
prevent faults within the VFD.
For remote condenser units, the maximum recommended motor
cable length between the VFD and the motor without output chokes
is 30 m (100 ft). With output chokes the motor cable length may be
extended to 65 m (195 ft).
GP Series Portable Chillers
Chapter 3: Installation
16 of 90
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.
Figure 2: Typical GP20-50 Air Cooled Process Piping Connections
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. Flow control valves are not supplied, but should be added to the
system to adjust flow and pressure to the process and to isolate the chiller from the process if
necessary.
Note:
3-4
Be sure to reduce external pressure drop as much as possible by generously
sizing piping and tooling water passageways.
Bypass Valve Considerations
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.
GP Series Portable Chillers
Chapter 3: Installation
17 of 90
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.
Note:
3-6
Water Treatment Considerations
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:
3-7
The use of galvanized piping is discouraged because the rough inside surface
promotes debris to stick and eventually block the flow of the process fluid..
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 what type of treatment is needed.
Condenser Considerations
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 is labeled “Condenser Water In.” It is the
inlet for city or tower water. For the GPWC20-50, this connection is located near the bottom
of the chiller. For all other sizes this connection is located near the top of the chiller.
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 is labeled “Condenser Water Out.” It is the
outlet for water after it has passed through the condenser. For the GPWC20-50, this
connection is located near the bottom of the chiller. For all other sizes this connection is
located near the top of the chiller.
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.
GP Series Portable Chillers
Chapter 3: Installation
18 of 90
Figure 3: Typical GP20-50 Water Cooled Condenser Connections
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 75ºF (24ºC). Operation of the
equipment at a lower condenser entering air temperature can cause the chiller to malfunction.
For entering air temperatures below 75ºF (24°C), an optional fan motor speed control is
available. We recommend maintaining a minimum 75ºF (24°C) ambient temperature.
Note:
For all chillers manufactured with Variable Frequency Drives the
voltage may vary up to 10% from the converter nominal voltage.
However, the phase-to-phase input voltage imbalance must not
exceed 3%. If the input voltage does have an imbalance from phase
to phase greater than 3% then a line reactor must be installed to
prevent faults within the VFD.
For remote condenser units, the maximum recommended motor
cable length between the VFD and the motor without output chokes
is 30 m (100 ft). With output chokes the motor cable length may be
extended to 65 m (195 ft).
GP Series Portable Chillers
Chapter 3: Installation
19 of 90
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.
Piping should be hard/drawn type “L” or type “K” refrigerant grade copper
tubing only. Proper sizing and installation has a significant effect on system
performance, reliability, and safety.
Warning! The copper tubing and fittings used must have a minimum burst
pressure of 1,950 psi.
Note:
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 needs 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 applicable codes.
Flow dry nitrogen through the system when brazing copper joints 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 hydrogenfluoride 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 75 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 75 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.
GP Series Portable Chillers
Chapter 3: Installation
20 of 90
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 4 on page 21 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 or on a roof. Install a liquid line-charging valve to facilitate refrigerant charging. See
Figure 5 on page 21 for sizing information. See Figure 7 on page 25 for charge determination.
Discharge Line Sizing. Discharge line sizing is based on the velocity required for sufficient
oil return back to the compressor. See Figure 4: Equivalent Length in Feet for Valves and
Fittingson page 24 for discharge line sizing.
Note:
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.
Figure 4: Equivalent Length in Feet for Valves and Fittings
Line Size
OD (inches)
3/8
1/2
5/8
3/4
7/8
1-1/8
1-3/8
1-5/8
2-1/8
2-5/8
Angle
Valve
24
24
25
25
28
29
33
34
39
44
Short
Radius EL
4
4.7
5.7
6.5
7.8
2.7
3.2
3.8
5.2
6.5
Long
Radius EL
2.8
3.2
3.9
4.5
5.3
1.9
2.2
2.6
3.4
4.2
Figure 5: Liquid Line Sizing
GPRC-20
Total Equiv.
Length (Ft)
25
50
75
100
125
150
175
200
225
250
275
300
GPRC-30
Horizontal
or
Downflow
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
5/8
5/8
5/8
Liquid Line Size (OD")
Upflow
1-5 Ft
Upflow
6-10 Ft
Upflow
11-15 Ft
1/2
1/2
1/2
1/2
1/2
1/2
5/8
5/8
5/8
5/8
5/8
5/8
1/2
1/2
1/2
1/2
1/2
5/8
5/8
5/8
5/8
5/8
5/8
5/8
1/2
1/2
1/2
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
GP Series Portable Chillers
Total Equiv.
Length (Ft)
25
50
75
100
125
150
175
200
225
250
275
300
Chapter 3: Installation
Horizontal
or
Downflow
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
Liquid Line Size (OD")
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
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
3/4
3/4
3/4
5/8
5/8
5/8
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
3/4
21 of 90
GPRC-40
GPRC-50
Liquid Line Size (OD")
Total Equiv.
Length (Ft)
25
50
75
100
125
150
175
200
225
250
275
300
Liquid Line Size (OD")
Horizontal
or
Downflow
Upflow
1-5 Ft
Upflow
6-10 Ft
Upflow
11-15 Ft
5/8
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
5/8
3/4
3/4
3/4
3/4
3/4
3/4
3/4
7/8
7/8
7/8
7/8
3/4
3/4
3/4
3/4
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
GPRC-70
Total Equiv.
Length (Ft)
25
50
75
100
125
150
175
200
225
250
275
300
Horizontal
or
Downflow
Upflow
1-5 Ft
Upflow
6-10 Ft
Upflow
11-15 Ft
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
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
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
7/8
1-1/8
1-1/8
GPRC-90
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
7/8
7/8
7/8
7/8
25
1-1/8
1-1/8
1-1/8
1-1/8
50
7/8
7/8
7/8
7/8
50
1-1/8
1-1/8
1-1/8
1-1/8
75
7/8
7/8
7/8
7/8
75
1-1/8
1-1/8
1-1/8
1-1/8
100
7/8
7/8
7/8
7/8
100
1-1/8
1-1/8
1-1/8
1-1/8
125
7/8
7/8
7/8
7/8
125
1-1/8
1-1/8
1-1/8
1-1/8
150
7/8
7/8
7/8
1-1/8
150
1-1/8
1-1/8
1-1/8
1-1/8
175
7/8
7/8
7/8
1-1/8
175
1-1/8
1-1/8
1-1/8
1-1/8
200
7/8
7/8
1-1/8
1-1/8
200
1-1/8
1-1/8
1-1/8
1-1/8
225
7/8
7/8
1-1/8
1-1/8
225
1-1/8
1-1/8
1-1/8
1-1/8
250
7/8
7/8
1-1/8
1-1/8
250
1-1/8
1-1/8
1-1/8
1-1/8
275
7/8
1-1/8
1-1/8
1-1/8
275
1-1/8
1-1/8
1-1/8
1-1/8
300
7/8
1-1/8
1-1/8
1-1/8
300
1-1/8
1-1/8
1-1/8
1-1/8
GP Series Portable Chillers
Chapter 3: Installation
22 of 90
GPRC-105
GPRC-140
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
1-1/8
1-1/8
1-1/8
1-1/8
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
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
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
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
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
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
175
1-1/8
1-1/8
1-1/8
1-3/8
200
1-1/8
1-1/8
1-1/8
1-1/8
200
1-1/8
1-1/8
1-1/8
1-3/8
225
1-1/8
1-1/8
1-1/8
1-1/8
225
1-1/8
1-1/8
1-1/8
1-3/8
250
1-1/8
1-1/8
1-1/8
1-1/8
250
1-1/8
1-1/8
1-3/8
1-3/8
275
1-1/8
1-1/8
1-1/8
1-1/8
275
1-1/8
1-1/8
1-3/8
1-3/8
300
1-1/8
1-1/8
1-1/8
1-3/8
300
1-1/8
1-1/8
1-3/8
1-3/8
GPRC-175
GPRC-210
Liquid Line Size (OD")
Total Equiv.
Length (Ft)
Horizontal
or
Downflow
Upflow
1-5 Ft
Upflow
6-10 Ft
Liquid Line Size (OD")
Upflow
11-15 Ft
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
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
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
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
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
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
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
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
200
1-3/8
1-3/8
1-3/8
1-5/8
225
1-3/8
1-3/8
1-3/8
1-3/8
225
1-3/8
1-3/8
1-3/8
1-5/8
250
1-3/8
1-3/8
1-3/8
1-3/8
250
1-3/8
1-3/8
1-3/8
1-5/8
275
1-3/8
1-3/8
1-3/8
1-3/8
275
1-3/8
1-3/8
1-5/8
1-5/8
300
1-3/8
1-3/8
1-3/8
1-3/8
300
1-3/8
1-3/8
1-5/8
1-5/8
GP Series Portable Chillers
Chapter 3: Installation
23 of 90
Figure 6: Discharge Line Sizing
Horizontal or Downflow Discharge Line Sizes (OD")
Total Equivalent Length (Ft)
Model
25
50
75
100
125
150
175
200
225
250
275
300
GPRC-20
5/8
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
3/4
3/4
7/8
GPRC-30
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
GPRC-40
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
GPRC-50
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
GPRC-70
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
GPRC-90
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
GPRC-105
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
GPRC-140
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
GPRC-175
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
GPRC-210
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")
Circuit
Tons
GPRC-20
GPRC-30
GPRC-40
GPRC-50
GPRC-70
GPRC-90
GPRC-105
GPRC-140
GPRC-175
GPRC-210
Total Equivalent Length (Ft)
25
50
75
100
125
150
175
200
225
250
275
300
5/8
5/8
5/8
5/8
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-5/8
B-5/8
B-5/8
B-5/8
B-5/8
B-5/8
B-5/8
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-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
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
B-7/8
B-7/8
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-1-3/8
B-1-3/8
1-1/8
1-1/8
7/8
1-1/8
1-1/8
1-1/8
1-3/8
1-5/8
7/8
1-1/8
1-1/8
1-3/8
1-3/8
1-5/8
GP Series Portable Chillers
1-1/8
1-3/8
1-3/8
1-5/8
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
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
1-3/8
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
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
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
Chapter 3: Installation
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
A-3/4
B-1-5/8
B-1-5/8
B-1-5/8
B-1-5/8
B-1-5/8
B-1-5/8
24 of 90
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 7, determine the amount of charge based on the model 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 7: Refrigerant Charge Determination
Condenser and Chiller Charge (LBS of R-410a)
Chiller
Model
Minimum Design Ambient - °F
60
50
40
30
20
10
0
-10
-20
GPRC-20
9
9
10
11
12
13
13
13
14
GPRC-30
10
10
12
14
15
16
16
17
17
GPRC--40
13
13
15
17
19
20
21
21
22
GPRC-50
18
19
22
25
27
29
30
31
32
GPRC-70
25
25
25
26
31
34
36
38
40
GPRC-90
30
30
30
32
37
41
44
47
49
GPRC-105
51
51
51
52
52
58
63
67
71
GPRC-140
51
51
51
51
51
51
55
55
65
GPRC-175
70
70
70
70
70
70
76
76
88
GPRC-210
80
80
80
80
80
80
80
88
94
Line Size
OD (inches)
3/8
1/2
5/8
3/4
7/8
1-1/8
1-3/8
1-5/8
2-1/8
2-5/8
Discharge Line
LBS of R-410a
0.3
0.6
1.0
1.5
2.1
3.7
5.6
7.9
13.7
21.2
Liquid Line
LBS of R-410a
3.2
6.0
9.6
14.4
20.0
34.1
52.0
73.6
128.0
197.4
Note: The amounts listed above 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.
GP Series Portable Chillers
Chapter 3: Installation
25 of 90
Figure 8: Remote Condenser Configurations
GP Series Portable Chillers
Chapter 3: Installation
26 of 90
Figure 9: Double Riser Detail
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.
Caution!
Do not allow the compressor to run backwards for any length of time. Doing
so will result in compressor damage..
Water Pumps
Correct pump rotation is indicated by a positive pressure of 20 to 40 psi shown on the home
screen of the display. 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.
GP Series Portable Chillers
Chapter 3: Installation
27 of 90
3-9
Water Reservoir
The standard water reservoir is rotationally molded polyethylene with a removable lid. The
tank is fully insulated to assist maintaining fluid temperature. 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 11: Ethylene Glycol and Propylene
Glycol Curves on page 30. Add a pre-mixed solution of industrial quality (not automotive),
inhibited 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 45ºF (7ºC) or contact the service
department.
Warning! Operating the chiller setpoint below 45°F (7°C) without the proper
amount of glycol for freeze protection could result in a damaged
evaporator. ACS Group does not warrant the freeze up of the
evaporator under any circumstances.
The following glycol products are available:
Part Number
Description
A0541358
Ethylene glycol, 5 gallons (18.9 liters)
A0539637
Ethylene glycol, 55 gallons (208.2 liters)
A0542990
Propylene glycol, 5 gallons (18.9 liters)
A0542991
Propylene glycol, 55 gallons (208.2 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.
GP Series Portable Chillers
Chapter 3: Installation
28 of 90
Figure 10: Suggested Overhead Piping Configuration
GP Series Portable Chillers
Chapter 3: Installation
29 of 90
Figure 11: Ethylene Glycol and Propylene Glycol Curves
Percent Glycol Curves for Freeze Protection
40.0
30.0
Ethylene Glycol
20.0
Propylene Glycol
10.0
0.0
-10.0
-20.0
-30.0
-40.0
-50.0
-60.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
% Glycol by Volume
Example: 45°F set point minus 20°F = 25°F.
From Figure 28, 25°F equates to 10% by volume of glycol required.
Note:
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.
GP Series Portable Chillers
Chapter 3: Installation
30 of 90
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.
Note:
When the unit is selected with the optional, closed stainless steel tank, a
pressure reducing valve is added to the automatic water make-up option. This
valve is set to be full open at 5 psig (0.3 bar).
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.
GP Series Portable Chillers
Chapter 3: Installation
31 of 90
To Process
From Process
Complete chilled water To Process and From Process connections. It is suggested that
shut-off valves are added to unit to control the flow rate to process and for completely
isolating the chiller from the process.
If the optional automatic water makeup system was not installed on the
chiller, remove the side panel to the
left of the process connections and fill
the tank and chilled water circuit
piping until the tank is approximately
¾ full. Fill with water (or a
water/glycol mixture if the desired
setpoint is lower than 45°F (7°C)).
The water/ glycol mixture should
provide for freeze protection to at
least 20°F (11ºC) below the leaving
water temperature you want.
GP Series Portable Chillers
Chapter 3: Installation
32 of 90
Warning! Operating the chiller setpoint below 45°F (7°C) without the
proper amount of glycol for freeze protection could result in a
damaged evaporator. ACS Group does not warrant the freeze
up of the evaporator under any circumstances.
The air-cooled condenser should have an adequate supply of 75º to 115ºF (24º 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
best route for the main power wiring is from
the floor up to the right side of the enclosure
on the top.
Power Cable (highlighted in
yellow)
The crankcase heater is automatically energized
when the main power is applied (main power switch
in the ON ( | )position. It should be on for at least 24 hours before startup to force dissolved
refrigerant from the compressor oil.
Finally, the cable for the display is coiled up under the control enclosure and the display is
shipped inside the control enclosure. The handle on the panel in front of the control
enclosure has a hole in the corner to feed the cable to the outside of the cabinet. Plug the
cable into the back of the display.
Turn the power switch to the ON ( | ) position. The display’s backlight will turn on and the
controller will go through a self-diagnostic routine prior to displaying the main status screen.
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.
GP Series Portable Chillers
Chapter 3: Installation
33 of 90
Warning! If you choose to establish passwords store them in a secure
location because if they are forgotten there is no way to reset them
without a service call.
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.
Note:
If you choose to define an Operator Password you must also define a
Supervisor Password to complete the security setup.
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
Password
or
until the following screen appears for the Operator or Supervisor
4. Press
to accept the screen, and then press
Password line is highlighted.
or
5. Press
0 and 9999.
6. Press
.
until the Operator or Supervisor
to increment or decrement the number. The password can be between
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.
GP Series Portable Chillers
Chapter 3: Installation
34 of 90
Chapter 4:
4-1
Operation
Panel Buttons, Indicator Lights, and Switches
Microprocessor Controller
The standard chillers use a microprocessor-based PID controller. The Carel PCO controller is
located in the control enclosure. The Carel PGD1 Interface is housed in a block of rigid
plastic with a magnetic backing that allows the user to “stick” the interface on any metallic
surface. The GP20 through GP50 units come standard with a 10 ft (3 m) cable, and the GP70
through GP210 units come standard with a 20 ft (6 m) cable. Longer cables are available
through the After Market Sales Group. The controller 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).
Warning! Operating the chiller setpoint below 45°F (7°C) without the proper
amount of glycol for freeze protection could result in a damaged
evaporator. ACS Group does not warrant the freeze up of the
evaporator under any circumstances.
Figure 12: Controller Display
GP Series Portable Chillers
Chapter 4: Operation
35 of 90
Button
4-2
Button Description
Detailed description
Menu Button
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.
Initial Start-up
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 13: Main Status Screen
3. Set the Leaving Fluid temperature by depressing the
the menu.
button to display
Figure 14: 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
Chapter 4: Operation
36 of 90
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
appear.
to accept the password. The following screen will
Figure 15: Operator Setpoints Screen
5. Depress
to move the cursor to the CHILLED FLUID SP line. Use the
or
button to increment or decrement the value. Depress
accept the value and move the cursor down one line.
6. Depress the
4-3
to
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.
Status Screens
The controller has eight (8) preconfigured status screens. The main status screen (shown in
Figure Figure 16) 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.
GP Series Portable Chillers
Chapter 4: Operation
37 of 90
Figure 16: Main Chiller Status Screen
cycles through the following screens (shown below) – Analog I/O, Digital
Depressing
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.
GP Series Portable Chillers
Chapter 4: Operation
38 of 90
GP Series Portable Chillers
Chapter 4: Operation
39 of 90
The chiller can be equipped with a tempered fluid loop inside of the chiller. If this option is
installed, the main screen changes to the following.
GP Series Portable Chillers
Chapter 4: Operation
40 of 90
4-4
Access Levels
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.
4-5
Controller Setpoints
Variable
Chilled Fluid SP
Chil Hi Temp Wrn
Chil Hi Temp Flt
Process SP
Proc Hi Temp Wrn
Proc Hi Temp Flt
Proc Low Temp Wrn
Proc Low Temp Flt
Cooling Enabled
Heating Enabled
Fluid Freeze Point
Chill On Diff
Chill Off Diff
Proc On Diff
Proc Off Diff
Proc Hi Temp Dly
GP Series Portable Chillers
Description
Temperature of chilled fluid out to process
Setpoint for alarm to warn when chilled leaving fluid
temperature is too high
Setpoint to shut down pump and compressor based
on leaving fluid temperature
Temperature of tempered fluid out to process
Setpoint for alarm to warn when tempered leaving
fluid temperature is too high
Setpoint for alarm to warn when tempered leaving
fluid temperature is too high
Setpoint for alarm to warn when tempered leaving
fluid temperature is too low
Setpoint for alarm to warn when tempered leaving
fluid temperature is too low
Access Level
Operator
Supervisor
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Refrigeration system allowed to operate
x
Optional Process temperature heater allowed to
operate
Lowest temperature fluid will operate without
freezing. Below 32°F (0°C) glycol must be added.
Forces lowest Chilled fluid setpoint to be 13°F (7°C)
above FFP
Temperature difference above chilled fluid setpoint
before compressor turns on
Temperature difference below chilled fluid setpoint
before compressor turns off
Temperature difference below process setpoint
before process heater turns on
Temperature difference above process setpoint
before process heater turns off
Time (in seconds) Process High Temperature alarm
is ignored before activating
Chapter 4: Operation
x
x
x
x
x
x
x
41 of 90
Variable
Chil Hi Temp Dly
Hi Temp Flt Type
Chil Lo T Wrn Dif
Chil Lo T Flt Dif
Comp, Lead Cmp On Delay
Comp, Lead Cmp Off
Delay
Lag Cmp On Dly
Lag Cmp Off Dly
Cond Fan Start
Cond Fan Stop
Pump Stop Delay
Heater On Delay
Heater Cycle Tm
Description
Access Level
Operator
Supervisor
Time (in seconds) Chilled High Temperature alarm
is ignored before activating
When set to CRIT, chiller and process high temp
alarms will deactivate compressors and pumps.
When set to WARN, compressors and pumps are
allowed to continue to operate when a high temp
alarm occurs
Temperature difference below the chiller setpoint
before the chiller low temp warning alarm occurs
Temperature difference below the chiller setpoint
before the chiller low temp fault alarm occurs.
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
Time (in minutes) before lag compressor is
energized once Chilled fluid reaches 2°F (1.1°C)
above Chilled Fluid setpoint
Time (in minutes) before lag compressor is deenergized once chilled fluid reaches 2°F (1.1°C)
below Chilled Fluid setpoint
x
x
x
x
x
x
x
x
Discharge pressure which energizes condenser fan
x
Discharge pressure which de-energizes condenser
fan
Delay time in seconds between fault and stopping
the pump
Time (in seconds) before the heater is allowed to
activate once the last compressor stages off
Time (in seconds) between sampling the output of
the heater’s PID loop. For example, if this variable
is set to ten (10), the heater PID loop output is
checked every ten seconds. If the heater PID loop
output is 70% when sampled the heater output will
be on for 7 seconds and off for 3 seconds.
x
x
x
x
Heater P
P parameter of the heater PID loop
x
Heater I
I parameter of the heater PID loop
x
Heater D
D parameter of the heater PID loop
x
Cooling Valve P
P parameter of the cooling valve PID loop
x
Cooling Valve I
I parameter of the cooling valve PID loop
x
Cooling Valve D
D parameter of the cooling valve PID loop
x
Cooling Valve Mode
Cooling Valve Pos
Tank Min Lvl
GP Series Portable Chillers
When in AUTO, the cooling valve is controlled by
the cooling valve PID loop. When in MANUAL,
the cooling valve is forced open to the percent
dictated by the Cooling Valve Pos variable.
When the Cooling Valve Mode is set to MANUAL,
this variable dictates what percentage the valve is
forced to.
Minimum tank level. Used to set the default low
tank lefvel alarm setpoints as well as the auto-water
makeup on setpoint.
Chapter 4: Operation
x
x
x
42 of 90
Variable
Tank Max Lvl
Low Level Fault
Low Level Warning
Wtr Makeup On
Wtr Makeup Off
High Lvl Warning
High Lvl Fault
Description
Maximum tank level. Used to set the default high
tank level alarm setpoints as well as the auto-water
makeup off setpoint.
Tank level that will activate Low Level Warning
fault
Tank level that will activate Low Level Warning
alarm
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.
Tank level that will activate High Level Warning
alarm
Tank level that will activate High Level Warning
fault
Access Level
Operator
Supervisor
x
x
x
x
x
x
x
Mkup Min Rt X.X”/XXS
The minimum allowable rate for filling the tank
x
Operator Password
4 digit password to limit operator interaction
x
Operator Pw Time
Time in minutes for operator password to be active
x
Sprvisor Password
4 digit password for supervisory interaction
x
Sprvisor Pw Time
Time in minutes for supervisor password to be active
x
Alarm Silence Time
Set Clock
Reset to Defaults
Time in minutes to silence alarm (with optional
audible alarm). After time alarm will reactivate.
Allows for the time to be set if the clock card option
is installed
Resets all parameters to the default parameters,
including configuration
1. Set the Leaving Fluid temperature by depressing the
the menu.
x
x
x
button to display
Figure 17: Menu Screen
2. Depress the
or
button to highlight SETTINGS 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
Chapter 4: Operation
43 of 90
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 18: Operator Setpoints Screen
3. Depress
to move the cursor to the Leaving Temp line. Use the
button to increment or decrement the value. Depress
value and move the cursor down one line.
to accept the
4. Adjust the Hi Temp Warning and Hi Temp Fault in the same manner.
5. Depress the
GP Series Portable Chillers
button twice to return to the main status screen.
Chapter 4: Operation
or
44 of 90
4-6
Configuration Settings
Within the Supervisor Menu the chiller can be configured if options are added in the field.
These configurations are described below.
Variable
Tank Level Inst
Auto Water Make-up
Fan Control
Disch Press Cntl
Sensor Pack Inst
Cond Diff Sw Inst
Chill Diff Sw Inst
Description
Access Level
Operator
Supervisor
Activates/Deactivates the tank level control sensor
x
Activates the automatic water makeup valve within
the controller
Set to CYCLING when a standard fan starter is used
to control the fan. Set to VFD when a variable
frequency drive is used to control the fan
When set to SP, the chiller will control to a static SP.
When set to AUTO, the chiller will adjust the
discharge pressure setpoint based on the current
conditions to increase efficiency.
Activates the optional temperature sensors for
refrigerant liquid line and suction line temperatures,
and entering air or water temperature (depending on
condenser type)
Activates the optional water cooled condenser
differential water pressure switch
Activates the optional evaporator differential water
pressure switch
x
x
x
x
x
x
Clock Board Inst
Activates the optional controller real time clock card
x
Heater Installed
Activates the optional process heater
x
Analog IN2
Remote SP Mode
Rem SP mA Range
Analog In 6
Chil Loop Type
Proc Loop Type
Primary Loop
Analog Out 2
GP Series Portable Chillers
Determines how analog input 2 is used. It can be set
to CHIL IN (chiller in temperature), FROM PROC
(from process temperature), CHIL REM SP (chiller
remote setpoint) or PROC REM SP (process remote
setpoint).
When Analog IN2 is set to REM SP, this determines
if the LOCAL (entered through the display) setpoint
or REMOTE (Analog IN2) setpoint is used to
control the chiller.
Determines the signal type (0-20mA or 2-20mA) for
the Remote Setpoint
Determines how analog input 6 is used. It can be set
to CHIL IN (chiller in temperature), FROM PROC
(from process temperature) or TO PROC (to process
temperature).
Determines the chiller loop’s type (COOL or
HEAT/COOL)
Determines the process loop’s type (COOL,
HEAT/COOL or HEAT).
Determines which loop’s (PROC or CHIL)
information to display on the first status page of the
display.
Determines how analog output 2 is used. It can be
set to CHIL IN (retransmission of the chiller in
temperature), CHIL OUT (retransmission of the
chiller out temperature), FROM PROC
(retransmission of the from process temperature),
TO PROC (retransmission of the to process
temperature) or COOL VLV (process loop cooling
valve).
Chapter 4: Operation
x
x
x
x
x
x
x
x
45 of 90
Variable
Analog Out 3
Analog Out 4
Digital In 8
Start Mode
Chil Cntl Sens
Proc Cntl Sens
Pump 2 OL Alm
Flow 2 Alm Type
Alarm Out
Network Prot
Network Baudrate
Network Address
Units
GP Series Portable Chillers
Description
Determines how analog output 3 is used. It can be
set to CHIL IN (retransmission of the chiller in
temperature), CHIL OUT (retransmission of the
chiller out temperature), FROM PROC
(retransmission of the from process temperature) or
TO PROC (retransmission of the to process
temperature).
Determines how analog output 4 is used. It can be
set to CHIL IN (retransmission of the chiller in
temperature), CHIL OUT (retransmission of the
chiller out temperature), FROM PROC
(retransmission of the from process temperature) or
TO PROC (retransmission of the to process
temperature).
Determines how digital input 8 is used. It can be set
to START/STOP (remote start stop), NO
WARNING (normally open warning alarm), NC
WARNING (normally closed warning alarm), NO
FAULT (normally open fault alarm), NC Fault
(normally closed fault), PHASE MNTR (power
phase monitor), TMP SAFETY (high temp safety)
When Digital In 8 is configured to START/STOP
this determines if the chiller’s online status is
determined by the button on the display (LOCAL) or
digital input 8 (REMOTE).
Determines which sensor is used to control the
chiller. It can be set to CHIL OUT (chiller out
temperature), CHIL IN (chiller in temperature), TO
PROC (to process temperature) or FRM PROC
(from process temperature).
Determines which sensor is used to control the
process loop. It can be set to TO PROC (to process
temperature) or FRM PROC (from process
temperature).
When set to CRIT, the pump 2 overload alarm will
deactivate compressors and pumps. When set to
WARN, compressors and pumps are allowed to
continue to run when the pump 2 overload alarm
occurs.
When set to CRIT, the flow 2 alarm will deactivate
compressors and pumps. When set to WARN,
compressors and pumps are allowed to continue to
run when the flow 2 alarm occurs.
Determines when the alarm output is activated.
When set to ALL ALARMS, the output is activated
when any new alarm occurs. When set to CRIT
ALARMS, the output will only activate when
critical alarms (those that force the pump or
compressor off) occur.
Determines what network protocol is used for
communications. This can be set to BACNET485,
BACNET IP, MODBUS485, MODBUS IP, LON or
WEB.
Access Level
Operator
Supervisor
x
x
x
x
x
x
x
x
x
x
Determines the baudrate for communications.
x
Determines the network address of the chiller on the
network.
Determines if STANDARD (English) or METRIC
units are used.
Chapter 4: Operation
x
x
46 of 90
4-7
Alarms
4-8
Optional Communications
The controller is setup with multiple alarms, most of them configurable using the Supervisor
password. Section 4-5 Controller Setpoints on page 41 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.
Serial communications use a RS-485 hardware interface. Protocols available are BACNet,
LONWorks, CANBus, and ModBus RTU (Slave mode only). See Appendix for the
controller data that is available through these protocols.
Network communications use a RJ-45 hardware interface using the basic Ethernet TCP/IP
layer stack. Protocols available are BACNet (Ethernet, IP, or MS/TP) and ModBus IP. See
Appendix for the controller data that is available through these protocols.
GP Series Portable Chillers
Chapter 4: Operation
47 of 90
Chapter 5:
5-1
Maintenance
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 185P F (85P 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.
5-2
Refrigeration compressors are hermetically sealed and no lubrication is required.
Filter Cleaning
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. Remove the top side panel(s) to expose the condenser section.
3. Slide the filter rod to release it from the frame at the top and bottom.
4. 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.
5-3
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.
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 (GPWC20-50). 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 (GPWC70-210). 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
48 of 90
5-4
5-5
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.
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 Non-Acid De-Scaling Solution (Part No.
A0553840). Follow the directions on the container.
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.
5-6
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.
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
49 of 90
Chapter 6:
Troubleshooting
Many problems that can occur while operating the chiller can be avoided by following the recommended
installation, operation, and maintenance outlined within this manual. If you do have a problem this
Chapter will help you determine the cause and the potential solution.
Before beginning the troubleshooting process
Locate all wiring, piping, and assembly drawings that were shipped with the chiller. The
diagrams will note any custom options not covered in this manual.
Locate all manuals for any equipment that this chiller is connected to as they may provide
additional information to solve the problem.
WARNING!: Improper installation, operation, or any servicing may result in damage or personal
injusry
This chiller should only be installed, operated, and maintained by qualified technical
personnel who are familiar with the construction, operation, and potential hazards.
All wiring, disconnects, and over-current protection devices should be installed by a qualified
electrician in accordance will all local codes and ordinances in your region.
WARNING!: Electrical Hazard
Before performing any service on this equipment disconnect and lockout all electrical sources
to prevent injury from unexpected energization or startup. Follow all safety rules when
performing any maintenance or service to this equipment.
WARNING!: Refrigeration Hazard
Only certified refrigeration technicians should perform any refrigeration related maintenance.
CAUTION!: Hot Surfaces
Protect yourself from hot surfaces when working on the refrigeration or process temperature
sections of this equipment. These devices can reach temperatures of 180°F (82°C). Allow
the equipment to cool prior to performing any maintenance or service.
6-1
Identifying the Cause of a Problem
Types of conditions the user may see include alarm conditions and control problems.
Alarm Conditions
When an alarm condition occurs the
button backlight will flash, and if the optional
audible/visual alarm is installed the strobe and horn will energize. The light and horn will
remain on until the condition is corrected. Pressing the enter button will silence the audible
alarm, but the strobe will continue to flash.
The display will show the cause the alarm and will indicate a possible solution. To accept the
alarm press
, and follow the suggested solution to correct the alarm condition. The
following table shows the possible alarm messages that could appear on the display.
GP Series Portable Chillers
Chapter 6: Troubleshooting
50 of 90
CC = Compressor Critical
Alarm Name
SC = System Critical
PC = Process Critical
W = Warning
#
Type
Possible Cause
Solution
Allow the compressor to cool
MCP Failure
down. If the compressor does
not restart, disconnect power
Compressor Fault
1
CC
Compressor module has failed and verify operation of the
MCP internal module. Replace
if necessary.
Sensor Failure
Check the wiring connection at
Electrical connection at
the sensor, and at the controller.
Discharge Pressure Sensor Failure
2
W
sensor open
If necessary replace sensor.
Electrical connection at
controller open
Allow the fan to cool down. If
the fan does not restart when
Internal fan motor overload
Fan Overload
3
CC
called upon by controller,
tripped
replace fan motor.
Locate the drive and write
down the fault code shown on
Drive has detected internal
the display of drive. Contact
VFD Fault
4
CC
fault
customer service for assistance.
High Discharge Pressure Fault
5
CC
Dirty air cooled condenser or
inlet filter
Dirty water cooled condenser
or condenser valve failure
Condenser fan overload
Condenser fan VFD fault
Ambient air or condenser
water temperature too high
Too much refrigerant in
system.
Liquid line valves closed.
High Discharge Pressure Switch
6
CC
Discharge pressure switch
failure
Dirty air cooled condenser or
inlet filter
Dirty water cooled condenser
or condenser valve failure
Condenser fan overload
Condenser fan VFD fault
Ambient air or condenser
water temperature too high
Too much refrigerant in
system.
Liquid line valves closed
High Suction Pressure Fault
CC = Compressor Critical
Alarm Name
Low Discharge Pressure Fault
GP Series Portable Chillers
7
CC
Discharge pressure switch
failure
From Process fluid
temperature too high
Clean filter or condenser
Clean condenser or verify
operation of condenser valve
See Fan Overload Fault
See VFD Fault
Verify supply temperature or air
removal capacity.
Contact Customer Service for
assistance
Verify operation of valve and
wiring on controller
See Discharge Pressure Sensor
Failure
Clean filter or condenser
Clean condenser or verify
operation of condenser valve
See Fan Overload Fault
See VFD Fault
Verify supply temperature or air
removal capacity.
Contact Customer Service for
assistance
Verify operation of valve and
wiring on controller
See Discharge Pressure Sensor
Failure
Verify flow through system.
Make corrections as necessary.
SC = System Critical
PC = Process Critical
W = Warning
#
Type
Possible Cause
Solution
Verify ambient air temperature
Ambient air or condenser
and air flow or condenser inlet
water temperature too low
water temperature.
8
CC
Too little refrigerant in
Contact customer service for
system.
service call
Chapter 6: Troubleshooting
51 of 90
Water cooled condenser valve
stuck open
Fan VFD output at 100%
Low Fluid Temp Fault
9
CC
Low process fluid flow
Plugged Y-strainer
System low on refrigerant
Liquid line valves closed
Low Suction Pressure Fault
Low Superheat Fault (only will
appear if optional sensor pack is
installed)
Suction Pressure Sensor Failure
Leaving Water Temp Sensor
Failure
10
11
12
13
CC
CC
CC
SC
Chilled fluid setpoint too
close to freeze protection
setpoint.
Process fluid flow rate too
low.
Thermal expansion valve
failure.
Thermal expansion valve
failure
Temperature Sensor Failure
Sensor failure
Electrical connection at
sensor open
Electrical connection at
controller open
Sensor wires loose from
controller terminal block
Sensor wires broke between
sensor and controller terminal
block.
Tank level too low
Low Level Fault
14
SC
Optional water makeup valve
failure
Tank level sensor failure
System valve(s) closed
No Flow
15
SC
Low flow sensor failure
Pump failure
CC = Compressor Critical
Alarm Name
Pump Overload
High Fluid Temp Fault
GP Series Portable Chillers
Verify cooling valve operation.
Verify VFD is in remote versus
manual operation. Verify
controller output to VFD.
Verify system valve operation
and adjust if necessary
Clean y-strainer through blowdown valve or cleaning internal
strainer.
Contact Customer Service
Verify wiring or output between
controller and valve
Adjust setpoint or fluid
freezepoint temperature (will
require adding glycol to fluid)
Verify system valve operation
and adjust if necessary
Contact Customer Service
Contact Customer
Verify sensor wiring between
controller and sensor.
Check the wiring connection at
the sensor, and at the controller.
If necessary replace sensor.
Check the wiring connection at
the controller terminal block
Replace Sensor
Verify tank level parameters.
Add fluid if necessary.
Verify wiring between
controller and makeup valve.
Replace valve if necessary
Replace Sensor
Verify that all system valves are
operational and adjust.
Verify the sensor at the sensor
and at the terminal block.
Verify the operation of the
pump (i.e. motor circuit
protector or pump rotation)
SC = System Critical
PC = Process Critical
W = Warning
#
Type
Possible Cause
Solution
Verify motor circuit protector
operation. Verify motor wiring
Motor circuit protector open
and amp draw while under load.
Verify system valves are
16
SC
operational and properly set.
Pump flow rate in excess of
Contact customer service or
capacity
sales if pump is sized too small
for application.
Fluid temperature higher than Verify parameter and adjust if
necessary.
17
SC/W parameter.
Check for any refrigeration
Refrigeration system fault
Chapter 6: Troubleshooting
52 of 90
Chiller too small for load
Low Condenser Differential
Pressure Warning
18
W
Condenser Inlet Temp Sensor
Failure (optional with sensor
pack)
19
W
Chiller In Fluid Temp Sensor
Failure
Evaporator Differential Pressure
High Discharge Pressure Warning
20
21
22
W
W
W
Low discharge pressure or
high suction pressure
Sensor wires loose from
controller terminal block
Sensor wires broke between
sensor and controller terminal
block.
Sensor wires loose from
controller terminal block
Sensor wires broke between
sensor and controller terminal
block.
Blocked evaporator
Blocked Y-strainer
Dirty air cooled condenser or
inlet filter
Dirty water cooled condenser
or condenser valve failure
Condenser fan overload
Condenser fan VFD fault
Ambient air or condenser
water temperature too high
Too much refrigerant in
system.
Liquid line valves closed.
Fluid temperature higher than
parameter.
High Fluid Temp Warning
23
W
Refrigeration system fault
Chiller too small for load
system fault
Verify with sales representative
the sizing of the chiller for the
application.
Contact customer service
Verify wiring at terminal block.
.
Replace temperature sensor
Verify wiring at terminal block.
.
Replace temperature sensor
Backflush evaporator
Blow down y-strainer by
opening blow-down valve or
clean internal strainer.
Clean filter or condenser
Clean condenser or verify
operation of condenser valve
See Fan Overload Fault
See VFD Fault
Verify supply temperature or air
removal capacity.
Contact Customer Service for
assistance
Verify operation of valve and
wiring on controller
Verify parameter and adjust if
necessary.
Check for any refrigeration
system fault
Verify with sales representative
the sizing of the chiller for the
application.
CC = Compressor Critical
Alarm Name
SC = System Critical
PC = Process Critical
W = Warning
Solution
#
Type
Possible Cause
Fluid level higher than
Verify value in parameter
parameter setting.
Open drain valve and remove
High Level Fault
24
W
Too much fluid in system
some fluid from system so that
level is below high level fault.
Replace sensor
Tank sensor failure
Fluid level higher than
Verify value in parameter
parameter setting.
Open drain valve and remove
some fluid from system so that
High Level Warning
25
W
Too much fluid in system
level is below high level
warning.
Tank sensor failure
Replace sensor
Compressor Differential Pressure
Low discharge pressure or
Contact customer service
26
CC
Fault
high suction pressure
From Process fluid
Verify flow through system.
High Suction Pressure Warning
27
W
temperature too high
Make corrections as necessary.
Low Discharge Pressure Warning
28
W
Ambient air or condenser
Verify ambient air temperature
GP Series Portable Chillers
Chapter 6: Troubleshooting
53 of 90
water temperature too low
Too little refrigerant in
system.
Water cooled condenser valve
stuck open
Fan VFD output at 100%
Low Fluid Temp Warning
29
W
Low Level Warning
30
W
Compressor Differential Pressure
Warning
31
W
Fluid level lower than
parameter setting.
Optional Water Makeup valve
failure
Tank sensor failure
Low discharge pressure or
high suction pressure
System low on refrigerant
Liquid line valves closed
Low Suction Pressure Warning
32
W
Pump Down Override Time
Expired
33
W
CC = Compressor Critical
Alarm Name
Pump Flow Sensor Failure
Pump Pressure Sensor Failure
Refrig Liquid Temp Sensor
Failure
Refrig Suction Temp Sensor
Failure
Tank Level Sensor Failure
Water make-up failure
GP Series Portable Chillers
Chilled fluid setpoint too
close to freeze protection
setpoint.
Process fluid flow rate too
low.
Thermal expansion valve
failure.
Liquid line valve open
Hot gas bypass valve open
and air flow or condenser inlet
water temperature.
Contact customer service for
service call
Verify cooling valve operation.
Verify VFD is in remote versus
manual operation. Verify
controller output to VFD.
Verify value in parameter. Add
fluid to the system if necessary
Verify wiring between
controller and makeup valve.
Replace valve if necessary
Replace sensor
Contact customer service
Contact Customer Service
Verify wiring or output between
controller and valve
Adjust setpoint or fluid
freezepoint temperature (will
require adding glycol to fluid)
Verify system valve operation
and adjust if necessary
Contact Customer Service
Contact customer service
SC = System Critical
PC = Process Critical
W = Warning
#
Type
Possible Cause
Solution
Verify wiring of flow sensor at
34
W
Optional flow sensor failed
sensor and terminal block of
controller
Sensor wires loose from
controller terminal block
Verify wiring of sensor at
sensor and terminal block of
35
W
Sensor wires broke between
sensor and controller terminal controller
block.
Sensor wires loose from
Verify wiring of sensor at
sensor and terminal block of
controller terminal block
controller
36
W
Sensor wires broke between
sensor and controller terminal
block.
Sensor wires loose from
Verify wiring of sensor at
controller terminal block
sensor and terminal block of
controller
37
W
Sensor wires broke between
sensor and controller terminal
block.
Sensor wires loose from
Verify wiring of sensor at
controller terminal block
sensor and terminal block of
controller
38
W
Sensor wires broke between
sensor and controller terminal
block.
Verify wiring of solenoid valve
Make up solenoid failure
at valve and at terminal block.
40
W
Increase water pressure to be
Insufficient water pressure
above 5 psig (0.3 bar)
Chapter 6: Troubleshooting
54 of 90
Auxilliary Alarm
41
SC/W
Low Suction Pressure at Startup
42
CC
To ProcTemperature Sensor
Failure
43
PC
Process High Temp Fault
44
W
Process High Temp Warning
46
W
Process Low Temp Fault
48
W
Process Low Temp Warning
50
W
Pump 2 No Flow
52
SC/W
For Units with a Tempered Loop
CC = Compressor Critical
Alarm Name
Pump 2 Overload
High Temp Safety Switch
Phase Monitor Fault
From Proc Sensor Failure
Unit does not run.
GP Series Portable Chillers
Loose or broken sensor wire
Process heater on
Process cooling valve off
Process heater on
Process cooling valve off
Process heater off
Process cooling valve on
Process heater off
Process cooling valve on
Optional process flow switch
failure
Process valves closed
Adjust parameter for length of
time to build suction pressure
Contact Customer Service
Verify wiring of temperature
sensor at sensor and terminal
block of controller
Verify heater contactor
operation
Verify cooling valve operation
Verify heater contactor
operation
Verify cooling valve operation
Verify heater contactor
operation
Verify cooling valve operation
Verify heater contactor
operation
Verify cooling valve operation
Verify operation of flow switch.
Verify operation of process
valves and adjust as necessary
SC = System Critical
PC = Process Critical
W = Warning
#
Type
Possible Cause
Solution
Verify motor circuit protector
Motor circuit protector open
operation. Verify motor wiring
and amp draw while under load.
Verify system valves are
53
SC/W
operational and properly set.
Pump flow rate in excess of
Contact customer service or
capacity
sales if pump is sized too small
for application.
Verify operation of heater and
Heater failure
cooling valve. .
54
PC
Verify wiring at cooling valve
Cooling Valve failure
and at terminal bloc
Sensor failure
Replace sensor if necessary.
Reverse two wires at line-side
of power switch on electrical
Unit wired incorrectly
panel.
55
SC
Loss of phase during
Verify sensor wiring at sensor
operation
and at terminal bloc.
Replace sensor if necessary.
Sensor failure
Sensor wires loose from
Verify wiring at sensor and at
controller terminal block
terminal block. y.
56
W
Sensor wires broke between
Replace sensor if necessar
sensor and controller terminal
block.
Non-Controller Related Issues
Problem
This alarm is configurable
Parameter set too short for
remote condenser installation
Refrigerant amount too low
Possible cause
No power.
Wrong voltage supplied to unit.
Chapter 6: Troubleshooting
Solution
Check main disconnect, fuses, wiring,
and power lead to unit.
Voltage must be within plus or minus
10% of nameplate rating.
55 of 90
Problem
Possible cause
Control circuit fuse blown.
Defective control transformer.
Piping flow switch circuit open.
Pump motor off on overload.
GP Series Portable Chillers
Chapter 6: Troubleshooting
Solution
Replace control circuit fuse.
Check transformer.
Check for a short circuit.
Replace.
Add water or water/glycol solution as
required.
Reset and test.
56 of 90
Problem
Possible cause
Leaving fluid setpoint set higher
than temperature of liquid in
system.
Compressor internal overload or
MCP is open.
Pump runs; compressor does not.
Compressor contactor holding coil
open.
Defective compressor auxiliary
contact.
Broken wire in the compressor
control circuit.
Plugged Y-strainer
Pump runs, compressor cycles at
short intervals.
Hot gas not coming on
Low process water flow
Restricted condenser air flow.
Unit runs continuously, but not
enough cooling power.
GP Series Portable Chillers
Unit low on refrigerant.
Compressor not operating
efficiently.
Unit under-sized for application.
Chapter 6: Troubleshooting
Solution
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 loose compressor electrical
connections.
Failed compressor motor
Repair or replace.
Repair or replace.
Locate and repair.
Clean
Check hot gas analog output value
through status screen. Contact Service
if output value remains at 0%
throughout compressor cycle.
Check internal bypass valve to verify it
is open and free of debris.
Install bypass between to-and-from
process line
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.
57 of 90
Chapter 7:
7-1
Appendix
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 manufacturerʼs discretion, if
the item is found to be defective in materials or workmanship. Purchased components are covered
under their specific warranty terms.
7-2
Technical Assistance
Parts Department
Call toll-free Monday – Friday, 7am–5pm CST [800] 423-3183 or call [262] 641-8610,
Fax [262] 641-8653
GP Series Portable Chillers
Chapter 7: Appendix
58 of 90
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 Monday – Friday, 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.
GP Series Portable Chillers
Chapter 7: Appendix
59 of 90
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.
GPAC-20
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
4.65
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
4936
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
11.31
BTU/WATT
CONDENSER AIR FLOW
4230
CFM
86
dBA
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
11
GPM
SOUND POWER LEVEL
7
PSID
SOUND PRESSURE LEVEL @ 1 METER
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
6-24
GPM
60-115
°F
MINIMUM LOAD
0.944
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
3 LBS R-410A
CONDENSER FANS
24 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
1/2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
20 GALLON POLYETHYLENE
WEIGHT (OPERATING)
690
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
520
LBS
CONTROL CIRCUIT
120
VDC
COMPRESSOR FULL LOAD AMPS
10.7
AMPS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPAC-30
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
7.30
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
7579
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
11.56
BTU/WATT
CONDENSER AIR FLOW
6343
CFM
18
GPM
SOUND POWER LEVEL
92
dBA
7
PSID
SOUND PRESSURE LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
9-36
GPM
60-115
°F
MINIMUM LOAD
1.504
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
4 LBS R-410A
CONDENSER FANS
24 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
1 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
20 GALLON POLYETHYLENE
WEIGHT (OPERATING)
870
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
700
LBS
CONTROL CIRCUIT
120
VDC
COMPRESSOR FULL LOAD AMPS
16.4
AMPS
GP Series Portable Chillers
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
60 of 90
GPAC-40
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
9.91
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
10070
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
11.81
BTU/WATT
CONDENSER AIR FLOW
8458
CFM
24
GPM
SOUND POWER LEVEL
87
dBA
7
PSID
SOUND PRESSURE LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
12-48
GPM
60-115
°F
MINIMUM LOAD
2.022
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
6 LBS R-410A
CONDENSER FANS
32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
1 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
40 GALLON POLYETHYLENE
WEIGHT (OPERATING)
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
CONTROL CIRCUIT
120
VDC
20
AMPS
COMPRESSOR FULL LOAD AMPS
1090
LBS
760
LBS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPAC-50
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
15.19
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
14882
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
12.25
BTU/WATT
CONDENSER AIR FLOW
12687
CFM
36
GPM
SOUND POWER LEVEL
93
dBA
7
PSID
SOUND PRESSURE LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
18-72
GPM
60-115
°F
MINIMUM LOAD
3.016
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
8 LBS R-410A
CONDENSER FANS
32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
40 GALLON POLYETHYLENE
WEIGHT (OPERATING)
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
CONTROL CIRCUIT
COMPRESSOR FULL LOAD AMPS
GP Series Portable Chillers
120
VDC
30
AMPS
1290
LBS
950
LBS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
61 of 90
GPAC-70
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
20.16
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
20048
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
12.07
BTU/WATT
CONDENSER AIR FLOW
16916
CFM
48
GPM
SOUND POWER LEVEL
89
dBA
7
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
AMBIENT AIR TEMPERATURE
60-115
°F
COOLANT FLOW
°F
MINIMUM LOAD
24-96
GPM
4.03
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
12 LBS R-410A
CONDENSER FANS
(2) 24 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(2) 1/2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2180
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1520
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 17.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPAC-90
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
25.47
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
25504
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
11.98
BTU/WATT
CONDENSER AIR FLOW
25374
CFM
61
GPM
SOUND POWER LEVEL
95
dBA
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
7
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
60-115
°F
COOLANT FLOW
°F
MINIMUM LOAD
30-120
GPM
5.09
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
12 LBS R-410A
CONDENSER FANS
(2) 32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(2) 2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2580
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1900
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 23.1 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
62 of 90
GPAC-105
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
30.21
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
COOLANT
TONS
50
°F
95
°F
WATER
COOLANT FLOW
UNIT PRESSURE DROP
ALTITUDE
COMPRESSOR POWER
SEA LEVEL
29731
WATTS
EER
12.19
BTU/WATT
CONDENSER AIR FLOW
25374
CFM
72
GPM
SOUND POWER LEVEL
7
PSID
SOUND PRESS LEVEL @ 1 METER
95
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
60-115
°F
MINIMUM LOAD
36-144
GPM
6.04
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
16 LBS R-410A
CONDENSER FANS
(2) 32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(2) 2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2580
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1900
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 26.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPAC-140
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
40
TONS
COOLANT SUPPLY TEMPERATURE
50
°F
95
°F
AMBIENT AIR TEMPERATURE
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
ALTITUDE
COMPRESSOR POWER
SEA LEVEL
38153
WATTS
EER
12.58
BTU/WATT
CONDENSER AIR FLOW
38061
CFM
98
dBA
96
GPM
SOUND POWER LEVEL
7
PSID
SOUND PRESS LEVEL @ 1 METER
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
60-115
°F
COOLANT FLOW
°F
MINIMUM LOAD
48-192
GPM
8.00
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
18 LBS R-410A
CONDENSER FANS
(3) 32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(3) 2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 30.4 AMPS EACH
3870
LBS
2850
LBS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
63 of 90
GPAC-175
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
49.41
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
48693
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
12.18
BTU/WATT
CONDENSER AIR FLOW
38061
CFM
118
GPM
SOUND POWER LEVEL
98
dBA
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
7
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
60-115
°F
MINIMUM LOAD
60-240
GPM
9.88
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
24 LBS R-410A
CONDENSER FANS
(3) 32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(3) 2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
3870
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
2850
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 41.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPAC-210
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
63.95
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
63589
WATTS
AMBIENT AIR TEMPERATURE
95
°F
EER
12.07
BTU/WATT
CONDENSER AIR FLOW
50748
CFM
153
GPM
SOUND POWER LEVEL
99
dBA
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
7
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
AMBIENT AIR TEMPERATURE
20-80
°F
COOLANT FLOW
60-115
°F
MINIMUM LOAD
72-288
GPM
12.79
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
ALUMINUM
REFRIGERANT
32 LBS R-410A
CONDENSER FANS
(4) 32 INCH AXIAL
FRAME
GALVANIZED STEEL
CONDENSER FAN MOTOR
(4) 2 HP OAO, 1140 RPM
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
5160
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
3800
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 54.5 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
64 of 90
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.
GPWC-20
PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)
COOLING CAPACITY
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
COOLANT
5.12
TONS
UNIT PRESSURE DROP
SEA LEVEL
°F
COMPRESSOR POWER
4064
WATTS
85
°F
EER
15.13
BTU/WATT
15.9
GPM
13
GPM
SOUND POWER LEVEL
dBA
7
PSID
SOUND PRESSURE LEVEL @ 1 METER
dBA
WATER
COOLANT FLOW
ALTITUDE
50
CONDENSER WATER FLOW
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
20-80
50-90
°F
COOLANT FLOW
6-24
GPM
°F
MINIMUM LOAD
1.06
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
TUBE IN TUBE
REFRIGERANT
3 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
20 GALLON POLYETHYLENE
WEIGHT (OPERATING)
690
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
520
LBS
CONTROL CIRCUIT
120
VDC
COMPRESSOR FULL LOAD AMPS
10.7
AMPS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPWC-30
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
COOLANT
7.98
TONS
50
°F
85
°F
WATER
COOLANT FLOW
20
UNIT PRESSURE DROP
7
GPM
PSID
ALTITUDE
COMPRESSOR POWER
SEA LEVEL
6416
WATTS
EER
14.92
BTU/WATT
CONDENSER WATER FLOW
25.08
GPM
SOUND POWER LEVEL
SOUND PRESSURE LEVEL @ 1
METER
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
20-80
°F
COOLANT FLOW
9-36
GPM
50-90
°F
MINIMUM LOAD
1.672
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
20 MESH
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
TUBE IN TUBE
REFRIGERANT
4 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
20 GALLON POLYETHYLENE
WEIGHT (OPERATING)
870
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
700
LBS
CONTROL CIRCUIT
120
VDC
COMPRESSOR FULL LOAD AMPS
16.4
AMPS
GP Series Portable Chillers
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
65 of 90
GPWC-40
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
COOLANT
10.94
TONS
50
°F
85
°F
WATER
COOLANT FLOW
UNIT PRESSURE DROP
27
GPM
7
PSID
ALTITUDE
SEA LEVEL
COMPRESSOR POWER
8450
WATTS
EER
15.53
BTU/WATT
CONDENSER WATER FLOW
33.93
GPM
SOUND POWER LEVEL
SOUND PRESSURE LEVEL @ 1
METER
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
20-80
°F
COOLANT FLOW
12-48
GPM
50-90
°F
MINIMUM LOAD
2.262
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
TUBE IN TUBE
REFRIGERANT
6 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
40 GALLON POLYETHYLENE
WEIGHT (OPERATING)
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
CONTROL CIRCUIT
COMPRESSOR FULL LOAD AMPS
120
VDC
20
AMPS
20 MESH
1090
LBS
760
LBS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPWC-50
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
COOLANT
16.66
TONS
UNIT PRESSURE DROP
SEA LEVEL
°F
COMPRESSOR POWER
12778
WATTS
85
°F
EER
15.65
BTU/WATT
CONDENSER WATER FLOW
50.28
GPM
WATER
COOLANT FLOW
ALTITUDE
50
40
GPM
7
PSID
SOUND POWER LEVEL
SOUND PRESSURE LEVEL @ 1
METER
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
CONDENSER INLET WATER
TEMPERATURE
20-80
°F
COOLANT FLOW
18-72
GPM
50-90
°F
MINIMUM LOAD
3.352
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
STAINLESS STEEL CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
TUBE IN TUBE
REFRIGERANT
8 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
40 GALLON POLYETHYLENE
WEIGHT (OPERATING)
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
CONTROL CIRCUIT
COMPRESSOR FULL LOAD AMPS
GP Series Portable Chillers
120
VDC
30
AMPS
1290
LBS
950
LBS
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
66 of 90
GPWC-70
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
22.68
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
16970
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
16.04
BTU/WATT
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
CONDENSER WATER FLOW
68
GPM
74
dBA
54
GPM
SOUND POWER LEVEL
7
PSID
SOUND PRESS LEVEL @ 1 METER
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
24-96
GPM
4.54
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
20 MESH
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
12 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2180
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1520
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 17.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPWC-90
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
28.43
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
21716
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
15.71
BTU/WATT
CONDENSER WATER FLOW
85
GPM
68
GPM
SOUND POWER LEVEL
74
dBA
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
COOLANT FLOW
UNIT PRESSURE DROP
7
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
30-120
GPM
5.69
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
20 MESH
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
12 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2580
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1900
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 23.1 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
67 of 90
GPWC-105
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
33.64
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
25508
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
15.83
BTU/WATT
80
GPM
SOUND POWER LEVEL
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
CONDENSER WATER FLOW
COOLANT FLOW
UNIT PRESSURE DROP
7
101
GPM
76
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
36-144
GPM
6.73
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
16 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
70 GALLON POLYETHYLENE
WEIGHT (OPERATING)
2580
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
1900
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 26.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPWC-140
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
43.35
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
32685
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
15.92
BTU/WATT
104
GPM
SOUND POWER LEVEL
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
CONDENSER WATER FLOW
COOLANT FLOW
UNIT PRESSURE DROP
7
130
GPM
79
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
48-192
GPM
8.67
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
20 MESH
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
18 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
3870
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
2850
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 30.4 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
68 of 90
GPWC-175
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
54.46
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
41633
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
15.70
BTU/WATT
130
GPM
SOUND POWER LEVEL
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
CONDENSER WATER FLOW
COOLANT FLOW
UNIT PRESSURE DROP
7
163
GPM
82
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
60-240
GPM
10.89
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
24 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
3870
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
2850
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
24/120
VAC
(2) @ 41.9 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
GPWC-210
PERFORMANCE (NOMINAL DESIGN CONDITIONS)
COOLING CAPACITY
70.63
TONS
ALTITUDE
SEA LEVEL
COOLANT SUPPLY TEMPERATURE
50
°F
COMPRESSOR POWER
54315
WATTS
CONDENSER INLET WATER TEMP
85
°F
EER
15.60
BTU/WATT
169
GPM
SOUND POWER LEVEL
PSID
SOUND PRESS LEVEL @ 1 METER
COOLANT
WATER
CONDENSER WATER FLOW
COOLANT FLOW
UNIT PRESSURE DROP
7
212
GPM
81
dBA
dBA
OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE
20-80
°F
COOLANT FLOW
CONDENSER INLET WATER TEMP
50-90
°F
MINIMUM LOAD
72-288
GPM
14.13
TONS
SPECIFICATIONS
COMPRESSOR
SCROLL
EVAPORATOR FILTER
20 MESH
COOLANT PUMP
SST CENTRIFUGAL
COOLANT CIRCUIT
NON-FERROUS
EVAPORATOR
BRAZED PLATE
CAPACITY CONTROL
HOT GAS BYPASS
CONDENSER
SHELL & TUBE
REFRIGERANT
32 LBS R-410A
FRAME
GALVANIZED STEEL
PANELS
POWDER COATED STEEL
RESERVOIR
140 GALLON POLYETHYLENE
WEIGHT (OPERATING)
5160
LBS
POWER
460V/3PH/60HZ
WEIGHT (SHIPPING)
3800
LBS
CONTROL CIRCUIT
COMPRESSOR RATED LOAD AMPS
GP Series Portable Chillers
24/120
VAC
(2) @ 54.5 AMPS EACH
ELECTRICAL ENCLOSURE
NEMA 12
CONTROL
MICROPROCESSOR
Chapter 7: Appendix
69 of 90
7-3
Pump Curves, Flow, and Pressure Considerations
60 Hertz Pump Curves
20-50 ALL 60 Hz
ACS CHILLER PUMPS
September 8, 2009
300
120
250
100
10 HP 3U 32-200-1100D3G
200
80
3 HP 2CDU 70/306
150
Psi
Head [ft]
5 HP 2CDU 200/506
60
2 HP CDU 70/520D3G
3 HP CDU120/530D3G
100
40
1.5 HP CDU 70/315D3G
50
20
0
0
0
10
20
30
40
50
60
70
80
Capacity [Gal/min]
HP
1.5
2
3
3
5
10
GP Series Portable Chillers
Model
CDU 70/315D3G
CDU 70/520D3G
CDU 120/530D3G
2CDU 70/306
2CDU 200/506
3U 32-200-1100D3G
GP 20 GP 30
STD
OPT STD
OPT
OPT
OPT OPT
Chapter 7: Appendix
GP 40 GP 50
STD
OPT
STD
OPT
OPT
OPT
OPT
70 of 90
70-210 ALL 60 Hz
ACS CHILLER PUMPS
September 8, 2009
300
120
250
100
15 HP 3U 40-200B150D3G
200
5 HP 2CDU 200/506
10 HP 3U 32-200-1100D3G
80
150
Bar
Head [ft]
30 HP 3UB 65-200300D3G
5 HP 3U 32-160B50D3G
10 HP 3U 40-160-1100D3G
60
7.5 HP 3U 40-160-75D3G
5 HP CDU200/550D3G
100
5 HP 3U 40-125B-50D3G
50
40
20
0
0
60
120
180
240
0
300
Capacity [Gal/min]
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
GP Series Portable Chillers
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
Chapter 7: Appendix
71 of 90
50 Hertz Pump Curves
20-50 ALL 50 Hz
ACS CHILLER PUMPS
September 8, 2009
70
6
60
10 HP 3U 32-200-1100D3G
5
50
40
4
Bar
Head [m]
5 HP 2CDU 200/506
3 HP 2CDU 70/306
3
30
2
20
2 HP CDU 70/520D3G
3 HP CDU120/530D3G
1.5 HP CDU 70/315D3G
1
10
0
0
50
100
150
200
250
0
300
Capacity [liter/min]
HP
1.5
2
3
3
5
10
GP Series Portable Chillers
Model
CDU 70/315D3G
CDU 70/520D3G
CDU 120/530D3G
2CDU 70/306
2CDU 200/506
3U 32-200-1100D3G
GP 20 GP 30
STD
OPT STD
OPT
OPT
OPT OPT
Chapter 7: Appendix
GP 40 GP 50
STD
OPT
STD
OPT
OPT
OPT
OPT
72 of 90
70-210 ALL 50 Hz
ACS CHILLER PUMPS
September 8, 2009
70
7
60
6
5 HP 2CDU 200/506
50
10 HP 3U 32-200-1100D3G
30 HP 3UB 65-200300D3G
5
Head [m]
5 HP 3U 32-160B50D3G
10 HP 3U 40-160-1100D3G
30
4
7.5 HP 3U 40-160-75D3G
3
5 HP 3U 40-125B-50D3G
20
5 HP CDU200/550D3G
2
10
1
0
0
120
240
360
480
600
720
840
960
1080
0
1200
Capacity [liter/min]
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
GP Series Portable Chillers
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
Chapter 7: Appendix
73 of 90
Bar
15 HP 3U 40-200B150D3G
40
Pure Water at >40°F
GPXC-20
GPXC-30
GPXC-40
GPXC-50
GPM
DP (PSI)
GPM
DP (PSI)
GPM
DP (PSI)
GPM
DP (PSI)
0.5X Nominal
6
1.0X Nominal
12
1.7
9
1.7
12
1.6
18
1.8
5.9
18
6.1
24
5.8
36
2.0X Nominal
24
6.4
21.4
36
21.9
48
20.7
72
23.3
0.5X Nominal
24
1.7
30
1.8
36
1.7
48
1.8
1.0X Nominal
48
6.1
60
6.5
72
6.1
96
6.4
2.0X Nominal
96
21.9
120
23.5
144
22.1
192
23.6
0.5X Nominal
72
1.7
1.0X Nominal
144
6.2
2.0X Nominal
288
22.7
GPXC-70
GPXC-90
GPXC-140
GPXC-175
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.
GP Series Portable Chillers
Chapter 7: Appendix
74 of 90
7-4
Remote Air-Cooled Chiller Configurations
GP Series Portable Chillers
Chapter 7: Appendix
75 of 90
Figure 19: Double Riser Detail
GP Series Portable Chillers
Chapter 7: Appendix
76 of 90
7-5
Typical Ductwork for Air-Cooled Chillers
Model
GPAC-20
GPAC-30
GPAC-40
GPAC-50
GPAC-70
GPAC-90
GPAC-105
GPAC-140
GPAC-175
GPAC-210
Fan
HP
0.5
1.0
1.0
2.0
(2) 1.0
(2) 2.0
(2) 2.0
(3) 2.0
(3) 2.0
(4) 2.0
kW
0.4
0.7
0.7
1.5
(2) 0.7
(2) 1.4
(2) 1.4
(3) 1.4
(3) 1.4
(4) 1.4
60 Hz Discharge
air volume
3
CFM
m /min
4230
120
6343
180
8458
240
12687
360
16916
479
25374
718
25374
718
38061
1077
38061
1077
50748
1436
50 Hz Discharge air
volume
3
CFM
m /min
3525
100
5286
150
7048
200
10573
300
14097
399
21145
598
21145
598
31718
898
31718
898
42290
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.
GP Series Portable Chillers
Chapter 7: Appendix
77 of 90
Notes:
Customer use of ductwork requires the high pressure fan option.
Allow 30 in. (77 cm) minimum clearance around the chiller footprint to facilitate free passage of
cooling air and service accessibility.
Figure 20 shows the pressure loss per foot of ductwork. Calculate the total equivalent length before
using the data below.
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. Size the
damper so that the pressure drop across is no greater than 0.2 in WG (50 Pascal) at the rated output.
Chillers are designed to operate at a condensing entering air temperature of 60ºF (16ºC) minimum
without optional Variable Frequency Drive.
Figure 20 - Loss of Pressure through round duct - inches of water column per equivalent foot
60 hz Condenser Fan Flow Rate (cfm / cmm)
Nominal
Duct
Diameter
(in / cm)
18 / 45
50 hz Condenser Fan Flow Rate (cfm / cmm)
GPAC-20
GPAC-30
GPAC-40
GPAC-50
GPAC-20
GPAC-30
GPAC-40
GPAC-50
4230 / 120
0.003
6343 /
180
0.007
8458 /
240
0.013
12687 /
360
0.03
3525 /
100
0.002
5286 /
150
0.005
7048 /
200
0.009
10573 /
300
0.020
0.001
20 / 50
0.002
0.005
0.008
0.02
0.003
0.005
0.012
22 / 55
0.001
0.003
0.005
0.01
0.002
0.003
0.007
24 / 60
0.002
0.003
0.007
0.001
0.002
0.005
26 / 65
0.001
0.002
0.004
0.001
0.003
0.001
28 / 70
0.003
0.002
30 / 75
0.002
0.002
32 / 80
0.002
0.001
36 / 90
0.001
Note: 1 inch of water column = 250 Pascal
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Piping Diagrams
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