Sterling Refrigerator 882.93092.00 User's Manual
Contents
1. COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 4 LBS R 410A CONDENSER FANS Peer 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 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 16 4 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 42 of 64 G PAC 40 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 95 EER BTU WATT COOLANT WATER CONDENSER AIR FLOW CFM COOLANT FLOW 24 SOUND POWER LEVEL dBA UNIT PRESSURE DROP ya SOUND PRESSURE LEVEL 1 METER dBA PM OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 E AMBIENT AIR TEMPERATURE COOLANT FLOW G 60 115 F MINIMUM LOAD 2 022 TONS SPECIFICATIONS EVAPORATOR FILTER COOLANT CIRCUIT COMPRESSOR COOLANT PUMP SCROLL STAINLESS STEEL CENTRIFUGAL 20 MESH NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 6 LBS R 410A CONDENSER FANS 32 INCH AXIA2. deseo Cete re qos acetate qe mene 23 3 11 Initial Start Upas sae a ettet c mo o metodi Ce PR OUR E ERR eee 23 3 12 Finishing Setup Setting Up PasswordS AEN 23 GP Series Portable Chillers lii CHAPTER 4 OPERATION eene 26 4 1 Panel Buttons Indicator Lights and Switches ma aaawi 26 Microprocessor Eet EE 26 4 2 Initial Start up EE 27 423 Status SORSOIS raka ag duit tr tirer en aga lante 29 4 4 ECOS IS EA AA TOS 3i 4 5 HEEM ebe ER e EE EL EE 34 4 7 Optional Communications irem ee erbe aaa d ee db Qo E Re anana ve Ki ie Rea 34 CHAPTER 5 MAINTENANCE eere enne 36 Bat Ee er ue das 36 5 2 Filter Cleaning asas tes Uo cae sat Tod EE 36 5 3 Maintaining the Condenser seeesssssesseseeeeeeeeennn nennen nnne nnns 36 Air and Remote Air Cooled Chillers AAA 36 Water Gooled Chillers x emm otio sese ve Boar detnr rales ate cd 36 5 4 Maintaining the Evaporator ussncici eaaa eaaa eea Ie Uo eto Loco idee pce bci Reap ed geeks 37 5 5 Evaporator Process Piping Vale acond 37 5 6 Preventative Maintenance Service AEN 37 CHAPTER 6 TROUBLESHOOTING mA 38 CHAPTER 7 APPEND ID 2 tpe eerie nne eee aa aaa kaken 40 2 1 Returned Material Policy nian dies reir Ee eege ed 40 Credit E 40 7 2 Technical ASSISTAMCO coepere IUe re NANG cat xx Ut lane 41 PAHS Department udo Moor diii A a qu em E UR anaa 41 Service EE 41 Sales Depa time om c 41
3. 5 1 Lubrication Grease all fan motors and pump motors that do not have permanently sealed bearings Be sure to use an all purpose industrial grease with a temperature reference of 185 F 85 C Remove the grease relief plug motors only before adding grease add grease until a small amount pours out and replace the plug when finished Caution Failure to remove the grease relief plug will result in dislodging the bearing grease seal eventually causing bearing failure Refrigeration compressors are hermetically sealed and no lubrication is required 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 Slide the filter rod to release it from the frame at the top and bottom 3 Wash down the filter with clean water preferably with a garden hose directing the flow of water opposite the direction of airflow If dirt is heavy use a mild detergent and rinse well Allow the filter to dry completely before replacing it on the chiller Note Keep a spare air filter set on hand Install and use it while cleaning Caution Do not use compressed air to blow off a dirty filter It will not clean very well and the filter could be damaged Never run the chiller without properly installed filters Maintaining the Condenser Dirty condenser he
4. POWER 460V 3PH 60HZ WEIGHT SHIPPING 950 LBS CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers 30 AMPS CONTROL Chapter 7 Appendix MICROPROCESSOR 43 of 64 Water Cooled Portable Chillers Nominal operating parameters for water cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained G PWC 20 PERFORMANCE NOMINAL DESIGN CONDITIONS 60 HZ COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER 4064 WATTS CONDENSER INLET WATER TEMPERATURE EER 15 13 BTU WATT COOLANT CONDENSER WATER FLOW 15 9 GPM COOLANT FLOW SOUND POWER LEVEL dBA UNIT PRESSURE DROP SOUND PRESSURE LEVEL 1 METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW GPM CONDENSER INLET WATER TEMPERATURE 50 90 F MINIMUM LOAD 1 06 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP 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 5
5. BACKDRAFT BIRD SCREEN DAMPER NU ROOF FLASHING 3 NON CANA WA RENE a Sy KR SASK XC NON AN SAMS 2 OPPOSED 6 DOUBLE DAMPERS DEFLECTION amp LINKAGE N K e GRILLE BACKDRAFT T AN a DAMPER H Se eA AR H Ap d NOUT C v gt Ez a x ii p OPPOSED OPPOSED N LE DAMPERS DAMPERS Y BIRD SCREEN amp LINKAGE amp LINKAGE FLEXIBLE 4 FLEXIBLE CONNECTIONS CONNECTIONS NS ALL UNITS ALL UNITS EN A EN Ni AIRIN gt lt AIRIN ARIN gt LARIN NG Li Gi Le N wal S ma ke E N 30 00 MIN S n F n n cad 60 Hz Discharge 50 Hz Discharge Fan air volume air volume Model HP kw CFM m min CFM m min GPAC 20 0 5 0 4 4230 120 3525 100 GPAC 30 1 0 0 7 6343 180 5286 150 GPAC 40 1 0 0 7 8458 240 7048 200 GPAC 50 2 0 1 5 12687 360 10573 300 When locating your air cooled portable chiller and designing its ductwork note any potential high temperature conditions when discharging into your building and any negative pressures with the building when discharging air outside Notes e Customer use of ductwork requires the high pressure fan option e Allow 30 77 cm minimum clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility e Size the ductwork for maximum capacity e Support ductwork from the building structure not off of the chiller e Back draft damper to outside must be closed at all times
6. WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage GP Series Portable Chillers Chapter 1 Safety 5 of 64 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 Y Follow all SAFETY CODES Y Wear SAFETY GLASSES and WORK GLOVES Y Disconnect and or lock out power before servicing or maintaining the equipment Y Use care when LOADING UNLOADING RIGGING or MOVING this equipment kW Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you S Y Make sure the equipment and components are properly GROUNDED before you switch on power Y 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 Y Refrigera
7. C Please consult factory for the proper pump GP Series Portable Chillers Chapter 3 Installation 22 of 64 3 10 Automatic Water Make Up Option The chiller may be connected to an automatic make up system if the optional package pipe fittings solenoid valve and 1 2 NPT city water make up connection is factory installed If the automatic make up system is connected to a city water system make provisions to prevent backflow contamination Install an approved backflow preventer in accordance with local codes Caution Adding straight city water into a glycol water mixture dilutes the solution and eventually leads to system freeze up Damage from freeze up is not covered by the warranty To prevent system freeze up in automatic make up applications we recommend using either a chemical feeder or make up reservoir to replenish glycol Contact the sales department for more information about these configurations 3 11 Initial Start Up Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process that will be controlled Portable chillers are built with a voltage specific compressor and cannot be re wired for an alternate voltage Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must read within plus or minus ten percent 1046 of the voltage listed on the serial tag E
8. 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
9. manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations GP Series Portable Chillers Chapter 7 Appendix 41 of 64 7 3 Specifications Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 lpm per 3 517 kW with 95 F 35 C ambi
10. 1 2 NPT GP Series Portable Chillers Chapter 7 Appendix 55 of 64 D O 69 3 T 69 9 xa ZE OPTIONAL MAKE U TONAL nan IC En ENTERING FLUID 2 NPT Tou DRAIN N 1 2 NPT G 3 CONDENSER WATER OUT 13 1 1 4 NPT 28 Y CN CONDENSER WATER IN 1 1 4 NPT LEAVING FLUID 2 NPT G9 M2 G 3 s GP Series Portable Chillers Chapter 7 Appendix 56 of 64 9 0 69 39 T G9 0 ba AUTO WATER 250L MAKE UP OPTIONAL 1 2 NPT as ENTERING FLUID 2 NPT E rad DRAIN A Ve 12 3 A LEAVING FLUID 2 NPT GP Series Portable Chillers Chapter 7 Appendix 57 of 64 D 2 69 63 4 e 7 800 TYPE ACR we Gu 2 mec aca 5 8 0D TYPE ACR GP Series Portable Chillers Chapter 7 Appendix 5 Q 3 E AUTO WATER MAKE U ONAL Ka V2 RET ENTERING FLUID 2 NPT 1 HOSE Dx DRAIN Vl 1 2 NPT 3 207M LEAVING FLUID 2 NPT 58 of 64 E CONDENSER WATER OUT 1 1 2 NPT 28 CONDENSER WATER IN 1 1 2 NPT gen D 03 08 4 G9 epe te pe elis als e slo lo 0 HP E u MAKE U IONAL 2501 IER Ge ENTERING FLUID 2 NPT x DRAIN N 1 2 NPT LEAVING FLUID 2 NPT GP Series Portable Chillers Chapter 7 Appendix 59 of 64 9 APORTO agan sanan Mm ENTERING FLU iEn C9 0 69 3 4 D d 7 8 00 TYPE ACR DKI AUTO WATER 250L MAKE UP OPTIONAL 1 2 NPT Tv ENTERING FLUID 2 NPT gt lt DRAIN 1 2 NPT E 28 LEAVING
11. 3 2 1 2 6 0 5 8 9 6 3 4 14 4 7 8 20 0 1 1 8 34 1 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 19 of 64 3 8 Checking Motor Direction All of our portable chillers have their motor rotations properly phased at the factory If compressors pumps or fans are running in reverse rotation disconnect and lock out the power source and reverse any two power leads into the chiller disconnect switch Caution Do not switch leads at the motors motor starters or contactors Three Phase Compressors Scroll compressors are directionally dependent and compress in one rotational direction Reversing rotation direction results in an elevated sound level and a substantially reduced current draw Water Pumps Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure gauge Pump rotation should be clockwise when viewed from the motor end For chillers with optional pumps check the appropriate pump curve in the Appendix Caution Do not run pump dry Doing so will result in seal damage Condenser Fan A
12. 4 7 3 to move the cursor to the Leaving Temp line Use the Or button to increment or decrement the value Depress to accept the value and move the cursor down one line 4 Adjustthe Hi Temp Warning and Hi Temp Fault in the same manner 5 Depress the WA button twice to return to the main status screen Alarms The controller is setup with multiple alarms most of them configurable using the Supervisor password Section 4 5 Controller Setpoints gives a list of alarms that the controller is setup to display The alarms are broken up into two categories warnings and faults The warning notifies the user that the parameter has been exceeded and the chiller is allowed to keep operating but should be monitored to determine the cause of the warning The fault notifies the user that the parameter has been exceeded and the chiller and pump has been shut down to protect the system Optional Communications The communications function allows you to monitor and set the parameters by a program prepared and running on a host computer connected to the controller When using the communications function you must add on the unit for RS 485 Modbus communications The communications function allows you to read write parameters do operating instructions and select the setting level GP Series Portable Chillers Chapter 4 Operation 34 of 64 GP Series Portable Chillers Chapter 4 Operation 35 of 64 Chapter 5 Maintenance
13. COOLANT CONDENSER WATER FLOW GPM COOLANT FLOW SOUND POWER LEVEL dBA SOUND PRESSURE LEVEL 1 UNIT PRESSURE DROP METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW GPM CONDENSER INLET WATER TEMPERATURE 50 90 F MINIMUM LOAD 2 262 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP 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 1090 LBS POWER 460V 3PH 60HZ WEIGHT SHIPPING 760 LBS CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 20 AMPS CONTROL MICROPROCESSOR G PWC 50 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE EER BTU WATT COOLANT CONDENSER WATER FLOW i GPM COOLANT FLOW SOUND POWER LEVEL dBA SOUND PRESSURE LEVEL 1 UNIT PRESSURE DROP METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW GPM CONDENSER INLET WATER TEMPERATURE 50 90 F MINIMUM LOAD 3 352 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER TUBE I
14. Contract DepDA Tents eeh Ee e 41 FECE SPOCWICAWONS T 42 Air Cooled Portable Chillers casei ttt ado 42 Water Cooled Portable Chiers 44 7 4 Pump Curves Flow and Pressure Considerattons esses 46 60 Hertz Pump VES oia oct oho tesi blue e tiep eee ibat usb e abes 46 EE 47 7 5 Remote Air Cooled Chiller Configurations AE 49 7 6 Typical Ductwork for Air Cooled Chillers ANNE 50 Jf PpingDIagralris ala etui a ag akak TEN aa aa soe aa EN NA AK Aga nios E di essa kag 53 GP Series Portable Chillers 1v Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational 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
15. Sizing Horizontal or Downflow Discharge Line Sizes OD Total Equivalent Length Ft as s e 39 ss 50 ws 200 zs 250 25 5 8 3 4 3 4 3 4 3 4 3 4 3 4 3 4 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 Circuit Upflow Discharge Line Sizes OD Circuit Total Equivalent Length Ft B 5 8 B 5 8 B 5 8 B 5 8 B 5 8 B 5 8 B 5 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 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 7 8 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 7 8 B 7 8 B 7 8 B 7 8 B 1 1 8 B 1 1 8 GP Series Portable Chillers Chapter 3 Installation 18 of 64 Refrigerant Charge Determination The approximate amount of refrigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller Referring to Figure 5 determine the amount of charge based on the horsepower of the chiller and the amount of charge based on discharge and liquid line sizes and lengths Add these three numbers together to find the final operating charge The final operating charge must be verified by running the system and checking the liquid line sight glass Figure 5 Refrigerant Charge Determination Condenser and Chiller Charge per circuit Chiller Minimum Design Ambient F Model 60 50 40 30 20 10 o 10 arcs 9 9 0 11 32 59 75 13 Line Size Liquid Line OD inches LBS of R 410a 3 8
16. and efficiency Remove dirt and slime in the evaporator by reverse circulating with a mild detergent and water solution Remove mineral deposits by reverse circulating Liquid Citric Acid De Scaling Solution Part No A0536607 Follow the directions on the container 5 5 Evaporator Process Piping Y Strainer The process piping Y strainer requires periodic cleaning of its screen to insure the proper flow through the evaporator To clean the strainer screen remove the access plug and retaining cap and pull out the screen Wipe brush or vacuum out any dirt left in the strainer body Clean the screen and replace it in the strainer taking care to fit it squarely into the machined seat provided Caution Do not forget to re install the screen after cleaning it Operating the chiller with no strainer screen can potentially plug the evaporator with dirt The warranty does not cover chiller failures from a dirty evaporator 5 6 Preventative Maintenance Service Follow a systematic preventive maintenance program to help avoid costly down time Call the Service Department to arrange a schedule of inspections This service can be tailored to fit your maintenance requirements These inspections include but are not limited to e Checking refrigerant suction and discharge pressures e Checking safety and operating conditions e Checking voltage and amperage of all motors e Checking all electrical connections e Checking quantity of refrigerant e Check
17. 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 21 of 64 Figure 6 Ethylene Glycol and Propylene Glycol Curves 40 0 Percent Glyc ol Curves for Free ze Protec tion 30 0 20 0 Eth ylene G lycol Propylene Glycol 0 0 Temperature F 20 0 40 0 50 0 60 0 0 0 Note 10 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 The standard pumps used in the GPAC Serice chillers are not recommended to be used with fluid below 0 F 18
18. the discharge line after the compressor Within the program there are four settings that warn and fault based on these two pressure transducers The low suction warning is set for 110 psig 758 kPa and the compressor will fault at 100 psig 689 kPa The low discharge warning is set for 200 psig 1 379 kPa and the compressor will fault at 180 psig 1 241 kPa To prevent nuisance tripping there are delays built in to the program Note Call a refrigeration service technician to analyze the problem to prevent recurring low pressure faults Flow Switch The thermal dispersion flow switch cutout device mounted in the process piping shuts down the chiller if it senses that the water glycol flow rate through the evaporator has dropped below an acceptable level The flow switch opens the control circuit and shuts down the pumps and the chiller Remote Start Stop Interlock An additional contact is provided to allow the remote starting or stopping of the chiller To use this feature remove the jumper between terminals 1 and 23 and supply a switch or dry contact interlock connected in series between these two terminals Refer to the schematic inside the control enclosure door 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 Includes an electric water solenoid valve a level sensing pressure swit
19. 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 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 The use of poor quality water may result in inefficient operation heat exchanger damage and pump seal damage Consult a qualified water treatment specialist to determine whether treatment is needed GP Series Portable Chillers Chapter 3 Installation 14 of 64 3 7 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 ll make two connections to the water cooled condenser Condenser Water In The condenser water supply labeled Condenser Water In is located at the rear of the chiller It is the inlet for city or tower water Make sure that water is supplied at a maximum temperature of 85 F 29 C 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 adjus
20. 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 11 Table of Contents CHAPTER 1 SAFETY aiite eacus eese sae ce eue ee 1 1 How to Use This Manual 5 Safety Symbols Used in this Manual sese 5 1 2 Warnings and Precautions s eoo de oett iri Ee anna vai bares Dui EE Ue aana nne 6 E AGSponsIbiliV asana EET TUI TU t 6 CHAPTER 2 FUNCTIONAL DESCRIPTION 7 2 1 Models Covered in This Manual 7 2 2 General Di oio ad eto tecto tur tero tent ico ined tas 7 Chilled Water TT aana en da na Ag NGE TE a E a e TES aga a paa aaa 7 Refrigeration CIC iia dd ta 7
21. 20 LBS CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 10 7 AMPS CONTROL MICROPROCESSOR G PWC 30 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE EER i BTU WATT COOLANT CONDENSER WATER FLOW d GPM COOLANT FLOW SOUND POWER LEVEL dBA SOUND PRESSURE LEVEL Q 1 UNIT PRESSURE DROP METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW 22 5 GPM CONDENSER INLET WATER E TEMPERATURE 50 90 F MINIMUM LOAD 1 672 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP CENTRIFUGAL COOLANT CIRCUIT 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 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 16 4 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 44 of 64 G PWC 40 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY 2 ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE EER j BTU WATT
22. 4 2 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 8 Main Status Screen 3 Set the Leaving Fluid temperature by depressing the button to display the menu Figure 9 Menu Screen 9 4 Depress the B A button to highlight SETPOINTS and press iua 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 27 of 64 e Enter the established Operator Password by depressing the to move the position of the cursor and then depressing the ori 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 10 Operator Setpoints Screen 9o 10 GP Series Portable Chillers m to move the cursor to the Leaving Temp line Use the Or button to increment or decrement the value Depress to accept the value and move the cursor down one line Depress the 9 button twice to return to the main status screen Depress the KN to start the chiller Check pump rotation Check the pump amp draw and pump pressure Make sure that the amp draw readi
23. FLUID 2 NPT GP Series Portable Chillers Chapter 7 Appendix 60 of 64 Q9 gt 9 63 4 G9 Q 43 x AUTO WATER MAKE UP OPTIONAL SS s ENTERING FLUID 2 NPT a RAN 9 03 DISCHARGE GAS Ge la 2 90 nec e a INLET e eot benc 7 8 00 TYPE ACR CONDENSOR OUTLET LEAVING FLUID 2 NPT GP Series Portable Chillers Chapter 7 Appendix 61 of 64 o9 O G9 3 T G9 63 d uu EE MAKE U TONAL am e 14 Pe ENTERING FLUID 1 1 4 NPT ou kn DRAIN 1 2 NPT e E CONDENSER WATER QUT maip teo Ho e 1 NPT MN 28 CONDENSER 1700 HOSE WA d 30TM LEAVING FLUID 1 1 4 NPT GP Series Portable Chillers Chapter 7 Appendix 62 of 64 D 4D 9 d 4 G9 10 te 20 Eu az 23 E LI EN En El 29 Le O 13 a UE za Dx AUTO WATER 2SOL MAKE UP OPTIONAL 1 2 NPT Agen ENTERING FLUID 1 1 4 NPT Les px DRAIN Y 1 2 NPT E 1 CN LEAVING FLUID 1 1 4 NPT GP Series Portable Chillers Chapter 7 Appendix 63 of 64 GP Series Portable Chillers Chapter 7 Appendix 64 of 64 2 03 wa MAKE UP OPTIONAL x ngaya ENTERING FLUID 1 1 4 NPT MI HOSE X DRAIN d 1 2 NPT 13 C LN LEAVING FLUID 1 1 4 NPT
24. G 0 t 0 50 100 150 200 250 300 o Capacity liter min HP Modei GP 20 GP 30 GP 40 GP 50 15 cbu zo 3isDSG sto 2 cbu7o seopsG emer 3 2cou7osos_ OPT 10 faus2 200 1100086 OPT OPT GP Series Portable Chillers Chapter 7 Appendix 47 of 64 Pure Water at gt 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 1 0X Nominal 2 0X Nominal Calculating Chiller Nominal Flow and Pressure to Process e 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 48 of 64 7 5 Remote Air Cooled Chiller Configurations Configuration A Liquid line riser should not exceed 15 feet from base of air cooled condenser Configuration B GP Series Portable Chillers Chapter 7 Appendix 49 of 64 7 6 Typical Ductwork for Air Cooled Chillers
25. L FRAME GALVANIZED STEEL CONDENSER FAN MOTOR 1 HP OAO 1140 RPM PANELS POWDER COATED STEEL RESERVOIR 40 GALLON POLYETHYLENE WEIGHT OPERATING 1090 LBS POWER 460V 3PH 60HZ WEIGHT SHIPPING 760 LBS CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS G PAC 50 20 AMPS CONTROL MICROPROCESSOR PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 95 EER BTU WATT COOLANT WATER CONDENSER AIR FLOW CFM COOLANT FLOW 36 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 7 SOUND PRESSURE LEVEL 1 METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 F COOLANT FLOW dBA PM G AMBIENT AIR TEMPERATURE COMPRESSOR 60 115 F SCROLL SPECIFICATIONS MINIMUM LOAD EVAPORATOR FILTER 3 016 TONS 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 1290 LBS
26. N TUBE REFRIGERANT 8 LBS R 410A FRAME GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 40 GALLON POLYETHYLENE WEIGHT OPERATING 1290 LBS POWER 460V 3PH 60HZ WEIGHT SHIPPING 950 LBS CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 30 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 45 of 64 7 4 Pump Curves Flow and Pressure Considerations 60 Hertz Pump Curves ACS CHILLER PUMPS 5 15 ALL 60 Hz September 8 2009 300 250 10 HP 3U 32 200 1100D3G 200 5 HP 2CDU 200 506 4 80 150 3 HP 2CDU 70 306 Psi Head ft 2 HP CDU 70 520D3G 3 HP CDU120 530D3G 100 1 5 HP CDU 70 315D3G 50 20 30 40 50 60 70 80 Capacity Gal min 15 cbu 7osispsa_ sTo 2 cpu oseonsa__ _ sto sto 3 2cou7osos_ orr 10 3u 32 200 1100D3G OPT OPT GP Series Portable Chillers Chapter 7 Appendix 46 of 64 50 Hertz Pump Curves ACS CHILLER PUMPS 5 15 ALL 50 Hz September 8 2009 70 60 10 HP 3U 32 200 1100D3G 5 50 a 4 0 5 HP 2CDU 200 506 3 HP 2CDU 70 306 Bar Head m 30 2HP CDU 70 520D3G 3 HP CDU120 530D3G 20 HERI 12 1 5 HP CDU 70 315D3
27. PS Ele ELSA a tore en cae de ER A maa m rnm EE 8 Mechanical Features 8 Sege EE 8 Refrigeration Feature m 9 Controller E EE 9 Other Features eeu iii 9 2 4 Safety Devices and Interlocks AAA 9 elt 9 High ee EE 10 Low Pressure Cutout no switch but done through the transducer 10 FOV O EE 10 Remote Start Stop Interlock tet nin 10 2 5 Optional FOSIUI BS eoi ag Me tec See tare qoot ce idee etu og camp Ee 10 CHAPTER 3 INSTALLATION eren 19 3 1 nen Te mnc 13 3 2 Electrical Connechons sa ak n eaaa GE AN GAN EA KN TAN Es nmn GE aa a naa naas 13 3 3 Process Water Connections sasa aaa a aaa EEN AA BAN NK EN AA Gg aaa A EN ENE a Ba na a ap ap NE aaa 14 3 4 Bypass Valve Considerations sane eaa ciel Do EHI E de tor v cies awa bd 14 3 5 Galvanic Corrosion Considerations sasarane nunuwun eee 14 3 6 Water Treatment Considerations nnne eee 14 3 7 Condenser Consideration S nennen nnne La E rns a sans aan 15 Water Cooled Chiller CGondenserg eiiis ease eaae sane anna nna a aaa ana 15 Air Cooled Chiller Condenserg eese enne nnn nnne nnn nhan nn 15 Remote Air Cooled Chiller Condensers isses anna nana na 16 3 8 Checking Motor Direction as exe Gegen EISE Re EES 20 Three Phase Gompr ssSOFs 5e o E ee Ere etae AE Rete paene ies 20 Walter TUI needed ln eer 20 Gondenser FAN Asa Dios 20 3 9 Ee EE eaten een re oae e op Ene tod E Fa d e E 21 3 10 Automatic Water Make Up Option
28. Sterling GP Series Portable Chillers Part Number 882 93092 00 Bulletin Number SC2 620 1 Effective 9 18 2009 Write Down Your Serial Numbers Here For Future Reference 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 2009 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
29. This piping must be properly sized type L or type K refrigerant grade tubing high temperature brazed Install a customer supplied 650 psi approved refrigerant relief valve in the discharge line at the condenser following all codes When brazing copper joints flow dry nitrogen through the system to prevent carbon scale formation which causes contamination Isolate the refrigerant lines from the building preventing transfer of line vibration to the structure Do not secure the lines rigidly Leak check and evacuate the system down to 400 microns A decay of 50 microns after one hour is acceptable Warning To prevent injury or death due to explosion and or inhalation of phosgene gas purge system thoroughly while brazing refrigerant piping connections Use a pressure regulator in the line between the unit and the high pressure nitrogen cylinder to avoid over pressurization and possible explosion System Configuration The system can be configured in any of the arrangements shown on page 49 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 e 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 e The total distance bet
30. abinetry with 4 locking swivel casters e Internal process water bypass valve for system protection only e Fully insulated refrigeration and process water piping e 20 mesh Y strainer on process water piping into the evaporator e Tank level indication e Pump pressure indication Electrical Features e Fully accessible NEMA 12 style electrical control enclosure e Single point power and ground connection e Non fused disconnect switch lockable e Branch circuit fusing e 208 230 3 60 460 3 60 575 3 60 volt 400 3 50 volt GP Series Portable Chillers Chapter 2 Functional Description 8 of 64 Refrigeration Features HFC 410a refrigerant Electronic hot gas bypass capacity control High refrigerant pressure cutout switches Suction and discharge pressure transducers High pressure spring actuated relief valve Multiple refrigeration access ports Liquid line shut off ball valves Filter dryer Sight glass Externally equalized thermal expansion valve Liquid line solenoid Compressor crankcase heater Controller Features Off the shelf microprocessor based PID controller with To Process From Process and Set Point readout Time delay for proof of water flow pressure models w pump only Low refrigerant pressure time delay for low ambient start up on remote air cooled and air cooled chillers with the variable speed fan option 8 line x 20 character display with status alarm and service screens Other Features One year labor w
31. arranty and one year compressor warranty Two year parts warranty Two year limited controller warranty 2 4 Safety Devices and Interlocks Caution Protect the system from freezing with glycol 20 F 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 5 hp through 15 hp portable chillers have a crankcase heater It is wired through the control transformer that operates continuously whenever power is applied to the chiller Caution Energize the crankcase heater for at least 24 hours before initial startup to drive dissolved refrigerant from the compressor oil Failure to do so will damage the compressor GP Series Portable Chillers Chapter 2 Functional Description 9 of 64 High Pressure Cutout This electro mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 575 psi Note The high pressure cutout is a manual reset device typically mounted on the compressor discharge line inside the mechanical cabinet Call a refrigeration service technician to analyze the problem and reset the control Low Pressure Cutout no switch but done through the transducer There are two pressure transducers in the refrigeration piping one on the suction line before the compressor and one on
32. at 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 Standard 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 amp Tube Condensers Optional 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 36 of 64 Caution Do not use steam or water over 140 F 60 C to clean a condenser unless you are monitoring the refrigeration circuit for excessive pressure with gauges Only a trained technician should use this method 5 4 Maintaining the Evaporator Dirty evaporator heat exchange surfaces reduce system capacity
33. ch mounted in the reservoir tank and the necessary internal piping to connect the chiller to a make up water source See Appendix for typical piping diagrams Caution Customer piping must provide backflow protection and venting of tank to atmosphere to prevent over pressurization of the reservoir tank not needed for open tank See Error Reference source not found on page Error Bookmark not defined Process Water Side stream Filter Not available on chillers less pump and reservoir tank This option includes a 50 micron filter flow meter ball valve for throttling water flow and the necessary piping to provide constant filtering of the process water at about one gallon per minute 1 gpm 3 8lpm GP Series Portable Chillers Chapter 2 Functional Description 10 of 64 General Fault Indicator Audible Visual Alarm This option includes a 100 dB audible alarm horn visual alarm strobe and silence button with provisions for customer wiring indication interlock The alarm signals anytime that a fault is recognized during the operation of the chiller Communications Options RS 485 serial Modbus communications High Pressure Fans Provides for an additional 1 0 WC 250 Pa of static pressure on fan discharge High pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork They can be retrofitted without sheet metal modification but will require changing out fan blades and in som
34. e cases fan motors and electrical components Variable Speed Fan Reduces the speed of the fan based on entering air temperature and system load allowing the chiller to operate in ambient temperatures below 60 F 15 5 C This option will also reduce fan noise in ambient temperatures below 95 F 35 C Stainless Steel Reservoir Manufactured from 304 stainless steel Mounting Features e Mounting rails with feet Optional Operating Voltages 208 230 3 60 460 3 60 575 3 60 and 400 3 50 volt available UL Labeled Electrical Subpanel This option provides for the subpanel to be listed with Underwriters Laboratory with UL related benefits and features Optional Pumps Pump options are available for greater pressure and flow rates A recirculation pump is required whenever process water flow is less than 1 2 gpm per ton or greater than 4 8 gpm per ton See Figure 1 on page 12 for optional pump amperages NEMA 4 Electrical Enclosure Provides for NEMA 4 level electrical enclosure protection GP Series Portable Chillers Chapter 2 Functional Description 11 of 64 Figure 1 Optional Pump Amperages Voltage Construction HP Full Load Amps 460 3 60 SS 1 1 7 1 5 2 3 2 4 0 3 4 2 5 8 2 10 12 0 GP Series Portable Chillers Chapter 2 Functional Description 12 of 64 Chapter 3 Installation 3 1 Uncrating All models are shipped mounted on a skid enclosed in a plastic wrapper and open crated on al
35. ed Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer ARMA 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 1596 75 00 minimum restocking charge All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms GP Series Portable Chillers Chapter 7 Appendix 40 of 64 7 2 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts
36. ent air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained G PAC 20 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE EER BTU WATT COOLANT CONDENSER AIR FLOW CFM COOLANT FLOW SOUND POWER LEVEL dBA UNIT PRESSURE DROP SOUND PRESSURE LEVEL 1 METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 F COOLANT FLOW GPM AMBIENT AIR TEMPERATURE 60 115 F MINIMUM LOAD 0 944 COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH STAINLESS STEEL COOLANT PUMP CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 3 LBS R 410A CONDENSER FANS RON 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 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 10 7 AMPS CONTROL MICROPROCESSOR G PAC 30 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE EER BTU WATT COOLANT CONDENSER AIR FLOW CFM COOLANT FLOW SOUND POWER LEVEL dBA UNIT PRESSURE DROP SOUND PRESSURE LEVEL 1 METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 F COOLANT FLOW GPM AMBIENT AIR TEMPERATURE 60 115 MINIMUM LOAD 1 504 SPECIFICATIONS
37. h neither password set This allows every user access to all functions GP Series Portable Chillers Chapter 3 Installation 23 of 64 Operator Password If you define a password for operators then a password will be required to carry out any function other than reviewing the status screens Entering the operator s password will give the user access to the setpoints for leaving temperature high temperature warning high temperature fault Supervisor Password If you define a password for supervisors or setup personnel then most settings can be changed only after entering the password The password will be required to display the extended setpoints for operating parameters and alarms Section 4 6 shows a table of setpoints and the restrictions between Operator and Supervisor To set password protections 1 Press the button to access the menu screen 2 Press the j to highlight SETPOINTS and press WR 3 Press the l J until the following screen appears for the Operator Password 4 Press to accept the screen and then press untilthe Operator or Supervisor Password line is highlighted m 5 Press e or to increment or decrement the number The password can be between 0 and 9999 GP Series Portable Chillers Chapter 3 Installation 24 of 64 6 Press to accept the Password and move to the next line 7 For either Operator or Supervisor password the time that the password will allow the contr
38. ing compressor oil level on units with tandem compressors Checking lubrication of motor and pump bearings Checking circulating pump operation Checking flow through heat exchangers e Checking compressor efficiency Checking noise levels GP Series Portable Chillers Chapter 5 Maintenance 37 of 64 Chapter 6 Troubleshooting Problem Possible cause Solution Check main disconnect fuses wiring No power and power lead to unit e Voltage must be within plus or minus Wrong voltage supplied to unit 1096 of nameplate rating Defective display TEN Control circuit fuse blown Defective control transformer Add water or water glycol solution as required Pump motor off on overload Reset and test Leaving fluid setpoint set higher Lower the leaving fluid temperature than temperature of liquid in below the leaving temperature you system desire Allow time to cool and reset then check for high low volt age It must be within Compressor internal overload or plus or minus 1046 of the nameplate fuses are open rating Check for open fuses and loose compressor electrical connections Pump runs compressor does not Compressor contactor holding coil Repair or replace open Defective compressor auziliary Repair or replace contact Broken wire in the compressor control circuit Piping flow switch circuit open Locate and repair Plugged Y strainer Check hot gas analog output value through status screen Contac
39. iption 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for air water and remote air cooled portable chillers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our portable chiller models are designated by approximate compressor horsepower 5 7 1 2 10 13 and 15 etc and the cooling method used A for air cooled W for water cooled and R for remote air cooled 2 2 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 5 to 15 tons All are self contained fully portable and shipped ready to use Remote air cooled chillers require field installation by qualified technicians Standard range of operation is 20 F to 80 F 7 C to 27 C for applications using a water glycol mix and 45 F to 80 F 7 to 27 C for water only applications A factory installed crankcase pressure regulating valve option is available for processes requiring a leaving water temperature over 80 F 27 C 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 rese
40. ir should be drawn through the condenser and discharged vertically from the chiller GP Series Portable Chillers Chapter 3 Installation 20 of 64 3 9 Water Reservoir All portable chillers shipped during the fall winter or spring or those units that are shipped from stock are flushed at the factory with a water ethylene glycol solution to prevent piping components prone to retaining water from freezing During startup and when additional solution is required refer to the ethylene glycol and propylene glycol curves in Figure 6 on page 20 Add a pre mixed solution of industrial quality not automotive ethylene glycol or propylene glycol and water to provide freeze protection to a temperature 20 F 11 C below the normal chiller operating temperature set point Glycol and or water with an inhibitor should be used to protect the materials copper steel stainless steel and bronze in the system from corrosion If you intend to use straight water we strongly advise a minimum leaving water temperature of 45 F 7 C or contact the service department 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
41. is compressed in the compressor and flows through the discharge line as a gas to the condenser There it gives up its heat as it condenses to a liquid in the condenser An electronic hot gas bypass valve is used to control cooling capacity during intermittent or partial load conditions This feature contributes substantially to chiller longevity by eliminating excessive cycling of the compressor and providing close temperature control 2 3 Standard Features Mechanical Features Compressor Hermetic scroll compressors Evaporator Stainless steel copper brazed plate evaporators Air Cooled Condenser Aluminum fin tube with washable filters package unit only option on remotes Water Cooled Condenser Tube in tube condensers All come with electronic cooling water regulating valves 1 in NPT valves for GPWC20 amp 30 1 25 in NPT valves for GPWCAO and 1 50 in NPT valves for GPWC50 Remote Air Cooled Condenser Aluminum fin tube with low ambient control down to 20 F 29 C via a variable speed primary fan Reservoir 5 hp and 7 5 hp models use a 20 gallon polyethylene tank 10 hp and 15 hp models use a 40 gallon polyethylene tank Piping Non ferrous piping Pump TEFC motors Optional 10 HP is ODP only horizontally mounted stamped stainless steel construction Other Mechanical Features e Low process water thermal flow switch e NEMA rated fan motor s on air cooled models e Galvanized structural steel frame painted c
42. l four sides and top 1 Pry the crating away from the skid 2 Usea pry bar to remove the blocks securing the unit to the skid 3 Liftunit 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 Note the outline drawings for egress into the cabinet Make sure all electrical connections are tight Important Refer to your local electrical requirements for proper feeder conductor and supply disconnecting sizing For instance in the United States refer to National Electric Code NEC Article 430 24 through 430 26 Table 310 15 B 2 a GP Series Portable Chillers Chapter 3 Installation 13 of 64 3 3 Process Wa
43. lectrical connections must conform to all applicable codes Complete chilled water To Process and From Process connections Be sure the reservoir tank and chilled water circuit piping are filled a water glycol mixture The water glycol mixture should provide for freeze protection to at least 20 F 11 C below the leaving water temperature you want Should the display show a tank level less than 0 after the tank is filled check the clear tube leading from the tank to the tank level pressure switch for a blockage The air cooled condenser should have an adequate supply of 60 to 115 F 16 to 46 C air for proper operation The tower or city water condenser cooling in and out connections should be completed and an adequate supply of 85 F 30 C tower or 70 F 21 C 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 Ll is connected to the A phase line two 2 L2 is connected to the B phase and line three 3 L3 is connected to the C phase Check for proper rotation direction of fan s and pump s The crankcase heater is automatically energized when the main power is applied It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil 3 12 Finishing Setup Setting Up Passwords You can establish passwords for two levels of security operators and supervisors The controller comes from the factory wit
44. ng is within the running load and service factor amps Operate the chiller looking for any leaks and listening for unusual noises or vibrations that could indicate improper operation Chapter 4 Operation 28 of 64 Elevated sound level and substantially reduced current draw indicate reverse rotation After several minutes of operation the compressor internal protector trips 4 3 Status Screens The controller has eight 8 preconfigured status screens The main status screen shown in Figure 11 shows the main operating points of the chiller Entering and Leaving fluid temperatures Leaving fluid setpoint pump discharge pressure tank fluid level depth and percentage of hot gas bypass output Figure 11 Main Status Screen Depressing Al cycles through the following screens shown below Analog I O Digital I O and Test The Analog and Digital I O screens provide status of all of the inputs and outputs for the controller The Test aides in troubleshooting the chiller when it is not functioning properly by displaying the basic information that a service person will need to know to determine the problem GP Series Portable Chillers Chapter 4 Operation 29 of 64 GP Series Portable Chillers Chapter 4 Operation 30 of 64 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
45. oller to be active can be set by the Operator or Supervisor Password Time With the PW Time value highlighted press Por 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 25 of 64 Chapter 4 Operation 4 1 Panel Buttons Indicator Lights and Switches Microprocessor Controller The standard chillers use a microprocessor based PID controller The Carel PCO controller along with the Carel PGD1 Interface is a modular self contained unit that can slide from its mounting housing It is factory set and adjusted no field adjustment to the internal controls is necessary The standard operation range is 20 F to 80 F 7 C to 27 C Figure 7 Controller Display Button Button Description Detailed description Menu Button Used to access the menus structure of the PGD interface Di 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 4 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 A Down Arrow Button Used to decrement a data field or scroll down within a menu structure GP Series Portable Chillers Chapter 4 Operation 26 of 64
46. ow for filling x the tank Low Level Warning Tank level that will activate Low Level Warning alarm x Low Level Fault Tank level that will activate Low Level Warning fault x High Level Warning Tank level that will activate High Level Warning alarm x High Level Fault Tank level that will activate High Level Warning fault x High Temperature Delay time in minutes between fault and stopping the Delay compressor and pump f Time in minutes to silence alarm with optional audible Alarm Silence Time K alarm After time alarm will reactivate i a Password Time in minutes for operator password to be active K Supervisor Password M df A Time Time in minutes for supervisor password to be active D Chapter 4 Operation 32 of 64 1 Set the Leaving Fluid temperature by depressing the ___ button to display the menu Figure 12 Menu Screen 2 Depress the m button to highlight SETPOINTS and press If passwords were setup See Section 3 12 for information on the controller passwords the password screen will appear Enter the Operator Password by depressing the to move the position of the cursor and then depressing the ori button to increment or decrement the number Once all of the numbers have been entered depress GP Series Portable Chillers Chapter 4 Operation 33 of 64 LE Io accept the password The following screen will appear the Figure 13 Operator Setpoints Screen
47. rvoir tank The coolant is then pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle A manual pressure actuated process water bypass valve located between the supply line and reservoir tank single pump models only allows minimal flow through the unit during the intermittent fluctuating flow conditions It is not intended to provide continuous full bypass flow This minimal flow allows the temperature sensor to signal the controller to shut down the compressor because of the drop in process water temperature Typically the flow switch shuts down the chiller in this low flow condition This valve allows enough flow for the chiller to function when the flow is shut off to process Refrigeration Circuit Air water and remote air cooled refrigerant condensing differ only in the way the compressed gas is condensed to a liquid Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes through a shut off valve into a filter dryer that removes moisture and other contaminants A refrigerant sight glass is provided The refrigerant then passes through the thermal expansion valve which allows the refrigerant to expand boil off and cool remove the heat from the fluid inside of the evaporator The refrigerant gas flows through the suction line back into the compressor GP Series Portable Chillers Chapter 2 Functional Description 7 of 64 The refrigerant
48. t Service if output value remains at 0 throughout compressor cycle Eos Wak Ho Install bypass between to and from process line Make sure that the water glycol mixture protection is right for the process Pump runs compressor cycles at Hot gas not coming on short intervals Water glycol mixture inadequate for process Improperly set leaving fluid temperature warning or fault set point WA NGANA fu Call service to find and repair the leak 8 8 i then have refrigerant added Water temperature is too high GP Series Portable Chillers Chapter 6 Troubleshooting 38 of 64 Problem Possible cause Solution Verify rotation if running in reverse Pump process pressure low refer rotation reverse any two main power to curves for normal pressure for leads Re verify for correct pump various pumps rotation Check for partially closed valves etc Pump process pressure is too high Restricted water flow Make sure that all lines are properly sized Pump running in reverse Clean filters Restricted condenser air flow Check the refrigerant charge by viewing Unit runs continuously but not Unit low on refrigerant sight glass on liquid line upstream of the enough cooling power expansion valve Compressor not operatin E P H 5 Call service efficiently Unit under sized for application Call sales rep GP Series Portable Chillers Chapter 6 Troubleshooting 39 of 64 Chapter 7 Appendix 7 1 Return
49. t 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 85 F 27 C water at 25 psi entering condenser water pressure Condenser Water Out Condenser water return labeled Condenser Water Out is located at the rear of the chiller It is the outlet for water after it has passed through the condenser It is connected to the tower water return line or to a sewer or other approved discharge receiver A water regulating valve is a standard feature in the condenser water out line Air Cooled Chiller Condensers Air cooled chillers use the surrounding air to cool the condenser Install the chiller in an area where there is free passage of air for condensing and provisions for removal of heated air from the area Do not locate air cooled chillers in locations where steam hot air or fume exhausts can be drawn into the chiller Caution Clean air cooled condensers and filters frequently Failure to do so results in reduced capacity increased operating costs and possible failure of the equipment Cleaning instructions can be found in the Maintenance chapter of this manual Normal maximum refrigerant condensing pressure with 95 F 35 C 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 appro
50. ter Connections All of our portable chillers have two chilled water connections The chilled water supply labeled To Process is the outlet for the chilled water leading to the process being cooled The chilled water return labeled From Process is the inlet leading from the process back into the chiller to be cooled and re circulated All external chilled water connections should be run full size to the process Flow and pressure information is available in the Appendix The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment Note Be sure to reduce external pressure drop as much as possible by generously sizing piping and tooling water passageways 3 4 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 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
51. 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 GP Series Portable Chillers Chapter 4 Operation 3 of 64 4 5 Controller Setpoints Access Level GP Series Portable Chillers Variabl Descripti ARR PAN Operator Supervisor Leaving Temp Temperature of fluid out to process x x Hi Temp Warning Setpoint for alarm to warn when leaving fluid z z temperature is too high Hi Temp Fault Setpoint to shut down pump and compressor based on a a leaving fluid temperature Compressor On Temperature Difference between Leaving Fluid e Differential Temperature and Setpoint to turn on the compressor Compressor Off Temperature Difference between Leaving Fluid z Differential Temperature and Setpoint to turn off the compressor Pump Stop Delay Delay time in seconds between fault and stopping the gt pump Low Temperature Temperature to activate Low Temperature Warning x Warning alarm Low Temperature Fault Temperature to activate Low Temperature Fault alarm K Water Make up On The tank level to turn on optional water make up valve x based on size of tank Water Make up Off The tank level to turn off optional water make up valve 3 based on size of tank Water Make up Time The time in seconds that controller will all
52. tion 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 v Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled v Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor GP Series Portable Chillers Chapter 1 Safety 6 of 64 Chapter 2 Functional Descr
53. w oil to flow towards the condenser Discharge line sizing is based on the velocity required for sufficient oil return back to the compressor See Figure 4 on page 18 for discharge line sizing Figure 2 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 Valve Radius EL Radius EL 2 8 82 39 45 53 19 2 2 2 6 34 42 Figure 3 Liquid Line Sizing 5 TON CIRCUIT 7 5 TON CIRCUIT Total Equiv Length Ft 25 50 75 100 125 150 175 200 225 250 275 300 Liquid Line Size OD Liquid Line Size OD Horizontal Horizontal or Upflow Upflow Upflow Total Equiv or Upflow Upflow Downflow 1 5 Ft 6 10 Ft 11 15 Ft Length Ft powntiow 6 10 Ft 11 15 Ft 5 8 5 8 5 8 1 2 25 5 8 1 2 50 5 8 1 2 75 5 8 5 8 100 5 8 5 8 125 5 8 5 8 150 5 8 5 8 175 3 4 5 8 200 3 4 5 8 225 3 4 5 8 250 3 4 5 8 275 3 4 5 8 300 3 4 GP Series Portable Chillers Chapter 3 Installation 17 of 64 10 TON CIRCUIT 15 TON CIRCUIT Liquid Line Size OD Liquid Line Size OD n Horizontal g Horizontal Total Equiv or Upflow Upflow Total Equiv or Upflow Upflow Length Ft Downtiow 6 10 Ft 11 15 Ft Length Ft Downtlow 6 10 Ft 11 15 Ft 25 3 4 25 7 8 50 3 4 50 7 8 75 3 4 75 7 8 100 3 4 100 7 8 125 7 8 125 7 8 150 7 8 150 7 8 175 7 8 175 7 8 200 7 8 200 7 8 225 7 8 225 7 8 250 7 8 250 7 8 275 7 8 275 1 1 8 300 7 8 300 1 1 8 Figure 4 Discharge Line
54. ween the chiller and condenser must not exceed 200 feet or 300 equivalent pipe feet e Discharge line risers cannot exceed an elevation difference greater than 100 feet without a 246 efficiency decrease e Refer to page 49 of the Appendix for the location of traps e Refrigeration lines must not be crossed i e chiller liquid lines are to be piped to condenser liquid lines Sizing Refrigerant Lines To determine field installed liquid and discharge line sizes first establish the equivalent length of pipe for each line valve and elbow Chiller capacity and GP Series Portable Chillers Chapter 3 Installation 16 of 64 leaving water temperature range is also required See Figure 2 on page 17 for lengths of refrigerant valves and fittings Liquid Line Sizing The liquid line should be sized as small as possible while maintaining acceptable pressure drop to minimize the refrigerant charge Liquid line risers must not exceed 15 feet from the base of the air cooled condenser Horizontal runs do not require a pitch Insulation is not required unless the line is installed in a high ambient area i e boiler room Install a liquid line charging valve to facilitate refrigerant charging See Figure 3 on page 17 for sizing information See Figure 5 on page 19 for charge determination Discharge Line Sizing For horizontal runs the discharge line should be pitched downward in the direction of flow at a rate of 1 2 for every 10 feet This will allo
55. when fan blower is not operating e GP Series Portable Chillers Chapter 7 Appendix 50 of 64 Chillers with dual fans blower must have a back draft damper on the cycling fan blower to prevent recirculation of hot discharge air e Chillers are designed to operate at a condensing entering air temperature of 60 F 16 C minimum without optional Variable Frequency Drive e Maximum total static pressure drop external to the chiller must not exceed 0 30 WG 75 Pa GP Series Portable Chillers Chapter 7 Appendix 51 of 64 GP Series Portable Chillers Chapter 7 Appendix 52 of 64 7 8 Piping Diagrams WEE RUETIW 3o MM EJ Cl 2 E ii SS EJ EAR nan Ea i H f f i 4 y Fs DG 1 is J 9 fo p vue j 0 lt RN amp f E IO Pod AVIO ge 4 L 4 geni MEA an E Tapa Kai D e JAPA a zeng AR A mes Wgd A E E maan E peu H E 2 172 Ner fe wa Geen 1 d fe WWE QU emen 3 j EO Car d f fo l bad 1 LL i S ARENA Ven esc wE i wy C a a A gt A 4 SEND TP OF iy TQ mt eng p A LERE TOUS Uz NASEHAT GP Series Portable Chillers Chapter 7 Appendix 53 of 64 ENTERING FLUID 1 1 2 NPT DRAIN 1 2 NPT LEAVING FLUID 1 1 2 NPT 3QTM GP Series Portable Chillers Chapter 7 Appendix 54 of 64 eres ER U SS JEE ENTERING FLUID 1 1 2 NPT Ka DRAIN Y 1 2 NPT 1 1 2 HOSE Hai 7 8 00 TYPE ACR 5 3 00 TYPE ACR LEAVING FLUID 1
56. ximately 60 F 15 5 C Operation of the equipment at a lower condenser entering air temperature can cause the chiller to malfunction For entering air temperatures below 60 F 15 5 C an optional fan motor speed control is available We recommend maintaining a minimum 60 F 15 5 C ambient temperature GP Series Portable Chillers Chapter 3 Installation 15 of 64 Remote Air Cooled Chiller Condensers Remote air cooled portable chillers are shipped with nitrogen holding charge and a full charge of oil excluding the amount needed for field piping The remote air condenser is shipped with a dry nitrogen charge Verify that the holding charge has not been lost prior to installation If there is no pressure leak test the unit and repair before installing the interconnecting refrigerant piping Read this entire section before installation Note Piping should be type L or type K refrigerant grade copper tubing only Proper sizing and installation has a significant effect on system performance reliability and safety Interconnecting Refrigerant Piping The chiller and condenser refrigerant lines are terminated with a cap and brazed closed Use a tube cutter to remove caps Caution Do not use a saw to remove the end caps because this will allow copper chips to contaminate the system A certified refrigeration contractor need only to install the interconnecting refrigerant piping between the chiller and the outdoor air cooled condenser
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