GP Series Portable Chillers
Contents
1. 4 Press to accept the screen and then press until the Operator or Supervisor Password line is highlighted 5 Press e l or to increment or decrement the number The password can be between 0 and 9999 GP Series Portable Chillers Chapter 3 Installation 20 of 44 6 Press to accept the Password and move to the next line 7 For either Operator or Supervisor password the time that the password will allow the controller to be active can be set by the Operator or Supervisor Password Time With the PW Time value highlighted press or Ito 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 21 of 44 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 3 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 the2. go 10 GP Series Portable Chillers SR 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 L9 button twice to return to the main status screen I Depress the KN to start the chiller Check pump rotation Check the pump amp draw and pump pressure Make sure that the amp draw reading 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 24 of 44 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 sepoint pump discharge pressure tank fluid level depth and percentage of hot gas bypass output Figure 7 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
3. and union or non union installations Sterling Inc 2900 S 160 Street New Berlin WI 53151 www sterlco com GP Series Portable Chillers Chapter 7 Appendix 37 of 44 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 ambient 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 BTUMWATT 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 LEV
4. 5 Controller ptn 2e2a see EES Eed uacetedante elenessaca qaantdnalgeuasndsaenmedentendelene 28 e EE en EE 30 4 7 Optional Communications EE 30 CHAPTER 5 MAINTENANCE seenen S2 S HN Better OM DEE ER NN ln CICANING aa E e ara aE Eae ved neces EE Aa S AAAA E E EROARE ReRe EE 32 5 3 Maintaining the Condenser sez atcsaeds rees Eee operant telat ER Air and Remote Air Cooled Chillers AAA 32 Water Cooled RE 32 5 4 Maintaining the Evaporator gege begeage ed Ee aidcey Bia ean Ee Seefe 33 5 5 Evaporator Process Piping Y Strainer cccecsesceeeeseeceeeeeeeeeeeeeeseeeeeeeneseeeeeneees 33 5 6 Preventative Maintenance Service AAA 33 CHAPTER 6 TROUBLESHOOTING ccssssssseeeeeeeeeeeeeenees OF CHAPTER 7 APPENDIX siene eege eege dO 7 1 Returned Material Policy oiccccvoicsseteckstctuntstessniunenteacelensnies dace he Oiaenddaes SEENEN 36 Cr d ROLF O e a da and cases ee SEENEN EEN 36 1 2 Technical ASSISTANCE EN 37 PAMES DODANMIONE EE 37 Service DODALINOM Eeer 37 Sales Departments ierse a eege ENEE Sege 37 Contract EIERE 37 d EIERE 38 Air Cooled Portable Chiers 38 Water Cooled Portable Chilers cccccsccssssssssssssssssssessseceeesesecesesseesssssssssssseees 40 7 4 Pump Curves Flow and Pressure Considerattons rrenen ent 42 G0 Herz PUMP CUIVES iiss cc tassecs seek eceeclaale ee A EA E AEE aaie 42 7 5 Ee le RE Ee EE E 44 GP Series Portable Chillers iv Chapter 1 Safety 1 1 How to Use This Manual U
5. flow switch circuit open Check for open fuses and loose Pump runs compressor does not compressor electrical connections Compressor contactor holding coil Repair or replace open Defective compressor auxiliary Repair or replace contact Broken wire in the compressor RS Locate and repair control circuit Plugged Y strainer P Replace relay board on control bed hot ump runs compressor cycles at Hot gas not coming on i gas coil short intervals GE Install bypass between to and from process line Make sure that the water glycol mixture Water glycol mixture inadequate SE EEN S i q protection is right for the process for process Improperly set leaving fluid temperature warning or fault set point EE E 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 34 of 44 Problem Possible cause Solution Verify rotation if running in reverse rotation reverse any two main power leads Re verify for correct pump Pump pressure low refer to curves Pump running in reverse for normal pressure for various pumps rotation Check for foreign matter Clean the system Check for partially closed valves etc Pump pressure is too high Restricted water flow Make sure that all lines are properly sized Clean filters Restricted condenser air flow Unit runs continuously but not Unit
6. low on refrigerant Check the refrigerant charge enough cooling power i amp SP Compressor not operating Call service efficiently Unit under sized for application Call sales rep GP Series Portable Chillers Chapter 6 Troubleshooting 35 of 44 Chapter 7 Appendix 7 1 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS 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 RMS 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 s
7. that will be controlled Portable chillers are built with a voltage specific compressor and cannot be re wired for an alternate voltage e 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 410 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes Complete chilled water To Process and From Process connections Be sure the reservoir tank and chilled water circuit piping are filled a water glycol mixture The water glycol mixture should provide for freeze protection to at least 20 F 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 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 rotati
8. the flow is stopped to the process while the chiller is running the factory set bypass valve allows a small amount of water to flow through the chiller This action allows the chiller to keep functioning while the flow is stopped to process The bypass valve is not intended to provide continuous full bypass flow Caution Do not attempt to adjust or otherwise tamper with the internal bypass Your warranty will be voided 3 5 Galvanic Corrosion Considerations The materials used in the water circuit piping of these chillers are non ferrous and react electro chemically with ferrous metallic materials Some water has dissolved minerals that greatly accelerate the reaction between dissimilar metals PVC or non ferrous piping is recommended to reduce galvanic action If iron piping must be used use dielectric unions at the chiller 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 We offer a complete line of water treatment equipment Contact your sales representative for water testing and treatment options GP Series Portable Chillers Chapter 3 Installation 14 of 44 3 7 Condenser Considerations Water Coo
9. 0a 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 auto tuning 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 4 line x 20 character display with status alarm and service screens Other Features One year labor warranty and one year compressor warranty Two year parts warranty Two year limited controller warranty 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 Cautio
10. EL 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 E MINIMUM LOAD 1 504 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 ALUMINUM REFRIGERANT 4 LBS R 410A CONDENSER FANS PC 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 38 of 44 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 7i SOUND PRESSURE LEVEL 1 METER dBA PM OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 oF AMBIENT AI
11. ESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP GEES 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 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 10 7 AMPS CONTROL MICROPROCESSOR G PWC 30 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER WATTS Ee WATER EER BTU WATT COOLANT CONDENSER WATER FLOW GPM COOLANT FLOW SOUND POWER LEVEL dBA UNIT PRESSURE DROP Vee ee COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW 22 5 GPM NDENSER INLET WATER Sue 50 90 oF MINIMUM LOAD 1 672 COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP SERIE 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 G PWC 40 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY 1131 TONS ALTITUDE SEA LEVEL GP Series Portable Chillers Chapter 7 Appendix 40 of 44 COOLANT SUPPLY TEMPERATURE 50 oF COMP
12. GAL 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 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 39 of 44 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 lpm 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 COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER 4251 WATTS SPEAR UGE WATER EER 14 95 BTU WATT COOLANT CONDENSER WATER FLOW 15 9 GPM COOLANT FLOW SOUND POWER LEVEL dBA UNIT PRESSURE DROP SOUND PRESSURE LEVEL 1 METER COOLANT SUPPLY TEMPERATURE 20 80 COOLANT FLOW GPM SEET WATER 50 90 F MINIMUM LOAD 1 06 COMPR
13. MPRESSOR 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 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 41 of 44 7 4 Pump Curves Flow and Pressure Considerations 60 Hertz Pump Curves 300 1 120 250 100 design 4 deele B 3U 32 200 1 10HP 200 5 HP 2CDX 200 506 1 80 2CDX 120 406 3U 32 200 1 7 5HP z S Sg S bd 2 60 l 3 HP 2CDX 120 306 design 2 4 5 HP CDx 70 156 HP CDX 120 206 100 design 1 2CDX 120 206 40 1 HP CDX 70 106 s 20 0 0 10 20 30 40 50 S 2 x Capacity Gal min GP Series Portable Chillers Chapter 7 Appendix 42 of 44 Calculating Chiller Nominal Flow and Pressure to Process e Flow rate Obtain the flow reading from the appropriate pump curve e Pressure Obtain a corresponding pressure reading from the pump curve
14. R 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 AXIAL 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 CENTRIFU
15. RESSOR POWER 8323 WATTS CONDENSER INLET WATER TEMPERAT RE 85 F EER 16 31 BTU WATT COOLANT WATER CONDENSER WATER FLOW 33 93 GPM COOLANT FLOW 27 GPM SOUND POWER LEVEL dBA UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL dBA METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 F COOLANT FLOW 30 GPM CONDENSER INLET WATER S 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 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE 85 EER BTU WATT COOLANT WATER CONDENSER WATER FLOW GPM COOLANT FLOW 40 SOUND POWER LEVEL dBA SOUND PRESSURE LEVEL 1 UNIT PRESSURE DROP 7 METER OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 20 80 F COOLANT FLOW 45 GPM CONDENSER INLET WATER 4 TEMPERATURE 50 90 F MINIMUM LOAD 3 352 SPECIFICATIONS CO
16. Sterling GP Series Portable Chillers Part Number 882 93092 00 Bulletin Number SC2 620 Effective 5 1 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 regardin
17. afety Devices and Interlocks AAA 9 Oie TEA a eE E E E EE EA E EE 9 High ee EE 10 Low Pressure Cutout no switch but done through the transducer A 10 Flow SWUGH EE 10 Remote Start Stop Interlock secsscsceica cote vecaehatewtaseghctetetsucadeuseteepecateedeiaesatiebieveenstet 10 2 5 EIERE See tare cares ce idee Set ne Ee Ee 10 CHAPTER 3 INSTALLATION ccccsssscseeeesssseeseeeeeeeeeneseeeees 13 BaP UncratiN EE 13 3 2 Electrical Connechons tarrek tttntEneenntrrrnnnnnnnae reren Ennen 13 3 3 Process Water e ele 14 3 4 Bypass Valve trei etateEg gebei 14 3 5 Galvanic Corrosion Considerations ssesssseeeeessseeesnrrsstrrnrtertrttesrrrrnsrtnnnrnnnnneeene 14 3 6 Water Treatment Considerations Au 14 3 7 Condenser Cp IESELEN ekierekegi ee EES es 15 Water Cooled Chiller Condenserg AAA 15 Air Cooled Chiller Condenserg 15 3 8 Checking Motor Direction ass sdoncseneescentepdeeenedsadesee anaastateetptenteadenpsatieseneesoedeenacpanaes 16 Three Phase COMpreSsSors EE 16 Water REENEN 16 ale EE R E 16 3 9 Water Reservoir 17 3 10 Automatic Water Make Up Optton AEN 19 Ab WW CEET EE 19 3 12 Finishing Setup Setting Up PasswordS AEN 19 CHAPTER 4 OPRERGTION esgkegeeseeu keier EeeE Nee anann 22 GP Series Portable Chillers iii 4 1 Panel Buttons Indicator Lights and Switches sesseeseeneeeeeeeeeerrrnnrrnnesrnnnnnnnnnnnene 22 Microprocessor Controller EE 22 4 25 Initial Star EE 23 4 3 Status SCIOGNS EE 25 E NEE 26 4
18. all 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 Checking compressor oil level 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 33 of 44 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 10 of nameplate rating Defective on off switch E 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 High Low thermostat Ee Allow time to cool and reset then check for high low volt age It must be within Compressor internal overload or plus or minus 10 of the nameplate fuses are open rating Piping
19. ate 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 for cooling tower water or city water 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 cabinetry 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 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 44 Refrigeration Features HFC 41
20. by displaying the basic information that a service person will need to know to determine the problem H GP Series Portable Chillers Chapter 4 Operation 25 of 44 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 GP Series Portable Chillers Chapter 4 Operation 26 of 44 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 27 of 44 4 5 Controller Setpoints Access Level GP Series Portable Chillers Variabl Descripti DE E 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 A pump Low Temperature Tempera
21. chiller is On Back Button Used to back up from a menu and return to the main status screen t Up Arrow Button Used to increment a data field or scroll up within a menu structure v Enter Button Used to accept a data field value or to select a menu item 4 Down Arrow Button Used to decrement a data field or scroll down within a menu structure GP Series Portable Chillers Chapter 4 Operation 22 of 44 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 4 Main Status Screen 3 Set the Leaving Fluid temperature by depressing the button to display the menu Figure 5 Menu Screen fl 4 Depress the e a 7 button to highlight SETPOINTS and press Su 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 23 of 44 Enter the established Operator Password by depressing the to move the position of the cursor and then depressing the R 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 6 Operator Setpoints Screen
22. d to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage GP Series Portable Chillers Chapter 1 Safety 5 of 44 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 equ
23. ealed and requires no routine maintenance GP Series Portable Chillers Chapter 5 Maintenance 32 of 44 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 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 C
24. er wiring indication GP Series Portable Chillers Chapter 2 Functional Description 10 of 44 interlock The alarm signals anytime that a fault is recognized during the operation of the chiller Communications Options RS 485 serial Modbus communications High Pressure Fans Provides for an additional 1 0 WC 250 Pa of static pressure on fan discharge High pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork They can be retrofitted without sheet metal modification but will require changing out fan blades and in some cases fan motors and electrical components Variable Speed Fan 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 5 hp to 15 hp models only Manufactured from 304 stainless steel Mounting Features e Mounting rails with feet Optional Operating Voltages 208 230 3 60 575 3 60 and 400 3 50 volt available UL Labeled Electrical Subpanel 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 t
25. erature 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 44 The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser There it gives up its heat as it condenses to a liquid in the condenser An electronic hot gas bypass valve is used to control cooling capacity during intermittent or partial load conditions This feature contributes substantially to chiller longevity by eliminating excessive cycling of the compressor and providing close temperature control 2 3 Standard Features Mechanical Features Compressor Hermetic scroll compressors Evaporator Stainless steel copper brazed pl
26. g 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 T SAFETY ege ege eege Ee EE SEENEN 5 1 1 Howto Use This Manual 5 Safety Symbols Used in this Manual 5 1 2 Warnings EIERE Ee EE EE e 6 E FLOSPONSIDINMY EE 6 CHAPTER 2 FUNCTIONAL DESCRIPTION ccccssessseeeeees 7 2 1 Models Covered in This Manual 7 2 2 General Descriptio EE 7 Chilled Water EE 7 Refrigeration REESEN 7 2 3 Standard Feat re Sana E E E E E 8 Mechanical Features 8 Ele CtriCal EDA I enn regele EE ET 8 Refrigeration Feature EE 9 Contr ll r E 9 ELE ee 9 2 4 S
27. ime 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 44 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for air water and remote air cooled portable chillers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our portable chiller models are designated by approximate 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 Descrip
28. ipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices v Follow all SAFETY CODES v Wear SAFETY GLASSES and WORK GLOVES v Disconnect and or lock out power before servicing or maintaining the equipment v 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 kW v Make sure the equipment and components are properly GROUNDED before you switch on power v 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 v 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 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 pr
29. ld 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 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 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 s
30. led 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 adjust the pressure setting through the service section of the controller 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 conden
31. m 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 44 3 3 Process Water Connections All of our portable chillers have two chilled water connections The chilled water supply labeled To Process is the outlet for the chilled water leading to the process being cooled The chilled water return labeled From Process is the inlet leading from the process back into the chiller to be cooled and re circulated All external chilled water connections should be run full size to the process Flow and pressure information is available in the Appendix The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment Note Be sure to reduce external pressure drop as much as possible by generously sizing piping and tooling water passageways 3 4 Bypass Valve Considerations Our portable chillers have an internal manual bypass valve If
32. n 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 44 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 This electro mechanical cutout device opens the compressor control circuit if refrigeration system compressor suction pressure drops below 15 psi It automatically resets when refrigerant suction pressure reaches 30 psi Note The low pressure cutout is an automatic reset device typically mounted on the compressor suction line inside the mechanical cabinet Call a refrigeration service technician to analyze the problem and reset the control 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 chille
33. nd 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 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 reservoir fill and vent level 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 17 of 44 Figure 2 Ethylene Glycol and Propylene Glycol Cu
34. on 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 44 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 44 Chapter 3 Installation 3 1 Uncrating All models are 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 fro
35. on direction of fan s and pump s The crankcase heater is automatically energized when the main power is applied It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil 3 12 Finishing Setup Setting Up Passwords You can establish passwords for two levels of security operators and supervisors The controller comes from the factory with neither password set This allows every user access to all functions GP Series Portable Chillers Chapter 3 Installation 19 of 44 Operator Password If you define a password for operators then a password will be required to carry out any fuction 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 ls to highlight SETPOINTS and press G 3 Press the e l or until the following screen appears for the Operator Password or the following screen for the Supervisor Password
36. ors are directionally dependent and compress in one rotational direction Reversing rotation direction results in an elevated sound level and a substantially reduced current draw Water Pumps Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure gauge Pump rotation should be clockwise when viewed from the motor end For chillers with optional pumps check the appropriate pump curve in the Appendix Caution Do not run pump dry Doing so will result in seal damage Condenser Fan Air should be drawn through the condenser and discharged vertically from the chiller GP Series Portable Chillers Chapter 3 Installation 16 of 44 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 inte
37. pecific warranty terms GP Series Portable Chillers Chapter 7 Appendix 36 of 44 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 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 59m 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
38. r 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 X1 and 1 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 switch mounted in the reservoir tank and the necessary internal piping to connect the chiller to a make up water source See Appendix for typical piping diagrams Caution Customer piping must provide backflow protection and venting of tank to atmosphere to prevent over pressurization of the reservoir tank not needed for open tank See Error Reference source not found on page Error Bookmark not defined Process Water Sidestream Filter Not available on chillers less pump and reservoir tank Includes a 50 micron filter flow meter ball valve for throttling water flow and the necessary piping to provide constant filtering of the process water at about one gallon per minute 1 gpm 3 8lpm General Fault Indicator Audible Visual Alarm Includes a 100 dB audible alarm horn visual alarm strobe and silence button with provisions for custom
39. r the Operator Password by depressing the to move the position of the cursor and then depressing the 8 ori button to increment or decrement the number Once all of the numbers have been entered depress GP Series Portable Chillers Chapter 4 Operation 29 of 44 the to accept the password The following screen will appear Figure 9 Operator Setpoints Screen 4 7 D to move the cursor to the Leaving Temp line Use the T o 3 Depress a button to increment or decrement the value Depress to accept the value and move the cursor down one line 4 Adjust the Hi Temp Warning and Hi Temp Fault in the same manner 5 Depress the m 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
40. rves 40 0 Percent Glyc ol Curves for Free ze Protec tion 30 0 20 0 10 0 Eth ylene G lycol Propylene Glycol 0 0 Temperature F 20 0 40 0 60 0 0 0 10 0 GP Series Portable Chillers 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 Chapter 3 Installation 30 0 40 0 50 0 60 0 18 of 44 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 e Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process
41. se 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 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 include
42. sing 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 approximately 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 44 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 compress
43. tion 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 30 C for applications using a water glycol mix and 45 F to 80 F 7 to 30 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 30 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 reservoir tank The coolant is then pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle A manual pressure actuated process water bypass valve located between the supply line and reservoir tank single pump models only allows minimal flow through the unit during the intermittent fluctuating flow conditions It is not intended to provide continuous full bypass flow This minimal flow allows the temperature sensor to signal the controller to shut down the compressor because of the drop in process water temp
44. 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 30 of 44 GP Series Portable Chillers Chapter 4 Operation 31 of 44 Chapter 5 Maintenance 5 1 Lubrication Grease all blower bearings fan and blower 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 mi
45. ture to activate Low Temperature Warning x Warning alarm Low Temperature Fault Temperature to activate Low Temperature Fault alarm D 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 allow 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 P Delay compressor and pump Time in minutes to silence alarm with optional audible Alarm Silence Time D alarm After time alarm will reactivate i a Password Time in minutes for operator password to be active x Supervisor Password is ist Ae Time Time in minutes for supervisor password to be active x Chapter 4 Operation 28 of 44 1 Set the Leaving Fluid temperature by depressing the ___ button to display the menu Figure 8 Menu Screen 2 Depress the m L l 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 Ente
46. you selected then subtract the one pump pressure drop listed in the above table using the appropriate chiller hp and flow rate e For two pump Process Recirc chillers do not subtract pressure drop from table above for process pump GP Series Portable Chillers Chapter 7 Appendix 43 of 44 7 5 Electrical Schematic Please refer to your owner s information packet for more details regarding your specific unit GP Series Portable Chillers Chapter 7 Appendix 44 of 44
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