Sterling 882.93092.00 User Manual 2

GP Series Portable Chillers

Part Number: 882.9309

Bulletin Number: SC2-620.1

Effective: 9/18/200

Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

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© Copyright 2009
All rights reserved.

2.00

9

Shipping Information

Unpacking and Inspection

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

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage
Hold the damaged goods and packing material for the examining agent’s inspection. Do not

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

File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.

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

If the Shipment is Not Complete

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

Bill of lading
Packing list
Operating and Installation packet
Electrical schematic and panel layout drawings
Component instruction manuals (if applicable)

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

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and service department
immediately at [phone]. Have the order number and item number available.

Hold the items until you receive shipping instructions.

Returns

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

GP Series Portable Chillers ii

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Remote Air-Cooled Chiller Condensers ..............................................................16

3-8 Checking Motor Direction..........................................................................................20

Three-Phase Compressors .................................................................................20

Water Pumps.......................................................................................................20

Condenser Fan....................................................................................................20

3-9 Water Reservoir ........................................................................................................21

3-10 Automatic Water Make-Up Option.............................................................................23

3-11 Initial Start-Up............................................................................................................23

3-12 Finishing Setup: Setting Up Passwords....................................................................23

GP Series Portable Chillers iii

CHAPTER 4:

4-1 Panel Buttons, Indicator Lights, and Switches..........................................................26

4-2 Initial Start-up............................................................................................................27

4-3 Status Screens..........................................................................................................29

4-4 Access Levels ...........................................................................................................31

4-5 Controller Setpoints...................................................................................................32

4-6 Alarms.......................................................................................................................34

4-7 Optional Communications.........................................................................................34

OPERATION.......................................................26

Microprocessor Controller ...................................................................................26

CHAPTER 5: MAINTENANCE .................................................36

5-1 Lubrication.................................................................................................................36

5-2 Filter Cleaning...........................................................................................................36

5-3 Maintaining the Condenser .......................................................................................36

Air- and Remote Air-Cooled Chillers ...................................................................36

Water-Cooled Chillers .........................................................................................36

5-4 Maintaining the Evaporator .......................................................................................37

5-5 Evaporator Process Piping Y-Strainer.......................................................................37

5-6 Preventative Maintenance Service............................................................................37

CHAPTER 6: TROUBLESHOOTING .......................................38

CHAPTER 7: APPENDIX..........................................................40

7-1 Returned Material Policy...........................................................................................40

Credit Returns .....................................................................................................40

7-2 Technical Assistance.................................................................................................41

Parts Department ................................................................................................41

Service Department.............................................................................................41

Sales Department................................................................................................41

Contract Department...........................................................................................41

7-3 Specifications............................................................................................................42

Air-Cooled Portable Chillers................................................................................42

Water-Cooled Portable Chillers...........................................................................44

7-4 Pump Curves, Flow, and Pressure Considerations...................................................46

60 Hertz Pump Curves........................................................................................46

50 Hertz Pump Curves........................................................................................47

7-5 Remote Air-Cooled Chiller Configurations ................................................................49

7-6 Typical Ductwork for Air-Cooled Chillers...................................................................50

7-7 Piping Diagrams........................................................................................................53

GP Series Portable Chillers iv

Chapter 1: Safety

1-1 How to Use This Manual

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

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

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

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.

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

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

The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.

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

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING indicates a potentially hazardous situation or practice which, if not avoided,

could result in death or serious injury.

CAUTION indicates a potentially hazardous situation or practice which, if not avoided,

may result in minor or moderate injury or in property damage.

GP Series Portable Chillers Chapter 1: Safety 5 of 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:

9 Follow all SAFETY CODES.
9 Wear SAFETY GLASSES and WORK GLOVES.
9 Disconnect and/or lock out power before servicing or maintaining the equipment.
9 Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

9 Operate this equipment within design specifications.
9 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

9 Make sure the equipment and components are properly GROUNDED before you

switch on power.

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

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

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

(3,447.5 kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION
SYSTEM. This must be performed by a qualified service technician only.

9 Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

9 Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

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

1-3 Responsibility

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

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

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

Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.

GP Series Portable Chillers Chapter 1: Safety 6 of 64

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

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

Chilled Water Circuit

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

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

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

Refrigeration Circuit

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

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

GP Series Portable Chillers Chapter 2: Functional Description 7 of 64

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 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 & 30; 1.25 in. NPT valves for
GPWC40; and 1.50 in. NPT valves for GPWC50.

Remote Air-Cooled Condenser. Aluminum fin/tube with low ambient control down to –
20ºF (-29ºC) via a variable-speed primary fan.

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

Piping. Non-ferrous piping
Pump. TEFC motors (Optional 10 HP is ODP only)—horizontally mounted stamped

stainless steel construction.
Other Mechanical Features

• Low process water thermal flow switch

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

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

• Internal process water bypass valve for system protection only

• Fully insulated refrigeration and process water piping

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

• Tank level indication

• Pump pressure indication

Electrical Features

• Fully accessible NEMA 12-style electrical control enclosure

• Single-point power and ground connection

• Non-fused disconnect switch, lockable

• Branch circuit fusing

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

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 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 20ºF below the leaving water

temperature set point. Condensation may form inside the pump tank and dilute
the mixture, therefore the freezing point should be verified periodically. See
Figure 6 on page 18 for the correct mixture.

Crankcase Heater

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 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 switch mounted in the reservoir tank,
and the necessary internal piping to connect the chiller to a make-up water source. See
Appendix for typical piping diagrams.

Caution! Customer piping must provide backflow protection and venting of tank to

atmosphere to prevent over-pressurization of the reservoir tank (not needed for
open tank). See Error! Reference source not found. on page Error! Bookmark
not defined..

Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank.
This option includes a 50 micron filter, flow meter, ball valve for throttling water flow, and
the necessary piping to provide constant filtering of the process water at about one gallon per
minute (1 gpm/3.8lpm).

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 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 60ºF (15.5ºC).
This option will also reduce fan noise in ambient temperatures below 95ºF (35ºC).

Stainless Steel Reservoir. Manufactured from 304 stainless steel.
Mounting Features.

• Mounting rails with feet

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

UL Labeled Electrical Subpanel. This option provides for the subpanel to be listed with
Underwriters Laboratory, with UL-related benefits and features.

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

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

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: Inst allation

3-1 Uncrating

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

1. Pry the crating away from the skid.

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

3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant

from the centerline of the unit and the unit must be balanced on the forks. Lift slowly
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove
the skid from the unit.

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

position.

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

is found.

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.

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

Important!

310.15(B)(2)(a)

GP Series Portable Chillers Chapter 3: Installation 13 of 64

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

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

warranty will be voided.

3-5 Galvanic Corrosion Considerations

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

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

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 85ºF (29ºC) and a minimum

pressure of 25 psi.

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

Only a qualified refrigeration technician should adjust the pressure setting.
Please contact our service group at 800-423-3183 to schedule an appointment.

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

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

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

Air-Cooled Chiller Condensers

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

Caution! Clean air-cooled condensers and filters frequently. Failure to do so results in

reduced capacity, increased operating costs, and possible failure of the
equipment. Cleaning instructions can be found in the Maintenance chapter of
this manual

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

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

psi (2896 kPa).

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. 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.

• Leaving water temperature affects discharge line size. Be sure to inform the installing

contractor of the leaving water temperature range in which the chiller will be operating

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

equivalent pipe feet

• Discharge line risers cannot exceed an elevation difference greater than 100 feet

without a 2% efficiency decrease.

• Refer to page 49 of the Appendix for the location of traps.

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

condenser liquid lines.

Sizing Refrigerant Lines. To determine field installed liquid and discharge line sizes, first
establish the equivalent length of pipe for each line, valve, and elbow. Chiller capacity and

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 allow oil to flow towards
the condenser. Discharge line sizing is based on the velocity required for sufficient oil return
back to the compressor. See Figure 4 on page 18 for discharge line sizing.

Figure 2: Equivalent Length in Feet for Valves and Fittings

Line Size

OD (inches)

3/8 24 4 2.8
1/2 24 4.7 3.2
5/8 25 5.7 3.9
3/4 25 6.5 4.5

7/8 28 7.8 5.3
1-1/8 29 2.7 1.9
1-3/8 33 3.2 2.2
1-5/8 34 3.8 2.6
2-1/8 39 5.2 3.4
2-5/8 44 6.5 4.2

Angle
Valve

Short

Radius EL

Long

Radius EL

Figure 3: Liquid Line Sizing

5 TON CIRCUIT 7.5 TON CIRCUIT

Total Equiv.

Length (Ft)

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

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

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

100 1/2 1/2 1/2 5/8
125 1/2 1/2 1/2 5/8
150 1/2 1/2 5/8 5/8
175 1/2 5/8 5/8 5/8
200 1/2 5/8 5/8 5/8
225 1/2 5/8 5/8 5/8
250 5/8 5/8 5/8 5/8
275 5/8 5/8 5/8 5/8
300 5/8 5/8 5/8 5/8

Horizontal
Downflow

Liquid Line Size (OD")

or

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

Total Equiv.

Length (Ft)

25 5/8 5/8 5/8 5/8
50 5/8 5/8 5/8 5/8

75 5/8 5/8 5/8 5/8
100 5/8 5/8 5/8 5/8
125 5/8 5/8 5/8 5/8
150 5/8 5/8 5/8 5/8
175 5/8 5/8 5/8 3/4
200 5/8 5/8 5/8 3/4
225 5/8 5/8 5/8 3/4
250 5/8 5/8 3/4 3/4
275 5/8 5/8 3/4 3/4
300 5/8 5/8 3/4 3/4

Horizontal
Downflow

Liquid Line Size (OD")

or

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

GP Series Portable Chillers Chapter 3: Installation 17 of 64

10 TON CIRCUIT 15 TON CIRCUIT

Total Equiv.

Length (Ft)

Horizontal

or

Downflow

Liquid Line Size (OD")

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

Total Equiv.

Length (Ft)

Horizontal

or

Downflow

Liquid Line Size (OD")

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

25 5/8 5/8 5/8 3/4 25 7/8 7/8 7/8 7/8
50 5/8 5/8 3/4 3/4 50 7/8 7/8 7/8 7/8

75 5/8 5/8 3/4 3/4 75 7/8 7/8 7/8 7/8
100 5/8 3/4 3/4 3/4 100 7/8 7/8 7/8 7/8
125 3/4 3/4 3/4 7/8 125 7/8 7/8 7/8 7/8
150 3/4 3/4 3/4 7/8 150 7/8 7/8 7/8 7/8
175 3/4 3/4 3/4 7/8 175 7/8 7/8 7/8 7/8
200 3/4 3/4 3/4 7/8 200 7/8 7/8 7/8 7/8
225 3/4 3/4 7/8 7/8 225 7/8 7/8 7/8 7/8
250 3/4 3/4 7/8 7/8 250 7/8 7/8 7/8 7/8
275 3/4 3/4 7/8 7/8 275 7/8 7/8 7/8 1-1/8
300 3/4 3/4 7/8 7/8 300 7/8 7/8 7/8 1-1/8

Figure 4: Discharge Line Sizing

Horizontal or Downflow Discharge Line Sizes (OD")

Circuit

Tons

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

Total Equivalent Length (Ft)

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

7.5 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8
10 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
15 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8

Circuit

Tons

5

7.5

10

15

Upflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

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

5/8 5/8 5/8 5/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8

B-5/8 B-5/8 B-5/8 B-5/8 B-5/8 B-5/8 B-5/8 B-3/4
A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8
B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4
A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-3/8 A-1/2 A-1/2 A-1/2 A-1/2 A-1/2
B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-3/4 B-7/8 B-7/8 B-7/8 B-7/8 B-7/8

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

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

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

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

Chiller

Model

GPRC5 9 9 10 11 12 13 13 13 14

GPRC7.5 10 10 12 14 15 16 16 17 17

GPRC10 13 13 15 17 19 20 21 21 22
GPRC15 18 19 22 25 27 29 30 31 32

Line Size

OD (inches)

3/8 0.3 3.2
1/2 0.6 6.0
5/8 1.0 9.6
3/4 1.5 14.4
7/8 2.1 20.0

1-1/8 3.7 34.1

60 50 40 30 20 10 0 -10 -20

Condenser and Chiller Charge (per circuit)

Minimum Design Ambient - °F

Discharge Line

LBS of R-410a

Liquid Line

LBS of R-410a

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

Air 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 20ºF (11ºC) below

the normal chiller operating temperature set point.

Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel,

stainless steel, and bronze) in the system from corrosion. If you intend to use straight water,

we strongly advise a minimum leaving water temperature of 45ºF (7ºC) or contact the service

department.

The following glycol products are available:

Part Number Description

A0541358 Ethylene glycol, 5 gallons (18.9 liters)

A0539637 Ethylene glycol, 55 gallons (208.2 liters)

A0542990 Propylene glycol, 5 gallons (18.9 liters)

A0542991 Propylene glycol, 55 gallons (208.2 liters)

Caution! Do not connect make-up water directly to the chilled water reservoir unless you

have an approved automatic water make-up system installed.

Caution! Do not pressurize tank. Supply and return connections must be trapped and

vented to allow vertical risers to drain into tank. Do not overfill system. Allow
enough free space in tank for vertical piping to drain.

If your application has chilled water or process piping above the chiller, trap and vent the

supply and return lines to allow vertical piping to drain into tank.

Note: In applications where the process or process piping is above the reservoir, take

steps to prevent over pressurization of the reservoir. This condition can occur
on system shutdown when the water in the system drains into the reservoir. To
prevent this, a vacuum breaker should be installed at the high point of the “To
Process” and “From Process” lines.

GP Series Portable Chillers Chapter 3: Installation 21 of 64

Figure 6: Ethylene Glycol and Propylene Glycol Curves

Perce n t G lycol Cu rvesfor Free ze Protection

40.0

30.0

20.0

10.0

0.0

-10.0

-20.0

-30.0

-40.0

-50.0

-60.0

0.0 10.0 20.0 30.0 40.0 50.0 60.0

% Glycol by Volum e

Example: 45°F set point minus 20°F = 25°F.
From Figure 28, 25°F equates to 10% by volume of glycol required.

Eth ylene G lycol

Propylene Glycol

Note: The standard pumps used in the GPAC Serice chillers are not recommended to

be used with fluid below 0°F (-18°C). Please consult factory for the proper
pump.

GP Series Portable Chillers Chapter 3: Installation 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 (±10%) of the voltage listed on the serial tag.
Electrical connections must conform to all applicable codes.

• Complete chilled water To Process and From Process connections.

• Be sure the reservoir tank and chilled water circuit piping are filled a water/glycol

mixture. The water/glycol mixture should provide for freeze protection to at least 20°F
(11ºC) below the leaving water temperature you want. Should the display show a tank
level less than 0 after the tank is filled, check the clear tube leading from the tank to the
tank level pressure switch for a blockage.

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

air for proper operation.

• The tower or city water condenser cooling in and out connections should be completed

and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi
pressure, for proper operation.

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

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

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

3-12 Finishing Setup: Setting Up Passwords

You can establish passwords for two levels of security: operators and supervisors. The

controller comes from the factory with neither password set. This allows every user access to

all functions.

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

2. Press the

3. Press the

or the following screen for the Supervisor Password

button to access the menu screen.

or to highlight SETPOINTS, and press .

or until the following screen appears for the Operator Password

4. Press

Password line is highlighted.

5. Press

0 and 9999.

GP Series Portable Chillers Chapter 3: Installation 24 of 64

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

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

6. Press

to accept the Password and move to the next line.

7. For either Operator or Supervisor password the time that the password will allow the

controller to be active can be set by the Operator or Supervisor Password Time. With the
PW Time value highlighted, press

or to increment or decrement the time. The

password time for either setup can be from 0 to 99 minutes.

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 20ºF to 80ºF (-7ºC to 27ºC).

Figure 7 - Controller Display

Button Button Description Detailed description

Menu Button

On/Off Button

Back Button

Up Arrow Button

Enter Button

Down Arrow Button

Used to access the menus structure of the PGD interface

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

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

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

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

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

GP Series Portable Chillers Chapter 4: Operation 26 of 64

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

Figure 9 - Menu Screen

3. Set the Leaving Fluid temperature by depressing the

the menu.

4. Depress the

passwords were setup (See Section 3-12 for information on the controller
passwords) the password screen will appear.

or button to highlight SETPOINTS and press . If

button to display

GP Series Portable Chillers Chapter 4: Operation 27 of 64

Enter the established Operator Password by depressing the
position of the cursor, and then depressing the

increment or decrement the number. Once all of the numbers have been
entered depress the

appear.

Figure 10 - Operator Setpoints Screen

5. Depress

to move the

or button to

to accept the password. The following screen will

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

button to increment or decrement the value. Depress to accept the

value and move the cursor down one line.

6. Depress the

7. Depress the

8. Check pump rotation

9. Check the pump amp draw and pump pressure. Make sure that the amp draw

reading is within the running load and service factor amps.

10. Operate the chiller, looking for any leaks and listening for unusual noises or

vibrations that could indicate improper operation.

GP Series Portable Chillers Chapter 4: Operation 28 of 64

button twice to return to the main status screen.
to start the chiller.

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

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.

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

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 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 31 of 64

4-5 Controller Setpoints

Variable Description

Leaving Temp Temperature of fluid out to process x x

Hi Temp Warning

Hi Temp Fault
Compressor On

Differential
Compressor Off

Differential
Pump Stop Delay
Low Temperature

Warning
Low Temperature Fault Temperature to activate Low Temperature Fault alarm x

Water Make-up On

Water Make-up Off

Water Make-up Time

Low Level Warning Tank level that will activate Low Level Warning alarm x

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

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

Temperature Difference between Leaving Fluid
Temperature and Setpoint to turn on the compressor

Temperature Difference between Leaving Fluid
Temperature and Setpoint to turn off the compressor

Delay time in seconds between fault and stopping the
pump

Temperature to activate Low Temperature Warning
alarm

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

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

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

Access Level

Operator Supervisor

x x

x x

x

x

x

x

x

x

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
Alarm Silence Time
Operator Password

Time
Supervisor Password

Time

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

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

Time in minutes for operator password to be active x

Time in minutes for supervisor password to be active x

x

x

GP Series Portable Chillers Chapter 4: Operation 32 of 64

1. Set the Leaving Fluid temperature by depressing the

Figure 12 - Menu Screen

button to display

the menu.

2. Depress the

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
the cursor, and then depressing the

decrement the number. Once all of the numbers have been entered depress

or button to highlight SETPOINTS and press . If

to move the position of

or button to increment or

GP Series Portable Chillers Chapter 4: Operation 33 of 64

the

Figure 13 - Operator Setpoints Screen

to accept the password. The following screen will appear.

3. Depress

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

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

button twice to return to the main status screen.

4-6 Alarms

The controller is setup with multiple alarms, most of them configurable using the Supervisor

password. Section 4-5 Controller Setpoints gives a list of alarms that the controller is setup to

display. The alarms are broken up into two categories – warnings and faults. The warning

notifies the user that the parameter has been exceeded and the chiller is allowed to keep

operating, but should be monitored to determine the cause of the warning. The fault notifies

the user that the parameter has been exceeded and the chiller and pump has been shut down to

protect the system.

4-7 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

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.

5-2 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.

5-3 Maintaining the Condenser

Dirty condenser heat exchange surfaces reduce system capacity and efficiency.

Air- and Remote Air-Cooled Chillers

Brush or vacuum light dirt accumulations off the aluminum condenser fins. Avoid bending or

damaging them. Heavy dirt accumulations on the fins may require professional cleaning.

Water-Cooled Chillers

Proper water treatment will greatly reduce cleaning intervals.

Coaxial Condensers (Standard

reverse-circulating with a mild detergent and water solution. Remove mineral deposits by

reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through

the water side of the condenser. Follow the directions on the container.

Shell & Tube Condensers (Optional

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.

). Remove dirt and slime in the condenser tube water side by

). Remove dirt and slime in the condenser tube water

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 140ºF (60ºC) to clean a condenser unless you

are monitoring the refrigeration circuit for excessive pressure with gauges.
Only a trained technician should use this method.

5-4 Maintaining the Evaporator

Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt

and slime in the evaporator by reverse-circulating with a mild detergent and water solution.

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

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

5-5 Evaporator Process Piping Y-Strainer

The process piping Y-strainer requires periodic cleaning of its screen to insure the proper

flow through the evaporator. To clean the strainer screen, remove the access plug and

retaining cap, and pull out the screen.

Wipe, brush, or vacuum out any dirt left in the strainer body. Clean the screen and replace it

in the strainer taking care to fit it squarely into the machined seat provided.

Caution! Do not forget to re-install the screen after cleaning it. Operating the chiller

with no strainer screen can potentially plug the evaporator with dirt. The
warranty does not cover chiller failures from a dirty evaporator.

5-6 Preventative Maintenance Service

Follow a systematic preventive maintenance program to help avoid costly down time. Call

the Service Department to arrange a schedule of inspections. This service can be tailored to

fit your maintenance requirements. These inspections include, but are not limited to:

• Checking refrigerant suction and discharge pressures

• Checking safety and operating conditions

• Checking voltage and amperage of all motors

• Checking all electrical connections

• Checking quantity of refrigerant

• Checking compressor oil level on units with tandem compressors

• Checking lubrication of motor and pump bearings

• Checking circulating pump operation

• Checking flow through heat exchangers

• Checking compressor efficiency

• Checking noise levels

GP Series Portable Chillers Chapter 5: Maintenance 37 of 64

Chapter 6: Troubleshooting

Problem Possible cause Solution

Check main disconnect, fuses, wiring,
and power lead to unit.
Voltage must be within plus or minus
10% of nameplate rating.

Replace control circuit fuse.
Check transformer.
Check for a short circuit.

Add water or water/glycol solution as
required.

Lower the leaving fluid temperature
below the leaving temperature you
desire.
Allow time to cool and reset, then check
for high/low volt-age. It must be within
plus or minus 10% of the nameplate
rating.
Check for open fuses and loose
compressor electrical connections.

Repair or replace.

Repair or replace.

Unit does not run.

Pump runs; compressor does not.

No power.

Wrong voltage supplied to unit.
Defective display. Replace.

Control circuit fuse blown.

Defective control transformer. Replace.
Piping flow switch circuit open.
Pump motor off on overload. Reset and test.

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

Compressor internal overload or
fuses are open.

Compressor contactor holding coil
open.

Defective compressor auxiliary
contact.

Pump runs, compressor cycles at
short intervals.

Water temperature is too high.

Broken wire in the compressor
control circuit.

Plugged Y-strainer Clean

Hot gas not coming on

Low water flow

Water/glycol mixture inadequate
for process.

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

Refrigerant charge is low.

Locate and repair.

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

Install bypass between to-and-from
process line

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

Adjust.

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

GP Series Portable Chillers Chapter 6: Troubleshooting 38 of 64

Problem Possible cause Solution

Verify rotation; if running in reverse
Pump process pressure low (refer
to curves for normal pressure for
various pumps).

Pump process pressure is too high. Restricted water flow.

Unit runs continuously, but not
enough cooling power.

Pump running in reverse.

Check for foreign matter. Clean the system strainer.

Restricted condenser air flow.

Unit low on refrigerant.

Compressor not operating
efficiently.

Unit under-sized for application. Call sales rep.

rotation, reverse any two main power

leads. Re-verify for correct pump

rotation.

Check for partially closed valves etc.

Make sure that all lines are properly

sized.

Clean filters.

Clean condenser.

Check the refrigerant charge by viewing

sight glass on liquid line upstream of the

expansion valve.

Call service.

GP Series Portable Chillers Chapter 6: Troubleshooting 39 of 64

Chapter 7: Appendix

7-1 Returned Material Policy

Credit Returns

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

Reason for requesting the return must be given.
All returned Material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking

charge.
All

returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new

and unused condition, suitable for resale.

Warranty Returns

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

Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if

the item is found to be defective in materials or workmanship. Purchased components are covered
under their specific warranty terms.

GP Series Portable Chillers Chapter 7: Appendix 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

manufactured to engineering design specific ations, which will maximize your equipment’s performa nce
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 dedic ated 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. Co ntact 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 50ºF (10ºC) leaving wa ter temperature at 2.4
gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply
capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.

G-PAC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 4.65 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 4936 WATTS
AMBIENT AIR TEMPERATURE 95 °F EER 11.31 BTU/WATT
COOLANT WATER CONDENSER AIR FLOW 4230 CFM
COOLANT FLOW 11 GPM SOUND POWER LEVEL 86 dBA
UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL @ 1 METER dBA

OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW GPM
AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 0.944 TONS

SPECIFICATIONS

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

CONDENSER ALUMINUM REFRIGERANT 3 LBS R-410A
CONDENSER FANS
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

STAINLESS STEEL
CENTRIFUGAL

24 INCH
AXIAL

COOLANT CIRCUIT NON-FERROUS

FRAME GALVANIZED STEEL

G-PAC-30

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 7.30 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 7579 WATTS
AMBIENT AIR TEMPERATURE 95 °F EER 11.56 BTU/WATT
COOLANT WATER CONDENSER AIR FLOW 6343 CFM
COOLANT FLOW 18 GPM SOUND POWER LEVEL 92 dBA
UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL @ 1 METER dBA

OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW GPM
AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 1.504 TONS

SPECIFICATIONS

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

CONDENSER ALUMINUM REFRIGERANT 4 LBS R-410A
CONDENSER FANS
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

STAINLESS STEEL
CENTRIFUGAL

24 INCH
AXIAL

FRAME GALVANIZED STEEL

COOLANT CIRCUIT NON-FERROUS

GP Series Portable Chillers Chapter 7: Appendix 42 of 64

G-PAC-40

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 9.91 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 10070 WATTS
AMBIENT AIR TEMPERATURE 95 °F EER 11.81 BTU/WATT
COOLANT WATER CONDENSER AIR FLOW 8458 CFM
COOLANT FLOW 24 GPM SOUND POWER LEVEL 87 dBA
UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL @ 1 METER dBA

OPERATING PARAMETERS
COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW GPM

AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 2.022 TONS

SPECIFICATIONS
COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

CONDENSER ALUMINUM REFRIGERANT 6 LBS R-410A
CONDENSER FANS
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 20 AMPS CONTROL MICROPROCESSOR

G-PAC-50

STAINLESS STEEL
CENTRIFUGAL

32 INCH
AXIAL

COOLANT CIRCUIT NON-FERROUS

FRAME GALVANIZED STEEL

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 15.19 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 14882 WATTS
AMBIENT AIR TEMPERATURE 95 °F EER 12.25 BTU/WATT
COOLANT WATER CONDENSER AIR FLOW 12687 CFM
COOLANT FLOW 36 GPM SOUND POWER LEVEL 93 dBA
UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL @ 1 METER dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW GPM
AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 3.016 TONS

SPECIFICATIONS
COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

CONDENSER ALUMINUM REFRIGERANT 8 LBS R-410A
CONDENSER FANS
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 30 AMPS CONTROL MICROPROCESSOR

STAINLESS STEEL
CENTRIFUGAL

32 INCH
AXIAL

COOLANT CIRCUIT NON-FERROUS

FRAME GALVANIZED STEEL

GP Series Portable Chillers Chapter 7: Appendix 43 of 64

Water-Cooled Portable Chillers

Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60

Hz capacity flow rate must be maintained.

G-PWC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)

COOLING CAPACITY 5.12 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 4064 WATTS
CONDENSER INLET WATER

TEMPERATURE
COOLANT WATER CONDENSER WATER FLOW 15.9 GPM
COOLANT FLOW 13 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID SOUND PRESSURE LEVEL @ 1 METER dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 15 GPM
CONDENSER INLET WATER

TEMPERATURE

SPECIFICATIONS

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
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 7.98 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 6416 WATTS
CONDENSER INLET WATER

TEMPERATURE
COOLANT WATER CONDENSER WATER FLOW 25.08 GPM
COOLANT FLOW 20 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 22.5 GPM
CONDENSER INLET WATER

TEMPERATURE

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
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

85 °F EER 15.13 BTU/WATT

50-90 °F MINIMUM LOAD 1.06 TONS

STAINLESS STEEL
CENTRIFUGAL

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

85 °F EER 14.92 BTU/WATT

OPERATING PARAMETERS

50-90 °F MINIMUM LOAD 1.672 TONS

SPECIFICATIONS

STAINLESS STEEL
CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

SOUND PRESSURE LEVEL @ 1
METER

COOLANT CIRCUIT NON-FERROUS

dBA

GP Series Portable Chillers Chapter 7: Appendix 44 of 64

G-PWC-40

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 10.94 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 8450 WATTS
CONDENSER INLET WATER

TEMPERATURE
COOLANT WATER CONDENSER WATER FLOW 33.93 GPM
COOLANT FLOW 27 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 30 GPM
CONDENSER INLET WATER

TEMPERATURE

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
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

STAINLESS STEEL
CENTRIFUGAL

85 °F EER 15.53 BTU/WATT

SOUND PRESSURE LEVEL @ 1
METER

OPERATING PARAMETERS

50-90 °F MINIMUM LOAD 2.262 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

dBA

G-PWC-50

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 16.66 TONS ALTITUDE SEA LEVEL
COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 12778 WATTS
CONDENSER INLET WATER

TEMPERATURE
COOLANT WATER CONDENSER WATER FLOW 50.28 GPM
COOLANT FLOW 40 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 45 GPM
CONDENSER INLET WATER

TEMPERATURE

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH
COOLANT PUMP
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

STAINLESS STEEL
CENTRIFUGAL

85 °F EER 15.65 BTU/WATT

SOUND PRESSURE LEVEL @ 1
METER

OPERATING PARAMETERS

50-90 °F MINIMUM LOAD 3.352 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

dBA

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

300

250

200

150

Head [ft]

100

5-15 ALL 60 Hz

3 HP 2CDU 70/306

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D 3G

3 HP CDU120/530D3G

Septem ber 8, 2009

10 HP 3U 32-200-1100D3G

5 HP 2CDU 200/506

120

100

80

Psi

60

40

50

0

0 1020304050607080

Capacity [Gal/min]

HP GP 20 GP 30 GP 40 GP 50

1.5 CDU 70/315D3G STD
2 CDU 70/520D3G STD STD
3 CDU 120/530D3G OPT OPT OPT STD
3OPT
5 2CDU 200/506 OPT OPT OPT OPT

10 3U 32-200-1100D3G OPT OPT

Model

2CDU 70/306

20

0

GP Series Portable Chillers Chapter 7: Appendix 46 of 64

50 Hertz Pump Curves

ACS CHI LLER PUM PS

70

60

50

40

Head [m]

30

5-15 ALL 50 Hz

3 HP 2CDU 70/306

September 8, 2009

10 HP 3U 32-200-1100D3G

5 HP 2CDU 200/506

6

5

4

Bar

3

2 HP CDU 7 0 /5 20 D3G

20

1.5 HP CDU 70/3 1 5D3 G

10

0

0 50 100 150 200 250 300

3 HP CDU120/530D3G

Capac ity [lite r/min]

HP GP 20 GP 30 GP 40 GP 50

Model

1. 5 CDU 70/315D3G STD
2 CDU 70/ 520D3G STD ST D
3 CDU 120/530D3G OPT OPT OPT STD
3OPT

2CDU 70/306

5 2 CDU 20 0/ 506 OPT OPT O PT OPT

10 3U 32-2 00-1100D3G OPT OPT

2

1

0

GP Series Portable Chillers Chapter 7: Appendix 47 of 64

Pure Water at >40°F

GPXC-20 GPXC-30 GPXC-40 GPXC-50
GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) GPM DP (PSI)

0.5X Nominal 6 1.7 9 1.7 12 1.6 18 1.8

1.0X Nominal 12 5.9 18 6.1 24 5.8 36 6.4

2.0X Nominal 24 21.4 36 21.9 48 20.7 72 23.3

Calculating Chiller Nominal Flow and Pressure to Process

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

• Pressure: Obtain a corresponding pressure reading from the pump curve you selected,

then subtract the one-pump pressure drop listed in the above table using the
appropriate chiller hp and flow rate.

GP Series Portable Chillers Chapter 7: Appendix 48 of 64

7-5 Remote Air-Cooled Chiller Configurations

GP Series Portable Chillers Chapter 7: Appendix 49 of 64

7-6 Typical Ductwork for Air-Cooled Chillers

60 Hz Discharge

Model
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

Fan

HP kW CFM m

air volume

3

50 Hz Discharge

air volume

/min CFM m3/min

When locating your air-cooled portable chiller and designing its ductwork, note any potential high
temperature conditions when discharging into your building and any negative pressures with the building
when discharging air outside.
Notes: • Customer use of ductwork requires the high pressure fan option. • Allow 30” (77 cm) minimum
clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility •
Size the ductwork for maximum capacity • Support ductwork from the building structure, not off of the
chiller • Back draft damper to outside must be closed at all times when fan/blower is not operating •

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 • Chillers are designed to operate at a condensing entering air
temperature of 60ºF (16ºC) minimum without optional Variable Frequency Drive • Maximum total static
pressure drop external to the chiller must not exceed 0.30” WG (75 Pa)

GP Series Portable Chillers Chapter 7: Appendix 51 of 64

7-7

GP Series Portable Chillers Chapter 7: Appendix 52 of 64

7-8 Piping Diagrams

GP Series Portable Chillers Chapter 7: Appendix 53 of 64

GP Series Portable Chillers Chapter 7: Appendix 54 of 64

GP Series Portable Chillers Chapter 7: Appendix 55 of 64

GP Series Portable Chillers Chapter 7: Appendix 56 of 64

GP Series Portable Chillers Chapter 7: Appendix 57 of 64

GP Series Portable Chillers Chapter 7: Appendix 58 of 64

GP Series Portable Chillers Chapter 7: Appendix 59 of 64

GP Series Portable Chillers Chapter 7: Appendix 60 of 64

GP Series Portable Chillers Chapter 7: Appendix 61 of 64

GP Series Portable Chillers Chapter 7: Appendix 62 of 64

GP Series Portable Chillers Chapter 7: Appendix 63 of 64

GP Series Portable Chillers Chapter 7: Appendix 64 of 64