Sterling 882.93092.00 User Manual

GP Series Portable Chillers

Part Number: 882.93092.00

Bulletin Number: SC2-620.2

Effective: 1/12/2010

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

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© Copyright 2010
All rights reserved.

Shipping Information

Unpacking and Inspection

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

In the Event of Shipping Damage

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

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

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

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

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

If the Shipment is Not Complete

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

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

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

If the Shipment is Not Correct

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

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

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

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

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

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

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

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

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

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

GP Series Portable Chillers iii

Panel Buttons, Indicator Lights, and Switches..........................................................29

4-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GP Series Portable Chillers iv

Chapter 1: Safety

1-1 How to Use This Manual

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

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

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

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

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

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

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

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

Safety Symbols Used in this Manual

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

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

death or serious injury.

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

could result in death or serious injury.

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

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

GP Series Portable Chillers Chapter 1: Safety 5 of 73

1-2 Warnings and Precautions

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

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

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

equipment.

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

You should remove the fuses and carry them with you.

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

switch on power.

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

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

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

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

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

equipment and related components are fully reassembled.

9 Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

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

1-3 Responsibility

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

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

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

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

GP Series Portable Chillers Chapter 1: Safety 6 of 73

Chapter 2: Functional Description

2-1 Models Covered in This Manual

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

Our portable chiller models are designated by approximate output in kW of cooling (20, 30,
40, 50, etc) and the cooling method used: -A for air-cooled, -W for water-cooled, and –R for
remote-air cooled.

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

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

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

Chilled Water Circuit

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

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

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

Refrigeration Circuit

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

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

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

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

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

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

Water-Cooled Condenser. Tube-in-tube condensers (5-15 ton), Shell-and-tube condensers
(20-60 ton). All come with electronic cooling water regulating valves. 1 in. NPT valves for
GPWC20 & 30; 1.25 in. NPT valves for GPWC40; 1.50 in. NPT valves for GPWC50, 2 in
NPT valves for GPWC70 & 90, 2.5 in NPT valves for GPWC105, 3 in NPT valves for
GPWC140 & 175, and 4 in NPT valves for GPWC210.

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

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

Piping. Non-ferrous piping
Pump. ODP motors (TEFC Optional)—horizontally mounted stamped stainless steel

construction.
Other Mechanical Features

• Low process water thermal flow switch

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

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

• Internal process water bypass valve for system protection only

• Fully insulated refrigeration and process water piping

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

• Tank level indication

• Pump pressure indication

Electrical Features

• Fully accessible NEMA 12-style electrical control enclosure

• Single-point power and ground connection

• Non-fused disconnect switch, lockable

• Branch circuit fusing

GP Series Portable Chillers Chapter 2: Functional Description 8 of 73

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

Refrigeration Features

• HFC-410a refrigerant

• Electronic hot gas bypass capacity control

• High refrigerant pressure cutout switches

• Suction and discharge pressure transducers.

• High pressure spring actuated relief valve

• Multiple refrigeration access ports

• Liquid line shut-off ball valves

• Filter-dryer

• Sight glass

• Externally equalized thermal expansion valve

• Liquid line solenoid

• Compressor crankcase heater

Controller Features

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

Set Point readout

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

• Low refrigerant pressure time delay for low ambient start-up on remote air-cooled and

air-cooled chillers with the variable-speed fan option.

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

Other Features

• One year labor warranty and one year compressor warranty

• Two year parts warranty

• Two year limited controller warranty

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

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

GP Series Portable Chillers Chapter 2: Functional Description 9 of 73

Caution! Energize the crankcase heater for at least 24 hours before initial startup to

drive dissolved refrigerant from the compressor oil. Failure to do so will
damage the compressor.

High Pressure Cutout

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

Note: The high-pressure cutout is a manual reset device typically mounted on the

compressor discharge line inside the mechanical cabinet. Call a refrigeration
service technician to analyze the problem and reset the control.

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

There are two pressure transducers in the refrigeration piping – one on the suction line before
the compressor and one on the discharge line after the compressor. Within the program there
are four settings that warn and fault based on these two pressure transducers. The low suction
warning is set for 110 psig (758 kPa), and the compressor will fault at 100 psig (689 kPa).
The low discharge warning is set for 200 psig (1,379 kPa), and the compressor will fault at
180 psig (1,241 kPa). To prevent nuisance tripping there are delays built in to the program.

Note: Call a refrigeration service technician to analyze the problem to prevent

recurring low pressure faults.

Flow Switch

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

Remote Start/Stop Interlock

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

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..

GP Series Portable Chillers Chapter 2: Functional Description 10 of 73

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

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

Communications Options. RS-485 serial Modbus communications.
High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan

discharge. High-pressure fans are necessary and must be included in chiller installations
where exiting air exhausts through ductwork.

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

Variable Speed Fan – GPAC20-50. Reduces the speed of the fan based on entering air
temperature and system load, allowing the chiller to operate in ambient temperatures below
60ºF (15.5ºC). This option will also reduce fan noise in ambient temperatures below 95ºF
(35ºC).

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

• Mounting rails with feet

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

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

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

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

GP Series Portable Chillers Chapter 2: Functional Description 11 of 73

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

7.5 10.3
10 12.0
15 20.0
30 32.0

GP Series Portable Chillers Chapter 2: Functional Description 12 of 73

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 73

3-3 Process Water Connections

All of our portable chillers have two chilled water connections. The chilled water supply,
labeled “To Process” is the outlet for the chilled water leading to the process being cooled.
The chilled water return, labeled “From Process” is the inlet leading from the process back
into the chiller to be cooled and re-circulated.

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

Note: Be sure to reduce external pressure drop as much as possible by generously

sizing piping and tooling water passageways.

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 73

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 will make two connections to the water-cooled condenser:
Condenser Water In. The condenser water supply, labeled “Condenser Water In”, is located

at the rear of the chiller. It is the inlet for city or tower water.
Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum

pressure of 25 psi.

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

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

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

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

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

Air-Cooled Chiller Condensers

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

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

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

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

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

Remote Air-Cooled Chiller Condensers

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

psi (2896 kPa).

GP Series Portable Chillers Chapter 3: Installation 15 of 73

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

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

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

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

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

contaminate the system.

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

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

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

Warning! To prevent injury or death due to explosion and/or inhalation of phosgene gas,

purge system thoroughly while brazing refrigerant piping connections. Use a
pressure regulator in the line between the unit and the high-pressure nitrogen
cylinder to avoid over-pressurization and possible explosion.

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

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

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

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

equivalent pipe feet

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

without a 2% efficiency decrease.

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

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

condenser liquid lines.

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

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

GP Series Portable Chillers Chapter 3: Installation 16 of 73

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

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

GP Series Portable Chillers Chapter 3: Installation 17 of 73

Figure 4 on page 21 for discharge line sizing.

Figure 2: Equivalent Length in Feet for Valves and Fittings

Line Size

OD (inches)

Angle
Valve

Short

Radius EL

Long

Radius EL

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

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

Figure 3: Liquid Line Sizing

5 TON CIRCUIT 7.5 TON CIRCUIT

Total Equiv.

Length (Ft)

Horizontal

or

Downflow

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

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

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

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

Liquid Line Size (OD")

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 18 of 73

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

20 TON CIRCUIT 25 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
Downflow

25 7/8 7/8 7/8 7/8 25 1-1/8 1-1/8 1-1/8 1-1/8

50 7/8 7/8 7/8 7/8 50 1-1/8 1-1/8 1-1/8 1-1/8

75 7/8 7/8 7/8 7/8 75 1-1/8 1-1/8 1-1/8 1-1/8

100 7/8 7/8 7/8 7/8 100 1-1/8 1-1/8 1-1/8 1-1/8
125 7/8 7/8 7/8 7/8 125 1-1/8 1-1/8 1-1/8 1-1/8
150 7/8 7/8 7/8 1-1/8 150 1-1/8 1-1/8 1-1/8 1-1/8
175 7/8 7/8 7/8 1-1/8 175 1-1/8 1-1/8 1-1/8 1-1/8
200 7/8 7/8 1-1/8 1-1/8 200 1-1/8 1-1/8 1-1/8 1-1/8
225 7/8 7/8 1-1/8 1-1/8 225 1-1/8 1-1/8 1-1/8 1-1/8
250 7/8 7/8 1-1/8 1-1/8 250 1-1/8 1-1/8 1-1/8 1-1/8
275 7/8 1-1/8 1-1/8 1-1/8 275 1-1/8 1-1/8 1-1/8 1-1/8
300 7/8 1-1/8 1-1/8 1-1/8 300 1-1/8 1-1/8 1-1/8 1-1/8

Liquid Line Size (OD")

or

Upflow

1-5 Ft

Upflow
6-10 Ft

Upflow

11-15 Ft

GP Series Portable Chillers Chapter 3: Installation 19 of 73

30 TON CIRCUIT 40 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
Downflow

Liquid Line Size (OD")

or

Upflow

1-5 Ft

Upflow
6-10 Ft

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

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

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

100 1-1/8 1-1/8 1-1/8 1-1/8 100 1-1/8 1-1/8 1-1/8 1-1/8
125 1-1/8 1-1/8 1-1/8 1-1/8 125 1-1/8 1-1/8 1-1/8 1-1/8
150 1-1/8 1-1/8 1-1/8 1-1/8 150 1-1/8 1-1/8 1-1/8 1-1/8
175 1-1/8 1-1/8 1-1/8 1-1/8 175 1-1/8 1-1/8 1-1/8 1-3/8
200 1-1/8 1-1/8 1-1/8 1-1/8 200 1-1/8 1-1/8 1-1/8 1-3/8
225 1-1/8 1-1/8 1-1/8 1-1/8 225 1-1/8 1-1/8 1-1/8 1-3/8
250 1-1/8 1-1/8 1-1/8 1-1/8 250 1-1/8 1-1/8 1-3/8 1-3/8
275 1-1/8 1-1/8 1-1/8 1-1/8 275 1-1/8 1-1/8 1-3/8 1-3/8
300 1-1/8 1-1/8 1-1/8 1-3/8 300 1-1/8 1-1/8 1-3/8 1-3/8

50 TON CIRCUIT 60 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
Downflow

Liquid Line Size (OD")

or

Upflow

1-5 Ft

Upflow
6-10 Ft

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

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

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

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

Upflow

11-15 Ft

Upflow

11-15 Ft

GP Series Portable Chillers Chapter 3: Installation 20 of 73

Figure 4: Discharge Line Sizing

Horizontal or Downflow Discharge Line Sizes (OD")

Circuit

Tons

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
20 7/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8
25 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8
30 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8
40 1-1/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8
50 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8
60 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8 2-1/8

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

Total Equivalent Length (Ft)

Upflow Discharge Line Sizes (OD")

Circuit

Tons

5

7.5

10

15

20

25

30

40

50

60

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

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

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

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

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

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

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

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

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

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

B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8

Total Equivalent Length (Ft)

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

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

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

GP Series Portable Chillers Chapter 3: Installation 21 of 73

Refrigerant Charge Determination. The approximate amount of refrigerant charge required

by the system varies based on the total length of the refrigerant lines and the size of the

chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the

chiller and the amount of charge based on discharge and liquid line sizes and lengths. Add

these three numbers together to find the final operating charge. The final operating charge

must be verified by running the system and checking the liquid line sight glass.

Figure 5: Refrigerant Charge Determination

Line Size

OD (inches)

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
1-3/8 5.6 52.0
1-5/8 7.9 73.6
2-1/8 13.7 128.0
2-5/8 21.2 197.4
3-1/8 30.2 281.7
3-5/8 40.9 381.1
4-1/8 53.1 495.4

Discharge Line

LBS of R-410a

Liquid Line

LBS of R-410a

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

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

Calculate the amount of additional oil required by using the following formula:
Pints of oil (Copeland Ultra 22cc) = lbs of R-410a added for field installed piping / 100.

GP Series Portable Chillers Chapter 3: Installation 22 of 73