Sterling 882.93092.01 User Manual

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GP Series Portable Chillers

Part Number: 882.93092.01 Bulletin Number: SC2-620.4

Effective: 10/10/2011

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

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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Shipping Information

Unpacking and Inspection

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

In the Event of Shipping Damage

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

Notify the transportation company’s local agent if you discover damage

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

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

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

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

If the Shipment is Not Complete

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

Bill of lading

Packing list

Operating and Installation packet

Electrical schematic and panel layout drawings

Component instruction manuals (if applicable)

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

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and service department immediately at (262) 641-8610. Have the order number and item number available.

Hold the items until you receive shipping instructions.

Returns

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

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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

Typical Applications ............................................................................................... 7

System Limitations ................................................................................................ 7

Chilled Water Circuit .............................................................................................. 8

Refrigeration Circuit ............................................................................................... 9

2-3 Standard Features ..................................................................................................... 10

Mechanical Features ........................................................................................... 10

Electrical Features ............................................................................................... 11

Refrigeration Features ......................................................................................... 11

Controller Features .............................................................................................. 12

Other Features .................................................................................................... 12

2-4 Safety Devices and Interlocks .................................................................................... 12

Crankcase Heater ............................................................................................... 12

High Pressure Cutout .......................................................................................... 13

Low Pressure Cutout (no switch but done through the transducer) .................... 13

Flow Switch ......................................................................................................... 14

Remote Start/Stop Interlock ................................................................................ 14

2-5 Optional Features ...................................................................................................... 14

CHAPTER 3: INSTALLATION .................................................. 16

3-1 Uncrating .................................................................................................................... 16

3-2 Electrical Connections ............................................................................................... 16

3-3 Process Water Connections ...................................................................................... 17

3-4 Bypass Valve Considerations .................................................................................... 17

3-5 Galvanic Corrosion Considerations ........................................................................... 18

3-6 Water Treatment Considerations ............................................................................... 18

3-7 Condenser Considerations ........................................................................................ 18

Water-Cooled Chiller Condensers ....................................................................... 18

Air-Cooled Chiller Condensers ............................................................................ 19

Remote Air-Cooled Chiller Condensers .............................................................. 20

3-8 Checking Motor Direction ........................................................................................... 27

Three-Phase Compressors ................................................................................. 27

Water Pumps ....................................................................................................... 27

Condenser Fan ................................................................

3-9 Water Reservoir ......................................................................................................... 28

3-10 Automatic Water Make-Up Option ............................................................................. 31

3-11 Initial Start-Up ............................................................................................................ 31

3-12 Finishing Setup: Setting Up Passwords ..................................................................... 33

.................................... 27

CHAPTER 4: OPERATION ....................................................... 35

4-1 Panel Buttons, Indicator Lights, and Switches ........................................................... 35

Microprocessor Controller ................................................................................... 35

4-2 Initial Start-up ............................................................................................................. 36

4-3 Status Screens ........................................................................................................... 37

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4-4 Access Levels ............................................................................................................ 41

4-5 Controller Setpoints .................................................................................................... 41

4-6 Configuration Settings ................................................................................................ 45

4-7 Alarms ........................................................................................................................ 47

4-8 Optional Communications .......................................................................................... 47

CHAPTER 5: MAINTENANCE ................................................. 48

5-1 Lubrication ................................................................................................................. 48

5-2 Filter Cleaning ............................................................................................................ 48

5-3 Maintaining the Condenser ........................................................................................ 48

Air- and Remote Air-Cooled Chillers ................................................................... 48

Water-Cooled Chillers ......................................................................................... 48

5-4 Maintaining the Evaporator ........................................................................................ 49

5-5 Evaporator Process Piping Y-Strainer ....................................................................... 49

5-6 Preventative Maintenance Service ............................................................................ 49

CHAPTER 6: TROUBLESHOOTING ....................................... 50

6-1 Identifying the Cause of a Problem ............................................................................ 50

Non-Controller Related Issues ............................................................................ 55

CHAPTER 7: APPENDIX .......................................................... 58

7-1 Returned Material Policy ............................................................................................ 58

Credit Returns ..................................................................................................... 58

7-2 Technical Assistance ................................................................................................. 58

Parts Department ................................................................................................ 58

Service Department ............................................................................................. 59

Sales Department ................................................................................................ 59

Contract Department ........................................................................................... 59

7-3 Specifications ............................................................................................................. 60

Air-Cooled Portable Chillers ................................................................................ 60

Water-Cooled Portable Chillers ........................................................................... 65

7-4 Pump Curves, Flow, and Pressure Considerations ................................................... 70

60 Hertz Pump Curves ........................................................................................ 70

50 Hertz Pump Curves ........................................................................................ 72

7-5 Remote Air-Cooled Chiller Configurations ................................................................. 75

7-6 Typical Ductwork for Air-Cooled Chillers ................................................................... 77

7-7 Piping Diagrams ......................................................................................................... 79

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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.

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1-2 Warnings and Precautions

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

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

 Follow all SAFETY CODES.

 Wear SAFETY GLASSES and WORK GLOVES.

 Disconnect and/or lock out power before servicing or maintaining the equipment.

 Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

 Operate this equipment within design specifications.

 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

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

switch on power.

 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.

 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.

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

equipment and related components are fully reassembled.

 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.

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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, through 210) 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 20 kW through 210 kW (5 through 60 tons of refrigeration). All are self-contained, fully portable and shipped ready to use. (Remote air-cooled chillers require field installation by qualified technicians.) In the standard configuration the chiller basically consists of a pump, tank, compressor, condenser, evaporator, and a control platform. All of these components, plus the other integral components to maintain the leaving fluid temperature, are described throughout this Chapter as well as Chapters 3 and 4.

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

Typical Applications

This series of portable chillers can be used in any application that needs a constant source of cool process water. Typical applications include, but are not limited to, the following:

 Injection molding  Blow molding

 Extrusion  Thermoforming

 Machine tool  Metal plating

 Thermal spray  After-coolers (air compressors, dryers, etc.)

 Laser  Printing (offset, gravure, digita)

System Limitations

These packaged chillers should be chosen using the following criteria:

Process heat load – Choose the size of the chiller so that rated capacity is no greater than 10% more than the process heat load.

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Process Fluid Temperature – The standard range for the leaving fluid temperature for this series of packaged chillers is 20°F to 80°F (-6.7°C to 26.7°C). When the process requires fluid temperatures below 45°F (27.2°C) it is imperative that the process fluid is a mix of an industrial grade ethylene or propylene glycol and water to the proper percentage (by volume) to protect the system. See Chapter 3 for a further discussion regarding the use of glycol within the system for these applications.

WARNING! - ACS Group does not warrant the freeze up of the evaporator

under any circumstances.

Chilled Water Circuit

Cooling water “To Process” and “From Process” connections are made at the female NPT couplings provided outside the unit.

Warm coolant (water and glycol mixture) returns

from the process and goes into the reservoir tank.

The coolant is then pumped through the evaporator

where it is cooled.

The coolant flows to the process and returns to

repeat the cycle.

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

This minimal flow allows the flow switch to make when the process flow is stopped. If the flow switch is not made the controller shuts down the compressor to prevent freezing up the evaporator.

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Refrigeration Circuit

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

The refrigerant is compressed in the compressor and

flows through the discharge line as a gas to the condenser.

There it gives up its heat as it condenses to a liquid

in the condenser.

Liquid refrigerant from the condenser heat

exchanger flowing in the liquid line passes through a shut-off valve into a filter/dryer that removes moisture and other contaminants. After the filter/dryer the refrigerant passes through a solenoid valve to prevent liquid migration when the compressor is off. A refrigerant sight glass is provided to view the flow of liquid refrigerant, and to view if the system is free of moisture. The refrigerant then passes through the thermal expansion valve, which allows the refrigerant to expand (boil off) and cool (remove the heat from) the fluid inside of the evaporator.

From the evaporator the refrigerant gas flows

through the suction line back into the compressor.

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

System Control

Putting this all together, the controller maintains the desired leaving fluid temperature using multiple inputs to determine if, when and for how long the compressor(s) are on, and if, when, the percent open and for how long the modeling hot gas bypass valve is on.

Once the unit’s power is enabled and the controller is turned on (see Chapter 4 for more details on the operation of the controller) it verifies there is sufficient fluid level in the tank (if present). If there is not enough fluid in the tank the controller will warn the user, or fill the tank with water from a connected source if equipped with the optional automatic water makeup valve. See Chapter 3 for more information regarding the initial setup and startup of the unit.

Once the tank level is satisfied and the start button is pressed, the process pump turns on and provides flow to the process. The controller verifies the flow through the electronic flow switch. If the flow is not established within 10 seconds the controller will alarm and disable the refrigeration circuit. Upon flow verification the controller uses the leaving fluid temperature and the setpoint temperature to determine the operation of the compressor(s). When the leaving fluid temperature is greater than the setpoint plus the “compressor on

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differential” value the controller will enable the compressor; if equipped with two compressors the controller will enable the one with the least amount of hours. The second compressor will be enabled if the leaving fluid temperature remains above the setpoint plus the “compressor on differential” value for more than 60 seconds.

The hot gas valve is designed to trim the load of one compressor and will modulate in order to meet the desired leaving fluid setpoint via a PID algorithm. After the compressor starts, the hot gas valve is allowed to modulate. The compressor will shut off if the leaving fluid temperature drops below the “compressor off differential” and the hot gas valve is at 100% for the “compressor off delay” time. The hot gas will reset to 0% when the compressor is off. There is a “compressor anticyle” timer that will delay the time between compressor starts to prevent short cycling of the compressor. This is a start to start timer set at 5 minutes. For example, if the compressor has been running for 5 minutes and shuts off, then the compressor can start immediately if the demand is there. If it has only been running for 2 minutes, then it would not be able to start again for 3 minutes.

For a unit with two compressors, the second compressor or lag compressor starts when the lead compressor is on, the hot gas is at 0%, and the leaving fluid temperature is above the setpoint plus the “compressor on differential”. There is also an adjustable “lag compressor on delay” timer. Before starting either compressor, the compressor with the least amount of runtime hours is considered the lead compressor and the first to start. When both compressors are running, the compressor with the most hours is considered the lead compressor and is the first to stop. The lead compressor will shut off if the leaving fluid temperature drops below the “compressor off differential” and the hot gas valve is at 100% for the “lead compressor off delay” time. The compressor anti-cycle timers are active with the two compressor units.

There will be two PID controls running simultaneously for determining the position of the hot gas valve. One PID output will be based on leaving fluid temperature and the other based on a minimum saturated suction temperature for freeze protection. The hot gas valve position will be determined by which output is greater. If it is controlling to the saturated suction temperature to prevent freezing, a warning will display on the screen that the hot gas is in this mode. Once the control goes back to setpoint control, the warning will disappear. The saturated suction temperature is calculated from the suction pressure and the type of refrigerant.

The discharge pressure is controlled using an analog output signal to drive a fan for aircooled units or a water regulating valve for water-cooled units. The output signal is determined from a PID algorithm using a discharge pressure transducer as the process variable. The VFD or water regulating valve is controlled from the analog output to an adjustable discharge pressure setpoint. The analog output starts at the initial “discharge pressure start” % for a given time delay (discharge pressure hold). After the time delay, it will control to the discharge pressure setpoint via the PID control. There is also a setting to control the discharge pressure to the most efficient value.

2-3 Standard Features

Mechanical Features

Compressor – Hermetic scroll compressors.

Evaporator – Stainless steel copper brazed plate evaporators.

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Air-Cooled Condenser – Aluminum fin/ tube with washable filters, packaged units only. Variable speed fan control standard for all remote air cooled condensers and GPAC70 through 210. Optional on GPAC20 through 50.

Water-Cooled Condenser – Tube-in-tube condensers (GPWC20 – GPWC50), Shell-andtube condensers (GPWC70 – GPWC210). All come with electronic cooling water regulating valves.

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

Reservoir – GP20 and GP30 models use a 20 gallon (75 liter) polyethylene tank, GP40 and GP50 models use a 40 gallon (150 liter) polyethylene tank, GP70 thru GP105 models use a 70 gallon (265 liter) polyethylene tank, GP140 thru GP210 models use a 140 gallon (530 liter) polyethylene tank. 304SS is available as an option for all sizes.

Piping – Non-ferrous chilled water piping

Pump – ODP motors (TEFC Optional)—horizontally mounted stamped stainless steel

construction.

Other Mechanical Features

 Low process water thermal flow switch

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

 Galvanized structural steel frame, polyester powder coat painted cabinetry

 Internal process water bypass valve for system protection only

 Fully insulated refrigeration and process water piping

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

 Tank level indication via operator interface

 Pump pressure indication via operator interface

Electrical Features

 Fully accessible NEMA 4/12-style electrical control enclosure

 Single-point power and ground connection

 Non-fused disconnect switch, lockable

 Branch circuit protection

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

Refrigeration Features

 HFC-410a refrigerant

 Electronic modulating hot gas bypass capacity control

 High refrigerant pressure cutout switch (manual reset)

 Suction and discharge pressure transducers.

 High refrigerant pressure spring actuated relief valve

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 Multiple refrigeration access ports

 Liquid line shut-off ball valves

 Filter-dryer

 Sight glass

 Externally equalized thermal expansion valve

 Liquid line solenoid

 Compressor crankcase heater

Controller Features

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

Set Point readout

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

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

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

 8 line x 22 character display with status, alarm, and service screens

 Display has magnetic back and can be mounted anywhere.

Other Features

 One year labor warranty and one year compressor warranty

 Two year parts warranty

 Three year limited controller warranty

2-4 Safety Devices and Interlocks

Caution! Protect the system from freezing with inhibited industrial grade glycol 20ºF

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

Crankcase Heater

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

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

drive dissolved refrigerant from the compressor oil. Failure to do so will damage the compressor. If unit is mounted outdoors, power to the unit (and the main power switch) must remain on 24 hours per day, 7 days per week to prevent liquid migration to the compressor.

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High Pressure Cutout

High pressure cutout

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

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

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

Typical GPAC-20

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

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

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

recurring low pressure faults.

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Flow Switch

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

Remote Start/Stop Interlock

An additional contact is provided to allow the remote starting or stopping of the chiller. To use this feature install a switch or dry contact interlock connected in series between terminals 4 and 23. Refer to the electrical schematic supplied in the control enclosure. Once the wiring is complete the controller will need to be reconfigured in the supervisor settings.

2-5 Optional Features

Options marked with “*” indicate options that can be factory installed or retrofitted in the field.

Automatic Water Make-Up*. Not available on chillers less reservoir tank. This option includes an electric water solenoid valve, and the necessary internal piping to connect the chiller to a make-up water source. The controller uses the standard tank level pressure transducer to determine when to fill the tank. See Appendix for typical piping diagrams.

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

atmosphere to prevent over-pressurization of the reservoir tank (not needed for open tank). See Section 7-7 for flow schematics.

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

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

Communications Options*. This option provides the capability for the unit’s controller to communicate with an external device using a variety of serial communication protocols. Currently the unit can communicate over RS-485 Modbus RTU, BACNet, LONWorks, Ethernet Modbus.

High Pressure Fans. Provides either 0.3” WC (75 Pa) or 1.0”WC (250 Pa) of external static pressure on fan discharge. High-pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork.

The 0.3” WC (75 Pa) static fan can be retrofitted without sheet metal modification, but will require changing out fan housing, fan blades, fan motors and electrical components.

Variable Speed Fan – GPAC20-50. Reduces the speed of the fan based on refrigerant pressure and system load, allowing the chiller to operate in ambient temperatures below 75ºF (24ºC). This option will also reduce fan noise in lower ambient temperatures and low loads.

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Stainless Steel Reservoir. Manufactured from 304 stainless steel.

Voltage

Construction

HP (kW)

Full Load Amps

2 (1.5)

4.0

3 (2.2)

4.2

5 (3.7)

8.2

7.5 (5.6)

10.3

10 (7.5)

12.0

15 (11)

20.0

Mounting Features.

Mounting rails with feet – GP20-GP105 indoor units. Standard on GP140-GP210 and all outdoor packaged units.

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

UL/cUL Labeled Electrical Subpanel. This option provides for the subpanel to be listed with Underwriters Laboratory, with UL-related benefits and features. Sub-panels marked by the UL/cUL sticker are accepted within Canada.

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

Figure 1: Optional Pump Amperages

460/3/60 SS 1 (0.8) 1.7

1.5 (1.1) 2.3

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30 (22) 32.0

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Chapter 3: Installation

Important!

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. 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

Note: For all chillers manufactured with Variable Frequency Drives the

voltage may vary up to 10% from the converter nominal voltage. However, the phase-to-phase input voltage imbalance must not exceed 3%. If the input voltage does have an imbalance from phase to phase greater than 3% then a line reactor must be installed to prevent faults within the VFD.

For remote condenser units, the maximum recommended motor cable length between the VFD and the motor without output chokes is 30 m (100 ft). With output chokes the motor cable length may be extended to 65 m (195 ft).

310.15(B)(2)(a)

GP Series Portable Chillers Chapter 3: Installation 16 of 90

Page 17

3-3 Process Water Connections

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

Figure 2: Typical GP20-50 Air Cooled Process Piping Connections

All external chilled water connections should be run full size to the process. Flow and pressure information is available in the Appendix. The largest possible openings and passages should be provided for the flow of chilled water through platens, dies, molds, or other pieces of equipment. Flow control valves are not supplied, but should be added to the system to adjust flow and pressure to the process and to isolate the chiller from the process if necessary.

Note: 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.

GP Series Portable Chillers Chapter 3: Installation 17 of 90

Page 18

3-5 Galvanic Corrosion Considerations

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

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

Note: The use of galvanized piping is discouraged because the rough inside surface

promotes debris to stick and eventually block the flow of the process fluid..

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 what type of treatment is needed.

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 is labeled “Condenser Water In.” It is the inlet for city or tower water. For the GPWC20-50, this connection is located near the bottom of the chiller. For all other sizes this connection is located near the top of the chiller.

Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum pressure of 25 psi.

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

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

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

Condenser Water Out. Condenser water return is labeled “Condenser Water Out.” It is the outlet for water after it has passed through the condenser. For the GPWC20-50, this connection is located near the bottom of the chiller. For all other sizes this connection is located near the top of the chiller.

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

GP Series Portable Chillers Chapter 3: Installation 18 of 90

Page 19

Figure 3: Typical GP20-50 Water Cooled Condenser Connections

Air-Cooled Chiller Condensers

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

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

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

Normal maximum refrigerant condensing pressure with 95ºF (35ºC) air entering the condenser is 420 psi (2896 kPa).

Condensing Air Temperature. Our air-cooled portable chillers are designed to operate at a minimum condenser entering air temperature of approximately 75ºF (24ºC). Operation of the equipment at a lower condenser entering air temperature can cause the chiller to malfunction. For entering air temperatures below 75ºF (24°C), an optional fan motor speed control is available. We recommend maintaining a minimum 75ºF (24°C) ambient temperature.

Note: For all chillers manufactured with Variable Frequency Drives the

GP Series Portable Chillers Chapter 3: Installation 19 of 90

Page 20

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 hard/drawn type “L” or type “K” refrigerant grade copper

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

Warning! The copper tubing and fittings used must have a minimum burst

pressure of 1,950 psi.

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

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

contaminate the system.

A certified refrigeration contractor needs only to install the interconnecting refrigerant piping between the chiller and the outdoor air-cooled condenser. This piping must be properly sized, type “L” or type “K” refrigerant grade tubing, high temperature brazed. Install a customer

supplied 650 psi approved refrigerant relief valve in the discharge line at the condenser, following all applicable codes.

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

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

Warning! To prevent injury or death due to explosion and/or inhalation of hydrogen-

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

System Configuration. The system can be configured in any of the arrangements shown on page 75 of the Appendix. The configuration and distance between the chiller and the condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are limitations that must be adhered to for reliable and optimal operation.

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

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

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

equivalent pipe feet

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

without a 2% efficiency decrease.

 Refer to page 75 of the Appendix for the location of traps.

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

condenser liquid lines.

GP Series Portable Chillers Chapter 3: Installation 20 of 90

Page 21

Sizing Refrigerant Lines. To determine field installed liquid and discharge line sizes, first

OD (inches)

Valve

Radius EL

3/4

6.5

4.5

1-1/8

2.7

1.9

Length (Ft)

Liquid Line Size (OD")

Length (Ft)

Liquid Line Size (OD")

Horizontal

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

Horizontal

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

establish the equivalent length of pipe for each line, valve, and elbow. Chiller capacity and leaving water temperature range is also required. See Figure 4 on page 21 for lengths of refrigerant valves and fittings.

Liquid Line Sizing. The liquid line should be sized as small as possible while maintaining acceptable pressure drop to minimize the refrigerant charge. Liquid line risers must not exceed 15 feet from the base of the air-cooled condenser. Horizontal runs do not require a pitch. Insulation is not required unless the line is installed in a high ambient area, i.e., boiler room or on a roof. Install a liquid line-charging valve to facilitate refrigerant charging. See Figure 5 on page 21 for sizing information. See Figure 7 on page 25 for charge determination.

Discharge Line Sizing. Discharge line sizing is based on the velocity required for sufficient oil return back to the compressor. See Figure 4: Equivalent Length in Feet for Valves and Fittingson page 24 for discharge line sizing.

Note: For horizontal runs, the discharge line should be pitched downward, in the

direction of flow, at a rate of 1/2” for every 10 feet. This will allow oil to flow towards the condenser.

Figure 4: Equivalent Length in Feet for Valves and Fittings

Line Size

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

7/8 28 7.8 5.3

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

Short

Long

Figure 5: Liquid Line Sizing

GPRC-20 GPRC-30

Total Equiv.

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

Upflow

Total Equiv.

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

Upflow

GP Series Portable Chillers Chapter 3: Installation 21 of 90

Page 22

GPRC-40

GPRC-50

Length (Ft)

Liquid Line Size (OD")

Length (Ft)

Liquid Line Size (OD")

5/8

3/4 25

7/8

5/8

3/4

3/4 50

7/8

100

5/8

3/4

3/4 100

7/8

125

3/4

7/8 125

7/8

200

3/4

7/8 200

7/8

250

3/4

7/8

7/8 250

7/8

275

3/4

7/8

7/8 275

7/8

1-1/8

GPRC-70

GPRC-90

Length (Ft)

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

7/8

7/8 25

1-1/8

7/8

7/8 50

1-1/8

7/8

7/8 75

1-1/8

125

7/8

7/8 125

1-1/8

150

7/8

1-1/8 150

1-1/8

175

7/8

1-1/8 175

1-1/8

200

7/8

1-1/8

1-1/8 200

1-1/8

225

7/8

1-1/8

1-1/8 225

1-1/8

250

7/8

1-1/8

1-1/8 250

1-1/8

275

7/8

1-1/8

1-1/8 275

1-1/8

300

7/8

1-1/8

1-1/8 300

1-1/8

Total Equiv.

Horizontal

Downflow

Upflow

1-5 Ft

Upflow 6-10 Ft

Upflow

11-15 Ft

Total Equiv.

Horizontal

Downflow

Upflow

1-5 Ft

Upflow 6-10 Ft

75 5/8 5/8 3/4 3/4 75 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

225 3/4 3/4 7/8 7/8 225 7/8 7/8 7/8 7/8

300 3/4 3/4 7/8 7/8 300 7/8 7/8 7/8 1-1/8

Liquid Line Size (OD")

Total Equiv.

Horizontal

Upflow

Total Equiv.

Horizontal

100 7/8 7/8 7/8 7/8 100 1-1/8 1-1/8 1-1/8 1-1/8

Liquid Line Size (OD")

Upflow

11-15 Ft

Upflow

GP Series Portable Chillers Chapter 3: Installation 22 of 90

Page 23

GPRC-105

GPRC-140

Length (Ft)

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

1-1/8

1-1/8 50

1-1/8

1-1/8 75

1-1/8

100

1-1/8

1-1/8 100

1-1/8

175

1-1/8

1-1/8 175

1-1/8

1-3/8

200

1-1/8

1-1/8 200

1-1/8

1-3/8

225

1-1/8

1-1/8 225

1-1/8

1-3/8

250

1-1/8

1-1/8 250

1-1/8

1-3/8

275

1-1/8

1-1/8 275

1-1/8

1-3/8

300

1-1/8

1-3/8 300

1-1/8

1-3/8

1-3/8 GPRC-175

GPRC-210

Length (Ft)

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

Downflow

1-5 Ft

6-10 Ft

11-15 Ft

1-3/8

1-3/8 25

1-3/8

100

1-3/8

1-3/8 100

1-3/8

125

1-3/8

1-3/8 125

1-3/8

150

1-3/8

1-3/8 150

1-3/8

175

1-3/8

1-3/8 175

1-3/8

200

1-3/8

1-3/8 200

1-3/8

1-5/8

225

1-3/8

1-3/8 225

1-3/8

1-5/8

250

1-3/8

1-3/8 250

1-3/8

1-5/8

275

1-3/8

1-3/8 275

1-3/8

1-5/8

Total Equiv.

Horizontal

Liquid Line Size (OD")

Upflow

Total Equiv.

Horizontal

Liquid Line Size (OD")

Upflow

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

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

Total Equiv.

Horizontal

Liquid Line Size (OD")

Upflow

Total Equiv.

Horizontal

Liquid Line Size (OD")

Upflow

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

300 1-3/8 1-3/8 1-3/8 1-3/8 300 1-3/8 1-3/8 1-5/8 1-5/8

GP Series Portable Chillers Chapter 3: Installation 23 of 90

Page 24

Figure 6: Discharge Line Sizing

Model

Horizontal or Downflow Discharge Line Sizes (OD")

Tons

Upflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

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

GPRC-20

GPRC-30

GPRC-40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

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

7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8

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

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

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

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

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

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

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

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

Total Equivalent Length (Ft)

Circuit

GPRC-20

GPRC-30

GPRC-40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

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

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

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

1-1/8 1-1/8 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

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

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

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

1-1/8 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

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

1-3/8 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

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

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

GP Series Portable Chillers Chapter 3: Installation 24 of 90

Page 25

Refrigerant Charge Determination. The approximate amount of refrigerant charge required

OD (inches)

LBS of R-410a

1/2

0.6

6.0

3/4

1.5

14.4

1-1/8

3.7

34.1

1-3/8

5.6

52.0

2-1/8

13.7

128.0

by the system varies based on the total length of the refrigerant lines and the size of the chiller. Referring to Figure 7, determine the amount of charge based on the model of the chiller and the amount of charge based on discharge and liquid line sizes and lengths. Add these three numbers together to find the final operating charge. The final operating charge must be verified by running the system and checking the liquid line sight glass.

Figure 7: Refrigerant Charge Determination

Condenser and Chiller Charge (LBS of R-410a)

Chiller

Model

60 50 40 30 20 10 0 -10 -20

GPRC-20

GPRC-30

GPRC--40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

9 9 10 11 12 13 13 13 14

10 10 12 14 15 16 16 17 17

13 13 15 17 19 20 21 21 22

18 19 22 25 27 29 30 31 32

25 25 25 26 31 34 36 38 40

30 30 30 32 37 41 44 47 49

51 51 51 52 52 58 63 67 71

51 51 51 51 51 51 55 55 65

70 70 70 70 70 70 76 76 88

80 80 80 80 80 80 80 88 94

Line Size

Discharge Line

Minimum Design Ambient - °F

Liquid Line

3/8 0.3 3.2

5/8 1.0 9.6

7/8 2.1 20.0

1-5/8 7.9 73.6

2-5/8 21.2 197.4

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

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

Calculate the amount of additional oil required by using the following formula:

Pints of oil (Copeland Ultra 22cc) = lbs of R-410a added for field installed piping / 100.

GP Series Portable Chillers Chapter 3: Installation 25 of 90

Page 26

Figure 8: Remote Condenser Configurations

GP Series Portable Chillers Chapter 3: Installation 26 of 90

Page 27

Figure 9: Double Riser Detail

3-8 Checking Motor Direction

All of our portable chillers have their motor rotations properly phased at the factory. If compressors, pumps, or fans are running in reverse rotation, disconnect and lock out the power source and reverse any two power leads into the chiller disconnect switch.

Caution! Do not switch leads at the motors, motor starters, or contactors.

Three-Phase Compressors

Scroll compressors are directionally-dependent and compress in one rotational direction. Reversing rotation direction results in an elevated sound level and a substantially-reduced current draw.

Caution! Do not allow the compressor to run backwards for any length of time. Doing

so will result in compressor damage..

Water Pumps

Correct pump rotation is indicated by a positive pressure of 20 to 40 psi shown on the home screen of the display. Pump rotation should be clockwise when viewed from the motor end. For chillers with optional pumps, check the appropriate pump curve in the Appendix.

Caution! Do not run pump dry. Doing so will result in seal damage.

Condenser Fan

Air should be drawn through the condenser and discharged vertically from the chiller.

GP Series Portable Chillers Chapter 3: Installation 27 of 90

Page 28

3-9 Water Reservoir

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)

The standard water reservoir is rotationally molded polyethylene with a removable lid. The tank is fully insulated to assist maintaining fluid temperature. All portable chillers shipped during the fall, winter, or spring, or those units that are shipped from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping components prone to retaining water from freezing. During startup and when additional solution is required, refer to the ethylene glycol and propylene glycol curves in Figure 11: Ethylene Glycol and Propylene Glycol Curves on page 30. Add a pre-mixed solution of industrial quality (not automotive), inhibited ethylene glycol or propylene glycol and water to provide freeze protection to a temperature 20ºF (11ºC) below the normal chiller operating temperature set point.

Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel, stainless steel, and bronze) in the system from corrosion. If you intend to use straight water, we strongly advise a minimum leaving water temperature of 45ºF (7ºC) or contact the service department.

Warning! Operating the chiller setpoint below 45°F (7°C) without the proper

amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances.

The following glycol products are available:

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.

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Figure 10: Suggested Overhead Piping Configuration

GP Series Portable Chillers Chapter 3: Installation 29 of 90

Page 30

Percent Glycol Curves for Freeze Protection

-60.0

-50.0

-40.0

-30.0

-20.0

-10.0

0.0

10.0

20.0

30.0

40.0

0.0

10.0

20.0

30.0

40.0

50.0

60.0

% Glycol by Volume

Ethylene Glycol

Propylene Glycol

Figure 11: Ethylene Glycol and Propylene Glycol Curves

Example: 45°F set point minus 20°F = 25°F.

From Figure 28, 25°F equates to 10% by volume of glycol required.

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

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

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3-10 Automatic Water Make-Up Option

The chiller may be connected to an automatic make-up system if the optional package (pipe fittings, solenoid valve and 1/2” NPT city water make-up connection) is factory installed.

Note: When the unit is selected with the optional, closed stainless steel tank, a

pressure reducing valve is added to the automatic water make-up option. This valve is set to be full open at 5 psig (0.3 bar).

If the automatic make-up system is connected to a city water system, make provisions to prevent backflow contamination. Install an approved backflow preventer in accordance with local codes.

Caution! Adding straight city water into a glycol/water mixture dilutes the solution and

eventually leads to system freeze-up. Damage from freeze-up is not covered by the warranty.

To prevent system freeze-up in automatic make-up applications, we recommend using either a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for more information about these configurations.

3-11 Initial Start-Up

 Check the shipping papers against the serial tag to be sure chiller size, type and voltage

is correct for the process that will be controlled. Portable chillers are built with a voltage specific compressor and cannot be re-wired for an alternate voltage.

 Check the transformer primary voltage connections to be sure they are configured for

the electrical power you are using. The voltage at the main power connection must read within plus or minus ten percent (±10%) of the voltage listed on the serial tag. Electrical connections must conform to all applicable codes.

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To Process

From Process

 Complete chilled water To Process and From Process connections. It is suggested that

shut-off valves are added to unit to control the flow rate to process and for completely isolating the chiller from the process.

 If the optional automatic water make-

up system was not installed on the chiller, remove the side panel to the left of the process connections and fill the tank and chilled water circuit piping until the tank is approximately ¾ full. Fill with water (or a water/glycol mixture if the desired setpoint is lower than 45°F (7°C)). The water/ glycol mixture should provide for freeze protection to at least 20°F (11ºC) below the leaving water temperature you want.

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Warning! Operating the chiller setpoint below 45°F (7°C) without the

Power Cable (highlighted in

proper amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances.

 The air-cooled condenser should have an adequate supply of 75º to 115ºF (24º to 46ºC)

air for proper operation.

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

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

 Connect the main 3 phase incoming power to

the unit making certain that line one (1) L1 is connected to the A phase, line two (2) L2 is connected to the B phase, and line three (3) L3 is connected to the C phase. Check for proper rotation direction of fan(s) and pump(s). The best route for the main power wiring is from the floor up to the right side of the enclosure on the top.

yellow)

The crankcase heater is automatically energized

when the main power is applied (main power switch in the ON ( | )position. It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil.

Finally, the cable for the display is coiled up under the control enclosure and the display is shipped inside the control enclosure. The handle on the panel in front of the control enclosure has a hole in the corner to feed the cable to the outside of the cabinet. Plug the cable into the back of the display.

Turn the power switch to the ON ( | ) position. The display’s backlight will turn on and the controller will go through a self-diagnostic routine prior to displaying the main status screen.

3-12 Finishing Setup: Setting Up Passwords

You can establish passwords for two levels of security: operators and supervisors. The controller comes from the factory with neither password set. This allows every user access to all functions.

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Page 34

Warning! If you choose to establish passwords store them in a secure

location because if they are forgotten there is no way to reset them without a service call.

Operator Password. If you define a password for operators, then a password will be required to carry out any function (other than reviewing the status screens). Entering the operator’s password will give the user access to the setpoints for leaving temperature, high temperature warning, high temperature fault.

Note: If you choose to define an Operator Password you must also define a

Supervisor Password to complete the security setup.

Supervisor Password. If you define a password for supervisors (or setup personnel) then most settings can be changed only after entering the password. The password will be required to display the extended setpoints for operating parameters and alarms. Section 4-6 shows a table of setpoints and the restrictions between Operator and Supervisor.

To set password protections:

1. Press the

2. Press the

3. Press the

button to access the menu screen.

or to highlight SETPOINTS, and press .

or until the following screen appears for the Operator or Supervisor

Password

4. Press

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

Password line is highlighted.

5. Press

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

0 and 9999.

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.

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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 is located in the control enclosure. The Carel PGD1 Interface is housed in a block of rigid plastic with a magnetic backing that allows the user to “stick” the interface on any metallic surface. The GP20 through GP50 units come standard with a 10 ft (3 m) cable, and the GP70 through GP210 units come standard with a 20 ft (6 m) cable. Longer cables are available through the After Market Sales Group. The controller is factory set and adjusted; no field adjustment to the internal controls is necessary. The standard operation range is 20ºF to 80ºF (-7ºC to 27ºC).

Warning! Operating the chiller setpoint below 45°F (7°C) without the proper

amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances.

Figure 12: Controller Display

GP Series Portable Chillers Chapter 4: Operation 35 of 90

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Button

Button Description

Detailed description

Menu Button

Used to access the menus structure of the PGD interface

4-2 Initial Start-up

On/Off Button

Back Button

Up Arrow Button

Enter Button

Down Arrow Button

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.

1. Verify the initial start-up checklist from Chapter 3, Section 3-11.

2. With the main supply power switch in the ON position, the screen will

display the version of the software for a period of 5 seconds, and then display the main status screen.

Figure 13: Main Status Screen

3. Set the Leaving Fluid temperature by depressing the

button to display

the menu.

Figure 14: Menu Screen

4. Depress the

or button to highlight SETPOINTS and press . If passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear.

GP Series Portable Chillers Chapter 4: Operation 36 of 90

Page 37

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 15: Operator Setpoints Screen

5. Depress

or button to increment or decrement the value. Depress to

accept the value and move the cursor down one line.

6. Depress the

to move the

or button to

to accept the password. The following screen will

to move the cursor to the CHILLED FLUID SP line. Use the

button twice to return to the main status screen.

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.

Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of operation, the compressor internal protector trips.

to start the chiller.

4-3 Status Screens

The controller has eight (8) preconfigured status screens. The main status screen (shown in Figure Figure 16) shows the main operating points of the chiller: Entering and Leaving fluid temperatures; Leaving fluid setpoint, pump discharge pressure, tank fluid level (depth), and percentage of hot-gas bypass output.

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Figure 16: Main Chiller Status Screen

Depressing

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

I/O, and Test. The Analog and Digital I/O screens provide status of all of the inputs and outputs for the controller. The Test aides in troubleshooting the chiller when it is not functioning properly by displaying the basic information that a service person will need to know to determine the problem.

GP Series Portable Chillers Chapter 4: Operation 38 of 90

Page 39

GP Series Portable Chillers Chapter 4: Operation 39 of 90

Page 40

The chiller can be equipped with a tempered fluid loop inside of the chiller. If this option is installed, the main screen changes to the following.

GP Series Portable Chillers Chapter 4: Operation 40 of 90

Page 41

Access Level

Operator

Supervisor

temperature is too high

on leaving fluid temperature

Setpoint for alarm to warn when tempered leaving operate

Lowest temperature fluid will operate without

above FFP

before compressor turns on

before compressor turns off

4-4 Access Levels

The controller is setup to allow access to three distinct password groups: operator, supervisor, and service. Operator access allows the user to modify the Leaving Water Temp, Hi Temp Warning, and Hi Temp Fault setpoints. Supervisor access allows the supervisor to modify the above plus

Selecting any of the menus in the Menu Screen will display the Password Screen.

4-5 Controller Setpoints

Variable Description

Chilled Fluid SP Temperature of chilled fluid out to process x x

Chil Hi Temp Wrn

Chil Hi Temp Flt

Setpoint for alarm to warn when chilled leaving fluid

Setpoint to shut down pump and compressor based

x x

Process SP Temperature of tempered fluid out to process x x

Proc Hi Temp Wrn

Proc Hi Temp Flt

Proc Low Temp Wrn

Proc Low Temp Flt

Cooling Enabled Refrigeration system allowed to operate x

Heating Enabled

Fluid Freeze Point

Chill On Diff

Chill Off Diff

Proc On Diff

Proc Off Diff

Proc Hi Temp Dly

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

Setpoint for alarm to warn when tempered leaving fluid temperature is too low

fluid temperature is too low

Optional Process temperature heater allowed to

freezing. Below 32°F (0°C) glycol must be added. Forces lowest Chilled fluid setpoint to be 13°F (7°C)

Temperature difference above chilled fluid setpoint

Temperature difference below chilled fluid setpoint

Temperature difference below process setpoint before process heater turns on

Temperature difference above process setpoint before process heater turns off

Time (in seconds) Process High Temperature alarm is ignored before activating

x x

GP Series Portable Chillers Chapter 4: Operation 41 of 90

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Variable Description

Operator

Supervisor

is ignored before activating

When set to CRIT, chiller and process high temp

alarm occurs

Time (in minutes) before lag compressor is

above Chilled Fluid setpoint

Time (in minutes) before lag compressor is de-

below Chilled Fluid setpoint

fan

the pump

activate once the last compressor stages off

Time (in seconds) between sampling the output of

be on for 7 seconds and off for 3 seconds.

forced to.

makeup on setpoint.

Access Level

Chil Hi Temp Dly

Hi Temp Flt Type

Chil Lo T Wrn Dif

Chil Lo T Flt Dif

Comp, Lead Cmp On Delay

Comp, Lead Cmp Off Delay

Lag Cmp On Dly

Lag Cmp Off Dly

Cond Fan Start Discharge pressure which energizes condenser fan x

Cond Fan Stop

Pump Stop Delay

Time (in seconds) Chilled High Temperature alarm

alarms will deactivate compressors and pumps. When set to WARN, compressors and pumps are allowed to continue to operate when a high temp

Temperature difference below the chiller setpoint before the chiller low temp warning alarm occurs

Temperature difference below the chiller setpoint before the chiller low temp fault alarm occurs. Temperature Difference between Leaving Fluid Temperature and Setpoint to turn on the compressor

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

energized once Chilled fluid reaches 2°F (1.1°C)

energized once chilled fluid reaches 2°F (1.1°C)

Discharge pressure which de-energizes condenser

Delay time in seconds between fault and stopping

Heater On Delay

Heater Cycle Tm

Heater P P parameter of the heater PID loop

Heater I I parameter of the heater PID loop

Heater D D parameter of the heater PID loop

Cooling Valve P P parameter of the cooling valve PID loop

Cooling Valve I I parameter of the cooling valve PID loop

Cooling Valve D D parameter of the cooling valve PID loop

Cooling Valve Mode

Cooling Valve Pos

Time (in seconds) before the heater is allowed to

the heater’s PID loop. For example, if this variable is set to ten (10), the heater PID loop output is checked every ten seconds. If the heater PID loop output is 70% when sampled the heater output will

When in AUTO, the cooling valve is controlled by the cooling valve PID loop. When in MANUAL, the cooling valve is forced open to the percent dictated by the Cooling Valve Pos variable. When the Cooling Valve Mode is set to MANUAL, this variable dictates what percentage the valve is

Tank Min Lvl

GP Series Portable Chillers Chapter 4: Operation 42 of 90

Minimum tank level. Used to set the default low tank lefvel alarm setpoints as well as the auto-water

Page 43

Variable Description

Operator

Supervisor

Maximum tank level. Used to set the default high

makeup off setpoint.

Tank level that will activate High Level Warning fault

Resets all parameters to the default parameters,

Tank Max Lvl

tank level alarm setpoints as well as the auto-water

Access Level

Low Level Fault

Low Level Warning

Wtr Makeup On

Wtr Makeup Off

High Lvl Warning

High Lvl Fault

Mkup Min Rt X.X”/XXS The minimum allowable rate for filling the tank x

Operator Password 4 digit password to limit operator interaction x

Operator Pw Time Time in minutes for operator password to be active x

Sprvisor Password 4 digit password for supervisory interaction x

Sprvisor Pw Time Time in minutes for supervisor password to be active x

Alarm Silence Time

Set Clock

Tank level that will activate Low Level Warning fault

Tank level that will activate Low Level Warning alarm

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

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

alarm Tank level that will activate High Level Warning

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

Allows for the time to be set if the clock card option is installed

Reset to Defaults

Figure 17: Menu Screen

including configuration

1. Set the Leaving Fluid temperature by depressing the

button to display

the menu.

2. Depress the

or button to highlight SETTINGS and press . If passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear.

GP Series Portable Chillers Chapter 4: Operation 43 of 90

Page 44

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

the

to accept the password. The following screen will appear.

Figure 18: Operator Setpoints Screen

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.

to move the position of

or button to increment or

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

5. Depress the

button twice to return to the main status screen.

GP Series Portable Chillers Chapter 4: Operation 44 of 90

Page 45

Operator

Supervisor

the controller

Set to CYCLING when a standard fan starter is used

frequency drive is used to control the fan

conditions to increase efficiency.

Determines how analog input 2 is used. It can be set

setpoint).

When Analog IN2 is set to REM SP, this determines

control the chiller.

the Remote Setpoint

Determines how analog input 6 is used. It can be set

temperature).

HEAT/COOL)

HEAT/COOL or HEAT).

Determines which loop’s (PROC or CHIL)

display.

valve).

4-6 Configuration Settings

Within the Supervisor Menu the chiller can be configured if options are added in the field. These configurations are described below.

Variable Description

Tank Level Inst Activates/Deactivates the tank level control sensor x

Auto Water Make-up

Fan Control

Disch Press Cntl

Sensor Pack Inst

Cond Diff Sw Inst

Chill Diff Sw Inst

Clock Board Inst Activates the optional controller real time clock card x

Heater Installed Activates the optional process heater x

Analog IN2

Activates the automatic water makeup valve within

to control the fan. Set to VFD when a variable

When set to SP, the chiller will control to a static SP. When set to AUTO, the chiller will adjust the discharge pressure setpoint based on the current

Activates the optional temperature sensors for refrigerant liquid line and suction line temperatures, and entering air or water temperature (depending on condenser type) Activates the optional water cooled condenser differential water pressure switch

Activates the optional evaporator differential water pressure switch

to CHIL IN (chiller in temperature), FROM PROC (from process temperature), CHIL REM SP (chiller remote setpoint) or PROC REM SP (process remote

Access Level

Remote SP Mode

Rem SP mA Range

Analog In 6

Chil Loop Type

Proc Loop Type

Primary Loop

Analog Out 2

GP Series Portable Chillers Chapter 4: Operation 45 of 90

if the LOCAL (entered through the display) setpoint or REMOTE (Analog IN2) setpoint is used to

Determines the signal type (0-20mA or 2-20mA) for

to CHIL IN (chiller in temperature), FROM PROC (from process temperature) or TO PROC (to process

Determines the chiller loop’s type (COOL or

Determines the process loop’s type (COOL,

information to display on the first status page of the

Determines how analog output 2 is used. It can be set to CHIL IN (retransmission of the chiller in temperature), CHIL OUT (retransmission of the chiller out temperature), FROM PROC (retransmission of the from process temperature), TO PROC (retransmission of the to process temperature) or COOL VLV (process loop cooling

Page 46

Variable Description

Operator

Supervisor

Determines how analog output 3 is used. It can be

temperature).

Determines how analog output 4 is used. It can be

temperature).

Determines how digital input 8 is used. It can be set

phase monitor), TMP SAFETY (high temp safety)

digital input 8 (REMOTE).

(from process temperature).

Determines which sensor is used to control the

temperature).

When set to CRIT, the pump 2 overload alarm will

occurs.

When set to CRIT, the flow 2 alarm will deactivate

run when the flow 2 alarm occurs.

Determines when the alarm output is activated.

compressor off) occur.

WEB.

Analog Out 3

Analog Out 4

Digital In 8

Start Mode

Chil Cntl Sens

set to CHIL IN (retransmission of the chiller in temperature), CHIL OUT (retransmission of the chiller out temperature), FROM PROC (retransmission of the from process temperature) or TO PROC (retransmission of the to process

to START/STOP (remote start stop), NO WARNING (normally open warning alarm), NC WARNING (normally closed warning alarm), NO FAULT (normally open fault alarm), NC Fault (normally closed fault), PHASE MNTR (power

When Digital In 8 is configured to START/STOP this determines if the chiller’s online status is determined by the button on the display (LOCAL) or

Determines which sensor is used to control the chiller. It can be set to CHIL OUT (chiller out temperature), CHIL IN (chiller in temperature), TO PROC (to process temperature) or FRM PROC

Access Level

Proc Cntl Sens

Pump 2 OL Alm

Flow 2 Alm Type

Alarm Out

Network Prot

Network Baudrate Determines the baudrate for communications. x

Network Address

Units

GP Series Portable Chillers Chapter 4: Operation 46 of 90

process loop. It can be set to TO PROC (to process temperature) or FRM PROC (from process

deactivate compressors and pumps. When set to WARN, compressors and pumps are allowed to continue to run when the pump 2 overload alarm

compressors and pumps. When set to WARN, compressors and pumps are allowed to continue to

When set to ALL ALARMS, the output is activated when any new alarm occurs. When set to CRIT ALARMS, the output will only activate when critical alarms (those that force the pump or

Determines what network protocol is used for communications. This can be set to BACNET485, BACNET IP, MODBUS485, MODBUS IP, LON or

Determines the network address of the chiller on the network.

Determines if STANDARD (English) or METRIC units are used.

Page 47

4-7 Alarms

The controller is setup with multiple alarms, most of them configurable using the Supervisor password. Section 4-5 Controller Setpoints on page 41 gives a list of alarms that the controller is setup to display. The alarms are broken up into two categories – warnings and faults. The warning notifies the user that the parameter has been exceeded and the chiller is allowed to keep operating, but should be monitored to determine the cause of the warning. The fault notifies the user that the parameter has been exceeded and the chiller and pump has been shut down to protect the system.

4-8 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.

Serial communications use a RS-485 hardware interface. Protocols available are BACNet, LONWorks, CANBus, and ModBus RTU (Slave mode only). See Appendix for the controller data that is available through these protocols.

Network communications use a RJ-45 hardware interface using the basic Ethernet TCP/IP layer stack. Protocols available are BACNet (Ethernet, IP, or MS/TP) and ModBus IP. See Appendix for the controller data that is available through these protocols.

GP Series Portable Chillers Chapter 4: Operation 47 of 90

Page 48

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 185P F (85P C). Remove the grease relief plug (motors only) before adding grease, add grease until a small amount pours out, and replace the plug when finished.

Caution! Failure to remove the grease relief plug will result in dislodging the bearing

grease seal, eventually causing bearing failure.

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. Remove the top side panel(s) to expose the condenser section.

3. Slide the filter rod to release it from the frame at the top and bottom.

4. Wash down the filter with clean water (preferably with a garden hose), directing the flow

of water opposite the direction of airflow. If dirt is heavy, use a mild detergent and rinse well. Allow the filter to dry completely before replacing it on the chiller.

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 (GPWC20-50). Remove dirt and slime in the condenser tube water side by reverse-circulating with a mild detergent and water solution. Remove mineral deposits by reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the water side of the condenser. Follow the directions on the container.

Shell & Tube Condensers (GPWC70-210). Remove dirt and slime in the condenser tube water side by cleaning with a nylon tube brush. Remove mineral deposits by reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the tube water side of the condenser. Follow the directions on the container.

The refrigerant side is sealed and requires no routine maintenance.

GP Series Portable Chillers Chapter 5: Maintenance 48 of 90

Page 49

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 Non-Acid De-Scaling Solution (Part No. A0553840). 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 49 of 90

Page 50

Chapter 6: Troubleshooting

Many problems that can occur while operating the chiller can be avoided by following the recommended installation, operation, and maintenance outlined within this manual. If you do have a problem this Chapter will help you determine the cause and the potential solution.

Before beginning the troubleshooting process

 Locate all wiring, piping, and assembly drawings that were shipped with the chiller. The

diagrams will note any custom options not covered in this manual.

 Locate all manuals for any equipment that this chiller is connected to as they may provide

additional information to solve the problem.

WARNING!: Improper installation, operation, or any servicing may result in damage or personal

injusry

This chiller should only be installed, operated, and maintained by qualified technical personnel who are familiar with the construction, operation, and potential hazards.

All wiring, disconnects, and over-current protection devices should be installed by a qualified electrician in accordance will all local codes and ordinances in your region.

WARNING!: Electrical Hazard

Before performing any service on this equipment disconnect and lockout all electrical sources to prevent injury from unexpected energization or startup. Follow all safety rules when performing any maintenance or service to this equipment.

WARNING!: Refrigeration Hazard

Only certified refrigeration technicians should perform any refrigeration related maintenance.

CAUTION!: Hot Surfaces

Protect yourself from hot surfaces when working on the refrigeration or process temperature sections of this equipment. These devices can reach temperatures of 180°F (82°C). Allow the equipment to cool prior to performing any maintenance or service.

6-1 Identifying the Cause of a Problem

Types of conditions the user may see include alarm conditions and control problems.

Alarm Conditions

When an alarm condition occurs the button backlight will flash, and if the optional audible/visual alarm is installed the strobe and horn will energize. The light and horn will remain on until the condition is corrected. Pressing the enter button will silence the audible alarm, but the strobe will continue to flash.

The display will show the cause the alarm and will indicate a possible solution. To accept the

alarm press following table shows the possible alarm messages that could appear on the display.

, and follow the suggested solution to correct the alarm condition. The

GP Series Portable Chillers Chapter 6: Troubleshooting 50 of 90

Page 51

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

MCP Failure

Allow the compressor to cool

if necessary.

Sensor Failure

Electrical connection at sensor open

Electrical connection at controller open

Allow the fan to cool down. If

replace fan motor.

Locate the drive and write

Dirty air cooled condenser or inlet filter

Clean filter or condenser

Dirty water cooled condenser or condenser valve failure

Clean condenser or verify operation of condenser valve

Condenser fan overload

See Fan Overload Fault

Condenser fan VFD fault

See VFD Fault

Ambient air or condenser water temperature too high

Verify supply temperature or air removal capacity.

Too much refrigerant in system.

Contact Customer Service for assistance

Verify operation of valve and wiring on controller

Discharge pressure switch failure

See Discharge Pressure Sensor Failure

Dirty air cooled condenser or inlet filter

Clean filter or condenser

Dirty water cooled condenser or condenser valve failure

Clean condenser or verify operation of condenser valve

Condenser fan overload

See Fan Overload Fault

Condenser fan VFD fault

See VFD Fault

Ambient air or condenser water temperature too high

Verify supply temperature or air removal capacity.

Too much refrigerant in system.

Contact Customer Service for assistance

Liquid line valves closed

Verify operation of valve and wiring on controller

Discharge pressure switch failure

See Discharge Pressure Sensor Failure

High Suction Pressure Fault

From Process fluid temperature too high

Verify flow through system. Make corrections as necessary.

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

Ambient air or condenser

Verify ambient air temperature

water temperature.

Too little refrigerant in system.

Contact customer service for service call

Compressor Fault 1 CC

Discharge Pressure Sensor Failure 2 W

Compressor module has failed

down. If the compressor does not restart, disconnect power and verify operation of the MCP internal module. Replace

Check the wiring connection at the sensor, and at the controller. If necessary replace sensor.

Fan Overload 3 CC

VFD Fault 4 CC

High Discharge Pressure Fault 5 CC

Internal fan motor overload tripped

Drive has detected internal fault

Liquid line valves closed.

the fan does not restart when called upon by controller,

down the fault code shown on the display of drive. Contact customer service for assistance.

High Discharge Pressure Switch 6 CC

Low Discharge Pressure Fault 8 CC

GP Series Portable Chillers Chapter 6: Troubleshooting 51 of 90

water temperature too low

and air flow or condenser inlet

Page 52

Water cooled condenser valve stuck open

Verify cooling valve operation.

Verify VFD is in remote versus

controller output to VFD.

Low Fluid Temp Fault 9 CC

Verify system valve operation and adjust if necessary

Clean y-strainer through blow-

strainer.

System low on refrigerant

Contact Customer Service

Verify wiring or output between controller and valve

Chilled fluid setpoint too

setpoint.

Adjust setpoint or fluid

require adding glycol to fluid)

Process fluid flow rate too low.

Verify system valve operation and adjust if necessary

Thermal expansion valve failure.

Contact Customer Service

Thermal expansion valve failure

Contact Customer

Verify sensor wiring between controller and sensor.

Sensor failure

Electrical connection at sensor open

Electrical connection at controller open

Sensor wires loose from controller terminal block

Check the wiring connection at the controller terminal block

Sensor wires broke between

block.

Verify tank level parameters. Add fluid if necessary.

Verify wiring between

Replace valve if necessary

Tank level sensor failure

Replace Sensor

Verify that all system valves are operational and adjust.

Verify the sensor at the sensor and at the terminal block.

Verify the operation of the

protector or pump rotation)

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

Verify motor circuit protector

and amp draw while under load.

Verify system valves are

for application.

Fluid temperature higher than parameter.

Verify parameter and adjust if necessary.

Refrigeration system fault

Check for any refrigeration

Fan VFD output at 100%

Low process fluid flow

Plugged Y-strainer

Liquid line valves closed

manual operation. Verify

down valve or cleaning internal

Low Suction Pressure Fault 10 CC

Low Superheat Fault (only will appear if optional sensor pack is installed)

Suction Pressure Sensor Failure 12 CC

Leaving Water Temp Sensor Failure

Low Level Fault 14 SC

11 CC

13 SC

close to freeze protection

Temperature Sensor Failure

sensor and controller terminal

Tank level too low

Optional water makeup valve failure

System valve(s) closed

freezepoint temperature (will

Check the wiring connection at the sensor, and at the controller. If necessary replace sensor.

Replace Sensor

controller and makeup valve.

No Flow 15 SC

Low flow sensor failure

Pump failure

Motor circuit protector open

Pump Overload 16 SC

Pump flow rate in excess of capacity

High Fluid Temp Fault 17 SC/W

GP Series Portable Chillers Chapter 6: Troubleshooting 52 of 90

pump (i.e. motor circuit

operation. Verify motor wiring

operational and properly set. Contact customer service or sales if pump is sized too small

Page 53

system fault

Verify with sales representative

application.

Low Condenser Differential Pressure Warning

Low discharge pressure or high suction pressure

Contact customer service

Condenser Inlet Temp Sensor

Sensor wires loose from controller terminal block

Verify wiring at terminal block. .

Sensor wires broke between

block.

Replace temperature sensor Sensor wires loose from controller terminal block

Verify wiring at terminal block. .

Sensor wires broke between

block.

Replace temperature sensor

Blocked evaporator

Backflush evaporator

Blow down y-strainer by

clean internal strainer.

Dirty air cooled condenser or inlet filter

Clean filter or condenser

Dirty water cooled condenser or condenser valve failure

Clean condenser or verify operation of condenser valve

Condenser fan overload

See Fan Overload Fault

Condenser fan VFD fault

See VFD Fault

Ambient air or condenser water temperature too high

Verify supply temperature or air removal capacity.

Too much refrigerant in system.

Contact Customer Service for assistance

Verify operation of valve and wiring on controller

Fluid temperature higher than parameter.

Verify parameter and adjust if necessary.

Check for any refrigeration system fault

Verify with sales representative

application.

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

Fluid level higher than parameter setting.

Verify value in parameter

Open drain valve and remove

level is below high level fault.

Tank sensor failure

Replace sensor

Fluid level higher than parameter setting.

Verify value in parameter

Open drain valve and remove

warning.

Tank sensor failure

Replace sensor

Compressor Differential Pressure Fault

Low discharge pressure or high suction pressure

Contact customer service

From Process fluid temperature too high

Verify flow through system. Make corrections as necessary.

Low Discharge Pressure Warning

28 W Ambient air or condenser

Verify ambient air temperature

Failure (optional with sensor pack)

18 W

19 W

Chiller too small for load

sensor and controller terminal

the sizing of the chiller for the

Chiller In Fluid Temp Sensor Failure

Evaporator Differential Pressure 21 W

High Discharge Pressure Warning 22 W

High Fluid Temp Warning 23 W

20 W

sensor and controller terminal

Blocked Y-strainer

Liquid line valves closed.

Refrigeration system fault

Chiller too small for load

opening blow-down valve or

the sizing of the chiller for the

High Level Fault 24 W

High Level Warning 25 W

26 CC

High Suction Pressure Warning 27 W

GP Series Portable Chillers Chapter 6: Troubleshooting 53 of 90

Too much fluid in system

some fluid from system so that

some fluid from system so that level is below high level

Page 54

water temperature too low

and air flow or condenser inlet water temperature.

Too little refrigerant in system.

Contact customer service for service call

Water cooled condenser valve stuck open

Verify cooling valve operation.

Fan VFD output at 100%

Verify VFD is in remote versus

controller output to VFD.

Low Fluid Temp Warning

29 W

Fluid level lower than parameter setting.

Verify value in parameter. Add fluid to the system if necessary

Verify wiring between

Replace valve if necessary

Tank sensor failure

Replace sensor

Compressor Differential Pressure Warning

Low discharge pressure or high suction pressure

Contact customer service System low on refrigerant

Contact Customer Service

Verify wiring or output between controller and valve

Chilled fluid setpoint too

setpoint.

Adjust setpoint or fluid

require adding glycol to fluid)

Process fluid flow rate too low.

Verify system valve operation and adjust if necessary

Thermal expansion valve failure.

Contact Customer Service

Pump Down Override Time Liquid line valve open

Contact customer service Hot gas bypass valve open

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

Verify wiring of flow sensor at

controller

Sensor wires loose from controller terminal block

Sensor wires broke between

block.

Sensor wires loose from controller terminal block

Verify wiring of sensor at

Sensor wires broke between

block.

Sensor wires loose from controller terminal block

Verify wiring of sensor at

Sensor wires broke between

block.

Sensor wires loose from controller terminal block

Verify wiring of sensor at

Sensor wires broke between

block.

Verify wiring of solenoid valve at valve and at terminal block.

Increase water pressure to be above 5 psig (0.3 bar)

manual operation. Verify

Low Level Warning 30 W

31 W

Low Suction Pressure Warning 32 W

Expired

33 W

Optional Water Makeup valve failure

Liquid line valves closed

close to freeze protection

Pump Flow Sensor Failure 34 W Optional flow sensor failed

Pump Pressure Sensor Failure 35 W

sensor and controller terminal

controller and makeup valve.

freezepoint temperature (will

sensor and terminal block of

Verify wiring of sensor at sensor and terminal block of controller

Refrig Liquid Temp Sensor Failure

Refrig Suction Temp Sensor Failure

Tank Level Sensor Failure 38 W

Water make-up failure 40 W

GP Series Portable Chillers Chapter 6: Troubleshooting 54 of 90

36 W

sensor and controller terminal

37 W

sensor and controller terminal

Make up solenoid failure

Insufficient water pressure

sensor and terminal block of controller

Page 55

Auxilliary Alarm

SC/W

This alarm is configurable

Low Suction Pressure at Startup 42 CC

Parameter set too short for remote condenser installation

Adjust parameter for length of time to build suction pressure

Refrigerant amount too low

Contact Customer Service

For Units with a Tempered Loop

Verify wiring of temperature

block of controller

Verify heater contactor operation

Process cooling valve off

Verify cooling valve operation

Verify heater contactor operation

Process cooling valve off

Verify cooling valve operation

Verify heater contactor operation

Process cooling valve on

Verify cooling valve operation

Verify heater contactor operation

Process cooling valve on

Verify cooling valve operation

Optional process flow switch failure

Verify operation of flow switch.

Verify operation of process valves and adjust as necessary

CC = Compressor Critical SC = System Critical PC = Process Critical W = Warning

Alarm Name

Type

Possible Cause

Solution

Verify motor circuit protector

and amp draw while under load.

Verify system valves are

for application.

Verify operation of heater and cooling valve. .

Verify wiring at cooling valve and at terminal bloc

Sensor failure

Replace sensor if necessary.

Reverse two wires at line-side

panel.

Loss of phase during operation

Verify sensor wiring at sensor and at terminal bloc.

Sensor failure

Replace sensor if necessary.

Sensor wires loose from controller terminal block

Verify wiring at sensor and at terminal block. y.

Sensor wires broke between

block.

Replace sensor if necessar

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.

To ProcTemperature Sensor Failure

Process High Temp Fault 44 W

Process High Temp Warning 46 W

Process Low Temp Fault 48 W

Process Low Temp Warning 50 W

Pump 2 No Flow 52 SC/W

43 PC Loose or broken sensor wire

Pump 2 Overload 53 SC/W

Process heater on

Process heater off

Process valves closed

Motor circuit protector open

Pump flow rate in excess of capacity

sensor at sensor and terminal

operation. Verify motor wiring

operational and properly set. Contact customer service or sales if pump is sized too small

Heater failure

High Temp Safety Switch 54 PC

Phase Monitor Fault 55 SC

From Proc Sensor Failure 56 W

Cooling Valve failure

Unit wired incorrectly

sensor and controller terminal

Non-Controller Related Issues

No power.

Unit does not run.

Wrong voltage supplied to unit.

GP Series Portable Chillers Chapter 6: Troubleshooting 55 of 90

of power switch on electrical

Page 56

Problem

Possible cause

Solution

Control circuit fuse blown.

Replace control circuit fuse.

Check transformer.

Check for a short circuit.

Defective control transformer.

Replace.

Add water or water/glycol solution as required.

Pump motor off on overload.

Reset and test.

Piping flow switch circuit open.

GP Series Portable Chillers Chapter 6: Troubleshooting 56 of 90

Page 57

Problem

Possible cause

Solution

Leaving fluid setpoint set higher

system.

Lower the leaving fluid temperature

desire.

Allow time to cool and reset, then check

rating.

Check for loose compressor electrical connections.

Failed compressor motor

Compressor contactor holding coil open.

Defective compressor auxiliary Plugged Y-strainer

Clean

Check hot gas analog output value

throughout compressor cycle.

Check internal bypass valve to verify it

process line

Clean filters.

Clean condenser.

Check the refrigerant charge by viewing

expansion valve.

Compressor not operating efficiently.

Unit under-sized for application.

Call sales rep.

Pump runs; compressor does not.

Pump runs, compressor cycles at short intervals.

than temperature of liquid in

Compressor internal overload or MCP is open.

contact.

Broken wire in the compressor control circuit.

Hot gas not coming on

Low process water flow

below the leaving temperature you

for high/low volt-age. It must be within plus or minus 10% of the nameplate

Repair or replace.

Locate and repair.

through status screen. Contact Service if output value remains at 0%

is open and free of debris.

Install bypass between to-and-from

Unit runs continuously, but not enough cooling power.

Restricted condenser air flow.

Unit low on refrigerant.

sight glass on liquid line upstream of the

Call service.

GP Series Portable Chillers Chapter 6: Troubleshooting 57 of 90

Page 58

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

7-2 Technical Assistance

Parts Department

Call toll-free Monday – Friday, 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653

GP Series Portable Chillers Chapter 7: Appendix 58 of 90

Page 59

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free Monday – Friday, 8am–5pm CST [800] 423-3183 or call [262] 641-8610

Emergencies after 5pm CST, call [847] 439-5655 We have a qualified service department ready to help. Service contracts are available for most products.

Sales Department

[262]

Call

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.

641-8610 Monday–Friday, 8am–5pm CST

Contract Department

[262]

Call

641-8610 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.

GP Series Portable Chillers Chapter 7: Appendix 59 of 90

Page 60

Specifications

GPAC-20

OPERATING PARAMETERS

SPECIFICATIONS

GPAC-30

OPERATING PARAMETERS

SPECIFICATIONS

Air-Cooled Portable Chillers

Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.

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

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 6-24 GPM

AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 0.944 TONS

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 24 INCH AXIAL FRAME GALVANIZED STEEL

CONDENSER FAN MOTOR 1/2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

RESERVOIR 20 GALLON POLYETHYLENE WEIGHT (OPERATING) 690 LBS

POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 520 LBS

CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12

COMPRESSOR FULL LOAD AMPS 10.7 AMPS CONTROL MICROPROCESSOR

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

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

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 9-36 GPM

AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 1.504 TONS

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 24 INCH AXIAL FRAME GALVANIZED STEEL

CONDENSER FAN MOTOR 1 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

RESERVOIR 20 GALLON POLYETHYLENE WEIGHT (OPERATING) 870 LBS

POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 700 LBS

CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12

COMPRESSOR FULL LOAD AMPS 16.4 AMPS CONTROL MICROPROCESSOR

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

GP Series Portable Chillers Chapter 7: Appendix 60 of 90

Page 61

GPAC-40

GPAC-50

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 12-48 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 32 INCH AXIAL FRAME GALVANIZED STEEL

CONDENSER FAN MOTOR 1 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

RESERVOIR 40 GALLON POLYETHYLENE WEIGHT (OPERATING) 1090 LBS

POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 760 LBS

CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12

COMPRESSOR FULL LOAD AMPS 20 AMPS CONTROL MICROPROCESSOR

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

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 18-72 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 32 INCH AXIAL FRAME GALVANIZED STEEL

CONDENSER FAN MOTOR 2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

RESERVOIR 40 GALLON POLYETHYLENE WEIGHT (OPERATING) 1290 LBS

POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 950 LBS

CONTROL CIRCUIT 120 VDC ELECTRICAL ENCLOSURE NEMA 12

COMPRESSOR FULL LOAD AMPS 30 AMPS CONTROL MICROPROCESSOR

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

GP Series Portable Chillers Chapter 7: Appendix 61 of 90

Page 62

GPAC-70

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

20048

WATTS

AMBIENT AIR TEMPERATURE

°F

EER

12.07

BTU/WATT

COOLANT

WATER

CONDENSER AIR FLOW

16916

CFM

COOLANT FLOW

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

24-96

GPM

AMBIENT AIR TEMPERATURE

60-115

°F

MINIMUM LOAD

4.03

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

COOLANT PUMP

COOLANT CIRCUIT

NON-FERROUS

CONDENSER

ALUMINUM

REFRIGERANT

12 LBS R-410A

CONDENSER FANS

(2) 24 INCH AXIAL

FRAME

GALVANIZED STEEL

CONDENSER FAN MOTOR

(2) 1/2 HP OAO, 1140 RPM

PANELS

POWDER COATED STEEL

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1520

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

GPAC-90

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

25.47

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

25504

WATTS

AMBIENT AIR TEMPERATURE

°F

EER

11.98

BTU/WATT

COOLANT FLOW

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

30-120

GPM

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

CONDENSER

ALUMINUM

REFRIGERANT

12 LBS R-410A

CONDENSER FANS

(2) 32 INCH AXIAL

FRAME

GALVANIZED STEEL

RESERVOIR

70 GALLON POLYETHYLENE

WEIGHT (OPERATING)

2580

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1900

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

COMPRESSOR RATED LOAD AMPS

(2) @ 23.1 AMPS EACH

CONTROL

MICROPROCESSOR

COOLING CAPACITY 20.16 TONS ALTITUDE SEA LEVEL

STAINLESS STEEL CENTRIFUGAL

EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

RESERVOIR 70 GALLON POLYETHYLENE WEIGHT (OPERATING) 2180 LBS

COMPRESSOR RATED LOAD AMPS (2) @ 17.9 AMPS EACH CONTROL MICROPROCESSOR

COOLANT WATER CONDENSER AIR FLOW 25374 CFM

AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 5.09 TONS

SPECIFICATIONS

COOLANT PUMP

EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

CONDENSER FAN MOTOR (2) 2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

GP Series Portable Chillers Chapter 7: Appendix 62 of 90

Page 63

GPAC-105

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

30.21

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

29731

WATTS

COOLANT FLOW

GPM

SOUND POWER LEVEL

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

36-144

GPM

SPECIFICATIONS

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

ALUMINUM

REFRIGERANT

16 LBS R-410A

CONDENSER FAN MOTOR

(2) 2 HP OAO, 1140 RPM

PANELS

POWDER COATED STEEL

RESERVOIR

70 GALLON POLYETHYLENE

WEIGHT (OPERATING)

2580

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1900

LBS

COMPRESSOR RATED LOAD AMPS

(2) @ 26.9 AMPS EACH

CONTROL

MICROPROCESSOR

GPAC-140

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

TONS

ALTITUDE

SEA LEVEL

AMBIENT AIR TEMPERATURE

°F

EER

12.58

BTU/WATT

COOLANT FLOW

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

OPERATING PARAMETERS

AMBIENT AIR TEMPERATURE

60-115

°F

MINIMUM LOAD

8.00

TONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER FANS

(3) 32 INCH AXIAL

FRAME

GALVANIZED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

3870

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

COMPRESSOR RATED LOAD AMPS

(2) @ 30.4 AMPS EACH

CONTROL

MICROPROCESSOR

AMBIENT AIR TEMPERATURE 95 °F EER 12.19 BTU/WATT

COOLANT WATER CONDENSER AIR FLOW 25374 CFM

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

OPERATING PARAMETERS

AMBIENT AIR TEMPERATURE 60-115 °F MINIMUM LOAD 6.04 TONS

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH

COOLANT PUMP

CONDENSER FANS (2) 32 INCH AXIAL FRAME GALVANIZED STEEL

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

CONTROL CIRCUIT 24/120 VAC ELECTRICAL ENCLOSURE NEMA 12

COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 38153 WATTS

COOLANT WATER CONDENSER AIR FLOW 38061 CFM

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 48-192 GPM

SPECIFICATIONS

COOLANT PUMP

CONDENSER ALUMINUM REFRIGERANT 18 LBS R-410A

CONDENSER FAN MOTOR (3) 2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

STAINLESS STEEL CENTRIFUGAL

COOLANT CIRCUIT NON-FERROUS

POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 2850 LBS

GP Series Portable Chillers Chapter 7: Appendix 63 of 90

Page 64

GPAC-175

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

49.41

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

48693

WATTS

AMBIENT AIR TEMPERATURE

°F

EER

12.18

BTU/WATT

COOLANT FLOW

118

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

60-240

GPM

AMBIENT AIR TEMPERATURE

60-115

°F

MINIMUM LOAD

9.88

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

ALUMINUM

REFRIGERANT

24 LBS R-410A

CONDENSER FANS

(3) 32 INCH AXIAL

FRAME

GALVANIZED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

3870

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

2850

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

GPAC-210

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

63.95

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

63589

WATTS

AMBIENT AIR TEMPERATURE

°F

EER

12.07

BTU/WATT

COOLANT

WATER

CONDENSER AIR FLOW

50748

CFM

COOLANT FLOW

153

GPM

SOUND POWER LEVEL

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

72-288

GPM

AMBIENT AIR TEMPERATURE

60-115

°F

MINIMUM LOAD

12.79

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

COOLANT PUMP

COOLANT CIRCUIT

NON-FERROUS

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

ALUMINUM

REFRIGERANT

32 LBS R-410A

CONDENSER FANS

(4) 32 INCH AXIAL

FRAME

GALVANIZED STEEL

CONDENSER FAN MOTOR

(4) 2 HP OAO, 1140 RPM

PANELS

POWDER COATED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

5160

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

3800

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

COOLANT WATER CONDENSER AIR FLOW 38061 CFM

OPERATING PARAMETERS

COOLANT PUMP

CONDENSER FAN MOTOR (3) 2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL

COMPRESSOR RATED LOAD AMPS (2) @ 41.9 AMPS EACH CONTROL MICROPROCESSOR

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

STAINLESS STEEL CENTRIFUGAL

OPERATING PARAMETERS

COOLANT CIRCUIT NON-FERROUS

COMPRESSOR RATED LOAD AMPS (2) @ 54.5 AMPS EACH CONTROL MICROPROCESSOR

GP Series Portable Chillers Chapter 7: Appendix 64 of 90

STAINLESS STEEL CENTRIFUGAL

Page 65

GPWC-20

CONDENSER INLET WATER TEMPERATURE

GPWC-30

TEMPERATURE

SOUND PRESSURE LEVEL @ 1 METER

TEMPERATURE

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.

PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)

COOLING CAPACITY 5.12 TONS ALTITUDE SEA LEVEL

COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 4064 WATTS

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

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 6-24 GPM CONDENSER INLET WATER

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

STAINLESS STEEL CENTRIFUGAL

85 °F EER 15.13 BTU/WATT

OPERATING PARAMETERS

50-90 °F MINIMUM LOAD 1.06 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 7.98 TONS ALTITUDE SEA LEVEL

COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 6416 WATTS CONDENSER INLET WATER

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 9-36 GPM CONDENSER INLET WATER

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

STAINLESS STEEL CENTRIFUGAL

85 °F EER 14.92 BTU/WATT

dBA

OPERATING PARAMETERS

50-90 °F MINIMUM LOAD 1.672 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

GP Series Portable Chillers Chapter 7: Appendix 65 of 90

Page 66

GPWC-40

CONDENSER INLET WATER TEMPERATURE

SOUND PRESSURE LEVEL @ 1 METER

TEMPERATURE

GPWC-50

CONDENSER INLET WATER TEMPERATURE

SOUND PRESSURE LEVEL @ 1 METER

TEMPERATURE

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 10.94 TONS ALTITUDE SEA LEVEL

COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 8450 WATTS

85 °F EER 15.53 BTU/WATT

COOLANT WATER CONDENSER WATER FLOW 33.93 GPM

COOLANT FLOW 27 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 12-48 GPM CONDENSER INLET WATER

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

50-90 °F MINIMUM LOAD 2.262 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

dBA

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY 16.66 TONS ALTITUDE SEA LEVEL

COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 12778 WATTS

85 °F EER 15.65 BTU/WATT

COOLANT WATER CONDENSER WATER FLOW 50.28 GPM

COOLANT FLOW 40 GPM SOUND POWER LEVEL dBA

UNIT PRESSURE DROP 7 PSID

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE 20-80 °F COOLANT FLOW 18-72 GPM CONDENSER INLET WATER

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

50-90 °F MINIMUM LOAD 3.352 TONS

SPECIFICATIONS

COOLANT CIRCUIT NON-FERROUS

dBA

GP Series Portable Chillers Chapter 7: Appendix 66 of 90

Page 67

GPWC-70

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

16970

WATTS

COOLANT

WATER

CONDENSER WATER FLOW

GPM

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

24-96

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

4.54

TONS

SPECIFICATIONS

COOLANT PUMP

SST CENTRIFUGAL

COOLANT CIRCUIT

NON-FERROUS

CONDENSER

SHELL & TUBE

REFRIGERANT

12 LBS R-410A

PANELS

POWDER COATED STEEL

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1520

LBS

COMPRESSOR RATED LOAD AMPS

(2) @ 17.9 AMPS EACH

CONTROL

MICROPROCESSOR

GPWC-90

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

21716

WATTS

COOLANT

WATER

CONDENSER WATER FLOW

GPM

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

30-120

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

5.69

TONS

SPECIFICATIONS

COOLANT PUMP

SST CENTRIFUGAL

COOLANT CIRCUIT

NON-FERROUS

CONDENSER

SHELL & TUBE

REFRIGERANT

12 LBS R-410A

PANELS

POWDER COATED STEEL

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1900

LBS

COMPRESSOR RATED LOAD AMPS

(2) @ 23.1 AMPS EACH

CONTROL

MICROPROCESSOR

COOLING CAPACITY 22.68 TONS ALTITUDE SEA LEVEL

CONDENSER INLET WATER TEMP 85 °F EER 16.04 BTU/WATT

COOLANT FLOW 54 GPM SOUND POWER LEVEL 74 dBA

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH

EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

FRAME GALVANIZED STEEL

RESERVOIR 70 GALLON POLYETHYLENE WEIGHT (OPERATING) 2180 LBS

CONTROL CIRCUIT 24/120 VAC ELECTRICAL ENCLOSURE NEMA 12

COOLING CAPACITY 28.43 TONS ALTITUDE SEA LEVEL

CONDENSER INLET WATER TEMP 85 °F EER 15.71 BTU/WATT

COOLANT FLOW 68 GPM SOUND POWER LEVEL 74 dBA

COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH

EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS

FRAME GALVANIZED STEEL

RESERVOIR 70 GALLON POLYETHYLENE WEIGHT (OPERATING) 2580 LBS

CONTROL CIRCUIT 24/120 VAC ELECTRICAL ENCLOSURE NEMA 12

GP Series Portable Chillers Chapter 7: Appendix 67 of 90

Page 68

GPWC-105

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

33.64

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

25508

WATTS

CONDENSER INLET WATER TEMP

°F

EER

15.83

BTU/WATT

COOLANT FLOW

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

36-144

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

6.73

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

SHELL & TUBE

REFRIGERANT

16 LBS R-410A

FRAME

GALVANIZED STEEL

RESERVOIR

70 GALLON POLYETHYLENE

WEIGHT (OPERATING)

2580

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

1900

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

GPWC-140

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

43.35

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

32685

WATTS

CONDENSER INLET WATER TEMP

°F

EER

15.92

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

130

GPM

COOLANT FLOW

104

GPM

SOUND POWER LEVEL

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

48-192

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

8.67

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

COOLANT PUMP

SST CENTRIFUGAL

COOLANT CIRCUIT

NON-FERROUS

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

SHELL & TUBE

REFRIGERANT

18 LBS R-410A

FRAME

GALVANIZED STEEL

PANELS

POWDER COATED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

3870

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

2850

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

COOLANT WATER CONDENSER WATER FLOW 101 GPM

OPERATING PARAMETERS

COOLANT PUMP SST CENTRIFUGAL COOLANT CIRCUIT NON-FERROUS

PANELS POWDER COATED STEEL

COMPRESSOR RATED LOAD AMPS (2) @ 26.9 AMPS EACH CONTROL MICROPROCESSOR

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

OPERATING PARAMETERS

COMPRESSOR RATED LOAD AMPS (2) @ 30.4 AMPS EACH CONTROL MICROPROCESSOR

GP Series Portable Chillers Chapter 7: Appendix 68 of 90

Page 69

GPWC-175

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

54.46

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

41633

WATTS

CONDENSER INLET WATER TEMP

°F

EER

15.70

BTU/WATT

COOLANT FLOW

130

GPM

SOUND POWER LEVEL

dBA

UNIT PRESSURE DROP

PSID

SOUND PRESS LEVEL @ 1 METER

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

60-240

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

10.89

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

SHELL & TUBE

REFRIGERANT

24 LBS R-410A

FRAME

GALVANIZED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

3870

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

2850

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

GPWC-210

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

70.63

TONS

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

°F

COMPRESSOR POWER

54315

WATTS

CONDENSER INLET WATER TEMP

°F

EER

15.60

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

212

GPM

COOLANT FLOW

169

GPM

SOUND POWER LEVEL

dBA

COOLANT SUPPLY TEMPERATURE

20-80

°F

COOLANT FLOW

72-288

GPM

CONDENSER INLET WATER TEMP

50-90

°F

MINIMUM LOAD

14.13

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

20 MESH

COOLANT PUMP

SST CENTRIFUGAL

COOLANT CIRCUIT

NON-FERROUS

EVAPORATOR

BRAZED PLATE

CAPACITY CONTROL

HOT GAS BYPASS

CONDENSER

SHELL & TUBE

REFRIGERANT

32 LBS R-410A

FRAME

GALVANIZED STEEL

PANELS

POWDER COATED STEEL

RESERVOIR

140 GALLON POLYETHYLENE

WEIGHT (OPERATING)

5160

LBS

POWER

460V/3PH/60HZ

WEIGHT (SHIPPING)

3800

LBS

CONTROL CIRCUIT

24/120

VAC

ELECTRICAL ENCLOSURE

NEMA 12

COOLANT WATER CONDENSER WATER FLOW 163 GPM

OPERATING PARAMETERS

COOLANT PUMP SST CENTRIFUGAL COOLANT CIRCUIT NON-FERROUS

PANELS POWDER COATED STEEL

COMPRESSOR RATED LOAD AMPS (2) @ 41.9 AMPS EACH CONTROL MICROPROCESSOR

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

OPERATING PARAMETERS

COMPRESSOR RATED LOAD AMPS (2) @ 54.5 AMPS EACH CONTROL MICROPROCESSOR

GP Series Portable Chillers Chapter 7: Appendix 69 of 90

Page 70

7-3 Pump Curves, Flow, and Pressure Considerations

ACS CHILLER PUMPS

20-50 ALL 60 Hz

HP GP 20 GP 30 GP 40 GP 50

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

3U 32-200-1100D3G

OPT OPT

2CDU 70/306

Model

September 8, 2009

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

3 HP 2CDU 70/306

5 HP 2CDU 200/506

10 HP 3U 32-200-1100D3G

100

150

200

250

300

0 10 20 30 40 50 60 70 80

Capacity [Gal/min]

Head [ft]

100

120

Psi

60 Hertz Pump Curves

GP Series Portable Chillers Chapter 7: Appendix 70 of 90

Page 71

ACS CHILLER PUMPS

70-210 ALL 60 Hz

HP GP70 GP90 GP105

GP 140

GP175 GP210 5 STD STD STD 5 OPT OPT OPT STD STD 5 STD 5 OPT

7.5 OPT 10 OPT OPT OPT 15 OPT OPT OPT OPT OPT OPT 30 OPT OPT

3UB 65-200300D3G

Model

CDU 200/550D3G

3U 32-160B50D3G

3U 40-125B50D3G

2CDU 200/506D3G

3U 40-160-75D3G

3U 32-200-1100D3G

3U 40-200B150D3G

September 8, 2009

5 HP CDU200/550D3G

10 HP 3U 32-200-1100D3G

15 HP 3U 40-200B150D3G

5 HP 3U 40-125B-50D3G

10 HP 3U 40-160-1100D3G

5 HP 3U 32-160B50D3G

5 HP 2CDU 200/506

7.5 HP 3U 40-160-75D3G

30 HP 3UB 65-200300D3G

100

150

200

250

300

0 60 120 180 240 300

Capacity [Gal/min]

Head [ft]

100

120

Bar

GP Series Portable Chillers Chapter 7: Appendix 71 of 90

Page 72

50 Hertz Pump Curves

ACS CHILLER PUMPS

20-50 ALL 50 Hz

HP GP 20 GP 30 GP 40 GP 50

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

3U 32-200-1100D3G

OPT OPT

2CDU 70/306

Model

September 8, 2009

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

3 HP 2CDU 70/306

5 HP 2CDU 200/506

10 HP 3U 32-200-1100D3G

0 50 100 150 200 250 300

Capacity [liter/min]

Head [m]

Bar

GP Series Portable Chillers Chapter 7: Appendix 72 of 90

Page 73

ACS CHILLER PUMPS

70-210 ALL 50 Hz

HP GP70 GP90 GP105

GP 140

GP175 GP210 5 STD STD STD 5 OPT OPT OPT STD STD 5 STD 5 OPT

7.5 OPT 10 OPT OPT OPT 15 OPT OPT OPT OPT OPT OPT 30 OPT OPT

September 8, 2009

3UB 65-200300D3G

Model

CDU 200/550D3G

3U 32-160B50D3G

3U 40-125B50D3G

2CDU 200/506D3G

3U 40-160-75D3G

3U 32-200-1100D3G

3U 40-200B150D3G

5 HP 3U 40-125B-50D3G

10 HP 3U 40-160-1100D3G

5 HP 3U 32-160B50D3G

5 HP 2CDU 200/506

5 HP CDU200/550D3G

10 HP 3U 32-200-1100D3G

15 HP 3U 40-200B150D3G

7.5 HP 3U 40-160-75D3G

30 HP 3UB 65-200300D3G

0 120 240 360 480 600 720 840 960 1080 1200

Capacity [liter/min]

Head [m]

Bar

GP Series Portable Chillers Chapter 7: Appendix 73 of 90

Page 74

Pure Water at >40°F

GPM

DP (PSI)

GPM

DP (PSI)

GPM

DP (PSI)

GPM

DP (PSI)

GPXC-20 GPXC-30 GPXC-40 GPXC-50

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

GPXC-70 GPXC-90 GPXC-140 GPXC-175

0.5X Nominal 24 1.7 30 1.8 36 1.7 48 1.8

1.0X Nominal 48 6.1 60 6.5 72 6.1 96 6.4

2.0X Nominal 96 21.9 120 23.5 144 22.1 192 23.6

GPXC-210

0.5X Nominal 72 1.7

1.0X Nominal 144 6.2

2.0X Nominal 288 22.7

Calculating Chiller Nominal Flow and Pressure to Process

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

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

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

GP Series Portable Chillers Chapter 7: Appendix 74 of 90

Page 75

7-4 Remote Air-Cooled Chiller Configurations

GP Series Portable Chillers Chapter 7: Appendix 75 of 90

Page 76

Figure 19: Double Riser Detail

GP Series Portable Chillers Chapter 7: Appendix 76 of 90

Page 77

Model

Fan

60 Hz Discharge

air volume

50 Hz Discharge air

volume

CFM

m3/min

CFM

m3/min

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

GPAC-70

(2) 1.0

(2) 0.7

16916

479

14097

399

GPAC-90

(2) 2.0

(2) 1.4

25374

718

21145

598

GPAC-105

(2) 2.0

(2) 1.4

25374

718

21145

598

GPAC-140

(3) 2.0

(3) 1.4

38061

1077

31718

898

GPAC-175

(3) 2.0

(3) 1.4

38061

1077

31718

898

GPAC-210

(4) 2.0

(4) 1.4

50748

1436

42290

1197

7-5 Typical Ductwork for Air-Cooled Chillers

GPAC-20 0.5 0.4 4230 120 3525 100

When locating your air-cooled portable chiller and designing its ductwork, note any potential high temperature conditions when discharging into your building and any negative pressures with the building when discharging air outside.

GP Series Portable Chillers Chapter 7: Appendix 77 of 90

Page 78

(in / cm)

GPAC-20

GPAC-30

GPAC-40

GPAC-50

GPAC-20

GPAC-30

GPAC-40

GPAC-50

4230 / 120

180

240

360

100

150

200

300

Notes:

 Customer use of ductwork requires the high pressure fan option.  Allow 30 in. (77 cm) minimum clearance around the chiller footprint to facilitate free passage of

cooling air and service accessibility.

 Figure 20 shows the pressure loss per foot of ductwork. Calculate the total equivalent length before

using the data below.

 Support ductwork from the building structure, not off of the chiller.  Back draft damper to outside must be closed at all times when fan/blower is not operating. Size the

damper so that the pressure drop across is no greater than 0.2 in WG (50 Pascal) at the rated output.

 Chillers are designed to operate at a condensing entering air temperature of 60ºF (16ºC) minimum

without optional Variable Frequency Drive.

Figure 20 - Loss of Pressure through round duct - inches of water column per equivalent foot

60 hz Condenser Fan Flow Rate (cfm / cmm) 50 hz Condenser Fan Flow Rate (cfm / cmm)

Nominal Duct Diameter

18 / 45 0.003 0.007 0.013 0.03 0.002 0.005 0.009 0.020 20 / 50 0.002 0.005 0.008 0.02 0.001 0.003 0.005 0.012 22 / 55 0.001 0.003 0.005 0.01 0.002 0.003 0.007 24 / 60 0.002 0.003 0.007 0.001 0.002 0.005 26 / 65 0.001 0.002 0.004 0.001 0.003 28 / 70 0.001 0.003 0.002 30 / 75 0.002 0.002 32 / 80 0.002 0.001 36 / 90 0.001

6343 /

8458 /

12687 /

3525 /

5286 /

7048 /

10573 /

Note: 1 inch of water column = 250 Pascal

GP Series Portable Chillers Chapter 7: Appendix 78 of 90

Page 79