Sterling 882.93092.00 manual

GP Series Portable Chillers Part Number: 882.93092.0 0 Bulletin Number: SC2-620.2 Effective: 1/12/2010 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing [...]

GP Series Portable Chillers ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughl y check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage Ac[...]

GP Series Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .........................................................[...]

GP Series Portable Chillers iv 4-1 Panel Buttons, Indicator Lights, and Switches .......................................................... 29 Microprocessor Controller ................................................................................... 29 4-2 Initial Start-up .........................................................................[...]

GP Series Portable Chillers Chapter 1: Safety 5 of 73 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 a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective ma[...]

GP Series Portable Chillers Chapter 1: Safety 6 of 73 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equi pm ent damage when installing, operating, or maintaining th[...]

GP Series Portable Chillers Chapter 2: Functional Description 7 of 73 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d 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 se[...]

GP Series Portable Chillers Chapter 2: Functional Description 8 of 73 The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser. There it gives up its heat as it condenses to a liquid in the condenser. An electronic hot gas bypass valve is used to control cooling capacity duri ng interm ittent or[...]

GP Series Portable Chillers Chapter 2: Functional Description 9 of 73 • 208-230/3/60, 460/ 3/60, 575/3/60 volt ; 400/3/50 volt Refrigeration Features • HFC-410a refrigerant • Electronic hot gas bypass capacity control • High refrigerant pressure cutout switches • Suction and discharge pressure transducers. • High pressure spring actuate[...]

GP Series Portable Chillers Chapter 2: Functional Description 10 of 73 Caution! Energize the crankcase heater for at le ast 24 hours before initial startup to drive dissolved refrigerant from th e compressor oil. Failure to do so will damage the compressor. High Pressure Cutout This electro-mechanical cutout device opens the compressor control circ[...]

GP Series Portable Chillers Chapter 2: Functional Description 11 of 73 Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank. This option includes a 50 micron filter, flow meter, ball valve for throttling water flow, and the necessary piping to provide constant filteri ng of the process water at about one gallon [...]

GP Series Portable Chillers Chapter 2: Functional Description 12 of 73 Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps 460/3/60 SS 1 1.7 1.5 2.3 2 4.0 3 4.2 5 8.2 7.5 10.3 10 12.0 15 20.0 30 32.0[...]

GP Series Portable Chillers Chapter 3: Installation 13 of 73 Chapter 3: Inst allation 3-1 Uncrating All models are shipped mounted on a skid, encl osed 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, [...]

GP Series Portable Chillers Chapter 3: Installation 14 of 73 3-3 Process Water Connections All of our portable chillers have two chille d water connections. The chilled water supply, labeled “To Process” is the outlet for the chille d water leading to the process being cooled. The chilled water return, labeled “From Process” is the inlet le[...]

GP Series Portable Chillers Chapter 3: Installation 15 of 73 3-7 Condenser Considerations Water-Cooled Chiller Condensers Water-cooled portable chillers can use city wate r or tower water as a cooling medium. Make sure that all external piping and connections suppl ying and discharging water to and from the condenser are full size. You will make tw[...]

GP Series Portable Chillers Chapter 3: Installation 16 of 73 installation. If there is no pressure, leak test the unit and repair before installing the interconnecting refrigerant piping. Read this entire section before installation. Note: Piping should be type “L” or type “K ” refrigerant grade copper tubing only. Proper sizing and install[...]

GP Series Portable Chillers Chapter 3: Installation 17 of 73 room. Install a liquid line-charging valve to f acilitate refrigerant charging. See Fi gure 3 on page 18 for sizing information. See Figure 5 on page 22 for charge determination. Discharge Line Sizing. For horizontal runs, the discharge line should be pitched downward, in the direction of[...]

GP Series Portable Chillers Chapter 3: Installation 18 of 73 Figure 4 on page 21 for discharge line sizing. Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size OD (inches) Angle Valve Short Radius EL Long Radius EL 3/8 24 4 2.8 1/2 24 4.7 3.2 5/8 25 5.7 3.9 3/4 25 6.5 4.5 7/8 28 7.8 5.3 1-1/8 29 2.7 1.9 1-3/8 33 3.2 2.2 1-5/8 34 3[...]

GP Series Portable Chillers Chapter 3: Installation 19 of 73 10 TON CIRCUIT 15 TON CIRCUIT Liquid Line Size (OD") Liquid Line Size (OD") Total Equiv. Length (Ft) Horizontal or Downflow Upflow 1-5 Ft Upflow 6-10 Ft Upflow 11-15 Ft Total Equiv. Length (Ft) Horizontal or Downflow Upflow 1-5 Ft Upflow 6-10 Ft Upflow 11-15 Ft 25 5/8 5/8 5/8 3/[...]

GP Series Portable Chillers Chapter 3: Installation 20 of 73 30 TON CIRCUIT 40 TON CIRCUIT Liquid Line Size (OD") Liquid Line Size (OD") Total Equiv. Length (Ft) Horizontal or Downflow Upflow 1-5 Ft Upflow 6-10 Ft Upflow 11-15 Ft Total Equiv. Length (Ft) Horizontal or Downflow Upflow 1-5 Ft Upflow 6-10 Ft Upflow 11-15 Ft 25 1-1/8 1-1/8 1-[...]

GP Series Portable Chillers Chapter 3: Installation 21 of 73 Figure 4: Discharge Line Sizing Horizontal or Downflow Discharge Lin e Sizes (OD") Total Equivalent Lengt h (Ft) Circuit Tons 25 50 75 100 125 150 175 200 225 250 275 300 5 5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8 7.5 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 10 7/8 7/8 [...]

GP Series Portable Chillers Chapter 3: Installation 22 of 73 Refrigerant Charge Determination. The approximate amount of re frigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the chiller and th[...]

GP Series Portable Chillers Chapter 3: Installation 23 of 73 3-8 Checking Motor Direction All of our portable chillers have their moto r 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 lead s into the chiller disconnect switc[...]

GP Series Portable Chillers Chapter 3: Installation 24 of 73 3-9 Water Reservoir All portable chillers shipped during the fall, winter , or spring, or those units that are shipped from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping components prone to retaining water from fr eezing. During startup and when [...]

GP Series Portable Chillers Chapter 3: Installation 25 of 73 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G ly c ol C u r v e s f or Fr e e ze P r ot e c tio n -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 % Gl y col b y V ol um e Eth y l ene G ly c ol P r op y lene G lyc ol Examp[...]

GP Series Portable Chillers Chapter 3: Installation 26 of 73 3-10 Automatic Water Make-Up Option The chiller may be connected to an automatic make-up sy stem if the optional package (pipe fittings, solenoid valve and 1/2” NPT city wate r make-up connection) is factory installed. If the automatic make-up system is connected to a city water system,[...]

GP Series Portable Chillers Chapter 3: Installation 27 of 73 Operator Password. If you define a password for ope rators, 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[...]

GP Series Portable Chillers Chapter 3: Installation 28 of 73 6. Press to accept the Password and move to the next line. 7. For either Operator or Supervisor passwor d the time that the password will allow the controller to be active can be set by the Operat or or Supervisor Password Time. With the PW Time value highlighted, press or to increment or[...]

GP Series Portable Chillers Chapter 4: Operation 29 of 73 Chapter 4: Operation 4-1 Panel Buttons, Indicator Lights, and Switches Microprocessor Controller The standard chillers use a mi croprocessor-based PID controller. The Carel PCO controller along with the Carel PGD1 Interface is a modular , self-contained unit that can slide from its mounting [...]

GP Series Portable Chillers Chapter 4: Operation 30 of 73 4-2 Initial Start-up 1. Verify the initial start-up checklist from Chapter 3, Section 3-11. 2. With the main supply pow er switch in the ON position, the screen will display the version of the software fo r a period of 5 seconds, and then display the main status screen. Figure 8 - Main Statu[...]

GP Series Portable Chillers Chapter 4: Operation 31 of 73 appear. Figure 10 - Operator Setpoints Screen 5. Depress to move the cursor to the Leaving Temp line. Use the or button to increment or decrement the value. Depress to accept the value and move the cursor down one line. 6. Depress the button twice to return to the main status screen. 7. Depr[...]

GP Series Portable Chillers Chapter 4: Operation 32 of 73 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 33 of 73 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. Supervis or access allows the supervisor to modify t[...]

GP Series Portable Chillers Chapter 4: Operation 34 of 73 4-5 Controller Setpoints Access Level Variable Description Operator Supervisor Leaving Temp Temperature of fluid out to process x x Hi Temp Warning Setpoint for alarm to warn when leaving fluid temperature is too high x x Hi Temp Fault Setpoint to shut down pump and compressor based on leavi[...]

GP Series Portable Chillers Chapter 4: Operation 35 of 73 2. 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. Enter the Operator Password by depressing the to move the position of the cursor, and then depressing the or but[...]

GP Series Portable Chillers Chapter 4: Operation 36 of 73 When using the communications function, you must add on the u nit for RS-485 Modbus communications. The communications function a llows you to read/write parameters, do operating instructions, and select the setting level.[...]

GP Series Portable Chillers Chapter 4: Operation 37 of 73[...]

GP Series Portable Chillers Chapter 5: Maintenance 38 of 73 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 gr ease with a temperature reference of 185 ˚ F (85 ˚ C). Remove the grease relief plug (motors only) be fore adding grease[...]

GP Series Portable Chillers Chapter 5: Maintenance 39 of 73 Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you are monitoring the refrigeration circu it for excessive pressure with gauges. Only a trained technician should use this method. 5-4 Maintaining the Evaporator Dirty evaporator heat exchange surfaces redu[...]

GP Series Portable Chillers Chapter 6: Troubleshooting 40 of 73 Chapter 6: T r oubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage m ust be wit hin plus or minus 10% of nameplat e rating. Defective display. Replace. Replace control circuit fuse[...]

GP Series Portable Chillers Chapter 6: Troubleshooting 41 of 73 Problem Possible cause Solution Pump running in reverse. Verify rotation; if running in reverse rotation, reverse any two main power leads. Re-verify for c orrect pump rotation. Pump process pres sure low (refer to curves for n ormal pressure for various pum ps). Check for fore ign mat[...]

GP Series Portable Chillers Chapter 7: Appendix 42 of 73 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 purchase[...]

GP Series Portable Chillers Chapter 7: Appendix 43 of 73 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [262] 641-8610, Fax [262] 641-865 3 The ACS Customer Service Group w ill provide your compa ny with genuine OE M quality parts manufactured to engi neering design specifications, w hich will maxim[...]

GP Series Portable Chillers Chapter 7: Appendix 44 of 73 7-3 Specifications Air-Cooled Portable Chillers Nominal operating paramet ers for air-co oled models are 50ºF (10º C) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35º C) a mbient air. For 50 Hz applications , multiply capacity by 0.83 . Nom i nal 60 Hz ca[...]

GP Series Portable Chillers Chapter 7: Appendix 45 of 73 G-PAC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 9.91 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 10070 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 11.81 BTU/W A TT COOLANT WATER CONDENSER AIR FLOW 8458 CFM COOLANT FLOW 24 GPM SOUND POWER LEVEL 87 [...]

GP Series Portable Chillers Chapter 7: Appendix 46 of 73 GPAC-70 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 20.16 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR PO WER 20048 WATTS AMBIENT AIR TEMPE RATURE 95 °F EER 12.07 BTU/WATT COOLANT WATER CONDENSER AIR FLOW 16916 CFM COOLANT FLOW 48 GPM SOUND POWER LEVEL 8[...]

GP Series Portable Chillers Chapter 7: Appendix 47 of 73 GPAC-105 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 30.21 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR POWER 29731 W ATTS AMBIENT AIR TEMPE RATURE 95 °F EER 12.19 BTU/WATT COOLANT WATER CONDENSER AIR FLOW 25374 CFM COOLANT FLOW 72 GPM SOUND POWER LEVEL [...]

GP Series Portable Chillers Chapter 7: Appendix 48 of 73 GPAC-175 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 49.41 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR POWER 48693 WATTS AMBIENT AIR TEMPE RATURE 95 °F EER 12.18 BTU/WATT COOLANT WATER CONDENSER AIR FLOW 38061 CFM COOLANT FLOW 118 GPM SOUND POWE R LEVEL[...]

GP Series Portable Chillers Chapter 7: Appendix 49 of 73 Water-Cooled Portable Chillers Nominal operating parameters for w ater-cooled models are 50ºF (10ºC) leaving w ater tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 60 Hz capacity flow rate m[...]

GP Series Portable Chillers Chapter 7: Appendix 50 of 73 G-PWC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 10.94 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POW ER 8450 WATTS CONDENSER INLET WATER TEMPERATURE 85 °F EER 15.53 BTU/WATT COOLANT WATER CONDENSER WATER FLOW 33.93 GPM COOLANT FLOW 27 GPM SOUND POW[...]

GP Series Portable Chillers Chapter 7: Appendix 51 of 73 GPWC-70 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 22.68 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR POWER 16970 WATTS CONDENSER INLET W ATER TEMP 85 °F EER 16.04 BTU/WATT COOLANT WATER CONDENSER WATER FL O W 68 GPM COOLANT FLOW 54 GPM SOUND POWER LEVE[...]

GP Series Portable Chillers Chapter 7: Appendix 52 of 73 GPWC-105 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 33.64 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR POWER 25508 WATTS CONDENSER INLET W ATER TEMP 85 °F EER 15.83 BTU/WATT COOLANT WATER CON DENSER WATER FLOW 101 GPM COOLANT FLOW 80 GPM SOUND POWER LEV[...]

GP Series Portable Chillers Chapter 7: Appendix 53 of 73 GPWC-175 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 54.46 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEM PERATURE 50 °F COMPRESSOR POWER 41633 WATTS CONDENSER INLET W ATER TEMP 85 °F EER 15.70 BTU/WATT COOLANT WATER CON DENSER WATER FLOW 163 GPM COOLANT FLOW 130 GPM SOUND POWE R L[...]

GP Series Portable Chillers Chapter 7: Appendix 54 of 73 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves A C S CH IL L E R PU M PS 5-15 A LL 60 Hz H P G P 20 GP 30 GP 4 0 GP 50 1.5 C D U 7 0/3 15D 3G ST D 2 C DU 7 0/5 20D 3G ST D S T D 3 C DU 1 20/ 530D 3 G O PT OPT O PT ST D 3O P T 5 2C D U 200 /506 O PT OP T O PT OP T 10 3[...]

GP Series Portable Chillers Chapter 7: Appendix 55 of 73 ACS CH ILLER PUMPS 70-210 ALL 60 Hz HP GP70 GP90 GP 105 GP 140 GP175 GP210 5S T D S T D S T D 5 OPT OPT OPT STD STD 5S T D 5O P T 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 [...]

GP Series Portable Chillers Chapter 7: Appendix 56 of 73 50 Hertz Pump Curves ACS CHI LL E R P UM P S 5-15 A LL 50 Hz H P GP 2 0 GP 30 GP 4 0 G P 5 0 1 . 5 CDU 70 / 3 1 5 D3 G STD 2 CDU 70 / 52 0 D3 G S TD S T D 3 C D U 1 20/ 530D 3 G O P T OPT O PT ST D 3O P T 5 2 CDU 2 0 0 /5 0 6 O PT O P T O P T OPT 10 3U 3 2- 200 - 11 00D 3G OPT OP T 2C D U 70/[...]

GP Series Portable Chillers Chapter 7: Appendix 57 of 73 ACS CHI LL ER P UMP S 20-50 A LL 50 Hz HP GP 20 GP 30 GP 40 GP 50 1.5 CDU 70/315D3G STD 2 CDU 70/520D3G OPT STD S TD 3 CDU 120/530D3G OPT OPT STD 3O P T 5 2CDU 200/5 06 OPT OPT O PT OPT 10 3U 32-20 0-1100D3G O PT OPT 2CD U 70/306 Mod el September 8, 20 09 2 HP CDU 70/520 D3G 1.5 HP CDU 70/315[...]

GP Series Portable Chillers Chapter 7: Appendix 58 of 73 Pure Water at >40°F GPXC-20 GPXC-30 GPXC-40 GPXC-50 GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) 0.5X Nominal 6 1.7 9 1.7 12 1.6 18 1.8 1.0X Nominal 12 5.9 18 6.1 24 5.8 36 6.4 2.0X Nominal 24 21.4 36 21.9 48 20.7 72 23.3 GPXC-70 GPXC-90 GPXC-140 GPXC-175 0.5X Nominal 24 1.7 30 1.8[...]

GP Series Portable Chillers Chapter 7: Appendix 59 of 73 7-5 Remote Air-Cooled Chiller Configurations[...]

GP Series Portable Chillers Chapter 7: Appendix 60 of 73 7-6 Typical Ductwork for Air-Cooled Chillers Fan 60 Hz Discharge air volume 50 Hz Discharge air volume Model HP kW CFM m 3 /min CFM m 3 /min GPAC-20 0.5 0.4 4230 120 3525 100 GPAC-30 1.0 0.7 6343 180 5286 150 GPAC-40 1.0 0.7 8458 240 7048 200 GPAC-50 2.0 1.5 12687 360 10573 300 GPAC-70 (2) 1.[...]

GP Series Portable Chillers Chapter 7: Appendix 61 of 73 chiller • Back draft damper to outside must be closed at all times when fan/blower is not operating • Chillers with dual fans/blower must have a back dr aft damper on the cycling fan/blower to prevent recirculation of hot discharge air • Chillers are designed to operate at a condensing [...]

GP Series Portable Chillers Chapter 7: Appendix 62 of 73 7-7 Piping Diagrams[...]

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