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Sterling 882.93092.00 manual

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Table of contents for the manual

  • Page 1

    GP Series Portable Chillers Part Number: 882.9309 2 .0 0 Bulletin Number: SC2-620.1 Effective: 9/18/200 9 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continui[...]

  • Page 2

    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[...]

  • Page 3

    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 .........................................................[...]

  • Page 4

    GP Series Portable Chillers iv CHAPTER 4: OPERATION....................................................... 26 4-1 Panel Buttons, Indicator Lights, and Switches .......................................................... 26 Microprocessor Controller ................................................................................... 26 4-2 Initial Sta[...]

  • Page 5

    GP Series Portable Chillers Chapter 1: Safety 5 of 64 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[...]

  • Page 6

    GP Series Portable Chillers Chapter 1: Safety 6 of 64 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equi pm ent damage when installing, operating, or maintaining th[...]

  • Page 7

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

  • Page 8

    GP Series Portable Chillers Chapter 2: Functional Description 8 of 64 The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser. There it gives up its heat as it condenses to a liquid in the condenser. An electronic hot gas bypass valve is used to control cooling capacity duri ng interm ittent or[...]

  • Page 9

    GP Series Portable Chillers Chapter 2: Functional Description 9 of 64 Refrigeration Features • HFC-410a refrigerant • Electronic hot gas bypass capacity control • High refrigerant pressure cutout switches • Suction and discharge pressure transducers. • High pressure spring actuated relief valve • Multiple refrigeration access ports • [...]

  • Page 10

    GP Series Portable Chillers Chapter 2: Functional Description 10 of 64 High Pressure Cutout This electro-mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 575 psi.. Note: The high-pressure cutout is a manual reset device typically mounted on the compressor discharge line [...]

  • Page 11

    GP Series Portable Chillers Chapter 2: Functional Description 11 of 64 General Fault Indicator Audible/Visual Alarm*. This option includes a 100 dB audible alarm horn/ visual alarm strobe and silence button with provisions for customer wiring indication interlock. The alarm signals an ytime that a fault is recognized during the operation of the chi[...]

  • Page 12

    GP Series Portable Chillers Chapter 2: Functional Description 12 of 64 Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps 460/3/60 SS 1 1.7 1.5 2.3 2 4.0 3 4.2 5 8.2 10 12.0[...]

  • Page 13

    GP Series Portable Chillers Chapter 3: Installation 13 of 64 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, [...]

  • Page 14

    GP Series Portable Chillers Chapter 3: Installation 14 of 64 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[...]

  • Page 15

    GP Series Portable Chillers Chapter 3: Installation 15 of 64 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’ll make tw[...]

  • Page 16

    GP Series Portable Chillers Chapter 3: Installation 16 of 64 Remote Air-Cooled Chiller Condensers Remote air-cooled portable chillers are shipped with nitrogen holding charge and a full charge of oil (excluding the am ount needed for field piping). The remote air condenser is shipped with a dry nitrogen charge. Verify that the holding charge has no[...]

  • Page 17

    GP Series Portable Chillers Chapter 3: Installation 17 of 64 leaving water temperature range is also requi red. See Figure 2 on page 17 for lengths of refrigerant valves and fittings. Liquid Line Sizing. The liquid line should be sized as small as possible while maintaining acceptable pressure drop to minimize the refrigerant charge. Liquid line ri[...]

  • Page 18

    GP Series Portable Chillers Chapter 3: Installation 18 of 64 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/[...]

  • Page 19

    GP Series Portable Chillers Chapter 3: Installation 19 of 64 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[...]

  • Page 20

    GP Series Portable Chillers Chapter 3: Installation 20 of 64 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[...]

  • Page 21

    GP Series Portable Chillers Chapter 3: Installation 21 of 64 3-9 Water Reservoir All portable chillers shipped during the fall, winter , or spring, or those units that are shipped from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping components prone to retaining water from fr eezing. During startup and when [...]

  • Page 22

    GP Series Portable Chillers Chapter 3: Installation 22 of 64 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[...]

  • Page 23

    GP Series Portable Chillers Chapter 3: Installation 23 of 64 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,[...]

  • Page 24

    GP Series Portable Chillers Chapter 3: Installation 24 of 64 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[...]

  • Page 25

    GP Series Portable Chillers Chapter 3: Installation 25 of 64 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[...]

  • Page 26

    GP Series Portable Chillers Chapter 4: Operation 26 of 64 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 [...]

  • Page 27

    GP Series Portable Chillers Chapter 4: Operation 27 of 64 4-2 Initial Start-up 1. Verify the initial start-up checklist from Chapter 3, Section 3-11. 2. With the main supply 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[...]

  • Page 28

    GP Series Portable Chillers Chapter 4: Operation 28 of 64 Enter the established Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number. Once all of the num bers have been entered depress the to accept the password. The following screen will appear. Figure 10 - O[...]

  • Page 29

    GP Series Portable Chillers Chapter 4: Operation 29 of 64 Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of opera tion, the compressor internal protector trips. 4-3 Status Screens The controller has eight (8) preconfigured status screens. The main status screen (shown in Figure 11) shows[...]

  • Page 30

    GP Series Portable Chillers Chapter 4: Operation 30 of 64[...]

  • Page 31

    GP Series Portable Chillers Chapter 4: Operation 31 of 64 4-4 Access Levels The controller is setup to allow access to three distinct password groups: operator, supervisor, and service. Operator access allows the user to modify the Leaving Water Temp, Hi Temp Warning, and Hi Temp Fault setpoints. Supervis or access allows the supervisor to modify t[...]

  • Page 32

    GP Series Portable Chillers Chapter 4: Operation 32 of 64 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[...]

  • Page 33

    GP Series Portable Chillers Chapter 4: Operation 33 of 64 1. Set the Leaving Fluid temperature by depressing the button to display the menu. Figure 12 - Menu Screen 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[...]

  • Page 34

    GP Series Portable Chillers Chapter 4: Operation 34 of 64 the to accept the password. The following screen will appear. Figure 13 - Operator Setpoints Screen 3. 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. 4. Adjust the Hi T[...]

  • Page 35

    GP Series Portable Chillers Chapter 4: Operation 35 of 64[...]

  • Page 36

    GP Series Portable Chillers Chapter 5: Maintenance 36 of 64 Chapter 5: Maintenance 5-1 Lubrication Grease all fan motors, and pump motors that do not have permanently sealed bearings. Be sure to use an all-purpose industrial gr ease with a temperature reference of 185 ˚ F (85 ˚ C). Remove the grease relief plug (motors only) be fore adding grease[...]

  • Page 37

    GP Series Portable Chillers Chapter 5: Maintenance 37 of 64 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[...]

  • Page 38

    GP Series Portable Chillers Chapter 6: Troubleshooting 38 of 64 Chapter 6: T roubleshooting 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 o r minus 10% of nameplat e rating. Defective display. Replace. Replace control circuit fuse[...]

  • Page 39

    GP Series Portable Chillers Chapter 6: Troubleshooting 39 of 64 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 f or various pum ps). Check for fore ign ma[...]

  • Page 40

    GP Series Portable Chillers Chapter 7: Appendix 40 of 64 Chapter 7: Appendix 7-1 Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer . A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned Material purchase[...]

  • Page 41

    GP Series Portable Chillers Chapter 7: Appendix 41 of 64 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [262] 641-8610, Fax [262] 641-865 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[...]

  • Page 42

    GP Series Portable Chillers Chapter 7: Appendix 42 of 64 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[...]

  • Page 43

    GP Series Portable Chillers Chapter 7: Appendix 43 of 64 G-PAC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 9.91 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWE R 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 d[...]

  • Page 44

    GP Series Portable Chillers Chapter 7: Appendix 44 of 64 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[...]

  • Page 45

    GP Series Portable Chillers Chapter 7: Appendix 45 of 64 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[...]

  • Page 46

    GP Series Portable Chillers Chapter 7: Appendix 46 of 64 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 OP T ST D 3O P T 5 2C D U 200 /506 O PT OP T OPT OP T 10 3U[...]

  • Page 47

    GP Series Portable Chillers Chapter 7: Appendix 47 of 64 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 S TD 2 CDU 70 / 52 0 D3 G S TD S T D 3 C D U 1 20/ 530D 3 G O PT O PT O PT ST D 3O P T 5 2 CDU 2 0 0 /5 0 6 O P T O P T O P T O PT 10 3U 3 2- 200 - 11 00D 3G OPT OP T 2C D U [...]

  • Page 48

    GP Series Portable Chillers Chapter 7: Appendix 48 of 64 Pure Water at >40°F GPXC-20 GPXC-30 GPXC-40 GPXC-50 GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) 0.5X Nominal 6 1.7 9 1.7 12 1.6 18 1.8 1.0X Nominal 12 5.9 18 6.1 24 5.8 36 6.4 2.0X Nominal 24 21.4 36 21.9 48 20.7 72 23.3 Calculating Chiller Nominal Flow and Pressure to Process •[...]

  • Page 49

    GP Series Portable Chillers Chapter 7: Appendix 49 of 64 7-5 Remote Air-Cooled Chiller Configurations[...]

  • Page 50

    GP Series Portable Chillers Chapter 7: Appendix 50 of 64 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 When locating [...]

  • Page 51

    GP Series Portable Chillers Chapter 7: Appendix 51 of 64 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 entering ai r temperature of 60ºF (16ºC) m inimum wi thout optional Variable Frequency Drive • Maximum[...]

  • Page 52

    GP Series Portable Chillers Chapter 7: Appendix 52 of 64 7-7[...]

  • Page 53

    GP Series Portable Chillers Chapter 7: Appendix 53 of 64 7-8 Piping Diagrams[...]

  • Page 54

    GP Series Portable Chillers Chapter 7: Appendix 54 of 64[...]

  • Page 55

    GP Series Portable Chillers Chapter 7: Appendix 55 of 64[...]

  • Page 56

    GP Series Portable Chillers Chapter 7: Appendix 56 of 64[...]

  • Page 57

    GP Series Portable Chillers Chapter 7: Appendix 57 of 64[...]

  • Page 58

    GP Series Portable Chillers Chapter 7: Appendix 58 of 64[...]

  • Page 59

    GP Series Portable Chillers Chapter 7: Appendix 59 of 64[...]

  • Page 60

    GP Series Portable Chillers Chapter 7: Appendix 60 of 64[...]

  • Page 61

    GP Series Portable Chillers Chapter 7: Appendix 61 of 64[...]

  • Page 62

    GP Series Portable Chillers Chapter 7: Appendix 62 of 64[...]

  • Page 63

    GP Series Portable Chillers Chapter 7: Appendix 63 of 64[...]

  • Page 64

    GP Series Portable Chillers Chapter 7: Appendix 64 of 64[...]