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Sterling GP Series manual

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Table of contents for the manual

  • Page 1

    GP Series Portable Chillers Part Number: 882.93092.0 0 Bulletin Number: SC2-620 Effective: 5/1/2009 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing pro[...]

  • 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 4-1 Panel Buttons, Indicator Lights, and Switches .......................................................... 22 Microprocessor Controller ................................................................................... 22 4-2 Initial Start-up .........................................................................[...]

  • Page 5

    GP Series Portable Chillers Chapter 1: Safety 5 of 44 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 44 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 44 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 44 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 44 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 44 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 44 interlock. The alarm signals anytime that a fa ult is recognized during the o peration of the chiller. Communications Options. RS-485 serial Modbus communications. High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan discharge. High-pressure[...]

  • Page 12

    GP Series Portable Chillers Chapter 2: Functional Description 12 of 44 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 44 Chapter 3: Inst allation 3-1 Uncrating All models are are shipped mounted on a skid, en closed 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 sid[...]

  • Page 14

    GP Series Portable Chillers Chapter 3: Installation 14 of 44 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 44 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 44 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 17

    GP Series Portable Chillers Chapter 3: Installation 17 of 44 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 18

    GP Series Portable Chillers Chapter 3: Installation 18 of 44 Figure 2: 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 19

    GP Series Portable Chillers Chapter 3: Installation 19 of 44 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 20

    GP Series Portable Chillers Chapter 3: Installation 20 of 44 Operator Password. If you define a password for ope rators, then a password will be required to carry out any fuction (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 21

    GP Series Portable Chillers Chapter 3: Installation 21 of 44 6. Press to acce pt the Password and m ove 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 [...]

  • Page 22

    GP Series Portable Chillers Chapter 4: Operation 22 of 44 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 23

    GP Series Portable Chillers Chapter 4: Operation 23 of 44 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 4 - Main Statu[...]

  • Page 24

    GP Series Portable Chillers Chapter 4: Operation 24 of 44 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 6 - Op[...]

  • Page 25

    GP Series Portable Chillers Chapter 4: Operation 25 of 44 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 26

    GP Series Portable Chillers Chapter 4: Operation 26 of 44 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[...]

  • Page 27

    GP Series Portable Chillers Chapter 4: Operation 27 of 44 Warning, and Hi Temp Fault setpoints. Supervis or access allows the supervisor to modify the above plus Selecting any of the menus in the Menu Screen will display the Password Screen.[...]

  • Page 28

    GP Series Portable Chillers Chapter 4: Operation 28 of 44 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 29

    GP Series Portable Chillers Chapter 4: Operation 29 of 44 1. Set the Leaving Fluid temperature by depressing the button to display the menu. Figure 8 - 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 30

    GP Series Portable Chillers Chapter 4: Operation 30 of 44 the to accept the password. The following screen will appear. Figure 9 - 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 Te[...]

  • Page 31

    GP Series Portable Chillers Chapter 4: Operation 31 of 44[...]

  • Page 32

    GP Series Portable Chillers Chapter 5: Maintenance 32 of 44 Chapter 5: Maintenance 5-1 Lubrication Grease all blower bearings, fan and blower m otors, and pump motors that do not have permanently sealed bearings. Be sure to use an all-purpose industrial grease with a temperature reference of 185 ˚ F (85 ˚ C). Remove the grease relief plug (motors[...]

  • Page 33

    GP Series Portable Chillers Chapter 5: Maintenance 33 of 44 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 34

    GP Series Portable Chillers Chapter 6: Troubleshooting 34 of 44 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 or minus 10% of nameplat e rating. Defective on/off switch. Replace. Replace control circuit[...]

  • Page 35

    GP Series Portable Chillers Chapter 6: Troubleshooting 35 of 44 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 pressure low (refer to c urves for norm al pressure for vario us pumps). Check for foreign matter. Clea[...]

  • Page 36

    GP Series Portable Chillers Chapter 7: Appendix 36 of 44 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 RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned Material purchase[...]

  • Page 37

    GP Series Portable Chillers Chapter 7: Appendix 37 of 44 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 38

    GP Series Portable Chillers Chapter 7: Appendix 38 of 44 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 39

    GP Series Portable Chillers Chapter 7: Appendix 39 of 44 G-PAC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 10.11 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 9944 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 12.21 BTU/WATT COOLANT WATER CONDENSER AIR FLOW 8458 CFM COOLANT FLOW 24 GPM SOUND POWER LEVEL 87 dB[...]

  • Page 40

    GP Series Portable Chillers Chapter 7: Appendix 40 of 44 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 41

    GP Series Portable Chillers Chapter 7: Appendix 41 of 44 COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POW ER 8323 WATTS CONDENSER INLET WATER TEMPERATURE 85 °F EER 16.31 BTU/WATT COOLANT WATER CONDENSER WATER FLOW 33.93 GPM COOLANT FLOW 27 GPM SOUND POWER LEVEL dBA UNIT PRESSURE DROP 7 PSI D SOUND PRESSURE LEVEL @ 1 METER dBA OPERATING PARAMETERS [...]

  • Page 42

    GP Series Portable Chillers Chapter 7: Appendix 42 of 44 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves 1 H P C D X 70/106 1.5 H P C D X 70/156 3 H P 2C D X 120/306 5 H P 2C D X 200/506 2 H P C D X 120/206 3U 32- 200-1- 10H P 2C D X 120/206 2C D X 120/406 3U 32- 200- 1-7.5H P des i gn 1 des i gn 2 des i gn 3 des i gn 4 0 50[...]

  • Page 43

    GP Series Portable Chillers Chapter 7: Appendix 43 of 44 Calculating Chiller Nominal Flow and Pressure to Process • Flow rate: Obtain the flow reading from the appropriate pum p curve. • Pressure: Obtain a corresponding pressure read ing from the pump curve you selected, then subtract the one-pump pressure drop listed in the above table using t[...]

  • Page 44

    GP Series Portable Chillers Chapter 7: Appendix 44 of 44 7-5 Electrical Schematic Please refer to your owner’s information packet for more details regarding your specific unit .[...]