GP Series Portable Chillers Part Number: 882.93092.00 Bulletin Number: SC2-620.1 Effective: 9/18/2009 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. ECN No.
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.
Table of Contents CHAPTER 1: SAFETY................................................................ 5 1-1 1-2 1-3 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .....................................................................5 Warnings and Precautions .......................................................................................... 6 Responsibility .......................................
CHAPTER 4: OPERATION....................................................... 26 4-1 4-2 4-3 4-4 4-5 4-6 4-7 Panel Buttons, Indicator Lights, and Switches .......................................................... 26 Microprocessor Controller ...................................................................................26 Initial Start-up ............................................................................................................ 27 Status Screens ........................................
Chapter 1: 1-1 Safety 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.
1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: 9 Follow all SAFETY CODES. 9 Wear SAFETY GLASSES and WORK GLOVES. 9 Disconnect and/or lock out power before servicing or maintaining the equipment.
Chapter 2: 2-1 Functional Description 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.
The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser. There it gives up its heat as it condenses to a liquid in the condenser. An electronic hot gas bypass valve is used to control cooling capacity during intermittent or partial load conditions. This feature contributes substantially to chiller longevity by eliminating excessive cycling of the compressor and providing close temperature control. 2-3 Standard Features Mechanical Features Compressor.
Refrigeration Features • HFC-410a refrigerant • Electronic hot gas bypass capacity control • High refrigerant pressure cutout switches • Suction and discharge pressure transducers.
High Pressure Cutout This electro-mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 575 psi.. Note: The high-pressure cutout is a manual reset device typically mounted on the compressor discharge line inside the mechanical cabinet. Call a refrigeration service technician to analyze the problem and reset the control.
General Fault Indicator Audible/Visual Alarm*. This option includes a 100 dB audible alarm horn/ visual alarm strobe and silence button with provisions for customer wiring indication interlock. The alarm signals anytime that a fault is recognized during the operation of the chiller. Communications Options. RS-485 serial Modbus communications. High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan discharge.
Figure 1: Optional Pump Amperages Voltage Construction HP 460/3/60 SS 1 1.7 1.5 2.3 2 4.0 3 4.2 5 8.2 10 12.
Chapter 3: 3-1 Installation 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.
3-3 Process Water Connections All of our portable chillers have two chilled water connections. The chilled water supply, labeled “To Process” is the outlet for the chilled water leading to the process being cooled. The chilled water return, labeled “From Process” is the inlet leading from the process back into the chiller to be cooled and re-circulated. All external chilled water connections should be run full size to the process. Flow and pressure information is available in the Appendix.
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’ll make two connections to the water-cooled condenser: Condenser Water In. The condenser water supply, labeled “Condenser Water In”, is located at the rear of the chiller. It is the inlet for city or tower water.
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.
leaving water temperature range is also required. 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 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.
10 TON CIRCUIT 15 TON CIRCUIT Liquid Line Size (OD") Total Equiv. Length (Ft) 25 50 75 100 125 150 175 200 225 250 275 300 Liquid Line Size (OD") Horizontal or Downflow Upflow 1-5 Ft Upflow 6-10 Ft Upflow 11-15 Ft 5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8 7/8 7/8 7/8 3/4 3/4 3/4 3/4 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 Total Equiv.
Refrigerant Charge Determination. The approximate amount of refrigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the chiller and the amount of charge based on discharge and liquid line sizes and lengths. Add these three numbers together to find the final operating charge.
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.
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 freezing.
Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe rce n t G lyc o l Cu rves fo r F ree ze P ro tec tion 40.0 30.0 Eth ylene G lycol 20.0 P rop ylene G lyc ol 10.0 0.0 -10.0 -20.0 -30.0 -40.0 -50.0 -60.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 % Gl ycol by Vol um e Example: 45°F set point minus 20°F = 25°F. From Figure 28, 25°F equates to 10% by volume of glycol required.
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. 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.
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. Supervisor Password. If you define a password for supervisors (or setup personnel) then most settings can be changed only after entering the password.
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 or to increment or decrement the time. The PW Time value highlighted, press password time for either setup can be from 0 to 99 minutes.
Chapter 4: 4-1 Operation Panel Buttons, Indicator Lights, and Switches Microprocessor Controller The standard chillers use a microprocessor-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 housing. It 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).
4-2 Initial Start-up 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 8 - Main Status Screen 3. Set the Leaving Fluid temperature by depressing the the menu. button to display Figure 9 - Menu Screen or button to highlight SETPOINTS and press . If 4.
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 numbers have been entered depress the appear. to accept the password. The following screen will Figure 10 - Operator Setpoints Screen to move the cursor to the Leaving Temp line. Use the 5. Depress button to increment or decrement the value. Depress value and move the cursor down one line. 6.
Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of operation, 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 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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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 Leaving Temp Description Temperature of fluid out to process Low Temperature Warning Setpoint for alarm to warn when leaving fluid temperature is too high Setpoint to shut down pump and compressor based on leaving fluid temperature 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 Delay time in seconds between fault and stopping
1. Set the Leaving Fluid temperature by depressing the the menu. button to display 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 the Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number.
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 button to increment or decrement the value. Depress value and move the cursor down one line. or to accept the 4. Adjust the Hi Temp Warning and Hi Temp Fault in the same manner. 5. Depress the 4-6 button twice to return to the main status screen.
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Chapter 5: 5-1 Maintenance 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 185˚ F (85˚ 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.
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.
Chapter 6: Problem Troubleshooting Possible cause No power. Wrong voltage supplied to unit. Defective display. Unit does not run. Control circuit fuse blown. Defective control transformer. Piping flow switch circuit open. Pump motor off on overload. Leaving fluid setpoint set higher than temperature of liquid in system. Compressor internal overload or fuses are open. Pump runs; compressor does not. Compressor contactor holding coil open. Defective compressor auxiliary contact.
Problem Pump process pressure low (refer to curves for normal pressure for various pumps). Possible cause Pump running in reverse. Check for foreign matter. Pump process pressure is too high. Restricted water flow. Restricted condenser air flow. Unit runs continuously, but not enough cooling power. Unit low on refrigerant. Compressor not operating efficiently. Unit under-sized for application.
Chapter 7: 7-1 Appendix 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.
7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653 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.
7-3 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. G-PAC-20 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 4.
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.
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. G-PWC-20 PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ) COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMPERATURE COOLANT COOLANT FLOW UNIT PRESSURE DROP 5.
G-PWC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMPERATURE COOLANT COOLANT FLOW UNIT PRESSURE DROP 10.94 50 TONS °F 85 °F WATER 27 GPM 7 PSID ALTITUDE COMPRESSOR POWER 8450 SEA LEVEL WATTS EER 15.53 BTU/WATT CONDENSER WATER FLOW SOUND POWER LEVEL SOUND PRESSURE LEVEL @ 1 METER 33.
7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves 5-15 ALL 60 Hz ACS CHILLER PUMPS September 8, 2009 300 120 250 100 10 HP 3U 32-200-1100D3G 200 80 3 HP 2CDU 70/306 150 Psi Head [ft] 5 HP 2CDU 200/506 60 2 HP CDU 70/520D3G 3 HP CDU120/530D3G 100 40 1.5 HP CDU 70/315D3G 50 20 0 0 0 10 20 30 40 50 60 70 80 Capacity [Gal/min] HP 1.
50 Hertz Pump Curves 5-15 ALL 50 Hz ACS CHILLER PUMPS September 8, 2009 70 6 60 10 HP 3U 32-200-1100D3G 5 50 4 40 Bar Head [m] 5 HP 2CDU 200/506 3 HP 2CDU 70/306 3 30 3 HP CDU120/530D3G 2 HP CDU 70/520D3G 2 20 1.5 HP CDU 70/315D3G 1 10 0 0 0 50 100 150 200 250 300 Capacity [liter/min] HP 1.
Pure Water at >40°F GPXC-20 GPM DP (PSI) 0.5X Nominal 6 1.0X Nominal 12 2.0X Nominal 24 GPXC-30 GPXC-40 GPXC-50 GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) 1.7 9 1.7 12 1.6 18 1.8 5.9 18 6.1 24 5.8 36 6.4 21.4 36 21.9 48 20.7 72 23.3 Calculating Chiller Nominal Flow and Pressure to Process • Flow rate: Obtain the flow reading from the appropriate pump curve.
7-5 Remote Air-Cooled Chiller Configurations GP Series Portable Chillers Chapter 7: Appendix 49 of 64
7-6 Typical Ductwork for Air-Cooled Chillers Fan Model GPAC-20 GPAC-30 GPAC-40 GPAC-50 HP 0.5 1.0 1.0 2.0 kW 0.4 0.7 0.7 1.
Chillers with dual fans/blower must have a back draft damper on the cycling fan/blower to prevent recirculation of hot discharge air • Chillers are designed to operate at a condensing entering air temperature of 60ºF (16ºC) minimum without optional Variable Frequency Drive • Maximum total static pressure drop external to the chiller must not exceed 0.
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7-8 Piping Diagrams GP Series Portable Chillers Chapter 7: Appendix 53 of 64
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