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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:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and di
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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
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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
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4-4
Access Levels ............................................................................................................ 41
4-5
Controller Setpoints .................................................................................................... 41
4-6
Configuration Settings ................................................................................................ 45
4-7
Alarms ....................................................................
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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 featu
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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: ü Follow all SAFETY CODES. ü Wear SAFETY GLASSES and WORK GLOVES. ü Disconnect and/or lock out power before servicing or maintainin
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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 coolin
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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 applicat
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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 i
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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
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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-and- tube 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 variab
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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 chille
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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. High pressure cutout Typical GPAC-20 Low Pressure Cutout (no switch but done through the t
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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 conne
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Stainless Steel Reservoir. Manufactured from 304 stainless steel. 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 acc
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Chapter 3: Installation 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 b
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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 pr
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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 discourag
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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 r
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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: Pipi
