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GP Series
Portable Chillers
Part Number: 882.93092.00
Bulletin Number: SC2-620
Effective: 5/1/2009
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 dimensions described in
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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 Responsibility ..........................
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4-1 Panel Buttons, Indicator Lights, and Switches ..........................................................22 Microprocessor Controller ...................................................................................22 4-2 Initial Start-up ............................................................................................................23 4-3 Status Screens..........................................................................................................25 4-4 Access Lev
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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: Follow all SAFETY CODES. Wear SAFETY GLASSES and WORK GLOVES. Disconnect and/or lock out power before servicing or maintaining the
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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 compressor horsepower (5,7 1/2, 10, 13 and 15 etc) and the cooling m
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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 Featu
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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 • 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
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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 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. Low Pressure Cutout (no switch but done through the transducer) This electro-mechanical cutout
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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. High-pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork. They can be retrofitted without sheet metal modification, but will require changing out fan blades, and in
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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 GP Series Portable Chillers Chapter 2: Functional Description 12 of 44
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Chapter 3: Installation 3-1 Uncrating All models are 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 p
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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. All external chilled water connections should be run full size to the process. Flow and pressure information is available in the Append
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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. Make
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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. Reversing rot
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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. During startup and when additional solution is required, refer to the ethylene glycol and propylene glycol curves in Figure 6 on page 20 Add a pre-mixed solution of industrial quality (not automotive) ethylene glycol or propylene g
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Figure 2: Ethylene Glycol and Propylene Glycol Curves Pe rce nt Glyc ol Cu rves for Free ze Protec tion 40.0 30.0 Eth ylene G lycol 20.0 Propylene Glycol 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. GP Series Portable Chillers Chapter 3: Installation 18 of 44
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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. Caution! Adding straight city water into a glycol/water mixture dilutes the solution a
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Operator Password. If you define a password for operators, 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, 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. The password will be require
