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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:
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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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CHAPTER 4: OPERATION....................................................... 26 4-1 Panel Buttons, Indicator Lights, and Switches ..........................................................26 Microprocessor Controller ...................................................................................26 4-2 Initial Start-up ............................................................................................................27 4-3 Status Screens..........................................
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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) There are two pressure transduc
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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. High-pressure fans are necessary and must be incl
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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 64
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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. 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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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: Piping
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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 r
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10 TON CIRCUIT 15 TON CIRCUIT Liquid Line Size (OD") Liquid Line Size (OD") Horizontal Horizontal Total Equiv. Total Equiv. or Upflow Upflow Upflow or Upflow Upflow Upflow Length (Ft) Length (Ft) Downflow 1-5 Ft 6-10 Ft 11-15 Ft Downflow 1-5 Ft 6-10 Ft 11-15 Ft 25 5/8 5/8 5/8 3/4 25 7/8 7/8 7/8 7/8 50 5/8 5/8 3/4 3/4 50 7/8 7/8 7/8 7/8 75 5/8 5/8 3/4 3/4 75 7/8 7/8 7/8 7/8 100 5/8 3/4 3/4 3/4 100 7/8 7/8 7/8 7/8 125 3/4 3/4 3/4 7/8 125 7/8 7/8 7/8 7/8 150 3/4 3/4 3/
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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. The final operating charge must be verified by running the syste
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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
