Summary of the content on the page No. 1
GP Series Portable Chillers
Part Number: 882.93092.00
Bulletin Number: SC2-620.2
Effective: 1/12/2010
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 t
Summary of the content on the page No. 2
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
Summary of the content on the page No. 3
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 ..........................
Summary of the content on the page No. 4
4-1 Panel Buttons, Indicator Lights, and Switches ..........................................................29 Microprocessor Controller ...................................................................................29 4-2 Initial Start-up ............................................................................................................30 4-3 Status Screens..........................................................................................................31 4-4 Access Lev
Summary of the content on the page No. 5
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
Summary of the content on the page No. 6
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
Summary of the content on the page No. 7
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, etc) and the cooling method
Summary of the content on the page No. 8
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
Summary of the content on the page No. 9
• 208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt 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 Co
Summary of the content on the page No. 10
Caution! Energize the crankcase heater for at least 24 hours before initial startup to drive dissolved refrigerant from the compressor oil. Failure to do so will damage the compressor. 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 cabin
Summary of the content on the page No. 11
Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank. This option includes a 50 micron filter, flow meter, ball valve for throttling water flow, and the necessary piping to provide constant filtering of the process water at about one gallon per minute (1 gpm/3.8lpm). 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 interl
Summary of the content on the page No. 12
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 7.5 10.3 10 12.0 15 20.0 30 32.0 GP Series Portable Chillers Chapter 2: Functional Description 12 of 73
Summary of the content on the page No. 13
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
Summary of the content on the page No. 14
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
Summary of the content on the page No. 15
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 will 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. Ma
Summary of the content on the page No. 16
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 should be type “L” or type “K” refrigerant grade copper tubing only. Proper sizing and installation has a significant effect on system performance, reliability, and safety. Interconnecting Refrigerant Piping. The chiller and condenser refrigerant lines are terminated with a cap and brazed closed. Use a tube
Summary of the content on the page No. 17
room. Install a liquid line-charging valve to facilitate refrigerant charging. See Figure 3 on page 18 for sizing information. See Figure 5 on page 22 for charge determination. Discharge Line Sizing. For horizontal runs, the discharge line should be pitched downward, in the direction of flow, at a rate of 1/2” for every 10 feet. This will allow oil to flow towards the condenser. Discharge line sizing is based on the velocity required for sufficient oil return back to the compressor. See GP
Summary of the content on the page No. 18
Figure 4 on page 21 for discharge line sizing. Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size Angle Short Long OD (inches) Valve Radius EL Radius EL 3/8 24 4 2.8 1/2 24 4.7 3.2 5/8 25 5.7 3.9 3/4 25 6.5 4.5 7/8 28 7.8 5.3 1-1/8 29 2.7 1.9 1-3/8 33 3.2 2.2 1-5/8 34 3.8 2.6 2-1/8 39 5.2 3.4 2-5/8 44 6.5 4.2 Figure 3: Liquid Line Sizing 5 TON CIRCUIT 7.5 TON CIRCUIT Liquid Line Size (OD") Liquid Line Size (OD") Horizontal Horizontal Total Equiv.
Summary of the content on the page No. 19
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/
Summary of the content on the page No. 20
30 TON CIRCUIT 40 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) Downflow 1-5 Ft 6-10 Ft 11-15 Ft Length (Ft) Downflow 1-5 Ft 6-10 Ft 11-15 Ft 25 1-1/8 1-1/8 1-1/8 1-1/8 25 1-1/8 1-1/8 1-1/8 1-1/8 50 1-1/8 1-1/8 1-1/8 1-1/8 50 1-1/8 1-1/8 1-1/8 1-1/8 75 1-1/8 1-1/8 1-1/8 1-1/8 75 1-1/8 1-1/8 1-1/8 1-1/8 100 1-1/8 1-1/8 1-1/8 1-1/8 100 1-1/8 1-1/8
