Sterling 882.93092.00 - Manuals

Page 2 - Shipping Information; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact the parts and service department; Hold the items until you receive shipping instructions

GP Series Portable Chillers ii 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 s...

Page 3 - Table of Contents

GP Series Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual ..........

Page 5 - GP Series Portable Chillers; -1 How to Use This Manual; Safety Symbols Used in this Manual

GP Series Portable Chillers Chapter 1: Safety 5 of 73 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 producti...

Page 6 - -2 Warnings and Precautions

GP Series Portable Chillers Chapter 1: Safety 6 of 73 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 dama...

Page 7 - Chapter 2: Functional Description; -1 Models Covered in This Manual; Chilled Water Circuit

GP Series Portable Chillers Chapter 2: Functional Description 7 of 73 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 th...

Page 8 - Features; Mechanical Features; Other Mechanical Features; Electrical Features

GP Series Portable Chillers Chapter 2: Functional Description 8 of 73 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...

Page 9 - Devices and Interlocks; Crankcase Heater

GP Series Portable Chillers Chapter 2: Functional Description 9 of 73 • 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 transdu...

Page 10 - Options marked with “

GP Series Portable Chillers Chapter 2: Functional Description 10 of 73 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...

Page 12 - Figure 1: Optional Pump Amperages

GP Series Portable Chillers Chapter 2: Functional Description 12 of 73 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

Page 13 - Chapter 3: Installation; Pry the crating away from the skid.; Connections

GP Series Portable Chillers Chapter 3: Installation 13 of 73 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...

Page 15 - Considerations; Water-Cooled Chiller Condensers; Condenser Water Out.; Air-Cooled Chiller Condensers; Condensing Air Temperature.; Remote Air-Cooled Chiller Condensers

GP Series Portable Chillers Chapter 3: Installation 15 of 73 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 fr...

Page 16 - Interconnecting Refrigerant Piping.; The chiller and condenser refrigerant lines are; System Configuration.; The system can be configured in any of the arrangements shown on; Sizing Refrigerant Lines.

GP Series Portable Chillers Chapter 3: Installation 16 of 73 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 copp...

Page 18 - Figure 2: Equivalent Length in Feet for Valves and Fittings

GP Series Portable Chillers Chapter 3: Installation 18 of 73 Figure 4 on page 21 for discharge line sizing. Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size OD (inches) Angle Valve Short Radius EL Long 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....

Page 21 - Figure 4: Discharge Line Sizing

GP Series Portable Chillers Chapter 3: Installation 21 of 73 Figure 4: Discharge Line Sizing Horizontal or Downflow Discharge Line Sizes (OD") Total Equivalent Length (Ft) Circuit Tons 25 50 75 100 125 150 175 200 225 250 275 300 5 5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8 7.5 7/8 7/8 7/8 ...

Page 22 - Refrigerant Charge Determination.; The approximate amount of refrigerant charge required; Figure 5: Refrigerant Charge Determination; Oil Charge Determination.; The remote air-cooled portable chillers are factory charged with

GP Series Portable Chillers Chapter 3: Installation 22 of 73 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 cha...

Page 23 - -8 Checking Motor Direction; Do not switch leads at the motors, motor starters, or contactors.

GP Series Portable Chillers Chapter 3: Installation 23 of 73 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 t...

Page 24 - Reservoir; oC) or contact the service; Part Number

GP Series Portable Chillers Chapter 3: Installation 24 of 73 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 retaini...

Page 25 - Figure 6: Ethylene Glycol and Propylene Glycol Curves

GP Series Portable Chillers Chapter 3: Installation 25 of 73 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G lyc o l Cu rves fo r F ree z e P r o tec t ion -60.0 -50.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 % Gl y col b y V ol um e Eth y...

Page 26 - -12 Finishing Setup: Setting Up Passwords

GP Series Portable Chillers Chapter 3: Installation 26 of 73 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-...

Page 29 - Chapter 4: Operation; Microprocessor Controller; Figure 7 - Controller Display

GP Series Portable Chillers Chapter 4: Operation 29 of 73 Chapter 4: Operation 4-1 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-...

Page 31 - Figure 10 - Operator Setpoints Screen; Screens; Figure 11 - Main Status Screen

GP Series Portable Chillers Chapter 4: Operation 31 of 73 appear. Figure 10 - Operator Setpoints Screen 5. Depress to move the cursor to the Leaving Temp line. Use the or button to increment or decrement the value. Depress to accept the value and move the cursor down one line. 6. Depress the button ...

Page 33 - Levels

GP Series Portable Chillers Chapter 4: Operation 33 of 73 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. Su...

Page 34 - Setpoints; Set the Leaving Fluid temperature by depressing the; Figure 12 - Menu Screen

GP Series Portable Chillers Chapter 4: Operation 34 of 73 4-5 Controller Setpoints Access Level Variable Description Operator Supervisor Leaving Temp Temperature of fluid out to process x x Hi Temp Warning Setpoint for alarm to warn when leaving fluid temperature is too high x x Hi Temp Fault Setpoi...

Page 35 - Figure 13 - Operator Setpoints Screen; Communications

GP Series Portable Chillers Chapter 4: Operation 35 of 73 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 posi...

Page 38 - Chapter 5: Maintenance; Cleaning; Water-Cooled Chillers; Coaxial Condensers

GP Series Portable Chillers Chapter 5: Maintenance 38 of 73 Chapter 5: Maintenance 5-1 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 ...

Page 40 - Chapter 6: Troubleshooting

GP Series Portable Chillers Chapter 6: Troubleshooting 40 of 73 Chapter 6: Troubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage must be within plus or minus 10% of nameplate rating. Defective d...

Page 42 - Chapter 7: Appendix; -1 Returned Material Policy; Credit Returns; Warranty Returns

GP Series Portable Chillers Chapter 7: Appendix 42 of 73 Chapter 7: Appendix 7-1 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 re...

Page 43 - Assistance; Parts Department

GP Series Portable Chillers Chapter 7: Appendix 43 of 73 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 ...

Page 58 - Calculating Chiller Nominal Flow and Pressure to Process; Obtain the flow reading from the appropriate pump curve.; subtract; the one-pump pressure drop listed in the above table using the

GP Series Portable Chillers Chapter 7: Appendix 58 of 73 Pure Water at >40°F GPXC-20 GPXC-30 GPXC-40 GPXC-50 GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) 0.5X Nominal 6 1.7 9 1.7 12 1.6 18 1.8 1.0X Nominal 12 5.9 18 6.1 24 5.8 36 6.4 2.0X Nominal 24 21.4 36 21.9 48 20.7 72 23.3 GPXC-70 GPX...

Page 59 - -5 Remote Air-Cooled Chiller Configurations

GP Series Portable Chillers Chapter 7: Appendix 59 of 73 7-5 Remote Air-Cooled Chiller Configurations

Page 60 - -6 Typical Ductwork for Air-Cooled Chillers; Customer use of ductwork requires the high pressure fan option.

GP Series Portable Chillers Chapter 7: Appendix 60 of 73 7-6 Typical Ductwork for Air-Cooled Chillers Fan 60 Hz Discharge air volume 50 Hz Discharge air volume Model HP kW CFM m 3 /min CFM m 3 /min GPAC-20 0.5 0.4 4230 120 3525 100 GPAC-30 1.0 0.7 6343 180 5286 150 GPAC-40 1.0 0.7 8458 240 7048 200 ...

Page 62 - Diagrams

GP Series Portable Chillers Chapter 7: Appendix 62 of 73 7-7 Piping Diagrams