Sterling 882.93092.01 - Manuals

GP Series Portable Chillers Chapter 1: Safety 6 of 90 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...

GP Series Portable Chillers Chapter 2: Functional Description 7 of 90 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...

GP Series Portable Chillers Chapter 2: Functional Description 8 of 90 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 imper...

GP Series Portable Chillers Chapter 2: Functional Description 10 of 90 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 tempera...

GP Series Portable Chillers Chapter 2: Functional Description 12 of 90 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 micropr...

GP Series Portable Chillers Chapter 2: Functional Description 14 of 90 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 fl...

GP Series Portable Chillers Chapter 2: Functional Description 15 of 90 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...

GP Series Portable Chillers Chapter 3: Installation 16 of 90 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...

GP Series Portable Chillers Chapter 3: Installation 17 of 90 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...

GP Series Portable Chillers Chapter 3: Installation 18 of 90 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 ...

GP Series Portable Chillers Chapter 3: Installation 19 of 90 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 ...

GP Series Portable Chillers Chapter 3: Installation 20 of 90 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 nitro...

GP Series Portable Chillers Chapter 3: Installation 21 of 90 Sizing Refrigerant Lines. To determine field installed liquid and discharge line sizes, first establish the equivalent length of pipe for each line, valve, and elbow. Chiller capacity and leaving water temperature range is also required. S...

GP Series Portable Chillers Chapter 3: Installation 24 of 90 Figure 6: Discharge Line Sizing Model Horizontal or Downflow Discharge Line Sizes (OD") Total Equivalent Length (Ft) 25 50 75 100 125 150 175 200 225 250 275 300 GPRC-20 5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8 GPRC-30 7/8 7/8 7...

GP Series Portable Chillers Chapter 3: Installation 25 of 90 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 7, determine the amount of cha...

GP Series Portable Chillers Chapter 3: Installation 26 of 90 Figure 8: Remote Condenser Configurations

GP Series Portable Chillers Chapter 3: Installation 27 of 90 Figure 9: Double Riser Detail 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 ...

GP Series Portable Chillers Chapter 3: Installation 28 of 90 3-9 Water Reservoir The standard water reservoir is rotationally molded polyethylene with a removable lid. The tank is fully insulated to assist maintaining fluid temperature. All portable chillers shipped during the fall, winter, or sprin...

GP Series Portable Chillers Chapter 3: Installation 29 of 90 Figure 10: Suggested Overhead Piping Configuration

GP Series Portable Chillers Chapter 3: Installation 30 of 90 Figure 11: Ethylene Glycol and Propylene Glycol Curves Percent Glycol Curves for Freeze Protection -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 % Glycol by Volume Ethylene Glycol Propylene G...

GP Series Portable Chillers Chapter 3: Installation 31 of 90 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. Note: When the unit is...

GP Series Portable Chillers Chapter 3: Installation 33 of 90 Warning! Operating the chiller setpoint below 45°F (7°C) without the proper amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances. Th...

GP Series Portable Chillers Chapter 4: Operation 35 of 90 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 is located in the control enclosure. The Carel PGD1 Int...

GP Series Portable Chillers Chapter 4: Operation 36 of 90 Button Button Description Detailed description Menu Button Used to access the menus structure of the PGD interface On/Off Button Used to turn the entire chiller On or Off. The button is backlit and will turn amber when the chiller is On. Back...

GP Series Portable Chillers Chapter 4: Operation 37 of 90 Enter the established Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number. Once all of the numbers have been entered depress the to accept the password...

GP Series Portable Chillers Chapter 4: Operation 38 of 90 Figure 16: Main Chiller Status Screen Depressing cycles through the following screens (shown below) – Analog I/O, Digital I/O, and Test. The Analog and Digital I/O screens provide status of all of the inputs and outputs for the controller. Th...

GP Series Portable Chillers Chapter 4: Operation 41 of 90 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...

GP Series Portable Chillers Chapter 4: Operation 43 of 90 Variable Description Access Level Operator Supervisor Tank Max Lvl Maximum tank level. Used to set the default high tank level alarm setpoints as well as the auto-water makeup off setpoint. x Low Level Fault Tank level that will activate Low ...

GP Series Portable Chillers Chapter 4: Operation 44 of 90 Enter the Operator Password by depressing the to move the position of the cursor, and then depressing the or button to increment or decrement the number. Once all of the numbers have been entered depress the to accept the password. The follow...

GP Series Portable Chillers Chapter 4: Operation 45 of 90 4-6 Configuration Settings Within the Supervisor Menu the chiller can be configured if options are added in the field. These configurations are described below. Variable Description Access Level Operator Supervisor Tank Level Inst Activates/D...

GP Series Portable Chillers Chapter 4: Operation 47 of 90 4-7 Alarms The controller is setup with multiple alarms, most of them configurable using the Supervisor password. Section 4-5 Controller Setpoints on page 41 gives a list of alarms that the controller is setup to display. The alarms are broke...

GP Series Portable Chillers Chapter 5: Maintenance 48 of 90 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 P F (85 P C). Remove the grease ...

GP Series Portable Chillers Chapter 5: Maintenance 49 of 90 Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you are monitoring the refrigeration circuit for excessive pressure with gauges. Only a trained technician should use this method. 5-4 Maintaining the Evaporat...

GP Series Portable Chillers Chapter 6: Troubleshooting 50 of 90 Chapter 6: Troubleshooting Many problems that can occur while operating the chiller can be avoided by following the recommended installation, operation, and maintenance outlined within this manual. If you do have a problem this Chapter ...

GP Series Portable Chillers Chapter 7: Appendix 58 of 90 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...

GP Series Portable Chillers Chapter 7: Appendix 59 of 90 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or f...

GP Series Portable Chillers Chapter 7: Appendix 60 of 90 Specifications Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply ...

GP Series Portable Chillers Chapter 7: Appendix 70 of 90 7-3 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves ACS CHILLER PUMPS 20-50 ALL 60 Hz HP GP 20 GP 30 GP 40 GP 50 1.5 CDU 70/315D3G STD 2 CDU 70/520D3G OPT STD STD 3 CDU 120/530D3G OPT OPT STD 3 OPT 5 2CDU 200/506 OPT OPT OP...

GP Series Portable Chillers Chapter 7: Appendix 74 of 90 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...

GP Series Portable Chillers Chapter 7: Appendix 75 of 90 7-4 Remote Air-Cooled Chiller Configurations

GP Series Portable Chillers Chapter 7: Appendix 76 of 90 Figure 19: Double Riser Detail

GP Series Portable Chillers Chapter 7: Appendix 77 of 90 7-5 Typical Ductwork for Air-Cooled Chillers Model Fan 60 Hz Discharge air volume 50 Hz Discharge air volume 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 ...

GP Series Portable Chillers Chapter 7: Appendix 79 of 90 7-6 Piping Diagrams