Sterling Refrigerator 8829309201 User Manual

GP Series Portable Chillers

Part Number: 882.93092.01

Bulletin Number: SC2-620.4

Effective: 10/10/2011

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 this manual are subject to change without notice.

ECN No. ____________

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Table of Contents

CHAPTER 1:ꢀ SAFETY................................................................ 5ꢀ

1-1ꢀ How to Use This Manual..............................................................................................5ꢀ

Safety Symbols Used in this Manual.....................................................................5ꢀ

1-2ꢀ Warnings and Precautions...........................................................................................6ꢀ

1-3ꢀ Responsibility...............................................................................................................6ꢀ

CHAPTER 2:ꢀ FUNCTIONAL DESCRIPTION ............................. 7ꢀ

2-1ꢀ Models Covered in This Manual ..................................................................................7ꢀ

2-2ꢀ General Description .....................................................................................................7ꢀ

Typical Applications...............................................................................................7ꢀ

System Limitations ................................................................................................7ꢀ

Chilled Water Circuit..............................................................................................8ꢀ

Refrigeration Circuit...............................................................................................9ꢀ

2-3ꢀ Standard Features .....................................................................................................10ꢀ

Mechanical Features...........................................................................................10ꢀ

Electrical Features...............................................................................................11ꢀ

Refrigeration Features.........................................................................................11ꢀ

Controller Features..............................................................................................12ꢀ

Other Features ....................................................................................................12ꢀ

2-4ꢀ Safety Devices and Interlocks....................................................................................12ꢀ

Crankcase Heater ...............................................................................................12ꢀ

High Pressure Cutout..........................................................................................13ꢀ

Low Pressure Cutout (no switch but done through the transducer) ....................13ꢀ

Flow Switch .........................................................................................................14ꢀ

Remote Start/Stop Interlock ................................................................................14ꢀ

2-5ꢀ Optional Features ......................................................................................................14ꢀ

CHAPTER 3:ꢀ INSTALLATION.................................................. 16ꢀ

3-1ꢀ Uncrating....................................................................................................................16ꢀ

3-2ꢀ Electrical Connections ...............................................................................................16ꢀ

3-3ꢀ Process Water Connections ......................................................................................17ꢀ

3-4ꢀ Bypass Valve Considerations ....................................................................................17ꢀ

3-5ꢀ Galvanic Corrosion Considerations ...........................................................................18ꢀ

3-6ꢀ Water Treatment Considerations...............................................................................18ꢀ

3-7ꢀ Condenser Considerations ........................................................................................18ꢀ

Water-Cooled Chiller Condensers.......................................................................18ꢀ

Air-Cooled Chiller Condensers............................................................................19ꢀ

Remote Air-Cooled Chiller Condensers ..............................................................20ꢀ

3-8ꢀ Checking Motor Direction...........................................................................................27ꢀ

Three-Phase Compressors .................................................................................27ꢀ

Water Pumps.......................................................................................................27ꢀ

Condenser Fan....................................................................................................27ꢀ

3-9ꢀ Water Reservoir .........................................................................................................28ꢀ

3-10ꢀ Automatic Water Make-Up Option .............................................................................31ꢀ

3-11ꢀ Initial Start-Up ............................................................................................................31ꢀ

3-12ꢀ Finishing Setup: Setting Up Passwords.....................................................................33ꢀ

CHAPTER 4:ꢀ OPERATION....................................................... 35ꢀ

4-1ꢀ Panel Buttons, Indicator Lights, and Switches...........................................................35ꢀ

Microprocessor Controller ...................................................................................35ꢀ

4-2ꢀ Initial Start-up.............................................................................................................36ꢀ

4-3ꢀ Status Screens...........................................................................................................37ꢀ

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4-4ꢀ Access Levels............................................................................................................41ꢀ

4-5ꢀ Controller Setpoints....................................................................................................41ꢀ

4-6ꢀ Configuration Settings................................................................................................45ꢀ

4-7ꢀ Alarms........................................................................................................................47ꢀ

4-8ꢀ Optional Communications..........................................................................................47ꢀ

CHAPTER 5:ꢀ MAINTENANCE ................................................. 48ꢀ

5-1ꢀ Lubrication .................................................................................................................48ꢀ

5-2ꢀ Filter Cleaning............................................................................................................48ꢀ

5-3ꢀ Maintaining the Condenser........................................................................................48ꢀ

Air- and Remote Air-Cooled Chillers ...................................................................48ꢀ

Water-Cooled Chillers .........................................................................................48ꢀ

5-4ꢀ Maintaining the Evaporator........................................................................................49ꢀ

5-5ꢀ Evaporator Process Piping Y-Strainer .......................................................................49ꢀ

5-6ꢀ Preventative Maintenance Service ............................................................................49ꢀ

CHAPTER 6:ꢀ TROUBLESHOOTING ....................................... 50ꢀ

6-1ꢀ Identifying the Cause of a Problem............................................................................50ꢀ

Non-Controller Related Issues ............................................................................55ꢀ

CHAPTER 7:ꢀ APPENDIX.......................................................... 58ꢀ

7-1ꢀ Returned Material Policy............................................................................................58ꢀ

Credit Returns .....................................................................................................58ꢀ

7-2ꢀ Technical Assistance .................................................................................................58ꢀ

Parts Department ................................................................................................58ꢀ

Service Department.............................................................................................59ꢀ

Sales Department................................................................................................59ꢀ

Contract Department...........................................................................................59ꢀ

7-3ꢀ Specifications.............................................................................................................60ꢀ

Air-Cooled Portable Chillers................................................................................60ꢀ

Water-Cooled Portable Chillers...........................................................................65ꢀ

7-4ꢀ Pump Curves, Flow, and Pressure Considerations ...................................................70ꢀ

60 Hertz Pump Curves........................................................................................70ꢀ

50 Hertz Pump Curves........................................................................................72ꢀ

7-5ꢀ Remote Air-Cooled Chiller Configurations .................................................................75ꢀ

7-6ꢀ Typical Ductwork for Air-Cooled Chillers ...................................................................77ꢀ

7-7ꢀ Piping Diagrams.........................................................................................................79ꢀ

GP Series Portable Chillers

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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

features. Additional sections within the manual provide instructions for installation, pre-

operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup

of the equipment. We can also provide the assistance of a factory-trained technician to help

train your operator(s) for a nominal charge. This section includes instructions, checks, and

adjustments that should be followed before commencing with operation of the equipment.

These instructions are intended to supplement standard shop procedures performed at shift,

daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in

addition to information for operating the equipment safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and

disassembly instructions for those areas of the equipment requiring service. Preventive

maintenance sections are included to ensure that your equipment provides excellent, long

service.

The Troubleshooting chapter serves as a guide for identification of most common problems.

Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, and parts lists. A

spare parts list with part numbers specific to your machine is provided with your shipping

paperwork package. Refer to this section for a listing of spare parts for purchase. Have your

serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.

Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING indicates a potentially hazardous situation or practice which, if not avoided,

could result in death or serious injury.

CAUTION indicates a potentially hazardous situation or practice which, if not avoided,

may result in minor or moderate injury or in property damage.

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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 equipment.

ꢀ Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

ꢀ Operate this equipment within design specifications.

ꢀ OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

ꢀ Make sure the equipment and components are properly GROUNDED before you

switch on power.

ꢀ When welding or brazing in or around this equipment, make sure

VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or

sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER

should be close at hand and ready for use if needed.

ꢀ Refrigeration systems can develop refrigerant pressures in excess of 500 psi

(3,447.5 kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION

SYSTEM. This must be performed by a qualified service technician only.

ꢀ Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

ꢀ Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our

equipment with operator safety as a prime consideration. We expect you, as a user, to abide

by the foregoing recommendations in order to make operator safety a reality.

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard

operating conditions and when recommended instructions are followed in the maintenance

and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as

described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its

vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.

All warning and danger signs must be observed and obeyed. All actual or potential danger

areas must be reported to your immediate supervisor.

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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 output in kW of cooling (20, 30,

40, 50, through 210) and the cooling method used: -A for air-cooled, -W for water-cooled,

and –R for remote-air cooled.

2-2 General Description

Our portable chillers are reliable, accurate, and easy to use process cooling units. They are

available in air-, water-, and remote air-cooled designs in a range of sizes from 20 kW

through 210 kW (5 through 60 tons of refrigeration). All are self-contained, fully portable and

shipped ready to use. (Remote air-cooled chillers require field installation by qualified

technicians.) In the standard configuration the chiller basically consists of a pump, tank,

compressor, condenser, evaporator, and a control platform. All of these components, plus the

other integral components to maintain the leaving fluid temperature, are described throughout

this Chapter as well as Chapters 3 and 4.

Standard range of operation is 20ºF to 80ºF (-7ºC to 27ºC) for applications using a

water/glycol mix and 45ºF to 80ºF (7º to 27ºC) for water only applications.

Typical Applications

This series of portable chillers can be used in any application that needs a constant source of

cool process water. Typical applications include, but are not limited to, the following:

ꢀ

Injection molding

Extrusion

ꢀ

Blow molding

Thermoforming

Machine tool

Thermal spray

Laser

Metal plating

After-coolers (air compressors, dryers, etc.)

Printing (offset, gravure, digita)

System Limitations

These packaged chillers should be chosen using the following criteria:

Process heat load – Choose the size of the chiller so that rated capacity is no greater than

10% more than the process heat load.

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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 imperative that the process fluid is a mix of an

industrial grade ethylene or propylene glycol and water to the proper percentage (by volume)

to protect the system. See Chapter 3 for a further discussion regarding the use of glycol

within the system for these applications.

WARNING! - ACS Group does not warrant the freeze up of the evaporator

under any circumstances.

Chilled Water Circuit

Cooling water “To Process” and “From Process”

connections are made at the female NPT couplings

provided outside the unit.

Warm coolant (water and glycol mixture) returns

from the process and goes into the reservoir tank.

The coolant is then pumped through the evaporator

where it is cooled.

The coolant flows to the process and returns to

repeat the cycle.

A process water bypass valve located between the supply

line and reservoir tank (single pump models only) allows

minimal flow through the unit during the intermittent

fluctuating flow conditions. It is not intended to provide

continuous full bypass flow.

This minimal flow allows the flow switch to make when

the process flow is stopped. If the flow switch is not made the controller shuts down the

compressor to prevent freezing up the evaporator.

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Refrigeration Circuit

Air-, water-, and remote air-cooled refrigerant condensing differ only in the way the

compressed gas is condensed to a liquid. Shown below is a water cooled version.

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.

Liquid refrigerant from the condenser heat

exchanger flowing in the liquid line passes through

a shut-off valve into a filter/dryer that removes

moisture and other contaminants. After the

filter/dryer the refrigerant passes through a solenoid

valve to prevent liquid migration when the

compressor is off. A refrigerant sight glass is

provided to view the flow of liquid refrigerant, and

to view if the system is free of moisture. The

refrigerant then passes through the thermal

expansion valve, which allows the refrigerant to

expand (boil off) and cool (remove the heat from)

the fluid inside of the evaporator.

From the evaporator the refrigerant gas flows

through the suction line back into the compressor.

A modulating 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.

System Control

Putting this all together, the controller maintains the desired leaving fluid temperature using

multiple inputs to determine if, when and for how long the compressor(s) are on, and if,

when, the percent open and for how long the modeling hot gas bypass valve is on.

Once the unit’s power is enabled and the controller is turned on (see Chapter 4 for more

details on the operation of the controller) it verifies there is sufficient fluid level in the tank (if

present). If there is not enough fluid in the tank the controller will warn the user, or fill the

tank with water from a connected source if equipped with the optional automatic water

makeup valve. See Chapter 3 for more information regarding the initial setup and startup of

the unit.

Once the tank level is satisfied and the start button is pressed, the process pump turns on and

provides flow to the process. The controller verifies the flow through the electronic flow

switch. If the flow is not established within 10 seconds the controller will alarm and disable

the refrigeration circuit. Upon flow verification the controller uses the leaving fluid

temperature and the setpoint temperature to determine the operation of the compressor(s).

When the leaving fluid temperature is greater than the setpoint plus the “compressor on

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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 temperature remains above the setpoint plus

the “compressor on differential” value for more than 60 seconds.

The hot gas valve is designed to trim the load of one compressor and will modulate in order

to meet the desired leaving fluid setpoint via a PID algorithm. After the compressor starts,

the hot gas valve is allowed to modulate. The compressor will shut off if the leaving fluid

temperature drops below the “compressor off differential” and the hot gas valve is at 100%

for the “compressor off delay” time. The hot gas will reset to 0% when the compressor is off.

There is a “compressor anticyle” timer that will delay the time between compressor starts to

prevent short cycling of the compressor. This is a start to start timer set at 5 minutes. For

example, if the compressor has been running for 5 minutes and shuts off, then the compressor

can start immediately if the demand is there. If it has only been running for 2 minutes, then it

would not be able to start again for 3 minutes.

For a unit with two compressors, the second compressor or lag compressor starts when the

lead compressor is on, the hot gas is at 0%, and the leaving fluid temperature is above the

setpoint plus the “compressor on differential”. There is also an adjustable “lag compressor on

delay” timer. Before starting either compressor, the compressor with the least amount of

runtime hours is considered the lead compressor and the first to start. When both

compressors are running, the compressor with the most hours is considered the lead

compressor and is the first to stop. The lead compressor will shut off if the leaving fluid

temperature drops below the “compressor off differential” and the hot gas valve is at 100%

for the “lead compressor off delay” time. The compressor anti-cycle timers are active with

the two compressor units.

There will be two PID controls running simultaneously for determining the position of the hot

gas valve. One PID output will be based on leaving fluid temperature and the other based on

a minimum saturated suction temperature for freeze protection. The hot gas valve position

will be determined by which output is greater. If it is controlling to the saturated suction

temperature to prevent freezing, a warning will display on the screen that the hot gas is in this

mode. Once the control goes back to setpoint control, the warning will disappear. The

saturated suction temperature is calculated from the suction pressure and the type of

refrigerant.

The discharge pressure is controlled using an analog output signal to drive a fan for air-

cooled units or a water regulating valve for water-cooled units. The output signal is

determined from a PID algorithm using a discharge pressure transducer as the process

variable. The VFD or water regulating valve is controlled from the analog output to an

adjustable discharge pressure setpoint. The analog output starts at the initial “discharge

pressure start” % for a given time delay (discharge pressure hold). After the time delay, it

will control to the discharge pressure setpoint via the PID control. There is also a setting to

control the discharge pressure to the most efficient value.

2-3 Standard Features

Mechanical Features

Compressor – Hermetic scroll compressors.

Evaporator – Stainless steel copper brazed plate evaporators.

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Air-Cooled Condenser – Aluminum fin/ tube with washable filters, packaged units only.

Variable speed fan control standard for all remote air cooled condensers and GPAC70

through 210. Optional on GPAC20 through 50.

Water-Cooled Condenser – Tube-in-tube condensers (GPWC20 – GPWC50), Shell-and-

tube condensers (GPWC70 – GPWC210). All come with electronic cooling water regulating

valves.

Remote Air-Cooled Condenser– Aluminum fin/tube with low ambient control down to

–20ºF (-29ºC) via variable-speed fan(s).

Reservoir – GP20 and GP30 models use a 20 gallon (75 liter) polyethylene tank, GP40 and

GP50 models use a 40 gallon (150 liter) polyethylene tank, GP70 thru GP105 models use a

70 gallon (265 liter) polyethylene tank, GP140 thru GP210 models use a 140 gallon (530

liter) polyethylene tank. 304SS is available as an option for all sizes.

Piping – Non-ferrous chilled water piping

Pump – ODP motors (TEFC Optional)—horizontally mounted stamped stainless steel

construction.

Other Mechanical Features

ꢀ Low process water thermal flow switch

ꢀ NEMA-rated fan motor(s) on air-cooled models

ꢀ Galvanized structural steel frame, polyester powder coat painted cabinetry

ꢀ Internal process water bypass valve for system protection only

ꢀ Fully insulated refrigeration and process water piping

ꢀ 20 mesh Y strainer on process water piping into the evaporator

ꢀ Tank level indication via operator interface

ꢀ Pump pressure indication via operator interface

Electrical Features

ꢀ Fully accessible NEMA 4/12-style electrical control enclosure

ꢀ Single-point power and ground connection

ꢀ Non-fused disconnect switch, lockable

ꢀ Branch circuit protection

ꢀ 208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt

Refrigeration Features

ꢀ HFC-410a refrigerant

ꢀ Electronic modulating hot gas bypass capacity control

ꢀ High refrigerant pressure cutout switch (manual reset)

ꢀ Suction and discharge pressure transducers.

ꢀ High refrigerant pressure spring actuated relief valve

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ꢀ 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 PID controller with To Process, From Process and

Set Point readout

ꢀ Time delay for proof of water flow/pressure (models w/pump only)

ꢀ Low refrigerant pressure time delay for low ambient start-up on remote air-cooled and

air-cooled chillers with the variable-speed fan option.

ꢀ 8 line x 22 character display with status, alarm, and service screens

ꢀ Display has magnetic back and can be mounted anywhere.

Other Features

ꢀ One year labor warranty and one year compressor warranty

ꢀ Two year parts warranty

ꢀ Three year limited controller warranty

2-4 Safety Devices and Interlocks

Caution! Protect the system from freezing with inhibited industrial grade glycol 20ºF

below the leaving water temperature set point. Condensation may form inside

the pump tank and dilute the mixture, therefore the freezing point should be

verified periodically. See Figure 6 on page 18 for the correct mixture.

Crankcase Heater

All of the chillers are equipped with a compressor crankcase heater. It is wired through the

control transformer that operates continuously whenever power is applied to the chiller, and

the compressors are off.

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. If unit is mounted outdoors, power to the unit (and

the main power switch) must remain on 24 hours per day, 7 days per week to

prevent liquid migration to the compressor.

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Chapter 2: Functional Description

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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 psig.

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.

High pressure cutout

Typical GPAC-20

Low Pressure Cutout (no switch but done through the transducer)

There are two pressure transducers in the refrigeration piping – one on the suction line before

the compressor and one on the discharge line after the compressor. Within the program there

are four settings that warn and fault based on these two pressure transducers. The low suction

pressure warning and fault are calculated based on the Freeze Point value entered into the

controller. The low discharge warning is set for 200 psig (1,379 kPa), and the compressor

will fault at 180 psig (1,241 kPa). To prevent nuisance tripping there are delays built in to the

program.

Note:

Call a refrigeration service technician to analyze the problem to prevent

recurring low pressure faults.

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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 flow switch opens the control circuit and shuts down the

pump and the chiller.

Remote Start/Stop Interlock

An additional contact is provided to allow the remote starting or stopping of the chiller. To

use this feature install a switch or dry contact interlock connected in series between terminals

4 and 23. Refer to the electrical schematic supplied in the control enclosure. Once the wiring

is complete the controller will need to be reconfigured in the supervisor settings.

2-5 Optional Features

Options marked with “*” indicate options that can be factory installed or retrofitted in the

field.

Automatic Water Make-Up*. Not available on chillers less reservoir tank. This option

includes an electric water solenoid valve, and the necessary internal piping to connect the

chiller to a make-up water source. The controller uses the standard tank level pressure

transducer to determine when to fill the tank. See Appendix for typical piping diagrams.

Caution! Customer piping must provide backflow protection and venting of tank to

atmosphere to prevent over-pressurization of the reservoir tank (not needed for

open tank). See Section 7-7 for flow schematics.

Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank.

This option includes a 50 micron filter, flow indicator, 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 interlock. The alarm signals anytime that a fault is recognized during the operation

of the chiller.

Communications Options*. This option provides the capability for the unit’s controller to

communicate with an external device using a variety of serial communication protocols.

Currently the unit can communicate over RS-485 Modbus RTU, BACNet, LONWorks,

Ethernet Modbus.

High Pressure Fans. Provides either 0.3” WC (75 Pa) or 1.0”WC (250 Pa) of external static

pressure on fan discharge. High-pressure fans are necessary and must be included in chiller

installations where exiting air exhausts through ductwork.

The 0.3” WC (75 Pa) static fan can be retrofitted without sheet metal modification, but will

require changing out fan housing, fan blades, fan motors and electrical components.

Variable Speed Fan – GPAC20-50. Reduces the speed of the fan based on refrigerant

pressure and system load, allowing the chiller to operate in ambient temperatures below 75ºF

(24ºC). This option will also reduce fan noise in lower ambient temperatures and low loads.

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Chapter 2: Functional Description

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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. 208-230/3/60, 460/3/60, 575/3/60, and 400/3/50 volt

available

UL/cUL Labeled Electrical Subpanel. This option provides for the subpanel to be listed

with Underwriters Laboratory, with UL-related benefits and features. Sub-panels marked by

the UL/cUL sticker are accepted within Canada.

Optional Pumps. Pump options are available for greater pressure and flow rates. A

recirculation pump is required whenever process water flow is less than 1.2 gpm per ton or

greater than 4.8 gpm per ton. See Figure 1 below for optional pump amperages.

Figure 1: Optional Pump Amperages

Voltage Construction

460/3/60 SS

HP (kW)

1 (0.8)

Full Load Amps

1.7

2.3

1.5 (1.1)

2 (1.5)

4.0

3 (2.2)

4.2

5 (3.7)

8.2

7.5 (5.6)

10 (7.5)

15 (11)

30 (22)

10.3

12.0

20.0

32.0

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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 bar if necessary to carefully remove

the skid from the unit.

4. Lower slowly. The unit should land on its casters or rails and can then be moved into

position.

5. Retain the crating material for reshipping the chiller in case hidden shipping damage

is found.

3-2 Electrical Connections

Supply electricity of the voltage, phase, and cycle listed on the serial tag. Total running amps

are also found in the specification tables on pages in the Appendix.

Bring properly sized power leads and ground from a fused disconnect (installed by your

electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to

the National Electrical Code recommendations. Make sure all electrical connections are tight.

Important!

Refer to your local electrical requirements for proper feeder conductor and

supply disconnecting sizing. For instance, in the United States refer to

National Electric Code (NEC) Article 430-24 through 430-26, Table

310.15(B)(2)(a)

Note:

For all chillers manufactured with Variable Frequency Drives the

voltage may vary up to 10% from the converter nominal voltage.

However, the phase-to-phase input voltage imbalance must not

exceed 3%. If the input voltage does have an imbalance from phase

to phase greater than 3% then a line reactor must be installed to

prevent faults within the VFD.

For remote condenser units, the maximum recommended motor

cable length between the VFD and the motor without output chokes

is 30 m (100 ft). With output chokes the motor cable length may be

extended to 65 m (195 ft).

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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.

Figure 2: Typical GP20-50 Air Cooled Process Piping Connections

All external chilled water connections should be run full size to the process. Flow and

pressure information is available in the Appendix. The largest possible openings and

passages should be provided for the flow of chilled water through platens, dies, molds, or

other pieces of equipment. Flow control valves are not supplied, but should be added to the

system to adjust flow and pressure to the process and to isolate the chiller from the process if

necessary.

Note:

Be sure to reduce external pressure drop as much as possible by generously

sizing piping and tooling water passageways.

3-4 Bypass Valve Considerations

Our portable chillers have an internal manual bypass valve. If the flow is stopped to the

process while the chiller is running, the factory-set bypass valve allows a small amount of

water to flow through the chiller. This action allows the chiller to keep functioning while the

flow is stopped to process. The bypass valve is not intended to provide continuous full

bypass flow.

Caution! Do not attempt to adjust or otherwise tamper with the internal bypass. Your

warranty will be voided.

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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 the reaction between dissimilar metals.

PVC or non-ferrous piping is recommended to reduce galvanic action. If iron piping must be

used, use dielectric unions at the chiller, and water treatment is required.

Note:

The use of galvanized piping is discouraged because the rough inside surface

promotes debris to stick and eventually block the flow of the process fluid..

3-6 Water Treatment Considerations

Water treatment is an integral part of the system. In some locations, water may cause large

deposits of scale, erosion, algae, and/or corrosion.

Note:

The use of poor quality water may result in inefficient operation, heat

exchanger damage, and pump seal damage. Consult a qualified water

treatment specialist to determine what type of treatment is needed.

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 is labeled “Condenser Water In.” It is the

inlet for city or tower water. For the GPWC20-50, this connection is located near the bottom

of the chiller. For all other sizes this connection is located near the top of the chiller.

Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum

pressure of 25 psi.

Caution! The electronic water-regulating valves pressure setpoint is set at the factory.

Only a qualified refrigeration technician should adjust the pressure setting.

Please contact our service group at 800-423-3183 to schedule an appointment.

Normal HFC-410a refrigerant condensing pressure is 342 psi (2,360 kPa), with 85ºF (27ºC)

water at 25 psi entering condenser water pressure

Condenser Water Out. Condenser water return is labeled “Condenser Water Out.” It is the

outlet for water after it has passed through the condenser. For the GPWC20-50, this

connection is located near the bottom of the chiller. For all other sizes this connection is

located near the top of the chiller.

It is connected to the tower water return line or to a sewer or other approved discharge

receiver. A water-regulating valve is a standard feature in the condenser water out line.

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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 and provisions for removal of heated air

from the area. Do not locate air-cooled chillers in locations where steam, hot air, or fume

exhausts can be drawn into the chiller.

Caution! Clean air-cooled condensers and filters frequently. Failure to do so results in

reduced capacity, increased operating costs, and possible failure of the

equipment. Cleaning instructions can be found in the Maintenance chapter of

this manual

Normal maximum refrigerant condensing pressure with 95ºF (35ºC) air entering the

condenser is 420 psi (2896 kPa).

Condensing Air Temperature. Our air-cooled portable chillers are designed to operate at a

minimum condenser entering air temperature of approximately 75ºF (24ºC). Operation of the

equipment at a lower condenser entering air temperature can cause the chiller to malfunction.

For entering air temperatures below 75ºF (24°C), an optional fan motor speed control is

available. We recommend maintaining a minimum 75ºF (24°C) ambient temperature.

Note:

For all chillers manufactured with Variable Frequency Drives the

voltage may vary up to 10% from the converter nominal voltage.

However, the phase-to-phase input voltage imbalance must not

exceed 3%. If the input voltage does have an imbalance from phase

to phase greater than 3% then a line reactor must be installed to

prevent faults within the VFD.

For remote condenser units, the maximum recommended motor

cable length between the VFD and the motor without output chokes

is 30 m (100 ft). With output chokes the motor cable length may be

extended to 65 m (195 ft).

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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 should be hard/drawn type “L” or type “K” refrigerant grade copper

tubing only. Proper sizing and installation has a significant effect on system

performance, reliability, and safety.

Warning! The copper tubing and fittings used must have a minimum burst

pressure of 1,950 psi.

Interconnecting Refrigerant Piping. The chiller and condenser refrigerant lines are

terminated with a cap and brazed closed. Use a tube cutter to remove caps.

Caution! Do not use a saw to remove the end caps because this will allow copper chips to

contaminate the system.

A certified refrigeration contractor needs only to install the interconnecting refrigerant piping

between the chiller and the outdoor air-cooled condenser. This piping must be properly sized,

type “L” or type “K” refrigerant grade tubing, high temperature brazed. Install a customer

supplied 650 psi approved refrigerant relief valve in the discharge line at the condenser,

following all applicable codes.

Flow dry nitrogen through the system when brazing copper joints to prevent carbon/scale

formation; which causes contamination. Isolate the refrigerant lines from the building,

preventing transfer of line vibration to the structure. Do not secure the lines rigidly.

Leak check and evacuate the system down to 400 microns. A decay of 50 microns after one

hour is acceptable.

Warning! To prevent injury or death due to explosion and/or inhalation of hydrogen-

fluoride gas, purge system thoroughly while brazing refrigerant piping

connections. Use a pressure regulator in the line between the unit and the

high-pressure nitrogen cylinder to avoid over-pressurization and possible

explosion.

System Configuration. The system can be configured in any of the arrangements shown on

page 75 of the Appendix. The configuration and distance between the chiller and the

condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are

limitations that must be adhered to for reliable and optimal operation.

ꢀ Leaving water temperature affects discharge line size. Be sure to inform the installing

contractor of the leaving water temperature range in which the chiller will be operating

ꢀ The total distance between the chiller and condenser must not exceed 200 feet or 300

equivalent pipe feet

ꢀ Discharge line risers cannot exceed an elevation difference greater than 100 feet

without a 2% efficiency decrease.

ꢀ Refer to page 75 of the Appendix for the location of traps.

ꢀ Refrigeration lines must not be crossed, i.e., chiller liquid lines are to be piped to

condenser liquid lines.

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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. See Figure 4 on page 21 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

room or on a roof. Install a liquid line-charging valve to facilitate refrigerant charging. See

Figure 5 on page 21 for sizing information. See Figure 7 on page 25 for charge determination.

Discharge Line Sizing. Discharge line sizing is based on the velocity required for sufficient

oil return back to the compressor. See Figure 4: Equivalent Length in Feet for Valves and

Fittingson page 24 for discharge line sizing.

Note:

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.

Figure 4: Equivalent Length in Feet for Valves and Fittings

Line Size

OD (inches)

Angle

Valve

Short

Radius EL

Long

Radius EL

3/8

1/2

2.8

3.2

3.9

4.5

5.3

1.9

2.2

2.6

3.4

4.2

4.7

5.7

6.5

7.8

2.7

3.2

3.8

5.2

6.5

5/8

3/4

7/8

1-1/8

1-3/8

1-5/8

2-1/8

2-5/8

Figure 5: Liquid Line Sizing

GPRC-20

GPRC-30

Liquid Line Size (OD")

Horizontal

Downflow

Horizontal

Downflow

Total Equiv.

Length (Ft)

Total Equiv.

Length (Ft)

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

1/2

5/8

1/2

5/8

1/2

5/8

1/2

5/8

3/4

5/8

3/4

100

125

150

175

200

225

250

275

300

100

125

150

175

200

225

250

275

300

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GPRC-40

GPRC-50

Liquid Line Size (OD")

Horizontal

Downflow

Horizontal

Downflow

Total Equiv.

Length (Ft)

Total Equiv.

Length (Ft)

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

5/8

3/4

5/8

3/4

5/8

3/4

7/8

3/4

7/8

100

125

150

175

200

225

250

275

300

100

125

150

175

200

225

250

275

300

7/8

1-1/8

GPRC-70

GPRC-90

Liquid Line Size (OD")

Horizontal

Downflow

Horizontal

Downflow

Total Equiv.

Length (Ft)

Total Equiv.

Length (Ft)

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

7/8

1-1/8

7/8

100

125

150

175

200

225

250

275

300

7/8

100

125

150

175

200

225

250

275

300

7/8

1-1/8

7/8

1-1/8

7/8

1-1/8

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GPRC-105

GPRC-140

Liquid Line Size (OD")

Horizontal

Downflow

Horizontal

Downflow

Total Equiv.

Length (Ft)

Total Equiv.

Length (Ft)

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

1-1/8

1-3/8

1-1/8

1-3/8

1-1/8

1-3/8

100

125

150

175

200

225

250

275

300

100

125

150

175

200

225

250

275

300

GPRC-175

GPRC-210

Liquid Line Size (OD")

Horizontal

Downflow

Horizontal

Downflow

Total Equiv.

Length (Ft)

Total Equiv.

Length (Ft)

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

Upflow

1-5 Ft

Upflow

6-10 Ft

Upflow

11-15 Ft

1-3/8

1-5/8

1-3/8

1-5/8

100

125

150

175

200

225

250

275

300

100

125

150

175

200

225

250

275

300

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Figure 6: Discharge Line Sizing

Horizontal or Downflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

5/8

100

5/8

125

3/4

150

3/4

175

3/4

200

3/4

225

3/4

250

3/4

275

3/4

300

7/8

Model

GPRC-20

5/8

GPRC-30

GPRC-40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

7/8

1-1/8

1-3/8

1-5/8

2-1/8

1-1/8

1-3/8

1-5/8

2-1/8

1-1/8

1-3/8

1-5/8

2-1/8

1-1/8

1-3/8

1-5/8

2-1/8

1-1/8

1-3/8

1-5/8

2-1/8

7/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-5/8

2-1/8

7/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-5/8

Upflow Discharge Line Sizes (OD")

Total Equivalent Length (Ft)

Circuit

Tons

100

125

150

175

200

225

250

275

300

5/8

A-3/8

B-5/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-5/8

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-1-1/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-1-1/8

GPRC-20

GPRC-30

GPRC-40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

A-3/8

B-3/4

A-3/8

B-3/4

7/8

A-3/8

B-3/4

A-3/8

B-3/4

7/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-7/8

1-1/8

A-3/8

B-3/4

A-3/8

B-3/4

A-1/2

B-7/8

A-1/2

B-7/8

1-1/8

7/8

A-5/8

B-1-3/8

1-1/8

1-3/8

1-5/8

1-1/8

1-3/8

1-5/8

A-3/4

B-1-1/8

1-1/8

1-3/8

1-5/8

A-3/4

B-1-1/8

B-1-3/8

1-3/8

A-3/4

B-1-3/8

A-3/4

B-1-3/8

1-5/8

A-3/4

B-1-5/8

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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 7, determine the amount of charge based on the model 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 system and checking the liquid line sight glass.

Figure 7: Refrigerant Charge Determination

Condenser and Chiller Charge (LBS of R-410a)

Minimum Design Ambient - °F

Chiller

Model

-10

-20

GPRC-20

GPRC-30

GPRC--40

GPRC-50

GPRC-70

GPRC-90

GPRC-105

GPRC-140

GPRC-175

GPRC-210

Line Size

OD (inches)

Discharge Line

LBS of R-410a

Liquid Line

LBS of R-410a

3/8

1/2

0.3

0.6

3.2

6.0

5/8

1.0

9.6

3/4

1.5

14.4

20.0

34.1

52.0

73.6

128.0

197.4

7/8

2.1

1-1/8

1-3/8

1-5/8

2-1/8

2-5/8

3.7

5.6

7.9

13.7

21.2

Note: The amounts listed above are based on 100 feet of pipe. Actual amounts will be in

direct proportion to the actual length of the piping.

Oil Charge Determination. The remote air-cooled portable chillers are factory charged with

the amount of oil required without field-installed piping. Additional oil required is dependent

on the amount of additional refrigerant added.

Calculate the amount of additional oil required by using the following formula:

Pints of oil (Copeland Ultra 22cc) = lbs of R-410a added for field installed piping / 100.

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Figure 8: Remote Condenser Configurations

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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

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 rotation direction results in an elevated sound level and a substantially-reduced

current draw.

Caution! Do not allow the compressor to run backwards for any length of time. Doing

so will result in compressor damage..

Water Pumps

Correct pump rotation is indicated by a positive pressure of 20 to 40 psi shown on the home

screen of the display. Pump rotation should be clockwise when viewed from the motor end.

For chillers with optional pumps, check the appropriate pump curve in the Appendix.

Caution! Do not run pump dry. Doing so will result in seal damage.

Condenser Fan

Air should be drawn through the condenser and discharged vertically from the chiller.

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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 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 11: Ethylene Glycol and Propylene

Glycol Curves on page 30. Add a pre-mixed solution of industrial quality (not automotive),

inhibited ethylene glycol or propylene glycol and water to provide freeze protection to a

temperature 20ºF (11ºC) below the normal chiller operating temperature set point.

Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel,

stainless steel, and bronze) in the system from corrosion. If you intend to use straight water,

we strongly advise a minimum leaving water temperature of 45ºF (7ºC) or contact the service

department.

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.

The following glycol products are available:

Part Number Description

A0541358

A0539637

A0542990

A0542991

Ethylene glycol, 5 gallons (18.9 liters)

Ethylene glycol, 55 gallons (208.2 liters)

Propylene glycol, 5 gallons (18.9 liters)

Propylene glycol, 55 gallons (208.2 liters)

Caution! Do not connect make-up water directly to the chilled water reservoir unless you

have an approved automatic water make-up system installed.

Caution! Do not pressurize tank. Supply and return connections must be trapped and

vented to allow vertical risers to drain into tank. Do not overfill system. Allow

enough free space in tank for vertical piping to drain.

If your application has chilled water or process piping above the chiller, trap and vent the

supply and return lines to allow vertical piping to drain into tank.

Note:

In applications where the process or process piping is above the reservoir, take

steps to prevent over pressurization of the reservoir. This condition can occur

on system shutdown when the water in the system drains into the reservoir. To

prevent this, a vacuum breaker should be installed at the high point of the “To

Process” and “From Process” lines.

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Figure 10: Suggested Overhead Piping Configuration

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Figure 11: Ethylene Glycol and Propylene Glycol Curves

Percent Glycol Curves for Freeze Protection

40.0

30.0

20.0

Ethylene Glycol

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

% Glycol by Volume

Example: 45°F set point minus 20°F = 25°F.

From Figure 28, 25°F equates to 10% by volume of glycol required.

Note:

The standard pumps used in the GPAC Serice chillers are not recommended to

be used with fluid below 0°F (-18°C). Please consult factory for the proper

pump.

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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.

Note:

When the unit is selected with the optional, closed stainless steel tank, a

pressure reducing valve is added to the automatic water make-up option. This

valve is set to be full open at 5 psig (0.3 bar).

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 and

eventually leads to system freeze-up. Damage from freeze-up is not covered by

the warranty.

To prevent system freeze-up in automatic make-up applications, we recommend using either

a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for

more information about these configurations.

3-11 Initial Start-Up

ꢀ Check the shipping papers against the serial tag to be sure chiller size, type and voltage

is correct for the process that will be controlled. Portable chillers are built with a

voltage specific compressor and cannot be re-wired for an alternate voltage.

ꢀ Check the transformer primary voltage connections to be sure they are configured for

the electrical power you are using. The voltage at the main power connection must read

within plus or minus ten percent (±10%) of the voltage listed on the serial tag.

Electrical connections must conform to all applicable codes.

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To Process

From Process

ꢀ Complete chilled water To Process and From Process connections. It is suggested that

shut-off valves are added to unit to control the flow rate to process and for completely

isolating the chiller from the process.

ꢀ If the optional automatic water make-

up system was not installed on the

chiller, remove the side panel to the

left of the process connections and fill

the tank and chilled water circuit

piping until the tank is approximately

¾ full. Fill with water (or a

water/glycol mixture if the desired

setpoint is lower than 45°F (7°C)).

The water/ glycol mixture should

provide for freeze protection to at

least 20°F (11ºC) below the leaving

water temperature you want.

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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.

ꢀ The air-cooled condenser should have an adequate supply of 75º to 115ºF (24º to 46ºC)

air for proper operation.

ꢀ The tower or city water condenser cooling in and out connections should be completed

and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi

pressure, for proper operation.

ꢀ Connect the main 3 phase incoming power to

the unit making certain that line one (1) L1 is

connected to the A phase, line two (2) L2 is

connected to the B phase, and line three (3) L3

is connected to the C phase. Check for proper

rotation direction of fan(s) and pump(s). The

best route for the main power wiring is from

the floor up to the right side of the enclosure

on the top.

Power Cable (highlighted in

yellow)

The crankcase heater is automatically energized

when the main power is applied (main power switch

in the ON ( | )position. It should be on for at least 24 hours before startup to force dissolved

refrigerant from the compressor oil.

Finally, the cable for the display is coiled up under the control enclosure and the display is

shipped inside the control enclosure. The handle on the panel in front of the control

enclosure has a hole in the corner to feed the cable to the outside of the cabinet. Plug the

cable into the back of the display.

Turn the power switch to the ON ( | ) position. The display’s backlight will turn on and the

controller will go through a self-diagnostic routine prior to displaying the main status screen.

3-12 Finishing Setup: Setting Up Passwords

You can establish passwords for two levels of security: operators and supervisors. The

controller comes from the factory with neither password set. This allows every user access to

all functions.

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Warning! If you choose to establish passwords store them in a secure

location because if they are forgotten there is no way to reset them

without a service call.

Operator Password. If you define a password for operators, then a password will be

required to carry out any function (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.

Note:

If you choose to define an Operator Password you must also define a

Supervisor Password to complete the security setup.

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

required to display the extended setpoints for operating parameters and alarms. Section 4-6

shows a table of setpoints and the restrictions between Operator and Supervisor.

To set password protections:

1. Press the

2. Press the

button to access the menu screen.

to highlight SETPOINTS, and press

3. Press the

Password

until the following screen appears for the Operator or Supervisor

4. Press

to accept the screen, and then press

until the Operator or Supervisor

Password line is highlighted.

5. Press

to increment or decrement the number. The password can be between

0 and 9999.

6. Press

to accept the Password and move to the next line.

7. For either Operator or Supervisor password the time that the password will allow the

controller to be active can be set by the Operator or Supervisor Password Time. With the

PW Time value highlighted, press

to increment or decrement the time. The

password time for either setup can be from 0 to 99 minutes.

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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 Interface is housed in a block of rigid

plastic with a magnetic backing that allows the user to “stick” the interface on any metallic

surface. The GP20 through GP50 units come standard with a 10 ft (3 m) cable, and the GP70

through GP210 units come standard with a 20 ft (6 m) cable. Longer cables are available

through the After Market Sales Group. The controller is factory set and adjusted; no field

adjustment to the internal controls is necessary. The standard operation range is 20ºF to 80ºF

(-7ºC to 27ºC).

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.

Figure 12: Controller Display

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Button

Button Description

Detailed description

Menu Button

Used to access the menus structure of the PGD interface

Used to turn the entire chiller On or Off. The button is backlit and will

turn amber when the chiller is On.

On/Off Button

Back Button

Used to back up from a menu and return to the main status screen

Used to increment a data field or scroll up within a menu structure.

Used to accept a data field value or to select a menu item.

Up Arrow Button

Enter Button

Down Arrow Button

Used to decrement a data field or scroll down within a menu structure.

4-2 Initial Start-up

1. Verify the initial start-up checklist from Chapter 3, Section 3-11.

2. With the main supply power switch in the ON position, the screen will

display the version of the software for a period of 5 seconds, and then display

the main status screen.

Figure 13: Main Status Screen

3. Set the Leaving Fluid temperature by depressing the

the menu.

button to display

Figure 14: Menu Screen

4. Depress the

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.

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Enter the established Operator Password by depressing the

to move the

position of the cursor, and then depressing the

increment or decrement the number. Once all of the numbers have been

button to

entered depress the

appear.

to accept the password. The following screen will

Figure 15: Operator Setpoints Screen

5. Depress

to move the cursor to the CHILLED FLUID SP line. Use the

button to increment or decrement the value. Depress to

accept the value and move the cursor down one line.

6. Depress the button twice to return to the main status screen.

7. Depress the to start the chiller.

8. Check pump rotation

9. Check the pump amp draw and pump pressure. Make sure that the amp draw

reading is within the running load and service factor amps.

10. Operate the chiller, looking for any leaks and listening for unusual noises or

vibrations that could indicate improper operation.

Elevated sound level and substantially reduced current draw indicate reverse

rotation. After several minutes of operation, the compressor internal protector

trips.

4-3 Status Screens

The controller has eight (8) preconfigured status screens. The main status screen (shown in

Figure Figure 16) shows the main operating points of the chiller: Entering and Leaving fluid

temperatures; Leaving fluid setpoint, pump discharge pressure, tank fluid level (depth), and

percentage of hot-gas bypass output.

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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. The Test aides in troubleshooting the chiller when it is not

functioning properly by displaying the basic information that a service person will need to

know to determine the problem.

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The chiller can be equipped with a tempered fluid loop inside of the chiller. If this option is

installed, the main screen changes to the following.

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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. Supervisor access allows the supervisor to modify the

above plus

Selecting any of the menus in the Menu Screen will display the Password Screen.

4-5 Controller Setpoints

Access Level

Variable

Chilled Fluid SP

Chil Hi Temp Wrn

Chil Hi Temp Flt

Process SP

Description

Operator

Supervisor

Temperature of chilled fluid out to process

Setpoint for alarm to warn when chilled leaving fluid

temperature is too high

Setpoint to shut down pump and compressor based

on leaving fluid temperature

Temperature of tempered fluid out to process

Setpoint for alarm to warn when tempered leaving

fluid temperature is too high

Setpoint for alarm to warn when tempered leaving

fluid temperature is too high

Setpoint for alarm to warn when tempered leaving

fluid temperature is too low

Setpoint for alarm to warn when tempered leaving

fluid temperature is too low

Proc Hi Temp Wrn

Proc Hi Temp Flt

Proc Low Temp Wrn

Proc Low Temp Flt

Cooling Enabled

Heating Enabled

Refrigeration system allowed to operate

Optional Process temperature heater allowed to

operate

Lowest temperature fluid will operate without

freezing. Below 32°F (0°C) glycol must be added.

Forces lowest Chilled fluid setpoint to be 13°F (7°C)

above FFP

Fluid Freeze Point

Temperature difference above chilled fluid setpoint

before compressor turns on

Temperature difference below chilled fluid setpoint

before compressor turns off

Temperature difference below process setpoint

before process heater turns on

Temperature difference above process setpoint

before process heater turns off

Chill On Diff

Chill Off Diff

Proc On Diff

Proc Off Diff

Proc Hi Temp Dly

Time (in seconds) Process High Temperature alarm

is ignored before activating

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Access Level

Operator Supervisor

Variable

Description

Time (in seconds) Chilled High Temperature alarm

is ignored before activating

Chil Hi Temp Dly

When set to CRIT, chiller and process high temp

alarms will deactivate compressors and pumps.

When set to WARN, compressors and pumps are

allowed to continue to operate when a high temp

alarm occurs

Hi Temp Flt Type

Temperature difference below the chiller setpoint

before the chiller low temp warning alarm occurs

Temperature difference below the chiller setpoint

before the chiller low temp fault alarm occurs.

Temperature Difference between Leaving Fluid

Temperature and Setpoint to turn on the compressor

Temperature Difference between Leaving Fluid

Temperature and Setpoint to turn off the compressor

Time (in minutes) before lag compressor is

energized once Chilled fluid reaches 2°F (1.1°C)

above Chilled Fluid setpoint

Time (in minutes) before lag compressor is de-

energized once chilled fluid reaches 2°F (1.1°C)

below Chilled Fluid setpoint

Chil Lo T Wrn Dif

Chil Lo T Flt Dif

Comp, Lead Cmp On Delay

Comp, Lead Cmp Off

Delay

Lag Cmp On Dly

Lag Cmp Off Dly

Cond Fan Start

Cond Fan Stop

Pump Stop Delay

Heater On Delay

Discharge pressure which energizes condenser fan

Discharge pressure which de-energizes condenser

fan

Delay time in seconds between fault and stopping

the pump

Time (in seconds) before the heater is allowed to

activate once the last compressor stages off

Time (in seconds) between sampling the output of

the heater’s PID loop. For example, if this variable

is set to ten (10), the heater PID loop output is

checked every ten seconds. If the heater PID loop

output is 70% when sampled the heater output will

be on for 7 seconds and off for 3 seconds.

Heater Cycle Tm

Heater P

P parameter of the heater PID loop

Heater I

I parameter of the heater PID loop

Heater D

D parameter of the heater PID loop

P parameter of the cooling valve PID loop

I parameter of the cooling valve PID loop

D parameter of the cooling valve PID loop

Cooling Valve P

Cooling Valve I

Cooling Valve D

When in AUTO, the cooling valve is controlled by

the cooling valve PID loop. When in MANUAL,

the cooling valve is forced open to the percent

dictated by the Cooling Valve Pos variable.

When the Cooling Valve Mode is set to MANUAL,

this variable dictates what percentage the valve is

forced to.

Minimum tank level. Used to set the default low

tank lefvel alarm setpoints as well as the auto-water

makeup on setpoint.

Cooling Valve Mode

Cooling Valve Pos

Tank Min Lvl

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Access Level

Operator Supervisor

Variable

Tank Max Lvl

Description

Maximum tank level. Used to set the default high

tank level alarm setpoints as well as the auto-water

makeup off setpoint.

Tank level that will activate Low Level Warning

fault

Tank level that will activate Low Level Warning

alarm

The tank level to turn on optional water make-up

valve; based on size of tank

The tank level to turn off optional water make-up

valve; based on size of tank.

Tank level that will activate High Level Warning

alarm

Tank level that will activate High Level Warning

fault

Low Level Fault

Low Level Warning

Wtr Makeup On

Wtr Makeup Off

High Lvl Warning

High Lvl Fault

Mkup Min Rt X.X”/XXS

Operator Password

Operator Pw Time

Sprvisor Password

Sprvisor Pw Time

Alarm Silence Time

Set Clock

The minimum allowable rate for filling the tank

4 digit password to limit operator interaction

Time in minutes for operator password to be active

4 digit password for supervisory interaction

Time in minutes for supervisor password to be active

Time in minutes to silence alarm (with optional

audible alarm). After time alarm will reactivate.

Allows for the time to be set if the clock card option

is installed

Resets all parameters to the default parameters,

including configuration

Reset to Defaults

1. Set the Leaving Fluid temperature by depressing the

the menu.

button to display

Figure 17: Menu Screen

2. Depress the

button to highlight SETTINGS and press

. If

passwords were setup (See Section 3-12 for information on the controller

passwords) the password screen will appear.

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Enter the Operator Password by depressing the

the cursor, and then depressing the or

to move the position of

button to increment or

decrement the number. Once all of the numbers have been entered depress

the to accept the password. The following screen will appear.

Figure 18: Operator Setpoints Screen

3. Depress

to move the cursor to the Leaving Temp line. Use the

button to increment or decrement the value. Depress

value and move the cursor down one line.

to accept the

4. Adjust the Hi Temp Warning and Hi Temp Fault in the same manner.

5. Depress the button twice to return to the main status screen.

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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.

Access Level

Variable

Tank Level Inst

Description

Operator

Supervisor

Activates/Deactivates the tank level control sensor

Activates the automatic water makeup valve within

the controller

Auto Water Make-up

Fan Control

Set to CYCLING when a standard fan starter is used

to control the fan. Set to VFD when a variable

frequency drive is used to control the fan

When set to SP, the chiller will control to a static SP.

When set to AUTO, the chiller will adjust the

discharge pressure setpoint based on the current

conditions to increase efficiency.

Activates the optional temperature sensors for

refrigerant liquid line and suction line temperatures,

and entering air or water temperature (depending on

condenser type)

Disch Press Cntl

Sensor Pack Inst

Activates the optional water cooled condenser

differential water pressure switch

Activates the optional evaporator differential water

pressure switch

Cond Diff Sw Inst

Chill Diff Sw Inst

Clock Board Inst

Heater Installed

Activates the optional controller real time clock card

Activates the optional process heater

Determines how analog input 2 is used. It can be set

to CHIL IN (chiller in temperature), FROM PROC

(from process temperature), CHIL REM SP (chiller

remote setpoint) or PROC REM SP (process remote

setpoint).

Analog IN2

When Analog IN2 is set to REM SP, this determines

if the LOCAL (entered through the display) setpoint

or REMOTE (Analog IN2) setpoint is used to

control the chiller.

Determines the signal type (0-20mA or 2-20mA) for

the Remote Setpoint

Determines how analog input 6 is used. It can be set

to CHIL IN (chiller in temperature), FROM PROC

(from process temperature) or TO PROC (to process

temperature).

Remote SP Mode

Rem SP mA Range

Analog In 6

Determines the chiller loop’s type (COOL or

HEAT/COOL)

Determines the process loop’s type (COOL,

HEAT/COOL or HEAT).

Chil Loop Type

Proc Loop Type

Determines which loop’s (PROC or CHIL)

information to display on the first status page of the

display.

Primary Loop

Determines how analog output 2 is used. It can be

set to CHIL IN (retransmission of the chiller in

temperature), CHIL OUT (retransmission of the

chiller out temperature), FROM PROC

(retransmission of the from process temperature),

TO PROC (retransmission of the to process

temperature) or COOL VLV (process loop cooling

valve).

Analog Out 2

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Access Level

Operator Supervisor

Variable

Description

Determines how analog output 3 is used. It can be

set to CHIL IN (retransmission of the chiller in

temperature), CHIL OUT (retransmission of the

chiller out temperature), FROM PROC

(retransmission of the from process temperature) or

TO PROC (retransmission of the to process

temperature).

Determines how analog output 4 is used. It can be

set to CHIL IN (retransmission of the chiller in

temperature), CHIL OUT (retransmission of the

chiller out temperature), FROM PROC

(retransmission of the from process temperature) or

TO PROC (retransmission of the to process

temperature).

Determines how digital input 8 is used. It can be set

to START/STOP (remote start stop), NO

WARNING (normally open warning alarm), NC

WARNING (normally closed warning alarm), NO

FAULT (normally open fault alarm), NC Fault

(normally closed fault), PHASE MNTR (power

phase monitor), TMP SAFETY (high temp safety)

When Digital In 8 is configured to START/STOP

this determines if the chiller’s online status is

determined by the button on the display (LOCAL) or

digital input 8 (REMOTE).

Determines which sensor is used to control the

chiller. It can be set to CHIL OUT (chiller out

temperature), CHIL IN (chiller in temperature), TO

PROC (to process temperature) or FRM PROC

(from process temperature).

Determines which sensor is used to control the

process loop. It can be set to TO PROC (to process

temperature) or FRM PROC (from process

temperature).

When set to CRIT, the pump 2 overload alarm will

deactivate compressors and pumps. When set to

WARN, compressors and pumps are allowed to

continue to run when the pump 2 overload alarm

occurs.

When set to CRIT, the flow 2 alarm will deactivate

compressors and pumps. When set to WARN,

compressors and pumps are allowed to continue to

run when the flow 2 alarm occurs.

Analog Out 3

Analog Out 4

Digital In 8

Start Mode

Chil Cntl Sens

Proc Cntl Sens

Pump 2 OL Alm

Flow 2 Alm Type

Determines when the alarm output is activated.

When set to ALL ALARMS, the output is activated

when any new alarm occurs. When set to CRIT

ALARMS, the output will only activate when

critical alarms (those that force the pump or

compressor off) occur.

Determines what network protocol is used for

communications. This can be set to BACNET485,

BACNET IP, MODBUS485, MODBUS IP, LON or

WEB.

Alarm Out

Network Prot

Network Baudrate

Network Address

Units

Determines the baudrate for communications.

Determines the network address of the chiller on the

network.

Determines if STANDARD (English) or METRIC

units are used.

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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 broken up into two categories – warnings and

faults. The warning notifies the user that the parameter has been exceeded and the chiller is

allowed to keep operating, but should be monitored to determine the cause of the warning.

The fault notifies the user that the parameter has been exceeded and the chiller and pump has

been shut down to protect the system.

4-8 Optional Communications

The communications function allows you to monitor and set the parameters by a program

prepared and running on a host computer connected to the controller.

Serial communications use a RS-485 hardware interface. Protocols available are BACNet,

LONWorks, CANBus, and ModBus RTU (Slave mode only). See Appendix for the

controller data that is available through these protocols.

Network communications use a RJ-45 hardware interface using the basic Ethernet TCP/IP

layer stack. Protocols available are BACNet (Ethernet, IP, or MS/TP) and ModBus IP. See

Appendix for the controller data that is available through these protocols.

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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 185P F (85P C).

Remove the grease relief plug (motors only) before adding grease, add grease until a small

amount pours out, and replace the plug when finished.

Caution! Failure to remove the grease relief plug will result in dislodging the bearing

grease seal, eventually causing bearing failure.

Refrigeration compressors are hermetically sealed and no lubrication is required.

5-2 Filter Cleaning

Air filter cleaning is important to keep your air-cooled portable chiller operating at peak

efficiency and capacity. Clean the filters whenever they appear dirty, or at regularly

scheduled intervals.

1. Turn the chiller off.

2. Remove the top side panel(s) to expose the condenser section.

3. Slide the filter rod to release it from the frame at the top and bottom.

4. Wash down the filter with clean water (preferably with a garden hose), directing the flow

of water opposite the direction of airflow. If dirt is heavy, use a mild detergent and rinse

well. Allow the filter to dry completely before replacing it on the chiller.

Note:

Keep a spare air filter set on hand. Install and use it while cleaning).

Caution! Do not use compressed air to blow off a dirty filter. It will not clean very well,

and the filter could be damaged. Never run the chiller without properly

installed filters.

5-3 Maintaining the Condenser

Dirty condenser heat exchange surfaces reduce system capacity and efficiency.

Air- and Remote Air-Cooled Chillers

Brush or vacuum light dirt accumulations off the aluminum condenser fins. Avoid bending or

damaging them. Heavy dirt accumulations on the fins may require professional cleaning.

Water-Cooled Chillers

Proper water treatment will greatly reduce cleaning intervals.

Coaxial Condensers (GPWC20-50). Remove dirt and slime in the condenser tube water side

by reverse-circulating with a mild detergent and water solution. Remove mineral deposits by

reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through

the water side of the condenser. Follow the directions on the container.

Shell & Tube Condensers (GPWC70-210). Remove dirt and slime in the condenser tube

water side by cleaning with a nylon tube brush. Remove mineral deposits by reverse

circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the tube

water side of the condenser. Follow the directions on the container.

The refrigerant side is sealed and requires no routine maintenance.

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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 Evaporator

Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt

and slime in the evaporator by reverse-circulating with a mild detergent and water solution.

Remove mineral deposits by reverse-circulating Non-Acid De-Scaling Solution (Part No.

A0553840). Follow the directions on the container.

5-5 Evaporator Process Piping Y-Strainer

The process piping Y-strainer requires periodic cleaning of its screen to insure the proper

flow through the evaporator. To clean the strainer screen, remove the access plug and

retaining cap, and pull out the screen.

Wipe, brush, or vacuum out any dirt left in the strainer body. Clean the screen and replace it

in the strainer taking care to fit it squarely into the machined seat provided.

Caution! Do not forget to re-install the screen after cleaning it. Operating the chiller

with no strainer screen can potentially plug the evaporator with dirt. The

warranty does not cover chiller failures from a dirty evaporator.

5-6 Preventative Maintenance Service

Follow a systematic preventive maintenance program to help avoid costly down time. Call

the Service Department to arrange a schedule of inspections. This service can be tailored to

fit your maintenance requirements. These inspections include, but are not limited to:

ꢀ Checking refrigerant suction and discharge pressures

ꢀ Checking safety and operating conditions

ꢀ Checking voltage and amperage of all motors

ꢀ Checking all electrical connections

ꢀ Checking quantity of refrigerant

ꢀ Checking compressor oil level on units with tandem compressors

ꢀ Checking lubrication of motor and pump bearings

ꢀ Checking circulating pump operation

ꢀ Checking flow through heat exchangers

ꢀ Checking compressor efficiency

ꢀ Checking noise levels

GP Series Portable Chillers

Chapter 5: Maintenance

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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 will help you determine the cause and the potential solution.

Before beginning the troubleshooting process

ꢀ

Locate all wiring, piping, and assembly drawings that were shipped with the chiller. The

diagrams will note any custom options not covered in this manual.

ꢀ

Locate all manuals for any equipment that this chiller is connected to as they may provide

additional information to solve the problem.

WARNING!: Improper installation, operation, or any servicing may result in damage or personal

injusry

This chiller should only be installed, operated, and maintained by qualified technical

personnel who are familiar with the construction, operation, and potential hazards.

All wiring, disconnects, and over-current protection devices should be installed by a qualified

electrician in accordance will all local codes and ordinances in your region.

WARNING!: Electrical Hazard

Before performing any service on this equipment disconnect and lockout all electrical sources

to prevent injury from unexpected energization or startup. Follow all safety rules when

performing any maintenance or service to this equipment.

WARNING!: Refrigeration Hazard

Only certified refrigeration technicians should perform any refrigeration related maintenance.

CAUTION!: Hot Surfaces

Protect yourself from hot surfaces when working on the refrigeration or process temperature

sections of this equipment. These devices can reach temperatures of 180°F (82°C). Allow

the equipment to cool prior to performing any maintenance or service.

6-1 Identifying the Cause of a Problem

Types of conditions the user may see include alarm conditions and control problems.

Alarm Conditions

When an alarm condition occurs the

button backlight will flash, and if the optional

audible/visual alarm is installed the strobe and horn will energize. The light and horn will

remain on until the condition is corrected. Pressing the enter button will silence the audible

alarm, but the strobe will continue to flash.

The display will show the cause the alarm and will indicate a possible solution. To accept the

alarm press

, and follow the suggested solution to correct the alarm condition. The

following table shows the possible alarm messages that could appear on the display.

GP Series Portable Chillers

Chapter 6: Troubleshooting

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CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Allow the compressor to cool

down. If the compressor does

not restart, disconnect power

and verify operation of the

MCP internal module. Replace

if necessary.

MCP Failure

Compressor Fault

Compressor module has failed

Sensor Failure

Check the wiring connection at

the sensor, and at the controller.

If necessary replace sensor.

Electrical connection at

sensor open

Electrical connection at

controller open

Discharge Pressure Sensor Failure

Fan Overload

Allow the fan to cool down. If

the fan does not restart when

called upon by controller,

replace fan motor.

Internal fan motor overload

tripped

Locate the drive and write

down the fault code shown on

the display of drive. Contact

customer service for assistance.

Drive has detected internal

fault

VFD Fault

Dirty air cooled condenser or

inlet filter

Clean filter or condenser

Dirty water cooled condenser

or condenser valve failure

Condenser fan overload

Condenser fan VFD fault

Ambient air or condenser

water temperature too high

Too much refrigerant in

system.

Clean condenser or verify

operation of condenser valve

See Fan Overload Fault

See VFD Fault

Verify supply temperature or air

removal capacity.

High Discharge Pressure Fault

Contact Customer Service for

assistance

Verify operation of valve and

wiring on controller

Liquid line valves closed.

Discharge pressure switch

failure

See Discharge Pressure Sensor

Failure

Dirty air cooled condenser or

inlet filter

Clean filter or condenser

Dirty water cooled condenser

or condenser valve failure

Condenser fan overload

Condenser fan VFD fault

Ambient air or condenser

water temperature too high

Too much refrigerant in

system.

Clean condenser or verify

operation of condenser valve

See Fan Overload Fault

See VFD Fault

Verify supply temperature or air

removal capacity.

Contact Customer Service for

assistance

Verify operation of valve and

wiring on controller

See Discharge Pressure Sensor

Failure

Verify flow through system.

Make corrections as necessary.

High Discharge Pressure Switch

Liquid line valves closed

Discharge pressure switch

failure

From Process fluid

temperature too high

High Suction Pressure Fault

CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Verify ambient air temperature

and air flow or condenser inlet

water temperature.

Ambient air or condenser

water temperature too low

Low Discharge Pressure Fault

Too little refrigerant in

system.

Contact customer service for

service call

GP Series Portable Chillers

Chapter 6: Troubleshooting

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Water cooled condenser valve Verify cooling valve operation.

stuck open

Verify VFD is in remote versus

Fan VFD output at 100%

Low process fluid flow

Plugged Y-strainer

manual operation. Verify

controller output to VFD.

Verify system valve operation

and adjust if necessary

Clean y-strainer through blow-

down valve or cleaning internal

strainer.

Contact Customer Service

Verify wiring or output between

controller and valve

Low Fluid Temp Fault

System low on refrigerant

Liquid line valves closed

Chilled fluid setpoint too

close to freeze protection

setpoint.

Process fluid flow rate too

low.

Adjust setpoint or fluid

freezepoint temperature (will

require adding glycol to fluid)

Verify system valve operation

and adjust if necessary

Low Suction Pressure Fault

Thermal expansion valve

failure.

Contact Customer Service

Thermal expansion valve

failure

Contact Customer

Low Superheat Fault (only will

appear if optional sensor pack is

installed)

Verify sensor wiring between

controller and sensor.

Temperature Sensor Failure

Sensor failure

Electrical connection at

sensor open

Electrical connection at

controller open

Check the wiring connection at

the sensor, and at the controller.

If necessary replace sensor.

Suction Pressure Sensor Failure

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal Replace Sensor

block.

Check the wiring connection at

the controller terminal block

Leaving Water Temp Sensor

Failure

Verify tank level parameters.

Tank level too low

Add fluid if necessary.

Verify wiring between

controller and makeup valve.

Replace valve if necessary

Replace Sensor

Optional water makeup valve

failure

Low Level Fault

Tank level sensor failure

System valve(s) closed

Verify that all system valves are

operational and adjust.

Verify the sensor at the sensor

and at the terminal block.

Verify the operation of the

pump (i.e. motor circuit

Low flow sensor failure

Pump failure

No Flow

protector or pump rotation)

CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Verify motor circuit protector

operation. Verify motor wiring

and amp draw while under load.

Verify system valves are

operational and properly set.

Contact customer service or

sales if pump is sized too small

for application.

Motor circuit protector open

Pump Overload

Pump flow rate in excess of

capacity

Fluid temperature higher than Verify parameter and adjust if

parameter.

necessary.

High Fluid Temp Fault

SC/W

Check for any refrigeration

Refrigeration system fault

GP Series Portable Chillers

Chapter 6: Troubleshooting

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system fault

Verify with sales representative

the sizing of the chiller for the

application.

Chiller too small for load

Low Condenser Differential

Pressure Warning

Low discharge pressure or

high suction pressure

Contact customer service

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Verify wiring at terminal block.

Replace temperature sensor

Condenser Inlet Temp Sensor

Failure (optional with sensor

pack)

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Verify wiring at terminal block.

Replace temperature sensor

Chiller In Fluid Temp Sensor

Failure

Backflush evaporator

Blocked evaporator

Blow down y-strainer by

opening blow-down valve or

clean internal strainer.

Evaporator Differential Pressure

Blocked Y-strainer

Dirty air cooled condenser or

inlet filter

Clean filter or condenser

Dirty water cooled condenser

or condenser valve failure

Condenser fan overload

Condenser fan VFD fault

Ambient air or condenser

water temperature too high

Too much refrigerant in

system.

Clean condenser or verify

operation of condenser valve

See Fan Overload Fault

See VFD Fault

Verify supply temperature or air

removal capacity.

High Discharge Pressure Warning

Contact Customer Service for

assistance

Verify operation of valve and

wiring on controller

Liquid line valves closed.

Fluid temperature higher than Verify parameter and adjust if

parameter.

necessary.

Check for any refrigeration

system fault

Refrigeration system fault

High Fluid Temp Warning

Verify with sales representative

the sizing of the chiller for the

application.

Chiller too small for load

CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Fluid level higher than

parameter setting.

Verify value in parameter

Open drain valve and remove

some fluid from system so that

level is below high level fault.

Replace sensor

High Level Fault

Too much fluid in system

Tank sensor failure

Fluid level higher than

parameter setting.

Verify value in parameter

Open drain valve and remove

some fluid from system so that

level is below high level

warning.

Replace sensor

Contact customer service

High Level Warning

Too much fluid in system

Tank sensor failure

Compressor Differential Pressure

Fault

Low discharge pressure or

high suction pressure

From Process fluid

temperature too high

Ambient air or condenser

Verify flow through system.

Make corrections as necessary.

Verify ambient air temperature

High Suction Pressure Warning

Low Discharge Pressure Warning

GP Series Portable Chillers

Chapter 6: Troubleshooting

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water temperature too low

and air flow or condenser inlet

water temperature.

Too little refrigerant in

system.

Contact customer service for

service call

Water cooled condenser valve Verify cooling valve operation.

stuck open

Verify VFD is in remote versus

Fan VFD output at 100%

manual operation. Verify

controller output to VFD.

Low Fluid Temp Warning

Low Level Warning

Fluid level lower than

parameter setting.

Verify value in parameter. Add

fluid to the system if necessary

Verify wiring between

controller and makeup valve.

Replace valve if necessary

Replace sensor

Optional Water Makeup valve

failure

Tank sensor failure

Compressor Differential Pressure

Warning

Low discharge pressure or

high suction pressure

System low on refrigerant

Contact customer service

Contact Customer Service

Verify wiring or output between

controller and valve

Liquid line valves closed

Chilled fluid setpoint too

close to freeze protection

setpoint.

Process fluid flow rate too

low.

Adjust setpoint or fluid

freezepoint temperature (will

require adding glycol to fluid)

Verify system valve operation

and adjust if necessary

Low Suction Pressure Warning

Thermal expansion valve

failure.

Contact Customer Service

Contact customer service

Liquid line valve open

Hot gas bypass valve open

Pump Down Override Time

Expired

CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Verify wiring of flow sensor at

sensor and terminal block of

controller

Pump Flow Sensor Failure

Optional flow sensor failed

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Verify wiring of sensor at

sensor and terminal block of

controller

Pump Pressure Sensor Failure

Verify wiring of sensor at

sensor and terminal block of

controller

Refrig Liquid Temp Sensor

Failure

Verify wiring of sensor at

sensor and terminal block of

controller

Refrig Suction Temp Sensor

Failure

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Verify wiring of sensor at

sensor and terminal block of

controller

Tank Level Sensor Failure

Water make-up failure

Verify wiring of solenoid valve

at valve and at terminal block.

Increase water pressure to be

above 5 psig (0.3 bar)

Make up solenoid failure

Insufficient water pressure

GP Series Portable Chillers

Chapter 6: Troubleshooting

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Auxilliary Alarm

SC/W This alarm is configurable

Parameter set too short for

Adjust parameter for length of

time to build suction pressure

Contact Customer Service

remote condenser installation

Low Suction Pressure at Startup

For Units with a Tempered Loop

Refrigerant amount too low

Verify wiring of temperature

sensor at sensor and terminal

block of controller

Verify heater contactor

operation

Verify cooling valve operation

Verify heater contactor

operation

Verify cooling valve operation

Verify heater contactor

operation

Verify cooling valve operation

Verify heater contactor

operation

To ProcTemperature Sensor

Failure

Loose or broken sensor wire

Process heater on

Process High Temp Fault

Process High Temp Warning

Process Low Temp Fault

Process Low Temp Warning

Process cooling valve off

Process heater on

Process cooling valve off

Process heater off

Process cooling valve on

Process heater off

Process cooling valve on

Verify cooling valve operation

Optional process flow switch

failure

Verify operation of flow switch.

Pump 2 No Flow

SC/W

Verify operation of process

valves and adjust as necessary

Process valves closed

CC = Compressor Critical

Alarm Name

SC = System Critical

PC = Process Critical

W = Warning

Solution

Type

Possible Cause

Verify motor circuit protector

operation. Verify motor wiring

and amp draw while under load.

Verify system valves are

operational and properly set.

Contact customer service or

sales if pump is sized too small

for application.

Motor circuit protector open

Pump 2 Overload

SC/W

Pump flow rate in excess of

capacity

Verify operation of heater and

cooling valve. .

Heater failure

High Temp Safety Switch

Phase Monitor Fault

Verify wiring at cooling valve

and at terminal bloc

Replace sensor if necessary.

Reverse two wires at line-side

of power switch on electrical

panel.

Verify sensor wiring at sensor

and at terminal bloc.

Cooling Valve failure

Sensor failure

Unit wired incorrectly

Loss of phase during

operation

Sensor failure

Sensor wires loose from

controller terminal block

Sensor wires broke between

sensor and controller terminal

block.

Replace sensor if necessary.

Verify wiring at sensor and at

terminal block. y.

Replace sensor if necessar

From Proc Sensor Failure

Non-Controller Related Issues

Problem

Possible cause

Solution

Check main disconnect, fuses, wiring,

and power lead to unit.

Voltage must be within plus or minus

10% of nameplate rating.

No power.

Unit does not run.

Wrong voltage supplied to unit.

Chapter 6: Troubleshooting

GP Series Portable Chillers

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Problem

Possible cause

Solution

Replace control circuit fuse.

Check transformer.

Check for a short circuit.

Replace.

Add water or water/glycol solution as

required.

Control circuit fuse blown.

Defective control transformer.

Piping flow switch circuit open.

Pump motor off on overload.

Reset and test.

GP Series Portable Chillers

Chapter 6: Troubleshooting

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Problem

Possible cause

Solution

Leaving fluid setpoint set higher

than temperature of liquid in

system.

Lower the leaving fluid temperature

below the leaving temperature you

desire.

Allow time to cool and reset, then check

for high/low volt-age. It must be within

plus or minus 10% of the nameplate

rating.

Check for loose compressor electrical

connections.

Compressor internal overload or

MCP is open.

Failed compressor motor

Compressor contactor holding coil

open.

Pump runs; compressor does not.

Repair or replace.

Defective compressor auxiliary

contact.

Repair or replace.

Locate and repair.

Broken wire in the compressor

control circuit.

Plugged Y-strainer

Clean

Check hot gas analog output value

through status screen. Contact Service

if output value remains at 0%

throughout compressor cycle.

Check internal bypass valve to verify it

is open and free of debris.

Hot gas not coming on

Pump runs, compressor cycles at

short intervals.

Low process water flow

Install bypass between to-and-from

process line

Clean filters.

Clean condenser.

Check the refrigerant charge by viewing

sight glass on liquid line upstream of the

expansion valve.

Restricted condenser air flow.

Unit low on refrigerant.

Unit runs continuously, but not

enough cooling power.

Compressor not operating

efficiently.

Call service.

Unit under-sized for application.

Call sales rep.

GP Series Portable Chillers

Chapter 6: Troubleshooting

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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 return must be given.

All returned Material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking

charge.

All returns are to be shipped prepaid.

The invoice number and date or purchase order number and date must be supplied.

No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new

and unused condition, suitable for resale.

Warranty 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 return must be given.

All returns are to be shipped prepaid.

The invoice number and date or purchase number and date must be supplied.

After inspecting the material, a replacement or credit will be given, at the manufacturerʼs discretion, if

the item is found to be defective in materials or workmanship. Purchased components are covered

under their specific warranty terms.

7-2 Technical Assistance

Parts Department

[

]

Call toll-free Monday – Friday, 7am–5pm CST 800 423-3183 or call [262] 641-8610,

Fax [262] 641-8653

GP Series Portable Chillers

Chapter 7: Appendix

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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 fax order, please have the model and serial

number of your unit when you contact us. A customer replacement parts list is included in this manual

for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing

excellent customer service.

Service Department

[

]

Call toll-free Monday – Friday, 8am–5pm CST 800 423-3183 or call [262] 641-8610

Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most

products.

Sales Department

[262]

Call

641-8610 Monday–Friday, 8am–5pm CST

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales

Department for the name of the sales representative nearest you.

Contract Department

[262]

Call

641-8610 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services:

project planning; system packages including drawings; equipment, labor, and construction

materials; and union or non-union installations.

GP Series Portable Chillers

Chapter 7: Appendix

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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

capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.

GPAC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

4.65

TONS

°F

ALTITUDE

SEA LEVEL

WATTS

BTU/WATT

CFM

COMPRESSOR POWER

EER

4936

11.31

4230

WATER

°F

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

6-24

GPM

60-115

0.944

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

COOLANT PUMP

EVAPORATOR

HOT GAS BYPASS

3 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

24 INCH AXIAL

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

1/2 HP OAO, 1140 RPM

20 GALLON POLYETHYLENE

460V/3PH/60HZ

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

690

520

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

MICROPROCESSOR

10.7

AMPS

GPAC-30

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

7.30

TONS

°F

ALTITUDE

SEA LEVEL

COMPRESSOR POWER

EER

7579

11.56

6343

WATTS

BTU/WATT

CFM

°F

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

9-36

GPM

60-115

1.504

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

COOLANT PUMP

EVAPORATOR

HOT GAS BYPASS

4 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

24 INCH AXIAL

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

1 HP OAO, 1140 RPM

20 GALLON POLYETHYLENE

460V/3PH/60HZ

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

870

700

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

16.4

AMPS

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPAC-40

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

9.91

TONS

°F

ALTITUDE

SEA LEVEL

WATTS

BTU/WATT

CFM

COMPRESSOR POWER

EER

10070

11.81

8458

°F

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

12-48

2.022

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

COOLANT PUMP

EVAPORATOR

HOT GAS BYPASS

6 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

32 INCH AXIAL

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

1 HP OAO, 1140 RPM

40 GALLON POLYETHYLENE

460V/3PH/60HZ

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

1090

760

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

MICROPROCESSOR

AMPS

GPAC-50

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

15.19

TONS

°F

ALTITUDE

SEA LEVEL

COMPRESSOR POWER

EER

14882

12.25

12687

WATTS

BTU/WATT

CFM

°F

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESSURE LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

18-72

3.016

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

COOLANT PUMP

EVAPORATOR

HOT GAS BYPASS

8 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

32 INCH AXIAL

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

2 HP OAO, 1140 RPM

40 GALLON POLYETHYLENE

460V/3PH/60HZ

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

1290

950

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

AMPS

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPAC-70

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

20.16

TONS

°F

ALTITUDE

SEA LEVEL

20048

COMPRESSOR POWER

EER

WATTS

BTU/WATT

CFM

°F

12.07

16916

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

24-96

4.03

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

12 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(2) 24 INCH AXIAL

(2) 1/2 HP OAO, 1140 RPM

70 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2180

1520

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 17.9 AMPS EACH

MICROPROCESSOR

GPAC-90

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

25.47

TONS

ALTITUDE

SEA LEVEL

°F

COMPRESSOR POWER

EER

25504

11.98

25374

WATTS

BTU/WATT

CFM

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

30-120

5.09

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

12 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(2) 32 INCH AXIAL

(2) 2 HP OAO, 1140 RPM

70 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2580

1900

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 23.1 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPAC-105

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

30.21

TONS

°F

ALTITUDE

SEA LEVEL

29731

COMPRESSOR POWER

EER

WATTS

BTU/WATT

CFM

°F

12.19

25374

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

36-144

6.04

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

16 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(2) 32 INCH AXIAL

(2) 2 HP OAO, 1140 RPM

70 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2580

1900

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 26.9 AMPS EACH

MICROPROCESSOR

GPAC-140

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

TONS

°F

ALTITUDE

SEA LEVEL

COMPRESSOR POWER

EER

38153

12.58

38061

WATTS

BTU/WATT

CFM

°F

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

48-192

8.00

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

18 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(3) 32 INCH AXIAL

(3) 2 HP OAO, 1140 RPM

140 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

3870

2850

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 30.4 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPAC-175

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

49.41

TONS

°F

ALTITUDE

SEA LEVEL

48693

COMPRESSOR POWER

EER

WATTS

BTU/WATT

CFM

°F

12.18

38061

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

118

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

60-240

9.88

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

24 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(3) 32 INCH AXIAL

(3) 2 HP OAO, 1140 RPM

140 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

3870

2850

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 41.9 AMPS EACH

MICROPROCESSOR

GPAC-210

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

COOLANT

63.95

TONS

°F

ALTITUDE

SEA LEVEL

COMPRESSOR POWER

EER

63589

12.07

50748

WATTS

BTU/WATT

CFM

°F

WATER

CONDENSER AIR FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

153

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

AMBIENT AIR TEMPERATURE

20-80

°F

COOLANT FLOW

MINIMUM LOAD

72-288

12.79

GPM

60-115

TONS

SPECIFICATIONS

COMPRESSOR

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

COOLANT PUMP

EVAPORATOR

BRAZED PLATE

HOT GAS BYPASS

32 LBS R-410A

CONDENSER

ALUMINUM

CONDENSER FANS

CONDENSER FAN MOTOR

RESERVOIR

(4) 32 INCH AXIAL

(4) 2 HP OAO, 1140 RPM

140 GALLON POLYETHYLENE

460V/3PH/60HZ

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

5160

3800

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 54.5 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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Water-Cooled Portable Chillers

Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton

(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60

Hz capacity flow rate must be maintained.

GPWC-20

PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)

COOLING CAPACITY

5.12

TONS

°F

ALTITUDE

SEA LEVEL

4064

COOLANT SUPPLY TEMPERATURE

COMPRESSOR POWER

WATTS

CONDENSER INLET WATER

TEMPERATURE

°F

EER

15.13

15.9

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

GPM

dBA

COOLANT FLOW

UNIT PRESSURE DROP

GPM

PSID

SOUND PRESSURE LEVEL @ 1 METER

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

6-24

1.06

GPM

CONDENSER INLET WATER

TEMPERATURE

TONS

SPECIFICATIONS

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

NON-FERROUS

HOT GAS BYPASS

3 LBS R-410A

TUBE IN TUBE

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

20 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

690

520

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

10.7

AMPS

MICROPROCESSOR

GPWC-30

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

7.98

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

COMPRESSOR POWER

6416

14.92

25.08

WATTS

CONDENSER INLET WATER

TEMPERATURE

°F

EER

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

GPM

dBA

COOLANT FLOW

GPM

PSID

SOUND PRESSURE LEVEL @ 1

METER

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

9-36

GPM

CONDENSER INLET WATER

TEMPERATURE

1.672

TONS

SPECIFICATIONS

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

HOT GAS BYPASS

4 LBS R-410A

TUBE IN TUBE

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

20 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

870

700

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

16.4

AMPS

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPWC-40

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

10.94

TONS

°F

ALTITUDE

SEA LEVEL

WATTS

COOLANT SUPPLY TEMPERATURE

COMPRESSOR POWER

8450

15.53

33.93

CONDENSER INLET WATER

TEMPERATURE

°F

EER

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

GPM

dBA

COOLANT FLOW

GPM

PSID

SOUND PRESSURE LEVEL @ 1

METER

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

12-48

2.262

GPM

CONDENSER INLET WATER

TEMPERATURE

TONS

SPECIFICATIONS

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

HOT GAS BYPASS

6 LBS R-410A

TUBE IN TUBE

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

40 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

1090

760

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

MICROPROCESSOR

AMPS

GPWC-50

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

16.66

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

COMPRESSOR POWER

12778

15.65

50.28

WATTS

CONDENSER INLET WATER

TEMPERATURE

°F

EER

BTU/WATT

COOLANT

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

GPM

dBA

COOLANT FLOW

GPM

PSID

SOUND PRESSURE LEVEL @ 1

METER

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

18-72

3.352

GPM

CONDENSER INLET WATER

TEMPERATURE

TONS

SPECIFICATIONS

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

EVAPORATOR FILTER

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

20 MESH

NON-FERROUS

STAINLESS STEEL CENTRIFUGAL

BRAZED PLATE

HOT GAS BYPASS

8 LBS R-410A

TUBE IN TUBE

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

40 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

1290

950

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR FULL LOAD AMPS

120

VDC

NEMA 12

AMPS

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPWC-70

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

22.68

TONS

°F

ALTITUDE

SEA LEVEL

16970

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

WATTS

BTU/WATT

GPM

°F

16.04

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

24-96

4.54

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

12 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

70 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2180

1520

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 17.9 AMPS EACH

MICROPROCESSOR

GPWC-90

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

28.43

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

21716

15.71

WATTS

BTU/WATT

GPM

°F

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

30-120

5.69

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

12 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

70 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2580

1900

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 23.1 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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GPWC-105

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

33.64

TONS

°F

ALTITUDE

SEA LEVEL

25508

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

WATTS

BTU/WATT

GPM

°F

15.83

101

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

36-144

6.73

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

16 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

70 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

2580

1900

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 26.9 AMPS EACH

MICROPROCESSOR

GPWC-140

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

43.35

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

32685

15.92

130

WATTS

BTU/WATT

GPM

°F

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

104

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

48-192

8.67

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

18 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

140 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

3870

2850

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 30.4 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

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GPWC-175

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

54.46

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

41633

15.70

163

WATTS

°F

BTU/WATT

GPM

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

130

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

60-240

10.89

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

24 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

140 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

3870

2850

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 41.9 AMPS EACH

MICROPROCESSOR

GPWC-210

PERFORMANCE (NOMINAL DESIGN CONDITIONS)

COOLING CAPACITY

70.63

TONS

°F

ALTITUDE

SEA LEVEL

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

COOLANT

COMPRESSOR POWER

EER

54315

15.60

212

WATTS

BTU/WATT

GPM

°F

WATER

CONDENSER WATER FLOW

SOUND POWER LEVEL

SOUND PRESS LEVEL @ 1 METER

COOLANT FLOW

169

GPM

PSID

dBA

UNIT PRESSURE DROP

dBA

OPERATING PARAMETERS

COOLANT SUPPLY TEMPERATURE

CONDENSER INLET WATER TEMP

20-80

50-90

°F

COOLANT FLOW

MINIMUM LOAD

72-288

14.13

GPM

TONS

SPECIFICATIONS

EVAPORATOR FILTER

COMPRESSOR

COOLANT PUMP

EVAPORATOR

CONDENSER

SCROLL

20 MESH

NON-FERROUS

SST CENTRIFUGAL

BRAZED PLATE

SHELL & TUBE

COOLANT CIRCUIT

CAPACITY CONTROL

REFRIGERANT

HOT GAS BYPASS

32 LBS R-410A

FRAME

GALVANIZED STEEL

POWDER COATED STEEL

PANELS

RESERVOIR

140 GALLON POLYETHYLENE

460V/3PH/60HZ

WEIGHT (OPERATING)

WEIGHT (SHIPPING)

ELECTRICAL ENCLOSURE

CONTROL

5160

3800

LBS

POWER

CONTROL CIRCUIT

COMPRESSOR RATED LOAD AMPS

24/120

VAC

NEMA 12

(2) @ 54.5 AMPS EACH

MICROPROCESSOR

GP Series Portable Chillers

Chapter 7: Appendix

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7-3 Pump Curves, Flow, and Pressure Considerations

60 Hertz Pump Curves

ACS CHILLER PUMPS

September 8, 2009

20-50 ALL 60 Hz

300

120

250

200

150

100

10 HP 3U 32-200-1100D3G

5 HP 2CDU 200/506

3 HP 2CDU 70/306

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

Capacity [Gal/min]

Model

GP 20 GP 30 GP 40 GP 50

STD

1.5 CDU 70/315D3G

CDU 70/520D3G

CDU 120/530D3G

2CDU 70/306

OPT STD STD

OPT OPT STD

OPT

2CDU 200/506

OPT OPT OPT OPT

OPT OPT

10 3U 32-200-1100D3G

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ACS CHILLER PUMPS

September 8, 2009

70-210 ALL 60 Hz

300

120

250

100

15 HP 3U 40-200B150D3G

200

5 HP 2CDU 200/506

10 HP 3U 32-200-1100D3G

30 HP 3UB 65-200300D3G

150

100

5 HP 3U 32-160B50D3G

10 HP 3U 40-160-1100D3G

7.5 HP 3U 40-160-75D3G

5 HP 3U 40-125B-50D3G

5 HP CDU200/550D3G

120

180

240

300

Capacity [Gal/min]

Model

GP70 GP90 GP105 GP 140 GP175 GP210

STD STD STD

CDU 200/550D3G

3U 32-160B50D3G

3U 40-125B50D3G

OPT OPT OPT

STD

2CDU 200/506D3G OPT

7.5 3U 40-160-75D3G

10 3U 32-200-1100D3G

OPT

OPT OPT

OPT

15 3U 40-200B150D3G OPT OPT OPT

30 3UB 65-200300D3G

OPT

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50 Hertz Pump Curves

ACS CHILLER PUMPS

September 8, 2009

20-50 ALL 50 Hz

10 HP 3U 32-200-1100D3G

5 HP 2CDU 200/506

3 HP 2CDU 70/306

2 HP CDU 70/520D3G

1.5 HP CDU 70/315D3G

3 HP CDU120/530D3G

100

150

200

250

300

Capacity [liter/min]

Model

GP 20 GP 30 GP 40 GP 50

STD

1.5 CDU 70/315D3G

CDU 70/520D3G

CDU 120/530D3G

2CDU 70/306

OPT STD STD

OPT OPT STD

OPT

2CDU 200/506

OPT OPT OPT OPT

OPT OPT

10 3U 32-200-1100D3G

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ACS CHILLER PUMPS

September 8, 2009

70-210 ALL 50 Hz

5 HP 2CDU 200/506

10 HP 3U 32-200-1100D3G

30 HP 3UB 65-200300D3G

15 HP 3U 40-200B150D3G

5 HP 3U 32-160B50D3G

10 HP 3U 40-160-1100D3G

7.5 HP 3U 40-160-75D3G

5 HP 3U 40-125B-50D3G

5 HP CDU200/550D3G

120

240

360

480

600

720

840

960

1080

1200

Capacity [liter/min]

Model

GP70 GP90 GP105 GP 140 GP175 GP210

STD STD STD

CDU 200/550D3G

3U 32-160B50D3G

3U 40-125B50D3G

OPT OPT OPT

STD

2CDU 200/506D3G OPT

7.5 3U 40-160-75D3G

10 3U 32-200-1100D3G

OPT

OPT OPT

OPT

15 3U 40-200B150D3G OPT OPT OPT

30 3UB 65-200300D3G

OPT

GP Series Portable Chillers

Chapter 7: Appendix

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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

1.0X Nominal

2.0X Nominal

1.7

5.9

1.7

6.1

1.6

5.8

1.8

6.4

21.4

21.9

20.7

23.3

GPXC-70

GPXC-90

GPXC-140

GPXC-175

0.5X Nominal

1.0X Nominal

2.0X Nominal

1.7

6.1

1.8

6.5

1.7

6.1

1.8

6.4

21.9

120

23.5

144

22.1

192

23.6

GPXC-210

0.5X Nominal

1.0X Nominal

2.0X Nominal

1.7

6.2

144

288

22.7

Calculating Chiller Nominal Flow and Pressure to Process

ꢀ Flow rate: Obtain the flow reading from the appropriate pump curve.

ꢀ Pressure: Obtain a corresponding pressure reading from the pump curve you selected,

then subtract the one-pump pressure drop listed in the above table using the

appropriate chiller hp and flow rate.

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Chapter 7: Appendix

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7-4 Remote Air-Cooled Chiller Configurations

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Figure 19: Double Riser Detail

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7-5 Typical Ductwork for Air-Cooled Chillers

60 Hz Discharge

air volume

CFM

4230

50 Hz Discharge air

volume

m³/min

Fan

Model

0.5

1.0

2.0

(2) 1.0

(2) 2.0

(3) 2.0

(4) 2.0

0.4

0.7

1.5

m³/min

120

CFM

3525

GPAC-20

GPAC-30

GPAC-40

GPAC-50

GPAC-70

GPAC-90

GPAC-105

GPAC-140

GPAC-175

GPAC-210

100

150

200

300

399

598

898

1197

6343

8458

180

240

5286

7048

12687

16916

25374

38061

50748

360

479

718

1077

1436

10573

14097

21145

31718

42290

(2) 0.7

(2) 1.4

(3) 1.4

(4) 1.4

When locating your air-cooled portable chiller and designing its ductwork, note any potential high

temperature conditions when discharging into your building and any negative pressures with the building

when discharging air outside.

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Chapter 7: Appendix

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Notes:

ꢀ Customer use of ductwork requires the high pressure fan option.

ꢀ Allow 30 in. (77 cm) minimum clearance around the chiller footprint to facilitate free passage of

cooling air and service accessibility.

ꢀ Figure 20 shows the pressure loss per foot of ductwork. Calculate the total equivalent length before

using the data below.

ꢀ Support ductwork from the building structure, not off of the chiller.

ꢀ Back draft damper to outside must be closed at all times when fan/blower is not operating. Size the

damper so that the pressure drop across is no greater than 0.2 in WG (50 Pascal) at the rated output.

ꢀ Chillers are designed to operate at a condensing entering air temperature of 60ºF (16ºC) minimum

without optional Variable Frequency Drive.

Figure 20 - Loss of Pressure through round duct - inches of water column per equivalent foot

60 hz Condenser Fan Flow Rate (cfm / cmm)

50 hz Condenser Fan Flow Rate (cfm / cmm)

Nominal

Duct

GPAC-20 GPAC-30 GPAC-40 GPAC-50 GPAC-20 GPAC-30 GPAC-40 GPAC-50

Diameter

(in / cm)

6343 /

180

8458 /

240

12687 /

360

3525 /

100

5286 /

150

7048 /

200

10573 /

300

4230 / 120

0.003

18 / 45

20 / 50

22 / 55

24 / 60

26 / 65

28 / 70

30 / 75

32 / 80

36 / 90

0.007

0.005

0.003

0.002

0.001

0.013

0.008

0.005

0.003

0.002

0.001

0.03

0.02

0.002

0.001

0.005

0.003

0.002

0.001

0.009

0.005

0.003

0.002

0.001

0.020

0.012

0.007

0.005

0.003

0.002

0.001

0.002

0.001

0.01

0.007

0.004

0.003

0.002

0.001

Note: 1 inch of water column = 250 Pascal

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7-6 Piping Diagrams

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