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GP Series Chiller Operation Manual

1. GPWC 30 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER 5133 WATTS CONDENSER INLET WATER TEMPERATURE EER 14 92 BT U WATT COOLANT CONDENSER WATER FLOW 80 LPM COOLANT FLOW 70 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 EE BR POSURE CEMER R OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE C COOLANT FLOW LPM CONDENSER INLET WATER TEMPERATURE MINIMUM LOAD 4 5 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER TUBE IN TUBE REFRIGERANT 1 8 KGS R 410A FRAME GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 75 LITERS POLYETHYLENE WEIGHT OPERATING 395 KGS POWER 415V 3PH 50HZ WEIGHT SHIPPING 315 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS 14 7 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 65 of 88 GPWC 40 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEALEVEL COOLANT SUPPLY TEMPERATURE C COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE s FER PERAI COOLANT CONDENSER WATER FLOW LPM COOLANT FLOW 91 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 MENS EE OPERATING PARAMETERS COOLA
2. 1 cpu7osispsa__ sto 147 cbu7osesa opt STD STD 221 2CDU120 530D3G OPT OPT OPT 221 ecpu7osos opt 735 3U 32 200 1100D3G OPT OPT GP Series Portable Chillers Chapter 7 Appendix 70 of 88 ACS CHILLER PUMPS 70 210 ALL 50 Hz September 8 2009 70 g 60 16 N 3 68 2CDU 200 506D3G 50 tt 7 35 3U 32 200 1100D3G 99 NR ALIR AR ONNANNNAA 5 40 11 03 3U 40 200B150D3G E A E N 7 35 3U 32 200 1100D3G 14 ke a T 30 T T T 5 52 3U 40 160 75D3G 7 3 3 68 3U 40 125B50D3G 20 3 68 CDU 200 550D3G 2 10 1 0 0 0 120 240 360 480 600 720 840 960 1080 1200 Capacity liter min GP Series Portable Chillers 2CDU 200 506D3G OPT 3U 40 160 75D3G 3U 32 200 1100D3G a 22 06 3UB 65 200300D3G Chapter 7 Appendix 71 of 88 Bar Calculatin
3. Low Suction Pressure at 42 CC Parameter set too short for Adjust parameter for length Startup remote condenser of time to build suction GP Series Portable Chillers Chapter 6 Troubleshooting 55 of 88 Refrig Liquid Temp Sensor Failure Refrig Suction Temp Sensor Failure installation Refrigerant amount too low Contact Customer Service For Units with a Tempered Loop Verify wiring of temperature i de Temperature Sensor 43 PC SR or broken sensor are d terminal block of controller Verify heater contactor Process heater on operation Process High Temp Fault Verif T Process cooling valve off EU ORONI ELS operation Verify heater contactor Process heater on operation Process High Temp Warning Verif i Process cooling valve off NA operation Process kelte RER Verify heater contactor operation Process Low Temp Fault Verify cooling valve Brades hedera Verify heater contactor operation Process Low Temp Warning W Process cooling valve on veny cooling valve operation Optional process flow Verify operation of flow switch failure switch SCAN Pump 2 No Flow Verify operation of process Process vas cose valves closed valves and adjust as Process aves closed vas ae CC Compressor Critical SC System Critical PC Process Critical W Warning Alarm Name f Type Possible Cause Solution Verify motor circuit protector operation Verify motor wiring and amp draw while under load Pump 2
4. o dBA UNIT PRESSURE DROP B dBA e AB COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR no A PERFORMANCE NOMINAL DESIGN CONDITIONS W ALTITUDE C WATTS C BTUWATT SOUND PRESS LEVEL 1 METER COOLING CAPACITY COOLANT SUPPLY TEMPERATURE WEN 6 48 10 CONDENSER INLET WATER TEMP 30 39 0 4 COOLANT COOLANT FLOW 639 UNIT PRESSURE DROP ee OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE COOLANT FLOW 272 1090 CONDENSER INLET WATER TEMP 10 32 MINIMUM LOAD KW SPECIFICATIONS SCROLL 20 MESH SST CENTRIFUGAL NON FERROUS BRAZED PLATE HOT GAS BYPASS SHELL amp TUBE 14 5 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 529 LITERS POLYETHYLENE 2345 KGS POWER 415V 3PH 50HZ 1727 Kes CONTROL CIRCUIT VAC IP55 COMPRESSOR RATED LOAD AMPS 2 54 5 AMPS EACH MICROPROCESSOR K LP B M R A LPM dBA dBA LPM COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR no A GP Series Portable Chillers Chapter 7 Appendix 69 of 88 50 Hertz Pump Curves 5 7 35kW 3U 32 200 1100D3G 3 68kW 2CDU 200 506 Bar Head m 2 21kW 2CDU 120 530D3G 0 0 0 50 100 150 200 250 300 Capacity liter min
5. 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 GP Series Portable Chillers Chapter 3 Installation 28 of 88 Figure 10 Suggested Overhead Piping Configuration WARNING DO NOT OVER FILL SYSTEM ALLOW ENOUGH FREE SPACE IN TANK FOR VERTICAL PIPING TO DRAIN GP Series Portable Chillers VACUU B M ASSEMBLE R o IN 15 CM MIN 1 4 IN NPT FROM PROCESS 25 FT 7 6 MAXIMUM e CUSTO X MER s E amp FROM PROG HED UT OFF VALVES SS Chapter 3 Installation 29 of 88 Figure 11 Ethylene Glycol and Propylene Glycol Curves Percent Glycol Curves for Freeze Protection 4 4 21 41 mmm Ethylene Glycol 6 66 Propylene Glycol 12 22 O 9 17 77 D 23 33 S 23 D o 28 88 0 34 44 40 45 55 51 11 Glycol by Volume Example 77 set point minus 6 6 C 15 From Figure 28 3 8 C 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 18 C Please consult factory for the proper pump GP Series Portable Chillers Chapter 3 Installation 30 of 88 3 10 Aut
6. Warning Operating the chiller setpoint below 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 GP Series Portable Chillers Chapter 4 Operation 35 of 88 Button Description Detailed description Menu Button Used to access the menus structure of the PGD interface On Off Button Used to turn the entire chiller On or Off The button is backlit and will turn amber when the chiller is On Back Button Used to back up from a menu and return to the main status screen Up Arrow Button Used to increment a data field or scroll up within a menu structure Enter Button Used to accept a data field value or to select a menu item Down Arrow Used to decrement a data field or scroll down within a menu Button 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 a button to display the menu d Figure 14 Menu Screen 4 Depress the e lo z button to highlight SETPOINTS and press aem If passwords were setup See Section 3 12 for information on GP Seri
7. COMPRESSOR RATED LOAD AMPS MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 63 of 88 GPAC 175 PERFORMANCE NOMINAL DESIGN CONDITIONS ALTITUDE WATTS BTUWATT CFM SOUND POWER LEVEL SOUND PRESS LEVEL O 1 METER OPERATING PARAMETERS 5 25 COOLANT FLOW 227 908 LPM 15 5 46 MINIMUM LOAD KW SPECIFICATIONS COMPRESSOR 20 MESH COOLANT PUMP NON FERROUS EVAPORATOR HOT GAS BYPASS CONDENSER 11 5 KGS R 410A CONDENSER FANS GALVANIZED STEEL CONDENSER FAN MOTOR POWDER COATED STEEL RESERVOIR 1759 wes POWER 1295 kes CONTROL CIRCUIT P55 COMPRESSOR RATED LOAD AMPS MICROPROCESSOR GPAC 210 COOLING CAPACITY COOLANT SUPPLY TEMPERATURE AMBIENT AIR TEMPERATURE COOLANT COOLANT FLOW 173 O c1 jo K W C C LPM AR dBA UNIT PRESSURE DROP B dBA e AB COOLANT SUPPLY TEMPERATURE AMBIENT AIR TEMPERATURE PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY COOLANT SUPPLY TEMPERATURE LC 5 24 10 AMBIENT AIR TEMPERATURE 35 79 0 4 C COMPRESSOR POWER 63589 WATTS c 1207 BTUWATT K LP B COOLANT COOLANT FLOW MES UNIT PRESSURE DROP ERR OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE COOLANT FLOW 72 288 GPM AMBIENT AIR TEMPERATURE 15 5 46 MINIMUM LOAD 12 79 TONS SPECIFICATIONS COMPRESSOR 20 MESH COOLANT PUMP NON FERROUS EVAPORATOR HOT GAS BYPASS CONDENSER 14 5 KGS R 4104 CONDENSER FANS GALVANIZED STEEL CONDENSER FAN MOTOR POWDER COATED STEEL RESERVOIR
8. E H KEN ch Ab HE m n mig un la wi i I LA IT DEL GP Series Portable Chillers Chapter 7 Appendix 86 of 88 k v Le e LEE d E E o z E Dd UU HINT dE nnt act le 87 of 88 Chapter 7 Appendix GP Series Portable Chillers E ap wir IORN 1 CR LIN d En D re ER i J ki rr IF T A v E Es A A es A E E EE mM HR lle siehe da slk GP Series Portable Chillers Chapter 7 Appendix 88 of 88
9. COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 2 7 KGS R 410A CONDENSER FANS 810 MM AXIAL FRAME GALVANIZED STEEL CONDENSER FAN MOTOR 0 74 KW OAO 950 RPM PANELS POWDER COATED STEEL RESERVOIR 150 LITERS POLYETHYLENE WEIGHT OPERATING 495 KGS POWER 415V 3PH 50HZ WEIGHT SHIPPING 345 KGS CONTROL CIRCUIT 24 VDC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS GPAC 50 17 9 AMPS CONTROL MICROPROCESSOR PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 10 C COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 35 C EER BT U WATT COOLANT CONDENSER AIR FLOW M MIN COOLANT FLOW 135 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 SOUND PRESSURE LEVEL 1 METER dBA OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 5 25 C COOLANT FLOW 70 270 LPM AMBIENT AIR TEMPERATURE COMPRESSOR 15 45 C MINIMUM LOAD SPECIFICATIONS SCROLL EVAPORATOR FILTER 8 6 KW 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 3 5 KGS R 410A
10. 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 anticycle 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 096 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 compr
11. e Checking flow through heat exchangers e Checking compressor efficiency e Checking noise levels GP Series Portable Chillers Chapter 5 Maintenance 49 of 88 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 e 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 e 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 injury 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 energisation or startup Follow all safety rules wh
12. 2345 Kos POWER 1727 kes CONTROL CIRCUIT VAC IP55 COMPRESSOR RATED LOAD AMPS MICROPROCESSOR CONDENSER AIR FLOW 1437 M MIN SOUND POWER LEVEL g SOUND PRESS LEVEL 1 METER GS ALTITUDE SEA LEVEL A M dBA R dBA GP Series Portable Chillers Chapter 7 Appendix 64 of 88 Water Cooled Portable Chillers Nominal operating parameters for water cooled models are 10 C leaving water temperature at 9 1 lom per 3 517 kW with 29 C tower water GPWC 20 PERFORMANCE NOMINAL DESIGN CONDITIONS 60 HZ COOLING CAPACITY ALTITUDE SEALEVEL COOLANT SUPPLY TEMPERATURE COMPRESSOR POWER 3240 WATTS CONDENSER INLET WATER TEMPERATURE EER 15 13 BT U WATT COOLANT CONDENSER WATER FLOW 60 LPM COOLANT FLOW 45 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 SOUND PRESSURE LEVEL 1 METER dBA OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE C COOLANT FLOW CONDENSER INLET WATER TEMPERATURE MINIMUM LOAD 2 9 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER TUBE IN TUBE REFRIGERANT 1 35 KGS R 410A FRAME GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 20 GALLON POLYETHYLENE WEIGHT OPERATING 315 KGS POWER 415V 3PH 50HZ WEIGHT SHIPPING 235 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS 9 6 AMPS CONTROL MICROPROCESSOR
13. 5 28 5 28 5 28 5 28 5 Liquid Line Size OD mm Upflow Upflow 0 3 1 5 m 1 8 3m Liquid Line Size OD mm Upflow 0 3 1 5 m 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 Upflow 1 8 3m 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 Upflow 3 3 4 5 m 16 16 16 16 16 16 Upflow 3 3 4 5 m Upflow 3 3 4 5 m 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 28 5 22 of 88 GPRC 105 GPRC 140 Liquid Line Size OD mm Liquid Line Size OD mm Horizontal Horizontal Total Equiv or Upflow Upflow Upflow Total Equiv or Upflow Upflow Upflow Length m Downflow 0 3 1 5m 1 8 3 m 3 3 4 5 m Length m Downflow 0 3 1 5m 1 8 3 m 3 3 4 5 m 7 5 28 5 28 5 28 5 7 5 28 5 28 5 28 5 15 28 5 28 5 28 5 15 28 5 28 5 28 5 23 28 5 28 5 28 5 23 28 5 28 5 28 5 30 5 28 5 28 5 28 5 30 5 28 5 28 5 28 5 38 28 5 28 5 28 5 38 28 5 28 5 28 5 46 28 5 28 5 28 5 46 28 5 28 5 28 5 53 28 5 28 5 28 5 53 28 5 28 5 35 61 28 5 28 5 28 5 61 28 5 28 5 35 68 28 5 28 5 28 5 68 28 5 28 5 35 5 3 Co 9 5 91 5 28 5 76 28 5 28 5 28 5 76 28 5 35 35 83 28 5 28 5 28 5 83 28 5 35 35 91 28 5 28 5 35 91 28 5 35 GPRC 175 GPRC 210 Liquid Line Size OD mm Liquid Line Size OD mm Total Equiv d dne Upflow Upflow Upflow Total Equiv iode Upflow Upflow Upflow Length m Downflow 0 3 1 5 m 1 8 3m 3 3 4 5 m Length m Downflow 0 3 1 5m 1 8 3m 3 3 4 5 m 7 5 2 7 5 2o 15 2 s 15 B
14. MOVING this equipment Y Operate this equipment within design specifications v OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you v Make sure the equipment and components are properly GROUNDED before you switch on power v 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 v 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 Y Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled v 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 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 operatio
15. Process fluid flow rate too Mai SE valve laus operation and adjust if necessar failure Expired Hot gas bypass valve open CC z Compressor Critical SC z System Critical PC z Process Critical W z Warning Alarm Name f Type Possible Cause Solution Verify wiring of flow sensor Pump Flow Sensor Failure 34 W Optional flow sensor failed at sensor and terminal block of controller Sensor wires loose from controller terminal block Verify wiring of sensor at Pump Pressure Sensor Failure Sensor wires broke sensor and terminal block of between sensor and controller controller terminal block Sensor wires loose from Verify wiring of sensor at controller terminal block sensor and terminal block of Sensor wires broke controller between sensor and controller terminal block Sensor wires loose from Verify wiring of sensor at controller terminal block sensor and terminal block of Sensor wires broke controller between sensor and controller terminal block Sensor wires loose from Verify wiring of sensor at controller terminal block sensor and terminal block of Tank Level Sensor Failure Sensor wires broke controller between sensor and controller terminal block Make up soleno taiur Verify wiring of solenoid Make up solenoid failure valve at valve and at terminal Water make up failure W block Insufficient water pressure norease istud presoule 10 be above 5 psig 0 3 bar Auxiliary Alarm SC W This alarm is configurable
16. SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 1 8 KGS R 410A CONDENSER FANS 610 MM AXIAL FRAME GALVANIZED STEEL CONDENSER FAN MOTOR 0 74 KW OAO 950 RPM PANELS POWDER COATED STEEL RESERVOIR 75 LITERS POLYETHYLENE WEIGHT OPERATING 395 KGS POWER 415V 3PH 50HZ WEIGHT SHIPPING 315 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers 14 7 AMPS CONTROL Chapter 7 Appendix MICROPROCESSOR 60 of 88 GPAC 40 COOLING CAPACITY PERFORMANCE NOMINAL DESIGN CONDITIONS KW ALTITUDE SEALEVEL COOLANT SUPPLY TEMPERATURE 10 C COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 35 C EER BT U WATT COOLANT CONDENSER AIR FLOW M MIN COOLANT FLOW 90 LPM SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 BAR SOUND PRESSURE LEVEL 1 METER dBA OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE 5 45 C COOLANT FLOW 12 48 GPM AMBIENT AIR TEMPERATURE 15 45 C MINIMUM LOAD 2 022 TONS SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL
17. We recommend maintaining a minimum 24 C ambient temperature GP Series Portable Chillers Chapter 3 Installation 19 of 88 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 134 4 bar 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 suppli
18. X X X X Fluid Freeze Point Proc Off Diff Temperature difference above process setpoint before process heater turns off Proc Hi Temp Dly Time in seconds Process High Temperature alarm is ignored before activating nan Time in seconds Chilled High Temperature ETIN alarm is ignored before activating X X X X X X X X X X X X X X X X X GP Series Portable Chillers Chapter 4 Operation 4 of 88 Access Level Variable Description Operator Supervisor When set to CRIT chiller and process high temp alarms will deactivate compressors and Hi Temp Fit Type pumps When set to WARN compressors and pumps are allowed to continue to operate when a high temp alarm occurs Temperature difference below the chiller Chil Lo T Wrn Dif setpoint before the chiller low temp warning alarm occurs Temperature difference below the chiller Chil Lo T Fit Dif 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 Lag Cmp On Dly energized once Chilled fluid reaches 1 1 C above Chilled Fluid setpoint Time in minutes before lag compressor is de Lag Cmp Off Dly energized once chilled fluid reaches 1 1 C below Chilled Fluid setpoint Cond Fan Start d hage pressure which energizes conden
19. 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 3 8 LPM 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
20. 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 GP Series Portable Chillers Chapter 4 Operation 47 of 88 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 85 C Rem
21. 170 KGS POWER 415V 3PH 50HZ 670 CONTROL CIRCUIT VAC IP55 COMPRESSOR RATED LOAD AMPS 2 23 1 AMPS EACH MICROPROCESSOR COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COOLANT COOLANT FLOW UNIT PRESSURE DROP 79 8 K O o o W C C LPM AR e AB B LPM dBA dBA COOLANT SUPPLY TEMPERATURE LPM CONDENSER INLET WATER TEMP COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR A D 0 no A GP Series Portable Chillers Chapter 7 Appendix 67 of 88 GPWC 105 COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COOLANT COOLANT FLOW UNIT PRESSURE DROP e AB PERFORMANCE NOMINAL DESIGN CONDITIONS 951 1 WATER ALTITUDE WATTS BTUWATT vun SOUND PRESS LEVEL O 1 METER o KW C C 2 5 L PM BAR COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP OPERATING PARAMETERS 5 25 COOLANT FLOW 115 455 10 30 MINIMUM LOAD M SPECIFICATIONS dBA dBA LPM COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR POWER CONTROL CIRCUIT COMPRESSOR RATED LOAD AMPS GPWC 140 COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COOLANT COOLANT FLOW UNIT PRESSURE DROP COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR POWER CONTROL CIRCUIT COMPRESSOR RATED LOAD AMPS GP Series Portable Chillers 20 MESH NON FERR
22. 23 2 p 23 es 30 5 30 5 38 gt 38 3 53 Eg 53 Se 61 n 61 eom 68 is 68 is 76 m 76 eve 83 is 83 ae GP Series Portable Chillers Chapter 3 Installation 23 of 88 Figure 6 Discharge Line Sizing Horizontal or Downflow Discharge Line Sizes OD mm Total Equivalent Length m Model 75 15 23 305 38 46 53 61 68 76 83 91 GPRC 20 22 SPROSO 22 a 28 5 SPROSO 35 SC 4 SPRC90 4 GPRC 105 d SCH 35 54 ER 54 Eom 54 Upflow Discharge Line Sizes OD mm IST Total Equivalent Length m Circuit Tons 75 15 23 305 38 46 53 61 68 76 83 91 B 16 B 16 B 16 B 16 B 16 B 16 B 16 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 B 19 Big B19 B 19 B22 B22 B 22 B 22 B22 B 22 B22 B22 B22 B22 B22 B 22 B22 B285 B 28 5 B 22 B 22 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 35 B 35 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 B 28 5 wm A 20 A20 A20 A20 A20 A 20 A 20 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 35 B 41 B 41 B 41 B 41 B 41 B 41 GP Series Portable Chillers Chapter 3 Installation 24 of 88 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 determin
23. 6 Troubleshooting 52 of 88 Mw tional water makeu ely Wiring Seen p p controller and makeup valve E failure Replace valve if necessary Tank level sensor failure Replace Sensor System valve s closed Verify that all system valves are operational and adjust Verify the sensor at the No Flow 15 SC Low flow sensor failure sensor and at the terminal block Verify the operation of the Pump failure pump i e motor circuit protector or pump rotation CC z Compressor Critical SC z System Critical PC z Process Critical W z Warning Alarm Name f Type Possible Cause Solution Verify motor circuit protector Motor circuit protector open operalion very motor wiring and amp draw while under load Pump Overload 16 SC Verify system valves are Pump flow rate in excess operational and properly set E Contact customer service or of capacity E ope sales if pump is sized too small for application Fluid temperature higher Verify parameter and adjust than parameter if necessary 17 SC W Refrigeration system fault Check for any refrigeration system fault Verify with sales Chiller too small for load representative the sizing of the chiller for the application Pressure Warning high suction pressure Condenser Inlet Temp Sensor controller terminal block block Failure optional with sensor 19 W Sensor wires broke pack between sensor and controller terminal block controller terminal block block 20 W Sens
24. CONDENSER FANS 810 MM AXIAL FRAME GALVANIZED STEEL CONDENSER FAN MOTOR 1 5 KW OAO 950 RPM PANELS POWDER COATED STEEL RESERVOIR 150 LITERS POLYETHYLENE WEIGHT OPERATING 585 KGS POWER 415V 3PH 50HZ WEIGHT SHIPPING 430 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers 26 9 AMPS CONTROL Chapter 7 Appendix MICROPROCESSOR 61 of 88 GPAC 70 PERFORMANCE NOMINAL DESIGN CONDITIONS Ww ALTITUDE SEA LEVEL v COMPRESSOR POWER 16038 WATTS KW C C PM BAR BTUWATT vun COOLNTFLON s LPM souwpPOWERIEVEL 89 aa UNIT PRESSUREDROP os san sounperessuever imerer ep OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE COOLANT FLOW 90 365 LPM AMBIENT AIR TEMPERATURE 15 45 MINIMUM LOAD KW SPECIFICATIONS COMPRESSOR 20 MESH COOLANT PUMP NON FERROUS POWR asvarmsomz wert suippingy eof kes 2 179 AMPS EACH GPAC 90 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY COOLANT SUPPLY TEMPERATURE AMBIENT AIR TEMPERATURE COOLANT water conpenseramrtow soo mmn COOLANT FLOW UNIT PRESSURE DROP os sn souNDPRESSLEVELO rMETER a OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE COOLANT FLOW 115 455 LPM AMBIENT AIR TEMPERATURE 15 45 MINIMUM LOAD KW SPECIFICATIONS COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER CONDEN
25. EDUCE DOWN TO RD A DIAMETER INCOMING RD LINE DIAMETER REDUCE DOWN TO RD B LINE DIAMETER INCOMING RD B LINE DIAMETER N N INCOMING RD A LINE DIAMETER INCREASE UP TO RD LINE DIAMETER REDUCER TEE REDUCER TEE FROM COMPRESSOR DISCHARGE VALVE Ce RD 90 DEG 45 DEG STRAIGHT ELBOW STRAIGHT ELBOWS Figure 19 Double Riser Detail GP Series Portable Chillers Chapter 7 Appendix 74 of 88 d ES E 7 a PF pP P a EA Ed E Fi Ed D 5 z E af a A A d F E d d d d d A f Pi P Pi A FR d Pi 2 Pi Pi Fi D e d F A d Fr d V fa Fi a VK h s FF P a pe A a Fa 5 E E d AAA JO SX P F HAMAS P F Fa d fa S d F F D pF E A A vi S EJ d A Fl Pi Fi 50 Hz Discharge air Model Fan volume pT Ww mm 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 Notes e Customer use of ductwork requires the high pressure fan option e Allow 77 cm minimum clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility GP Series Portable Chillers Chapter 7 Appendix 75 of 88 e Figure 20 shows the pressure loss per foot of ductwork Calculate the total equivalent length before using the data below e Support ductwork fr
26. H 50HZ WEIGHT SHIPPING 430 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS 26 9 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7 Appendix 66 of 88 GPWC 70 PERFORMANCE NOMINAL DESIGN CONDITIONS ALTITUDE WATTS BTUWATT 280 LP 74 aa IBA OPERATING PARAMETERS 5 25 COOLANT FLOW 90 365 10 30 MINIMUM LOAD KW SPECIFICATIONS SCROLL 20 MESH SST CENTRIFUGAL NON FERROUS BRAZED PLATE HOT GAS BYPASS SHELL amp TUBE 5 5 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 265 LITERS POLYETHYLENE POWER 415V 3PH 50HZ 670 CONTROL CIRCUIT P55 COMPRESSOR RATED LOAD AMPS 2 17 9 AMPS EACH MICROPROCESSOR GPWC 90 O de COOLING CAPACITY COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COOLANT COOLANT FLOW O O o K W C C LPM AR UNIT PRESSURE DROP B e AB COOLANT SUPPLY TEMPERATURE CONDENSER INLET WATER TEMP COMPRESSOR COOLANT PUMP EVAPORATOR CONDENSER RESERVOIR A Q 0 AR A 0 PERFORMANCE NOMINAL DESIGN CONDITIONS ALTITUDE WATTS BTUWATT SOUND PRESS LEVEL 1 METER OPERATING PARAMETERS 5 25 COOLANT FLOW 115 455 10 30 MINIMUM LOAD kw SPECIFICATIONS SCROLL 20 MESH SST CENTRIFUGAL NON FERROUS BRAZED PLATE HOT GAS BYPASS SHELL amp TUBE 5 5 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 265 LITERS POLYETHYLENE 1
27. NT SUPPLY TEMPERATURE COOLANT FLOW CONDENSER INLET WATER TEMPERATURE MINIMUM LOAD 6 4 SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER TUBE IN TUBE REFRIGERANT 2 7 KGS R 410A FRAME GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 40 GALLON POLYETHYLENE WEIGHT OPERATING 495 KGS POWER 460V 3PH 60HZ WEIGHT SHIPPING 345 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS 17 9 AMPS CONTROL MICROPROCESSOR GPWC 50 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 10 C COMPRESSOR POWER WATTS CONDENSER INLET WATER TEMPERATURE 30 C EER BT U WATT COOLANT WATER CONDENSER WATER FLOW LPM COOLANT FLOW 136 SOUND POWER LEVEL dBA UNIT PRESSURE DROP 0 4 ELE A EEG OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE C COOLANT FLOW CONDENSER INLET WATER TEMPERATURE TEE SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER TUBE IN TUBE REFRIGERANT 3 6 KGS R 410A FRAME GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 150 LITERS POLYETHYLENE WEIGHT OPERATING 565 KGS POWER 300V 3P
28. OUS HOT GAS BYPASS 55 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 1170 kes 670 P55 2 26 9 AMPS EACH MICROPROCESSOR SCROLL SST CENTRIFUGAL BRAZED PLATE SHELL amp TUBE 265 LITERS POLYETHYLENE 415V 3PH 50HZ AR A 0 PERFORMANCE NOMINAL DESIGN CONDITIONS 43 35 TONS WATER ALTITUDE WATTS BTUWATT LPM IBA los emm SOUNDPRESSLEVEL TMETER a OPERATING PARAMETERS COOLANT FLOW 181 726 GPM 10 30 MINIMUM LOAD KW SPECIFICATIONS 20 MESH NON FERROUS HOT GAS BYPASS 8 2 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 1750 kas 1205 KeS P55 MICROPROCESSOR SCROLL SST CENTRIFUGAL BRAZED PLATE SHELL amp TUBE 529 LITERS POLYETHYLENE 415V 3PH 50HZ 24 VAC 2 30 4 AMPS EACH Chapter 7 Appendix 68 of 88 GPWC 175 KW C C PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY ALTITUDE COOLANT SUPPLY TEMPERATURE 10 WATTS CONDENSER INLET WATER TEMP BTU WATT COOLANT WATER LPM COOLANT FLOW 492 GPM AR sounn press LeveL METER OPERATING PARAMETERS 5 25 COOLANT FLOW 227 908 LPM 50 90 MINIMUM LOAD KW SPECIFICATIONS SCROLL 20 MESH SST CENTRIFUGAL NON FERROUS BRAZED PLATE HOT GAS BYPASS SHELL amp TUBE 10 9 KGS R 410A GALVANIZED STEEL POWDER COATED STEEL 529 LITERS POLYETHYLENE 1759 KGS POWER 415V 3PH 50HZ 1295 KGS CONTROL CIRCUIT NEMA 12 COMPRESSOR RATED LOAD AMPS 2 41 9 AMPS EACH MICROPROCESSOR GPWC 210
29. Overload Verify system valves are operational and properly set Contact customer service or sales if pump is sized too small for application Verify operation of heater EE and cooling valve PC Motor circuit protector open Pump flow rate in excess of capacity High Temp Safety Switch Verify wiring at cooling valve Reverse two wires at line side of power switch on electrical panel operation sensor and at terminal bloc controller terminal block terminal block y Sensor wires broke Replace sensor if necessary GP Series Portable Chillers Chapter 6 Troubleshooting 56 of 88 between sensor and controller terminal block Non Controller Related Issues Problem Possiblecause Solution N Check main disconnect fuses O power Se wiring and power lead to unit Voltage must be within plus or minus Wrong voltage supplied to unit 10 of nameplate rating Replace control circuit fuse Unit does not run Control circuit fuse blown Check transformer Check for a short circuit Defective control transformer Add water or water glycol solution as Piping flow switch circuit open required Pump motor off on overload Reset and test Leaving fluid setpoint set higher Lower the leaving fluid temperature than temperature of liquid in below the leaving temperature you system desire Allow time to cool and reset then check for high low volt age It must Gomer ena donder be with
30. SER FANS CONDENSER FAN MOTOR 265 LITERS POLYETHYLENE GP Series Portable Chillers Chapter 7 Appendix 62 of 88 GPAC 105 PERFORMANCE NOMINAL DESIGN CONDITIONS ALTITUDE WATTS BTUWATT M MIN SOUND PRESS LEVEL 1 METER OPERATING PARAMETERS oC COOLANT FLOW 115 545 C MINIMUM LOAD KW AMBIENT AIR TEMPERATURE SPECIFICATIONS COMPRESSOR 20 MESH COOLANT PUMP NON FERROUS EVAPORATOR HOT GAS BYPASS CONDENSER 7 KGS R 410A CONDENSER FANS GALVANIZED STEEL CONDENSER FAN MOTOR POWDER COATED STEEL RESERVOIR 1170 Kos POWER 860 CONTROL CIRCUIT P55 COMPRESSOR RATED LOAD AMPS MICROPROCESSOR GPAC 140 CO al COOLING CAPACITY COOLANT SUPPLY TEMPERATURE AMBIENT AIR TEMPERATURE COOLANT COOLANT FLOW O c1 JO K W C C LPM AR e AB UNIT PRESSURE DROP B dBA dBA COOLANT SUPPLY TEMPERATURE 5 25 LPM 15 45 A D 0 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE C 38153 WATTS AMBIENT AIR TEMPERATURE C 12 58 BTU WATT COOLANT 1077 wun COOLANT FLOW LPM dB UNIT PRESSURE DROP BAR dBA OPERATING PARAMETERS COOLANT SUPPLY TEMPERATURE C 181 726 AMBIENT AIR TEMPERATURE C 28 SPECIFICATIONS COMPRESSOR 20 MESH COOLANT PUMP NON FERROUS EVAPORATOR HOT GAS BYPASS CONDENSER 82 KGS R 410A CONDENSER FANS GALVANIZED STEEL CONDENSER FAN MOTOR POWDER COATED STEEL RESERVOIR 1759 kos POWER 1295 Kos CONTROL CIRCUIT VAC IP55
31. URE LEVEL 1 METER RAMETERS COOLANT FLOW dBA 35 90 LPM AMBIENT AIR TEMPERATURE 15 45 C MINIMUM LOAD 2 27 KW SPECIFICATIONS COMPRESSOR SCROLL EVAPORATOR FILTER 20 MESH COOLANT PUMP STAINLESS STEEL CENTRIFUGAL COOLANT CIRCUIT NON FERROUS EVAPORATOR BRAZED PLATE CAPACITY CONTROL HOT GAS BYPASS CONDENSER ALUMINUM REFRIGERANT 1 35 KGS R 410A CONDENSER FANS 610 MM AXIAL FRAME GALVANIZED STEEL CONDENSER FAN MOTOR 1 2 HP OAO 1140 RPM PANELS POWDER COATED STEEL RESERVOIR 75 LITERS POLYETHYLENE WEIGHT OPERATING 315 KGS POWER 460V 3PH 60HZ WEIGHT SHIPPING 235 KGS CONTROL CIRCUIT 24 VAC ELECTRICAL ENCLOSURE IP55 COMPRESSOR FULL LOAD AMPS GPAC 30 9 6 AMPS CONTROL MICROPROCESSOR PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEALEVEL COOLANT SUPPLY TEMPERATURE 10 C COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 35 C EER BT U WATT COOLANT CONDENSER AIR FLOW M MIN COOLANT FLOW 70 SOUND POWER LEVEL dBA UNIT PRESSURE DROP COOLANT SUPPLY TEMPERATURE 0 4 OPERATING PA 5 25 C SOUND PRESSURE LEVEL 1 METER RAMETERS COOLANT FLOW dBA 35 135 LPM AMBIENT AIR TEMPERATURE 15 45 C MINIMUM LOAD 5 13 TONS SPECIFICATIONS COMPRESSOR
32. Warning Low Level Warning alai X MES a SES SES oer Te SES SES amem OO e EMEN Wtr Makeup On The tank level to turn on optional water make up valve based on size of tank Mkup Min Rt X X XXS The minimum allowable rate for filling the tank Operator Password 4 digit password to limit operator interaction Operator Pw Time Time in minutes for operator password to be active Sprvisor Password 4 digit password for supervisory interaction Sprvisor Pw Time M minutes for supervisor password to be Alarm Silence Time Time in minutes to silence alarm with optional audible alarm After time alarm will reactivate Set Clock Allows for the time to be set if the clock card option is installed Resetto Defaults Resets all parameters to the default x parameters including configuration 1 Set the Leaving Fluid temperature by depressing the id button to display the menu e Figure 17 Menu Screen 2 Depress the lor M button to highlight SETTINGS and press Gen If passwords were setup See Section 3 12 for information on the controller passwords the password screen will appear GP Series Portable Chillers Chapter 4 Operation 43 of 88 cun pGD user interface Enter the Operator Password by depressing to move the position of the cursor and then depressing the orl button to increment or decrement the number Once all of the numbers have been entered depress the to accept the password The fol
33. _ 6 66 C Refrigerant Type 310A Max Temp 26 66 C Refrigerant Weight KGS Refrig Press tested to 575 PSI Max Refrig Press 620 PSI e 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 GP Series Portable Chillers Chapter 3 Installation 31 of 88 To Process From Process e 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 e f 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 34 full Fill with water or a water glycol mixture if the desired setpoint is lower than 7 C The water glycol mixture should provide for freeze protection to at least 11 C below the leaving water temperature you want GP Series Portable Chillers Chapter 3 Installation 32 of 88 Warning Operating the chiller setpoint below 7 C without the proper amount of glycol for freeze protection could result in a damaged evaporator ACS Group does no
34. additional oil required by using the following formula Pints of oil Copeland Ultra 22cc kgs of R 410a added for field installed piping 30 GP Series Portable Chillers Chapter 3 Installation 25 of 88 Configuration A hz Liquid line riser should not exceed 4 5 meters from base of air cooled condenser Configuration B DISCHARGE LINE A SEE DOUBLE RISER DETAIL ATTHHHHHHHHHHHHHHHH IHHHHHHHHHHHHHHHHHI Ce XTTHHRHHHHHHEHHHHHHR JHHHHHHHHHHHHHHHHHE Figure 8 Remote Condenser Configurations GP Series Portable Chillers Chapter 3 Installation 26 of 88 90 DEG STRAIGHT ELBOWS TO CONDENSER RD 7 REDUCE DOWN TO RD A DIAMETER we NN UNE GR DE L REDUCE DOWN TO RD B LINE DIAMETER N N INCOMING RD B LINE DIAMETER INCOMING RD A m M N INCREASE UP TO LINE DIAMETER RD LINE DIAMETER N A REDUCER TEE REDUCER TEE FROM COMPRESSOR DISCHARGE VALVE RD 90 DEG 45 DEG STRAIGHT ELBOW STRAIGHT ELBOWS 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 Comp
35. d 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 GP Series Portable Chillers Chapter 3 Installation 16 of 88 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 WM IO d A Tm Auto water make up optional To Proc ss From Process Drain 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
36. d cabinetry e nternal process water bypass valve for system protection only e Fully insulated refrigeration and process water piping e 20 mesh Y strainer on process water piping into the evaporator e Tank level indication via operator interface e Pump pressure indication via operator interface Electrical Features e Fully accessible NEMA 4 12 style electrical control enclosure e Single point power and ground connection e Non fused disconnect switch lockable e Branch circuit protection e 415 3 50 Refrigeration Features e HFC 410a refrigerant GP Series Portable Chillers Chapter 2 Functional Description 11 of 88 Electronic modulating hot gas bypass capacity control High refrigerant pressure cutout switch manual reset ouction and discharge pressure transducers High refrigerant pressure spring actuated relief valve Multiple refrigeration access ports Liquid line shut off ball valves Filter dryer Sight glass Externally equalized thermal expansion valve Liquid line solenoid Compressor crankcase heater Controller Features Off the shelf microprocessor based 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 magnet
37. d 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 7 C to 27 C for applications using a water glycol mix and 7 to 27 C 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 e Injection molding e Blow molding e Extrusion e Thermoforming e Machine tool e Metal plating e Thermal spray e After coolers air compressors dryers etc e Laser e 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 1096 more than the process heat load GP Series Portable Chillers Chapter 2 Functional Description 7 of 88 Process Fluid Temperature The standard range for the leaving fluid temperature for this series of packaged chillers is 6 7 C to 26 7 C When the process requires fluid temperatures below 6 7 C it is imperative that the process fluid is a mix of an industrial grade ethylene or propylene
38. dix 80 of 88 Cp IPS JTSOR TTR E ER Gr o TTSDR A enn Kaka ls SE pk be SE EG 81 of 88 Chapter 7 Appendix GP Series Portable Chillers Cp IPS JTSOR TTR E ER Gr o TTSDR A enn Kaka ls SE pk be SE EG 82 of 88 Chapter 7 Appendix GP Series Portable Chillers heen vials s HUN ONE TATE L D E ad hr 5 ER HEI or d emm E e E le ee i L T EU 17 I ui LI a I T a Br F Gain m L1 k it RER Iw L Amr j o 7 5 eg LAM EF LE mr E GP Series Portable Chillers Chapter 7 Appendix 83 of 88 OE SS OE EG 2 ES GER E ES ES 3 a ara Tj ri D mr ik if i oe Kek i Konin Ae gt EE i S eg 2581 E hr E BEE nnn E G HI Mat mm mum um Rd gru Saw GP Series Portable Chillers i Om 3j E 3 P i E T Chapter 7 Appendix newe wae ej aeaa def ls nhe n M M M M E Ad A AEN TEGH m d 84 of 88 A haora TAa del ads zijem em jee FETTE TATUR ka lk ae k 47 A vnius I ER KR ds p i li j DE A A EF EE o NENNEN DO a D VE E e TIT mcr j 7 7 PP a E i T TH H ree r E F um ep D IT 1 I GP Series Portable Chillers Chapter 7 Appendix 85 of 88 I CA 5 4 A 5 i z i i Bei iae i EIER I T i P
39. 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 GP Series Portable Chillers Chapter 2 Functional Description 14 of 88 temperatures below 24 C This option will also reduce fan noise in lower ambient temperatures and low loads 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 and 575 3 60 volt available Optional Pumps Pump options are available for greater pressure and flow rates A recirculation pump is required whenever
40. e 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 KGS of R 410a SE Minimum Design Ambient C 15 5 10 4 4 1 6 6 12 17 7 23 28 8 wem 4 3 eef s sss ss oo se wem as as se ea ee 73 78 77 77 wee 59 so es 77 es o os ss v wem e ee w ns zz 00 w es wen ns ws ma ne w wa ues va er wem 100 108 198 s 108 ws 20 as ze mem zm m we ze 23 ze 09 002 GPRC 140 MEN 23 3 25 29 5 a fa e jajajaja mom a sas A meme ssa 002 sz 002 002 002 302 009 s Co 00 Line Size Liquid Line OD mm KGS of R 410a KGS of R 410a 10 1451 12 272 16 4354 20 655i 22 9071 28 5 15 467 35 23 586 T 33 384 54 56 059 66 5 89 539 Note The amounts listed above are based on 30M 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
41. ed 44 8 bar 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 73 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 e 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 e he total distance between the chiller and condenser must not exceed 60 meters or 90 equivalent pipe meters e Discharge line risers cann
42. en 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 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 50 of 88 CC Compressor Critical SC System Critical PC Process Critical W Warning AlarmName______________ Type Possible Cause Solution Compressor Fault Discharge Pressure Sensor Fai
43. ential water pressure switch Chill Diff Sw Inst Activates the optional evaporator differential water pressure switch Clock Board Inst Activates the optional controller real time clock card Heater Installed 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 x CHIL REM SP chiller remote setpoint or PROC REM SP process remote setpoint X X X X X X X X X Analog IN2 Remote SP Mode Determines the signal type 0 20mA or 2 20mA for the Remote Setpoint X 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 Rem SP mA Range When Analog IN2 is set to REM SP this determines if the LOCAL entered through the gt display setpoint or REMOTE Analog IN2 setpoint is used to control the chiller Analog In 6 Determines the chiller loop s type COOL or AARS HEAT COOL Determines the process loop s type COOL Pure orl es HEAT COOL or HEAT X Determines which loop s PROC or CHIL Primary Loop information to display on the first status page of the display MEN 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 3 retransmission of the from process
44. ervice 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 s
45. es Portable Chillers Chapter 4 Operation 36 of 88 the controller passwords the password screen will appear Enter the established Operator Password by depressing the to move the position of the cursor and then depressing the e or E 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 15 Operator Setpoints Screen T 8 9 10 Depress to move the cursor to the CHILLED FLUID SP line Use the lo button to increment or decrement the value Depress Eto accept the value and move the cursor down one line Depress the LS button twice to return to the main status screen 1 Depress the m to start the chiller Check pump rotation Check the pump amp draw and pump pressure Make sure that the amp draw reading is within the running load and service factor amps 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 16 shows the main operating points of the chiller Entering and Leaving fluid temperatures Leaving fluid setpoint pump discharge
46. essor 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 se
47. f industrial quality not automotive inhibited ethylene glycol or propylene glycol and water to provide freeze protection to a temperature 11 C 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 7 C or contact the service department Warning Operating the chiller setpoint below 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 A0541358 Ethylene glycol 18 9 liters A0539637 Ethylene glycol 208 2 liters A0542990 Propylene glycol 18 9 liters A0542991 Propylene glycol 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
48. fault code shown on the display of drive Contact customer service for assistance Clean filter or condenser 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 Clean filter or condenser 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 51 of 88 CC Compressor Critical SC System Critical PC Process Critical W Warning AlarmName____________ Type Possible Cause Solution ll Recessay O CC z Compressor Critical SC z System Critical PC z Process Critical W z Warning Alarm Name K Type Possible Cause Solution Verify ambient air Ambient air or condenser temperature and air flow or water temperature too low condenser inlet water temperature Low Discharge Pressure Fault CC SDE IGEAN Water cooled condenser Verify cooling valve valve stuck open operation Verify VFD is in remote Fan VFD output at 100 versus manual operation Verify controller output to VED Veri
49. fy system valve Low process fluid flow operation and adjust if necessary EO KUN TAR SS Clean y strainer through Plugged Y strainer blow down valve or cleaning internal strainer System low on refrigerant Contact Customer Service m Verify wiring or output NS AMES clon between controller and valve Chilled fluid setpoint too Adjust setpoint or fluid freeze close to freeze protection point temperature will Low Suction Pressure Fault CC setpoint require adding glycol to fluid Verify system valve Process fluid flow rate too operation and adjust if low necessary Thermal expansion valve Contact Customer Service failure Low Superheat Fault only will Pd expansion valve Contact Customer appear if optional sensor pack CC T p emperature Sensor Verify sensor wiring between is installed i Failure controller and sensor Sensor failure Electrical connection at sensor open Check the wiring connection at the sensor and at the Suction Pressure Sensor Fail re 12 CC Electrical connection at controller necessary replace sensor controller open Check the wiring connection Sensor wires loose from g g i at the controller terminal i controller terminal block Leaving Water Temp Sensor SC block Failure Sensor wires broke between sensor and Replace Sensor controller terminal block Verify tank level parameters Low Level Fault Tank level too low Add fluid if necessary GP Series Portable Chillers Chapter
50. g Chiller Nominal Flow and Pressure to Process Pure Water at gt 4 4 C GPXC 20 GPXC 30 GPXC 40 GPXC 50 LPM DP BAR LPM DP BAR LPM DP BAR LPM DP BAR 0 5X Nominal 23 0 1 34 0 1 12 0 1 18 0 1 1 0X Nominal 45 0 4 68 0 4 24 0 4 36 0 4 2 0X Nominal 90 1 3 136 1 3 48 1 3 72 1 4 GPXC 70 GPXC 90 GPXC 140 GPXC 175 0 5X Nominal 90 0 1 113 0 1 181 0 1 226 0 1 1 0X Nominal 181 0 4 226 0 4 362 0 4 4526 0 4 2 0X Nominal 362 1 5 452 1 6 724 1 6 904 1 5 GPXC 210 0 5X Nominal 272 0 1 1 0X Nominal 544 0 4 2 0X Nominal 1088 1 6 e Flow rate Obtain the flow reading from the appropriate pump curve e 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 GP Series Portable Chillers Chapter 7 Appendix 72 of 88 7 4 Remote Air Cooled Chiller Configurations Configuration A GP Series Portable Chillers LIQUID LINE Liquid line riser should not exceed 4 5 meters from base of air cooled condenser Configuration B DISCHARGE LINE ig A SEE DOUBLE RISER DETAIL IHHHHLE Configuration C DISCHARGE LINE 73 of 88 Chapter 7 Appendix TE I n d 90 DEG STRAIGHT ELBOWS TO CONDENSER Ro 7 R
51. 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 Coolpak does not warrant the freeze up of the evaporator under any circumstances Chilled Water Circuit coe EE Cooling water To Process and From Process connections are made at the female BSPT couplings provided outside the unit Warm coolant water and glycol mixture returns from the process and goes into the reservoir tank 2 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 low through the unit during the AAN intermittent fluctuating flow conditions It is not 1 T 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 GP Series Portable Chillers Chapter 2 Functional Description 8 of 88 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 O The refrigerant is compressed in the c
52. hased from the manufacturer is subject to 1596 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 authorisation 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 manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms GP Series Portable Chillers Chapter 7 Appendix 58 of 88 7 2 Technical Assistance Australia Wide Phone Australia Wide Fax New Zealand Phone International Phone International Fax Email Sales NSW QLD and New Zealand Sales VIC ACT WA SA AND TAS Customer Service Shipping and Dispatch 1300 730 736 1300 730 739 0800 442 569 61 2 8976 9200 61 2 8976 9299 sales coolpakchillers com au Tim Fleming Stuart Mackenzie Anthea Harper Paul Norman tim fleming net au stuart fleming net au anthea fleming net a
53. 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 GP Series Portable Chillers Chapter 3 Installation 17 of 88 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 treat
54. he 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 GP Series Portable Chillers Chapter 2 Functional Description 9 of 88 greater than the setpoint plus the compressor on 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
55. i Ocoolpak A DIVISION OF FLEMING DYNAMICS PTY LTD GP Series Chiller Operation Manual 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 Sydney Melbourne fleming net au vic fleming net au Australia Ph 1300 730 736 n PO Box 638 PO Box 2119 Australia Fax 1300 730 739 Balgowlah NSW 2093 Moorabbin VIC 3189 New Zealand Ph 0800 442 569 20 32 Roseberry Street Shop 5 2 10 Central Avenue www fleming net au Balgowlah NSW 2093 Moorabbin VIC 3189 www coolpakchillers com au Fleming Dynamics Pty Ltd ABN 55 002 230 266 Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantia
56. iagnostic 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 GP Series Portable Chillers Chapter 3 Installation 33 of 88 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 a button to access the menu screen 2 Pressthe lo tlt highlight SETPOINTS and press 3 Pressthe lo
57. ic back and can be mounted anywhere Other Features e One year labor warranty and one year compressor warranty e Two year parts warranty e hree year limited controller warranty 2 4 Safety Devices and Interlocks Caution Protect the system from freezing with inhibited industrial grade glycol 6 C 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 GP Series Portable Chillers Chapter 2 Functional Description 12 of 88 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 High Pressure Cutout This electro mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 39 6 bar Note The high pressure cutout is a manual reset device typically mounted on the compressor discha
58. in plus or minus 10 of the eec dad add nameplate rating MCP is open p Check for loose compressor Pump runs compressor does electrical connections not Failed compressor motor Compressor contactor holding i Repair or replace coil open Defective compressor auxiliar p y Repair or replace contact Broken wire in the compressor control circuit Plugged Y strainer Check hot gas analog output value through status screen Contact MOL gas HOL coming SR Service if output value remains at Pump runs compressor cycles at 0 throughout compressor cycle SOR INEENS Check internal bypass valve to verify itis open and free of debris Locate and repair Low process water flow Install bypass between to and from process line Restricted condenser air flow SLE MB IE Check the refrigerant charge by Unit runs continuously but not Unit low on refrigerant viewing sight glass on liquid line enough cooling power upstream of the expansion valve Compressor not operating KR EE efficiently Unit under sized for application Call sales rep GP Series Portable Chillers Chapter 6 Troubleshooting 57 of 88 Chapter 7 Appendix 7 1 Returned Material Policy Credit Returns Prior to the return of any material authorisation 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 purc
59. ischarge line should be pitched downward in the direction of flow at a rate of 12 mm for every 3 meters This will allow oil to flow towards the condenser Figure 4 Equivalent Length in Feet for Valves and Fittings OD mm Valve Radius EL Radius EL 10 0 8 12 1 0 16 12 20 14 22 1 6 28 88 08 og 35 07 40 08 54 1 0 65 13 GP Series Portable Chillers Chapter 3 Installation 2 of 88 Figure 5 Liquid Line Sizing GPRC 20 Total Equiv Length m 7 5 15 23 30 5 38 46 53 61 68 76 83 91 GPRC 40 Total Equiv Length m 7 5 15 23 GPRC 70 Total Equiv Length m GP Series Portable Chillers Liquid Line Size OD mm Horizontal Downflow 0 3 1 5 m 1 8 3m Liquid Line Size OD mm exem mo or Upflow Upflow Downflow 0 3 1 5 m 1 8 3m Horizontal Downflow Liquid Line Size OD mm Upflow Upflow 0 3 1 5 m 1 8 3m Upflow 3 3 4 5 m 12 12 12 16 16 16 16 16 16 16 16 16 Upflow 3 3 4 5 m Upflow 3 3 4 5 m 22 GPRC 30 Total Equiv Length m 7 5 15 23 30 5 38 46 53 61 68 76 83 91 GPRC 50 Total Equiv Length m GPRC 90 Total Equiv Length m 7 5 15 23 30 5 38 46 53 6 68 76 83 9 Chapter 3 Installation Horizontal r Downflow Liquid Line Size OD mm Upflow 0 3 1 5 m Upflow 1 8 3 m Horizontal Horizontal r Downflow 28 5 28 5 28 5 28 5 28 5 28 5 28
60. lowing screen will appear Figure 18 Operator Setpoints Screen 3 Depress to move the cursor to the Leaving Temp line Use the or button to increment or decrement the value Depress s to accept the value and move the cursor down one line 4 Adjust the Hi Temp Warning and Hi Temp Fault in the same manner 5 Depress the WA button twice to return to the main status screen GP Series Portable Chillers Chapter 4 Operation 44 of 88 4 6 Configuration Settings Within the Supervisor Menu the chiller can be configured if options are added in the field These configurations are described below Variable Description Access Level j Supervisor Activates Deactivates the tank level control Tank Level Inst sensor Auto Water Make up Activates the automatic water makeup valve within the controller 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 EM Fan Control Disch Press Ontl refrigerant liquid line and suction line Sensor Pack Inst temperatures and entering air or water temperature depending on condenser type Cond Diff Sw Inst Activates the optional water cooled condenser differ
61. lt Tank sensor failure Replace sensor Fluid level higher than Verify value in parameter parameter setting 5 W High Level Fault Too much fluid in system Open drain valve and remove some fluid from system so that level is below high level warning Tank sensor failure Replace sensor Compressor Differential Low discharge pressure or Contact customer service 26 CC Pressure Fault high suction pressure High Suction Pressure 27 W From Process fluid MEE d em Warning temperature too high necessary Verify ambient air Ambient air or condenser temperature and air flow or water temperature too low condenser inlet water temperature Low Discharge Pressure system service call valve stuck open operation Verify VFD is in remote versus manual operation Verify controller output to VFD Low Fluid Temp Warning Bes c EE EEES Verify value in parameter INE lower than Add fluid to the system if Low Level Warning 30 W parameter setting be Optional Water Makeup Verify wiring between High Level Warning Too much fluid in system Fan VFD output at 100 GP Series Portable Chillers Chapter 6 Troubleshooting 54 of 88 Pressure Warning high suction pressure Liquid line valves closed Verity wiring or output between controller and valve Chilled fluid setpoint too Adjust setpoint or fluid freeze close to freeze protection point temperature will Low Suction Pressure Warning 2 W setpoint require adding glycol to fluid
62. lure NO Fan Overload VFD Fault High Discharge Pressure Fault High Discharge Pressure Switch 7 High Suction Pressure Fault GP Series Portable Chillers W C C C CC CC C MCP Failure Compressor module has failed sensor open controller open Internal fan motor overload tripped Drive has detected internal fault Dirty air cooled condenser or inlet filter 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 Liquid line valves closed Discharge pressure switch failure Dirty air cooled condenser or inlet filter 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 Liquid line valves closed Discharge pressure switch failure From Process fluid temperature too high Chapter 6 Troubleshooting 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 Check the wiring connection at the sensor and at the controller If necessary replace sensor Allow the fan to cool down If the fan does not restart when called upon by controller replace fan motor Locate the drive and write down the
63. ment 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 29 C and a minimum pressure of 1 7 bar 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 1300 730 736 to schedule an appointment Normal HFC 410a refrigerant condensing pressure is 23 5 bar with 27 C water at 1 7 bar 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 c
64. n 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 GP Series Portable Chillers Chapter 1 Safety 6 of 88 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 H 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 All are self contained fully portable and shipped ready to use Remote air cooled chillers require field installation by qualifie
65. naan nennen venen eenen venen venen venen eenenesenenvenen 7 2 2 General DESCHONOR eronder anke ended ete m 7 TYO ADDICAUONS eet 7 VSA EAR ER HORNS oere MEE TU E 7 CACO Wa EF CIO ee 8 Refrigeration Cut 9 A TT 11 Mechanical Features 11 mec E 11 Refrigeration Features 11 geet 12 On 12 2 4 Safety Devices and Interlocks esses 12 Grankcase TACO CL lt a 12 PUA Pressure COUN eege 13 Low Pressure Cutout no switch but done through the transducer 13 FOW OWUC ainia vna 14 Remote Start Stop Interlock ossis isses eene enne nna nnn 14 2 5 Weder NE UT 14 CHAPTER 3 INSTALLATION consensos 16 S ME uerius T ee oO E rt e 16 3 2 Electrical Connections snneenneennsennsennnrnnnnrnnnrrrrnnrrrsnrrnrrrnrrrnrrnnrrnnrrsnrrnrrrenrrenerenrene 16 3 3 Process Water Connections occccoccccoccnoconncconnconnnncnnnnonannnnannonnnnonnnnnnnnnonannnnarinenaninnas 17 3 4 Bypass Valve Considerations aans enn ennsenennsrnennsneneneneeenenssenensennsrnn daneen 17 3 5 Galvanic Corrosion Considerations naan eeen en ennenen eren enenen enen venee enen veneens 18 3 6 Water Treatment Considerations nun nen ennen eeen een ener senen senen venenvensen sens 18 3 7 Condenser Considerations nun enenn eneen envenensenenvenenvensneenensnnenvenenvenenn enne 18 Water Cooled Chiller Condensers nnen nneneneneenenenrennenennene nnen ennene nen 18 Air Cooled Chiller C
66. ncnnnnonnnnnonnnonnnnnonnnonnnnnonenenaninnnns 49 CHAPTER 6 TROUBLESHOOTING 50 6 1 Identifying the Cause of a Problem nan enennnenenenenenensen vaneen ennnnen vaneen 50 Non Controller Related leeues 57 CHAPTER 7 APPENDIX tennisbanen 58 7 1 Returned Material Policy uk 58 OR DN 58 2 Teena ASS e 59 Parts Department Error Bookmark not defined Service Department esses eene Error Bookmark not defined Sales Department Error Bookmark not defined Contract Department nanne eenen eneen Error Bookmark not defined e leia A e ro o E 60 Air Cooled Portable Chers 60 Water Cooled Portable Chillers oooccccccnnoccnnoconnoconncconnnnannonononconnnnnnnnnnos 65 7 3 Pump Curves Flow and Pressure Considerations nuno nen ennen enneen nen 70 7 4 Remote Air Cooled Chiller Configurations nnannnneennenenenen een ven eene nnnen nennen 73 7 5 Typical Ductwork for Air Cooled Chillers annae er ven een een een ennnenenenenn 75 76 PDN DAENS ER E TUIS 77 Ocoolpak 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 s
67. ns 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 GP Series Portable Chillers Chapter 5 Maintenance 48 of 88 Shell amp 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 Caution Do not use steam or water over 60 C 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 Hemove dirt and slime in the evaporator by reverse circulating with a mild detergent and water solution Remove mineral de
68. om the building structure not off of the chiller e 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 e Chillers are designed to operate at a condensing entering air temperature of 16 C minimum without optional Variable Frequency Drive Figure 20 Loss of Pressure through round duct inches of water column per equivalent foot 50 hz Condenser Fan Flow Rate cmm Nominal Duct GPAC 20 GPAC 30 GPAC 40 GPAC 50 Diameter cm 100 150 200 300 es Lee 005 oo 0 0 002 005 ET o 3 90e TT IT oo 8 TT 000 5 Note 1 inch of water column 250 Pascal GP Series Portable Chillers Chapter 7 Appendix 76 of 88 7 6 Piping Diagrams e ior Fe NONE T of 88 Chapter 7 Appendix GP Series Portable Chillers 78 of 88 Chapter 7 Appendix GP Series Portable Chillers rhel 79 of 88 Chapter 7 Appendix GP Series Portable Chillers O Les 2 0 ee i gt E rn At ri ferme 7 mor EE T TEE ARN Turm mp aight d Roscoe oe AA A M Qee X hR ES n m d ETST Wm 4 E L ck i i i5 GP Series Portable Chillers Chapter 7 Appen
69. omatic 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 BSPT 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 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 e 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 Model No Serial No Elem Diag Ctrl Volt 24V Line Volt Hz Ph FLA RMSQMAXV KA Max Feeder Overcurrent Protection Amps Comp HP RLA Process Pump HP FLA Fan HP FLA Min Temp
70. ompressor and flows through the discharge line as a gas to the condenser O There it gives up its heat as it condenses to a ES E dum liquid in the condenser gt Ve Liquid refrigerant from the condenser heat had hi WM a Sas He a t I gm 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 O 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 t
71. ondensers nnn nennennnnenenern ennen s enen ennen kernerne reen 19 Remote Air Cooled Chiller Condensers annae nennen enne esee nnn 20 3 8 Checking Motor DIFGCIOL star enke 27 Three F hase TEE 27 Waler FUNDS An nere Maca A A reel 27 Cordan ERE EE 27 3 9 Water Hesenvoir nennen nennen enemies sae RE ERE NERE asas ne sns sanis 28 3 10 Automatic Water Make Up Oppen 31 9 11 Intake Dm Tm 31 3 12 Finishing Setup Setting Up Hassworde nnn anneer neen nen eer ven eer ennnenennnenn 33 Ocoolpak CHAPTER OPERATION omen 35 4 1 Panel Buttons Indicator Lights and Switches annuus ennen eenen eeen eneen vens 35 Microprocessor Controller oane nennen eaa eaa EIA EL EEA 35 a EE Ee MO PME TERCER 36 4 3 Status Screens naan anvenenennnenennvenenennenvenenreneneennenennrennevenenenneneennensnnsnenen 37 4 4 Access level 41 2 5 Controler el E 41 4 6 E ele te een EE lee EE 45 TE LE 47 4 8 Optional Communications aaan anann en ennrenennenrennnerennnerennnervennerennnenrennenrenn 47 CHAPTER 5 MAINTENANCE nnn eeen n nnn nnns 48 Ol LUN oia 48 322 NCE GAMING maras 48 5 3 Maintaining the CGondenser 48 Air and Remote Air Cooled Chllere esee sess eene 48 Waer Cooled ONORS 48 5 4 Maintaining the Evaporator nnen seen enenneenenenenrenenenenennenenensnenennen nnne nnn 49 5 5 Evaporator Process Piping Y Strainer uu sees 49 5 6 Preventative Maintenance Service oocccccnnccocccccncnconn
72. onnected 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 GP Series Portable Chillers Chapter 3 Installation 18 of 88 To Process From Process Condenser Condenser Drain Water Out Water In Auto water make up optional 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 35 C air entering the condenser is 28 9 bar Condensing Air Temperature Our air cooled portable chillers are designed to operate at a minimum condenser entering air temperature of approximately 24 C Operation of the equipment at a lower condenser entering air temperature can cause the chiller to malfunction For entering air temperatures below 24 C an optional fan motor speed control is available
73. or wires broke between sensor and controller terminal block ien Blocked evaporator Back flush evaporator High Fluid Temp Fault Chiller In Fluid Temp Sensor Failure Evaporator Differential Pressure Blow down y strainer by Blocked Y Severe opening blow down valve or clean internal strainer Dirty air cooled condenser Clean filter or condenser or inlet filter 22 High Discharge Pressure Warning Dirty water cooled Clean condenser or verify condenser or condenser operation of condenser valve valve failure Condenser fan overload See Fan Overload Fault GP Series Portable Chillers Chapter 6 Troubleshooting 53 of 88 water temperature too high air removal capacity system for assistance Liquid line valves closed Verily operation of valve and wiring on controller Fluid temperature higher Verify parameter and adjust than parameter if necessary Check for any Prec ben call 23 W Refrigeration system fault system Refrigeration system fault Prec ben call fault Verify with sales Chiller too small for load representative the sizing of the chiller for the application CC Compressor Critical SC System Critical PC Process Critical W Warning AlarmName____________ f Type Possible Cause Solution Fluid level higher than Verify value in parameter parameter setting 4 W High Fluid Temp Warning Open drain valve and remove some fluid from system so that level is below high level fau
74. ot exceed an elevation difference greater than 30 meters without a 296 efficiency decrease GP Series Portable Chillers Chapter 3 Installation 20 of 88 e Refer to page 73 of the Appendix for the location of traps e Refrigeration lines must not be crossed i e chiller liquid lines are to be piped to condenser liquid lines 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 4 5 meters 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 22 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 Fittings on page 24 for discharge line sizing Note For horizontal runs the d
75. ove 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 accumulatio
76. pare parts list with part numbers specific to your machine is provided with your shipping paperwork package Reter 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 GP Series Portable Chillers Chapter 1 Safety 5 of 88 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 v Follow all SAFETY CODES Y Wear SAFETY GLASSES and WORK GLOVES v Disconnect and or lock out power before servicing or maintaining the equipment v Use care when LOADING UNLOADING RIGGING or
77. posits 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 e Checking refrigerant suction and discharge pressures e Checking safety and operating conditions e Checking voltage and amperage of all motors e Checking all electrical connections e Checking quantity of refrigerant e Checking compressor oil level on units with tandem compressors e Checking lubrication of motor and pump bearings e Checking circulating pump operation
78. pressure tank fluid level depth and percentage of hot gas bypass output GP Series Portable Chillers Chapter 4 Operation 37 of 88 CAREL pGD user interface 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 vert c user interface CAREL pGD user interface cU bGD user interface 38 of 88 GP Series Portable Chillers Chapter 4 Operation D cof bGD user interface Fre PGD user interface Emm cR bGD user interface is CAREL bGD user interface IE c user interface GP Series Portable Chillers Chapter 4 Operation 39 of 88 CARE pGD user interface 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 Ur pGD user interface GP Series Portable Chillers Chapter 4 Operation 40 of 88 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 Faul
79. process temperature or FRM PROC from process temperature Analog Out 3 Analog Out 4 Digital In 8 Start Mode Chil Cntl Sens 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 CHIT 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 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 MODBUSA85 MODBUS IP LON or WEB Network Baudrate Determines the baudrate for communications Determines the network address of the chiller Network Address on tense Determines if STANDARD English or METRIC Units units are used Proc Cntl Sens Pump 2 OL Alm Flow 2 Alm Type Alarm Out Network Prot GP Series Portable Chillers Chapter 4 Operation 46 of 88 4 7 Alarms The controller is setup with multiple alarms most of
80. process water flow is less than 19 LPM per ton or greater than 76 LPM per ton See Figure 1 below for optional pump amperages Figure 1 Optional Pump Amperages d 0 8 s 0 8 H8 BENE BENE GP Series Portable Chillers Chapter 2 Functional Description 15 of 88 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 Care must be taken not to cause damage to piping and water connections 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 oupply 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 Connect 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 size
81. r x until the following screen appears for the Operator or Supervisor Password 4 Press to accept the screen and then press E until the Operator or Supervisor Password line is highlighted 5 Press m to increment or decrement the number The password can be between 0 and 9999 Press to accept the Password and move to the next line 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 or A to increment or decrement the time The password time for either setup can be from 0 to 99 minutes GP Series Portable Chillers Chapter 3 Installation 34 of 88 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 3 m cable and the GP70 through GP210 units come standard with a 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 7 C to 27 C
82. ressors 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 1 4 to 2 8 bar 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 GP Series Portable Chillers Chapter 3 Installation 27 of 88 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 o
83. rge line inside the mechanical cabinet Call a refrigeration service technician to analyze the problem and reset the control DUTOT 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 13 8 bar and the compressor will fault at 12 4 bar To prevent nuisance tripping there are delays built in to the program Note Call a Coolpak refrigeration service technician on 1300 730 736 to analyze the problem to prevent recurring low pressure faults GP Series Portable Chillers Chapter 2 Functional Description 13 of 88 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
84. ser ZEN Cond Fan Stop Discharge pressure which de energizes CG condenser fan Comp Lead Cmp On Delay X Comp Lead Cmp Off Delay 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 att Irene RN ETC TN NN NN When in AUTO the cooling valve is controlled by the cooling valve PID loop When in MANUAL the cooling valve is forced open to X the percent dictated by the Cooling Valve Pos variable When the Cooling Valve Mode is set to Cooling Valve Pos MANUAL this variable dictates what X percentage the valve is forced to GP Series Portable Chillers Chapter 4 Operation 42 of 88 X X X X X X X X X Heater Cycle Tm X X X X Cooling Valve Mode Variable HESS Minimum tank level Used to set the default low Tank Min Lvl tank level alarm setpoints as well as the auto water makeup on setpoint Maximum tank level Used to set the default Tank Max Lvl high tank level alarm setpoints as well as the auto water makeup off setpoint Tank level that will activate Low Level Warning Low Level Fault fault Tank level that will activate Low Level
85. t 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 Variable Description Operator Chilled Fluid SP Temperature of chilled fluid out to process Chil Hi Temp Wrn Setpoint for alarm to warn when chilled leaving fluid temperature is too high Chil Hi Temp Fit Setpoint to shut down pump and compressor based on leaving fluid temperature Temperature of tempered fluid out to process Proc Hi Temp Wrn Setpoint for alarm to warn when tempered leaving fluid temperature is too high Setpoint for alarm to warn when tempered PEO TER E leaving fluid temperature is too high Setpoint for alarm to warn when tempered PIOC LOW PEMD YLIN leaving fluid temperature is too low Proc Low Temp Fit Setpoint for alarm to warn when tempered leaving fluid temperature is too low Cooling Enabled Refrigeration system allowed to operate Heating Enabled Optional Process temperature heater allowed to operate Lowest temperature fluid will operate without freezing Below 0 C glycol must be added Forces lowest Chilled fluid setpoint to be 7 C above FFP Chill On Diff Temperature difference above chilled fluid setpoint before compressor turns on Chill Off Diff Temperature difference below chilled fluid setpoint before compressor turns off Proc On Diff Temperature difference below process setpoint before process heater turns on X X X X
86. t warrant the freeze up of the evaporator under any circumstances e The air cooled condenser should have an adequate supply of 24 to 46 C air for proper operation e The tower or city water condenser cooling in and out connections should be completed and an adequate supply of 30 C tower or 21 C city water at 1 7 bar pressure for proper operation e 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 d
87. te the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have Bill of Lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact us immediately on 1300 730 736 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Ocoolpak Table of Contents CHAPITER 1 SAFETY ommen 5 TFT HOW WO USE This MANEN rica 5 Safety Symbols Used in this Manual 5 1 2 Warnings and Hrecautons rrt rterrennnne 6 pce rc 6 CHAPTER 2 FUNCTIONAL DESCRIPTION 7 2 1 Models Covered in This Manual
88. temperature TO PROC retransmission of the to process temperature or COOL VLV process loop cooling valve GP Series Portable Chillers Chapter 4 Operation 45 of 88 Analog Out 2 Tm Access Level Variable Description Supervisor 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
89. tpoint via the PID control There is also a setting to control the discharge pressure to the most efficient value GP Series Portable Chillers Chapter 2 Functional Description 10 of 88 2 3 Standard Features Mechanical Features Compressor Hermetic scroll compressors Evaporator Stainless steel copper brazed plate evaporators 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 29 C via variable speed fan s Reservoir GP20 and GP30 models use a 75 liter polyethylene tank GP40 and GP50 models use a 150 liter polyethylene tank GP70 thru GP105 models use a 265 liter polyethylene tank GP140 thru GP210 models use a 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 e Low process water thermal flow switch e NEMA rated fan motor s on air cooled models e Galvanized structural steel frame polyester powder coat painte
90. u paul fleming net au Coolpak Service 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 email 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 FLEMING DYNAMICS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service 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 59 of 88 Specifications Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 10 C leaving water temperatures at 9 1 LPM per 3 517 kW with 35 C ambient air GPAC 20 PERFORMANCE NOMINAL DESIGN CONDITIONS COOLING CAPACITY KW ALTITUDE SEALEVEL COOLANT SUPPLY TEMPERATURE 10 C COMPRESSOR POWER WATTS AMBIENT AIR TEMPERATURE 35 C EER BT U WATT COOLANT WATER CONDENSER AIR FLOW M MIN COOLANT FLOW 45 SOUND POWER LEVEL dBA UNIT PRESSURE DROP COOLANT SUPPLY TEMPERATURE 0 4 OPERATING PA 5 25 C SOUND PRESS

GP Series Chiller Operation Manual

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