Sterling Refrigerator 8829309200 User Manual
GP Series Portable Chillers  
Part Number: 882.93092.00  
Bulletin Number: SC2-620.1  
Effective: 9/18/2009  
Write Down Your Serial Numbers Here For Future Reference:  
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We are committed to a continuing program of product improvement.  
Specifications, appearance, and dimensions described in this manual are subject to change without notice.  
ECN No. ____________  
© Copyright 2009  
All rights reserved.  
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Table of Contents  
CHAPTER 1: SAFETY................................................................5  
1-1  
How to Use This Manual .............................................................................................5  
Safety Symbols Used in this Manual.....................................................................5  
Warnings and Precautions ..........................................................................................6  
Responsibility ..............................................................................................................6  
1-2  
1-3  
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................7  
2-1  
2-2  
Models Covered in This Manual..................................................................................7  
General Description.....................................................................................................7  
Chilled Water Circuit..............................................................................................7  
Refrigeration Circuit...............................................................................................7  
Standard Features.......................................................................................................8  
Mechanical Features.............................................................................................8  
Electrical Features.................................................................................................8  
Refrigeration Features...........................................................................................9  
Controller Features................................................................................................9  
Other Features ......................................................................................................9  
Safety Devices and Interlocks.....................................................................................9  
Crankcase Heater .................................................................................................9  
High Pressure Cutout..........................................................................................10  
Low Pressure Cutout (no switch but done through the transducer) ....................10  
Flow Switch .........................................................................................................10  
Remote Start/Stop Interlock ................................................................................10  
Optional Features......................................................................................................10  
2-3  
2-4  
2-5  
CHAPTER 3: INSTALLATION..................................................13  
3-1  
3-2  
Uncrating...................................................................................................................13  
Electrical Connections...............................................................................................13  
3-3 Process Water Connections .......................................................................................14  
3-4  
3-5  
3-6  
3-7  
Bypass Valve Considerations....................................................................................14  
Galvanic Corrosion Considerations...........................................................................14  
Water Treatment Considerations ..............................................................................14  
Condenser Considerations........................................................................................15  
Water-Cooled Chiller Condensers.......................................................................15  
Air-Cooled Chiller Condensers............................................................................15  
Remote Air-Cooled Chiller Condensers ..............................................................16  
Checking Motor Direction..........................................................................................20  
Three-Phase Compressors .................................................................................20  
Water Pumps.......................................................................................................20  
Condenser Fan....................................................................................................20  
Water Reservoir ........................................................................................................21  
3-8  
3-9  
3-10 Automatic Water Make-Up Option.............................................................................23  
3-11 Initial Start-Up............................................................................................................23  
3-12 Finishing Setup: Setting Up Passwords ....................................................................23  
GP Series Portable Chillers  
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CHAPTER 4: OPERATION.......................................................26  
4-1  
Panel Buttons, Indicator Lights, and Switches ..........................................................26  
Microprocessor Controller ...................................................................................26  
Initial Start-up ............................................................................................................27  
Status Screens..........................................................................................................29  
Access Levels ...........................................................................................................31  
Controller Setpoints...................................................................................................32  
Alarms .......................................................................................................................34  
Optional Communications .........................................................................................34  
4-2  
4-3  
4-4  
4-5  
4-6  
4-7  
CHAPTER 5: MAINTENANCE .................................................36  
5-1  
5-2  
5-3  
Lubrication.................................................................................................................36  
Filter Cleaning ...........................................................................................................36  
Maintaining the Condenser .......................................................................................36  
Air- and Remote Air-Cooled Chillers ...................................................................36  
Water-Cooled Chillers .........................................................................................36  
Maintaining the Evaporator .......................................................................................37  
Evaporator Process Piping Y-Strainer.......................................................................37  
Preventative Maintenance Service............................................................................37  
5-4  
5-5  
5-6  
CHAPTER 6: TROUBLESHOOTING .......................................38  
CHAPTER 7: APPENDIX..........................................................40  
7-1  
Returned Material Policy ...........................................................................................40  
Credit Returns .....................................................................................................40  
Technical Assistance.................................................................................................41  
Parts Department ................................................................................................41  
Service Department.............................................................................................41  
Sales Department................................................................................................41  
Contract Department...........................................................................................41  
Specifications ............................................................................................................42  
Air-Cooled Portable Chillers................................................................................42  
Water-Cooled Portable Chillers...........................................................................44  
Pump Curves, Flow, and Pressure Considerations...................................................46  
60 Hertz Pump Curves........................................................................................46  
50 Hertz Pump Curves........................................................................................47  
Remote Air-Cooled Chiller Configurations ................................................................49  
Typical Ductwork for Air-Cooled Chillers...................................................................50  
Piping Diagrams........................................................................................................53  
7-2  
7-3  
7-4  
7-5  
7-6  
7-7  
GP Series Portable Chillers  
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance  
equipment productivity.  
This manual covers only light corrective maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and optional  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the equipment. We can also provide the assistance of a factory-trained technician to help  
train your operator(s) for a nominal charge. This section includes instructions, checks, and  
adjustments that should be followed before commencing with operation of the equipment.  
These instructions are intended to supplement standard shop procedures performed at shift,  
daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the equipment safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that your equipment provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, and parts lists. A  
spare parts list with part numbers specific to your machine is provided with your shipping  
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your  
serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER indicates an imminently hazardous situation which, if not avoided, will result in  
death or serious injury.  
WARNING indicates a potentially hazardous situation or practice which, if not avoided,  
could result in death or serious injury.  
CAUTION indicates a potentially hazardous situation or practice which, if not avoided,  
may result in minor or moderate injury or in property damage.  
GP Series Portable Chillers  
Chapter 1: Safety  
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1-2 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
9 Follow all SAFETY CODES.  
9 Wear SAFETY GLASSES and WORK GLOVES.  
9 Disconnect and/or lock out power before servicing or maintaining the equipment.  
9 Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
9 Operate this equipment within design specifications.  
9 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
9 Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
9 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.  
9 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.  
9 Do not restore power until you remove all tools, test equipment, etc., and the  
equipment and related components are fully reassembled.  
9 Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
We have long recognized the importance of safety and have designed and manufactured our  
equipment with operator safety as a prime consideration. We expect you, as a user, to abide  
by the foregoing recommendations in order to make operator safety a reality.  
1-3 Responsibility  
These machines are constructed for maximum operator safety when used under standard  
operating conditions and when recommended instructions are followed in the maintenance  
and operation of the machine.  
All personnel engaged in the use of the machine should become familiar with its operation as  
described in this manual.  
Proper operation of the machine promotes safety for the operator and all workers in its  
vicinity.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All warning and danger signs must be observed and obeyed. All actual or potential danger  
areas must be reported to your immediate supervisor.  
GP Series Portable Chillers  
Chapter 1: Safety  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides operation, installation, and maintenance instructions for air-, water-and  
remote air-cooled portable chillers. Model numbers are listed on the serial tag. Make sure you  
know the model and serial number of your equipment before contacting the manufacturer for  
parts or service.  
Our portable chiller models are designated by approximate compressor horsepower (5,7 1/2,  
10, 13 and 15 etc) and the cooling method used: -A for air-cooled, -W for water-cooled, and –  
R for remote-air cooled.  
2-2 General Description  
Our portable chillers are reliable, accurate, and easy to use process cooling units. They are  
available in air-, water-, and remote air-cooled designs in a range of sizes from 5 to 15 tons.  
All are self-contained, fully portable and shipped ready to use. (Remote air-cooled chillers  
require field installation by qualified technicians.)  
Standard range of operation is 20ºF to 80ºF (-7ºC to 27ºC) for applications using a  
water/glycol mix and 45ºF to 80ºF (7º to 27ºC) for water only applications.  
A factory installed crankcase pressure regulating valve option is available for processes  
requiring a leaving water temperature over 80ºF (27ºC).  
Chilled Water Circuit  
Cooling water “To Process” and “From Process” connections are made at the female NPT  
couplings provided outside the unit. Warm coolant (water and glycol mixture) returns from  
the process and goes into the reservoir tank. The coolant is then pumped through the  
evaporator where it is cooled. The coolant flows to the process and returns to repeat the cycle.  
A (manual) pressure actuated process water bypass valve located between the supply line and  
reservoir tank (single pump models only) allows minimal flow through the unit during the  
intermittent fluctuating flow conditions. It is not intended to provide continuous full bypass  
flow.  
This minimal flow allows the temperature sensor to signal the controller to shut down the  
compressor because of the drop in process water temperature. Typically the flow switch shuts  
down the chiller in this low flow condition. This valve allows enough flow for the chiller to  
function when the flow is shut off to process.  
Refrigeration Circuit  
Air-, water-, and remote air-cooled refrigerant condensing differ only in the way the  
compressed gas is condensed to a liquid.  
Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes  
through a shut-off valve into a filter/dryer that removes moisture and other contaminants. A  
refrigerant sight glass is provided. 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. The refrigerant gas flows through the suction line back into the  
compressor.  
GP Series Portable Chillers  
Chapter 2: Functional Description  
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The refrigerant is compressed in the compressor and flows through the discharge line as a gas  
to the condenser. There it gives up its heat as it condenses to a liquid in the condenser.  
An electronic hot gas bypass valve is used to control cooling capacity during intermittent or  
partial load conditions. This feature contributes substantially to chiller longevity by  
eliminating excessive cycling of the compressor and providing close temperature control.  
2-3 Standard Features  
Mechanical Features  
Compressor. Hermetic scroll compressors.  
Evaporator. Stainless steel copper brazed plate evaporators.  
Air-Cooled Condenser. Aluminum fin/ tube with washable filters, package unit only (option  
on remotes).  
Water-Cooled Condenser. Tube-in-tube condensers. All come with electronic cooling  
water regulating valves. 1 in. NPT valves for GPWC20 & 30; 1.25 in. NPT valves for  
GPWC40; and 1.50 in. NPT valves for GPWC50.  
Remote Air-Cooled Condenser. Aluminum fin/tube with low ambient control down to –  
20ºF (-29ºC) via a variable-speed primary fan.  
Reservoir. 5 hp and 7.5 hp models use a 20 gallon polyethylene tank. 10 hp and 15 hp  
models use a 40 gallon polyethylene tank.  
Piping. Non-ferrous piping  
Pump. TEFC motors (Optional 10 HP is ODP only)—horizontally mounted stamped  
stainless steel construction.  
Other Mechanical Features  
• Low process water thermal flow switch  
• NEMA-rated fan motor(s) on air-cooled models  
• Galvanized structural steel frame, painted cabinetry, with 4” (locking) swivel casters  
• Internal process water bypass valve for system protection only  
• Fully insulated refrigeration and process water piping  
• 20 mesh Y strainer on process water piping into the evaporator  
• Tank level indication  
• Pump pressure indication  
Electrical Features  
• Fully accessible NEMA 12-style electrical control enclosure  
• Single-point power and ground connection  
• Non-fused disconnect switch, lockable  
• Branch circuit fusing  
• 208-230/3/60, 460/3/60, 575/3/60 volt; 400/3/50 volt  
GP Series Portable Chillers  
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Refrigeration Features  
• HFC-410a refrigerant  
• Electronic hot gas bypass capacity control  
• High refrigerant pressure cutout switches  
• Suction and discharge pressure transducers.  
• High pressure spring actuated relief valve  
• Multiple refrigeration access ports  
• Liquid line shut-off ball valves  
• Filter-dryer  
• Sight glass  
• Externally equalized thermal expansion valve  
• Liquid line solenoid  
• Compressor crankcase heater  
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 20 character display with status, alarm, and service screens  
Other Features  
• One year labor warranty and one year compressor warranty  
• Two year parts warranty  
• Two year limited controller warranty  
2-4 Safety Devices and Interlocks  
Caution! Protect the system from freezing with glycol 20ºF below the leaving water  
temperature set point. Condensation may form inside the pump tank and dilute  
the mixture, therefore the freezing point should be verified periodically. See  
Figure 6 on page 18 for the correct mixture.  
Crankcase Heater  
5 hp through 15 hp portable chillers have a crankcase heater. It is wired through the control  
transformer that operates continuously whenever power is applied to the chiller.  
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.  
GP Series Portable Chillers  
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High Pressure Cutout  
This electro-mechanical cutout device opens the compressor control circuit if the refrigeration  
system compressor discharge pressure exceeds 575 psi..  
Note:  
The high-pressure cutout is a manual reset device typically mounted on the  
compressor discharge line inside the mechanical cabinet. Call a refrigeration  
service technician to analyze the problem and reset the control.  
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  
warning is set for 110 psig (758 kPa), and the compressor will fault at 100 psig (689 kPa).  
The low discharge warning is set for 200 psig (1,379 kPa), and the compressor will fault at  
180 psig (1,241 kPa). To prevent nuisance tripping there are delays built in to the program.  
Note:  
Call a refrigeration service technician to analyze the problem to prevent  
recurring low pressure faults.  
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  
pumps 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, remove the jumper between terminals 1 and 23, and supply a switch or dry  
contact interlock connected in series between these two terminals. Refer to the schematic  
inside the control enclosure door.  
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. Includes an  
electric water solenoid valve, a level sensing pressure switch mounted in the reservoir tank,  
and the necessary internal piping to connect the chiller to a make-up water source. 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 Error! Reference source not found. on page Error! Bookmark  
not defined..  
Process Water Side-stream Filter*. Not available on chillers less pump and reservoir tank.  
This option includes a 50 micron filter, flow meter, ball valve for throttling water flow, and  
the necessary piping to provide constant filtering of the process water at about one gallon per  
minute (1 gpm/3.8lpm).  
GP Series Portable Chillers  
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General Fault Indicator Audible/Visual Alarm*. This option includes a 100 dB audible  
alarm horn/ visual alarm strobe and silence button with provisions for customer wiring  
indication interlock. The alarm signals anytime that a fault is recognized during the operation  
of the chiller.  
Communications Options. RS-485 serial Modbus communications.  
High Pressure Fans. Provides for an additional 1.0”WC (250 Pa) of static pressure on fan  
discharge. High-pressure fans are necessary and must be included in chiller installations  
where exiting air exhausts through ductwork.  
They can be retrofitted without sheet metal modification, but will require changing out fan  
blades, and in some cases, fan motors and electrical components.  
Variable Speed Fan. Reduces the speed of the fan based on entering air temperature and  
system load, allowing the chiller to operate in ambient temperatures below 60ºF (15.5ºC).  
This option will also reduce fan noise in ambient temperatures below 95ºF (35ºC).  
Stainless Steel Reservoir. Manufactured from 304 stainless steel.  
Mounting Features.  
• Mounting rails with feet  
Optional Operating Voltages. 208-230/3/60, 460/3/60, 575/3/60, and 400/3/50 volt  
available  
UL Labeled Electrical Subpanel. This option provides for the subpanel to be listed with  
Underwriters Laboratory, with UL-related benefits and features.  
Optional Pumps. Pump options are available for greater pressure and flow rates. A  
recirculation pump is required whenever process water flow is less than 1.2 gpm per ton or  
greater than 4.8 gpm per ton. See Figure 1 on page 12 for optional pump amperages.  
NEMA 4 Electrical Enclosure. Provides for NEMA 4-level electrical enclosure protection.  
GP Series Portable Chillers  
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Figure 1: Optional Pump Amperages  
Voltage  
Construction  
HP  
1
Full Load Amps  
460/3/60  
SS  
1.7  
2.3  
1.5  
2
4.0  
3
4.2  
5
8.2  
10  
12.0  
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Chapter 3: Installation  
3-1 Uncrating  
All models are shipped mounted on a skid, enclosed in a plastic wrapper, and open-crated on  
all four sides and top.  
1. Pry the crating away from the skid.  
2. Use a pry bar to remove the blocks securing the unit to the skid.  
3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant  
from the centerline of the unit and the unit must be balanced on the forks. Lift slowly  
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove  
the skid from the unit.  
4. Lower slowly. The unit should land on its casters or rails and can then be moved into  
position.  
5. Retain the crating material for reshipping the chiller in case hidden shipping damage  
is found.  
3-2 Electrical Connections  
Supply electricity of the voltage, phase, and cycle listed on the serial tag. Total running amps  
are also found in the specification tables on pages in the Appendix.  
Bring properly sized power leads and ground from a fused disconnect (installed by your  
electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to  
the National Electrical Code recommendations. Note the outline drawings for egress into the  
cabinet. Make sure all electrical connections are tight.  
Important!  
Refer to your local electrical requirements for proper feeder conductor and  
supply disconnecting sizing. For instance, in the United States refer to  
National Electric Code (NEC) Article 430-24 through 430-26, Table  
310.15(B)(2)(a)  
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3-3 Process Water Connections  
All of our portable chillers have two chilled water connections. The chilled water supply,  
labeled “To Process” is the outlet for the chilled water leading to the process being cooled.  
The chilled water return, labeled “From Process” is the inlet leading from the process back  
into the chiller to be cooled and re-circulated.  
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.  
Note:  
Be sure to reduce external pressure drop as much as possible by generously  
sizing piping and tooling water passageways.  
3-4 Bypass Valve Considerations  
Our portable chillers have an internal manual bypass valve. If the flow is stopped to the  
process while the chiller is running, the factory-set bypass valve allows a small amount of  
water to flow through the chiller. This action allows the chiller to keep functioning while the  
flow is stopped to process. The bypass valve is not intended to provide continuous full  
bypass flow.  
Caution! Do not attempt to adjust or otherwise tamper with the internal bypass. Your  
warranty will be voided.  
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.  
3-6 Water Treatment Considerations  
Water treatment is an integral part of the system. In some locations, water may cause large  
deposits of scale, erosion, algae, and/or corrosion.  
Note:  
The use of poor quality water may result in inefficient operation, heat  
exchanger damage, and pump seal damage. Consult a qualified water  
treatment specialist to determine whether treatment is needed.  
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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’ll make two connections to the water-cooled condenser:  
Condenser Water In. The condenser water supply, labeled “Condenser Water In”, is located  
at the rear of the chiller. It is the inlet for city or tower water.  
Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum  
pressure of 25 psi.  
Caution! The electronic water-regulating valves pressure setpoint is set at the factory.  
Only a qualified refrigeration technician should adjust the pressure setting.  
Please contact our service group at 800-423-3183 to schedule an appointment.  
Normal HFC-410a refrigerant condensing pressure is 342 psi (2,360 kPa), with 85ºF (27ºC)  
water at 25 psi entering condenser water pressure  
Condenser Water Out. Condenser water return, labeled “Condenser Water Out”, is located  
at the rear of the chiller. It is the outlet for water after it has passed through the condenser.  
It is connected to the tower water return line or to a sewer or other approved discharge  
receiver. A water-regulating valve is a standard feature in the condenser water out line.  
Air-Cooled Chiller Condensers  
Air-cooled chillers use the surrounding air to cool the condenser. Install the chiller in an area  
where there is free passage of air for condensing and provisions for removal of heated air  
from the area. Do not locate air-cooled chillers in locations where steam, hot air, or fume  
exhausts can be drawn into the chiller.  
Caution! Clean air-cooled condensers and filters frequently. Failure to do so results in  
reduced capacity, increased operating costs, and possible failure of the  
equipment. Cleaning instructions can be found in the Maintenance chapter of  
this manual  
Normal maximum refrigerant condensing pressure with 95ºF (35ºC) air entering the  
condenser is 420 psi (2896 kPa).  
Condensing Air Temperature. Our air-cooled portable chillers are designed to operate at a  
minimum condenser entering air temperature of approximately 60ºF (15.5ºC). Operation of  
the equipment at a lower condenser entering air temperature can cause the chiller to  
malfunction. For entering air temperatures below 60ºF (15.5°C), an optional fan motor speed  
control is available. We recommend maintaining a minimum 60ºF (15.5°C) ambient  
temperature.  
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Remote Air-Cooled Chiller Condensers  
Remote air-cooled portable chillers are shipped with nitrogen holding charge and a full  
charge of oil (excluding the amount needed for field piping). The remote air condenser is  
shipped with a dry nitrogen charge. Verify that the holding charge has not been lost prior to  
installation. If there is no pressure, leak test the unit and repair before installing the  
interconnecting refrigerant piping. Read this entire section before installation.  
Note:  
Piping should be type “L” or type “K” refrigerant grade copper tubing only.  
Proper sizing and installation has a significant effect on system performance,  
reliability, and safety.  
Interconnecting Refrigerant Piping. The chiller and condenser refrigerant lines are  
terminated with a cap and brazed closed. Use a tube 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 need only to install the interconnecting refrigerant piping  
between the chiller and the outdoor air-cooled condenser. This piping must be properly sized,  
type “L” or type “K” refrigerant grade tubing, high temperature brazed, Install a customer  
supplied 650 psi approved refrigerant relief valve in the discharge line at the condenser,  
following all codes.  
When brazing copper joints, flow dry nitrogen through the system 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 phosgene 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 49 of the Appendix. The configuration and distance between the chiller and the  
condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are  
limitations that must be adhered to for reliable and optimal operation.  
• Leaving water temperature affects discharge line size. Be sure to inform the installing  
contractor of the leaving water temperature range in which the chiller will be operating  
• The total distance between the chiller and condenser must not exceed 200 feet or 300  
equivalent pipe feet  
• Discharge line risers cannot exceed an elevation difference greater than 100 feet  
without a 2% efficiency decrease.  
• Refer to page 49 of the Appendix for the location of traps.  
• Refrigeration lines must not be crossed, i.e., chiller liquid lines are to be piped to  
condenser liquid lines.  
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  
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leaving water temperature range is also required. See Figure 2 on page 17 for lengths of  
refrigerant valves and fittings.  
Liquid Line Sizing. The liquid line should be sized as small as possible while maintaining  
acceptable pressure drop to minimize the refrigerant charge. Liquid line risers must not  
exceed 15 feet from the base of the air-cooled condenser. Horizontal runs do not require a  
pitch. Insulation is not required unless the line is installed in a high ambient area, i.e., boiler  
room. Install a liquid line-charging valve to facilitate refrigerant charging. See Figure 3 on  
page 17 for sizing information. See Figure 5 on page 19 for charge determination.  
Discharge Line Sizing. For horizontal runs, the discharge line should be pitched downward,  
in the direction of flow, at a rate of 1/2” for every 10 feet. This will allow oil to flow towards  
the condenser. Discharge line sizing is based on the velocity required for sufficient oil return  
back to the compressor. See Figure 4 on page 18 for discharge line sizing.  
Figure 2: Equivalent Length in Feet for Valves and Fittings  
Line Size  
OD (inches)  
Angle  
Valve  
Short  
Radius EL  
Long  
Radius EL  
3/8  
1/2  
24  
24  
25  
25  
28  
29  
33  
34  
39  
44  
4
2.8  
3.2  
3.9  
4.5  
5.3  
1.9  
2.2  
2.6  
3.4  
4.2  
4.7  
5.7  
6.5  
7.8  
2.7  
3.2  
3.8  
5.2  
6.5  
5/8  
3/4  
7/8  
1-1/8  
1-3/8  
1-5/8  
2-1/8  
2-5/8  
Figure 3: Liquid Line Sizing  
5 TON CIRCUIT  
7.5 TON CIRCUIT  
Liquid Line Size (OD")  
Liquid Line Size (OD")  
Horizontal  
or  
Downflow  
Horizontal  
Total Equiv.  
Length (Ft)  
Total Equiv.  
Length (Ft)  
Upflow  
1-5 Ft  
Upflow  
6-10 Ft  
Upflow  
11-15 Ft  
or  
Upflow  
1-5 Ft  
Upflow  
6-10 Ft  
Upflow  
11-15 Ft  
Downflow  
25  
50  
1/2  
1/2  
1/2  
1/2  
1/2  
1/2  
1/2  
1/2  
1/2  
5/8  
5/8  
5/8  
1/2  
1/2  
1/2  
1/2  
1/2  
1/2  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
1/2  
1/2  
1/2  
1/2  
1/2  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
1/2  
1/2  
1/2  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
25  
50  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
3/4  
3/4  
3/4  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
75  
75  
100  
125  
150  
175  
200  
225  
250  
275  
300  
100  
125  
150  
175  
200  
225  
250  
275  
300  
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10 TON CIRCUIT  
15 TON CIRCUIT  
Liquid Line Size (OD")  
Liquid Line Size (OD")  
Horizontal  
Horizontal  
Total Equiv.  
Length (Ft)  
Total Equiv.  
Length (Ft)  
or  
Upflow  
1-5 Ft  
Upflow  
6-10 Ft  
Upflow  
11-15 Ft  
or  
Upflow  
1-5 Ft  
Upflow  
6-10 Ft  
Upflow  
11-15 Ft  
Downflow  
Downflow  
25  
5/8  
5/8  
5/8  
5/8  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
5/8  
5/8  
5/8  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
5/8  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
3/4  
7/8  
7/8  
7/8  
7/8  
3/4  
3/4  
3/4  
3/4  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
25  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
50  
50  
75  
75  
7/8  
7/8  
100  
125  
150  
175  
200  
225  
250  
275  
300  
100  
125  
150  
175  
200  
225  
250  
275  
300  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
1-1/8  
1-1/8  
Figure 4: Discharge Line Sizing  
Horizontal or Downflow Discharge Line Sizes (OD")  
Total Equivalent Length (Ft)  
Circuit  
Tons  
25  
5/8  
7/8  
7/8  
7/8  
50  
5/8  
7/8  
7/8  
7/8  
75  
5/8  
100  
5/8  
125  
3/4  
150  
3/4  
175  
3/4  
200  
3/4  
225  
3/4  
250  
275  
300  
7/8  
5
3/4  
7/8  
3/4  
7/8  
7.5  
10  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-3/8  
1-1/8  
1-3/8  
15  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
Upflow Discharge Line Sizes (OD")  
Total Equivalent Length (Ft)  
Circuit  
Tons  
25  
50  
75  
100  
125  
150  
175  
200  
225  
250  
275  
300  
5/8  
5/8  
5/8  
5/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-1/2  
B-7/8  
A-3/8  
B-5/8  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
5
A-3/8  
B-3/4  
A-3/8  
B-3/4  
7/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
7/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
A-3/8  
B-3/4  
A-3/8  
B-3/4  
A-1/2  
B-7/8  
7.5  
10  
15  
A-1/2  
A-1/2  
B-1-1/8  
B-1-1/8  
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Refrigerant Charge Determination. The approximate amount of refrigerant charge required  
by the system varies based on the total length of the refrigerant lines and the size of the  
chiller. Referring to Figure 5, determine the amount of charge based on the horsepower 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 5: Refrigerant Charge Determination  
Condenser and Chiller Charge (per circuit)  
Minimum Design Ambient - °F  
Chiller  
Model  
60  
9
50  
9
40  
10  
12  
15  
22  
30  
11  
14  
17  
25  
20  
12  
15  
19  
27  
10  
13  
16  
20  
29  
0
-10  
13  
17  
21  
31  
-20  
14  
17  
22  
32  
GPRC5  
GPRC7.5  
GPRC10  
GPRC15  
13  
16  
21  
30  
10  
13  
18  
10  
13  
19  
Line Size  
OD (inches)  
Discharge Line  
LBS of R-410a  
Liquid Line  
LBS of R-410a  
3/8  
1/2  
0.3  
0.6  
1.0  
1.5  
2.1  
3.7  
3.2  
6.0  
5/8  
9.6  
3/4  
14.4  
20.0  
34.1  
7/8  
1-1/8  
Oil Charge Determination. The remote air-cooled portable chillers are factory charged with  
the amount of oil required without field-installed piping. Additional oil required is dependent  
on the amount of additional refrigerant added.  
Calculate the amount of additional oil required by using the following formula:  
Pints of oil (Copeland Ultra 22cc) = lbs of R-410a added for field installed piping / 100.  
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3-8 Checking Motor Direction  
All of our portable chillers have their motor rotations properly phased at the factory. If  
compressors, pumps, or fans are running in reverse rotation, disconnect and lock out the  
power source and reverse any two power leads into the chiller disconnect switch.  
Caution! Do not switch leads at the motors, motor starters, or contactors.  
Three-Phase Compressors  
Scroll compressors are directionally-dependent and compress in one rotational direction.  
Reversing rotation direction results in an elevated sound level and a substantially-reduced  
current draw.  
Water Pumps  
Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure  
gauge. Pump rotation should be clockwise when viewed from the motor end. For chillers with  
optional pumps, check the appropriate pump curve in the Appendix.  
Caution! Do not run pump dry. Doing so will result in seal damage.  
Condenser Fan  
Air should be drawn through the condenser and discharged vertically from the chiller.  
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3-9 Water Reservoir  
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 6 on  
page 20 Add a pre-mixed solution of industrial quality (not automotive) ethylene glycol or  
propylene glycol and water to provide freeze protection to a temperature 20ºF (11ºC) below  
the normal chiller operating temperature set point.  
Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel,  
stainless steel, and bronze) in the system from corrosion. If you intend to use straight water,  
we strongly advise a minimum leaving water temperature of 45ºF (7ºC) or contact the service  
department.  
The following glycol products are available:  
Part Number Description  
A0541358  
A0539637  
A0542990  
A0542991  
Ethylene glycol, 5 gallons (18.9 liters)  
Ethylene glycol, 55 gallons (208.2 liters)  
Propylene glycol, 5 gallons (18.9 liters)  
Propylene glycol, 55 gallons (208.2 liters)  
Caution! Do not connect make-up water directly to the chilled water reservoir unless you  
have an approved automatic water make-up system installed.  
Caution! Do not pressurize tank. Supply and return connections must be trapped and  
vented to allow vertical risers to drain into tank. Do not overfill system. Allow  
enough free space in tank for vertical piping to drain.  
If your application has chilled water or process piping above the chiller, trap and vent the  
supply and return lines to allow vertical piping to drain into tank.  
Note:  
In applications where the process or process piping is above the reservoir, take  
steps to prevent over pressurization of the reservoir. This condition can occur  
on system shutdown when the water in the system drains into the reservoir. To  
prevent this, a vacuum breaker should be installed at the high point of the “To  
Process” and “From Process” lines.  
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Figure 6: Ethylene Glycol and Propylene Glycol Curves  
Pe rce nt G lyc ol Cu rves for Free ze Protec tion  
40.0  
30.0  
20.0  
Eth ylene G lycol  
Prop ylene Glycol  
10.0  
0.0  
-10.0  
-20.0  
-30.0  
-40.0  
-50.0  
-60.0  
0.0  
10.0  
20.0  
30.0  
40.0  
50.0  
60.0  
% Gl ycol by Vol um e  
Example: 45°F set point minus 20°F = 25°F.  
From Figure 28, 25°F equates to 10% by volume of glycol required.  
Note:  
The standard pumps used in the GPAC Serice chillers are not recommended to  
be used with fluid below 0°F (-18°C). Please consult factory for the proper  
pump.  
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3-10 Automatic Water Make-Up Option  
The chiller may be connected to an automatic make-up system if the optional package (pipe  
fittings, solenoid valve and 1/2” NPT city water make-up connection) is factory installed.  
If the automatic make-up system is connected to a city water system, make provisions to  
prevent backflow contamination. Install an approved backflow preventer in accordance with  
local codes.  
Caution! Adding straight city water into a glycol/water mixture dilutes the solution and  
eventually leads to system freeze-up. Damage from freeze-up is not covered by  
the warranty.  
To prevent system freeze-up in automatic make-up applications, we recommend using either  
a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for  
more information about these configurations.  
3-11 Initial Start-Up  
• Check the shipping papers against the serial tag to be sure chiller size, type and voltage  
is correct for the process that will be controlled. Portable chillers are built with a  
voltage specific compressor and cannot be re-wired for an alternate voltage.  
• Check the transformer primary voltage connections to be sure they are configured for  
the electrical power you are using. The voltage at the main power connection must read  
within plus or minus ten percent (±10%) of the voltage listed on the serial tag.  
Electrical connections must conform to all applicable codes.  
• Complete chilled water To Process and From Process connections.  
• Be sure the reservoir tank and chilled water circuit piping are filled a water/glycol  
mixture. The water/glycol mixture should provide for freeze protection to at least 20°F  
(11ºC) below the leaving water temperature you want. Should the display show a tank  
level less than 0 after the tank is filled, check the clear tube leading from the tank to the  
tank level pressure switch for a blockage.  
• The air-cooled condenser should have an adequate supply of 60º to 115ºF (16º to 46ºC)  
air for proper operation.  
• The tower or city water condenser cooling in and out connections should be completed  
and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi  
pressure, for proper operation.  
• Connect the main 3 phase incoming power to the unit making certain that line one (1)  
L1 is connected to the A phase, line two (2) L2 is connected to the B phase, and line  
three (3) L3 is connected to the C phase. Check for proper rotation direction of fan(s)  
and pump(s).  
The crankcase heater is automatically energized when the main power is applied. It  
should be on for at least 24 hours before startup to force dissolved refrigerant from the  
compressor oil.  
3-12 Finishing Setup: Setting Up Passwords  
You can establish passwords for two levels of security: operators and supervisors. The  
controller comes from the factory with neither password set. This allows every user access to  
all functions.  
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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.  
Supervisor Password. If you define a password for supervisors (or setup personnel) then  
most settings can be changed only after entering the password. The password will be  
required to display the extended setpoints for operating parameters and alarms. Section 4-6  
shows a table of setpoints and the restrictions between Operator and Supervisor.  
To set password protections:  
1. Press the  
2. Press the  
3. Press the  
button to access the menu screen.  
or  
or  
to highlight SETPOINTS, and press  
.
until the following screen appears for the Operator Password  
or the following screen for the Supervisor Password  
4. Press  
to accept the screen, and then press  
until the Operator or Supervisor  
Password line is highlighted.  
5. Press  
or  
to increment or decrement the number. The password can be between  
0 and 9999.  
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6. Press  
to accept the Password and move to the next line.  
7. For either Operator or Supervisor password the time that the password will allow the  
controller to be active can be set by the Operator or Supervisor Password Time. With the  
PW Time value highlighted, press  
or  
to increment or decrement the time. The  
password time for either setup can be from 0 to 99 minutes.  
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Chapter 4: Operation  
4-1 Panel Buttons, Indicator Lights, and Switches  
Microprocessor Controller  
The standard chillers use a microprocessor-based PID controller. The Carel PCO controller  
along with the Carel PGD1 Interface is a modular, self-contained unit that can slide from its  
mounting housing. It is factory set and adjusted; no field adjustment to the internal controls is  
necessary. The standard operation range is 20ºF to 80ºF (-7ºC to 27ºC).  
Figure 7 - Controller Display  
Button  
Button Description  
Detailed description  
Menu Button  
Used to access the menus structure of the PGD interface  
Used to turn the entire chiller On or Off. The button is backlit and will  
turn amber when the chiller is On.  
On/Off Button  
Back Button  
Used to back up from a menu and return to the main status screen  
Used to increment a data field or scroll up within a menu structure.  
Used to accept a data field value or to select a menu item.  
Up Arrow Button  
Enter Button  
Down Arrow Button  
Used to decrement a data field or scroll down within a menu structure.  
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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 8 - Main Status Screen  
3. Set the Leaving Fluid temperature by depressing the  
button to display  
the menu.  
Figure 9 - Menu Screen  
4. Depress the  
or  
button to highlight SETPOINTS and press  
. If  
passwords were setup (See Section 3-12 for information on the controller  
passwords) the password screen will appear.  
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Enter the established Operator Password by depressing the  
to move the  
position of the cursor, and then depressing the  
or  
button to  
increment or decrement the number. Once all of the numbers have been  
entered depress the  
appear.  
to accept the password. The following screen will  
Figure 10 - Operator Setpoints Screen  
5. Depress  
to move the cursor to the Leaving Temp line. Use the  
or  
button to increment or decrement the value. Depress  
value and move the cursor down one line.  
to accept the  
6. Depress the  
7. Depress the  
button twice to return to the main status screen.  
to start the chiller.  
8. Check pump rotation  
9. Check the pump amp draw and pump pressure. Make sure that the amp draw  
reading is within the running load and service factor amps.  
10. Operate the chiller, looking for any leaks and listening for unusual noises or  
vibrations that could indicate improper operation.  
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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 11) shows the main operating points of the chiller: Entering and Leaving fluid  
temperatures; Leaving fluid setpoint, pump discharge pressure, tank fluid level (depth), and  
percentage of hot-gas bypass output.  
Figure 11 - Main Status Screen  
Depressing cycles through the following screens (shown below) – Analog I/O, Digital  
I/O, and Test. The Analog and Digital I/O screens provide status of all of the inputs and  
outputs for the controller. The Test aides in troubleshooting the chiller when it is not  
functioning properly by displaying the basic information that a service person will need to  
know to determine the problem.  
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4-4 Access Levels  
The controller is setup to allow access to three distinct password groups: operator, supervisor,  
and service. Operator access allows the user to modify the Leaving Water Temp, Hi Temp  
Warning, and Hi Temp Fault setpoints. Supervisor access allows the supervisor to modify the  
above plus  
Selecting any of the menus in the Menu Screen will display the Password Screen.  
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4-5 Controller Setpoints  
Access Level  
Variable  
Leaving Temp  
Hi Temp Warning  
Hi Temp Fault  
Description  
Operator  
Supervisor  
Temperature of fluid out to process  
x
x
x
x
Setpoint for alarm to warn when leaving fluid  
temperature is too high  
Setpoint to shut down pump and compressor based on  
leaving fluid temperature  
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  
Delay time in seconds between fault and stopping the  
pump  
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Compressor On  
Differential  
Compressor Off  
Differential  
Pump Stop Delay  
Low Temperature  
Warning  
Temperature to activate Low Temperature Warning  
alarm  
Low Temperature Fault Temperature to activate Low Temperature Fault alarm  
The tank level to turn on optional water make-up valve;  
based on size of tank  
The tank level to turn off optional water make-up valve;  
based on size of tank.  
Water Make-up On  
Water Make-up Off  
The time in seconds that controller will allow for filling  
Water Make-up Time  
the tank  
Low Level Warning  
Low Level Fault  
Tank level that will activate Low Level Warning alarm  
Tank level that will activate Low Level Warning fault  
Tank level that will activate High Level Warning alarm  
Tank level that will activate High Level Warning fault  
High Level Warning  
High Level Fault  
High Temperature  
Delay  
Delay time in minutes between fault and stopping the  
compressor and pump  
Time in minutes to silence alarm (with optional audible  
alarm). After time alarm will reactivate.  
Alarm Silence Time  
Operator Password  
Time  
Supervisor Password  
Time  
Time in minutes for operator password to be active  
Time in minutes for supervisor password to be active  
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1. Set the Leaving Fluid temperature by depressing the  
the menu.  
button to display  
Figure 12 - Menu Screen  
2. Depress the  
or  
button to highlight SETPOINTS and press  
. If  
passwords were setup (See Section 3-12 for information on the controller  
passwords) the password screen will appear.  
Enter the Operator Password by depressing the  
the cursor, and then depressing the or  
to move the position of  
button to increment or  
decrement the number. Once all of the numbers have been entered depress  
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the  
to accept the password. The following screen will appear.  
Figure 13 - 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  
value and move the cursor down one line.  
to accept the  
4. Adjust the Hi Temp Warning and Hi Temp Fault in the same manner.  
5. Depress the button twice to return to the main status screen.  
4-6 Alarms  
The controller is setup with multiple alarms, most of them configurable using the Supervisor  
password. Section 4-5 Controller Setpoints 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.  
4-7 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.  
When using the communications function, you must add on the unit for RS-485 Modbus  
communications. The communications function allows you to read/write parameters, do  
operating instructions, and select the setting level.  
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Chapter 5: Maintenance  
5-1 Lubrication  
Grease all fan motors, and pump motors that do not have permanently sealed bearings. Be  
sure to use an all-purpose industrial grease with a temperature reference of 185˚ F (85˚ C).  
Remove the grease relief plug (motors only) before adding grease, add grease until a small  
amount pours out, and replace the plug when finished.  
Caution! Failure to remove the grease relief plug will result in dislodging the bearing  
grease seal, eventually causing bearing failure.  
Refrigeration compressors are hermetically sealed and no lubrication is required.  
5-2 Filter Cleaning  
Air filter cleaning is important to keep your air-cooled portable chiller operating at peak  
efficiency and capacity. Clean the filters whenever they appear dirty, or at regularly  
scheduled intervals.  
1. Turn the chiller off.  
2. Slide the filter rod to release it from the frame at the top and bottom.  
3. Wash down the filter with clean water (preferably with a garden hose), directing the flow  
of water opposite the direction of airflow. If dirt is heavy, use a mild detergent and rinse  
well. Allow the filter to dry completely before replacing it on the chiller.  
Note:  
Keep a spare air filter set on hand. Install and use it while cleaning).  
Caution! Do not use compressed air to blow off a dirty filter. It will not clean very well,  
and the filter could be damaged. Never run the chiller without properly  
installed filters.  
5-3 Maintaining the Condenser  
Dirty condenser heat exchange surfaces reduce system capacity and efficiency.  
Air- and Remote Air-Cooled Chillers  
Brush or vacuum light dirt accumulations off the aluminum condenser fins. Avoid bending or  
damaging them. Heavy dirt accumulations on the fins may require professional cleaning.  
Water-Cooled Chillers  
Proper water treatment will greatly reduce cleaning intervals.  
Coaxial Condensers (Standard). Remove dirt and slime in the condenser tube water side by  
reverse-circulating with a mild detergent and water solution. Remove mineral deposits by  
reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through  
the water side of the condenser. Follow the directions on the container.  
Shell & Tube Condensers (Optional). Remove dirt and slime in the condenser tube water  
side by cleaning with a nylon tube brush. Remove mineral deposits by reverse circulating  
Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the tube water side  
of the condenser. Follow the directions on the container.  
The refrigerant side is sealed and requires no routine maintenance.  
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Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you  
are monitoring the refrigeration circuit for excessive pressure with gauges.  
Only a trained technician should use this method.  
5-4 Maintaining the Evaporator  
Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt  
and slime in the evaporator by reverse-circulating with a mild detergent and water solution.  
Remove mineral deposits by reverse-circulating Liquid Citric Acid De-Scaling Solution (Part  
No. A0536607). Follow the directions on the container.  
5-5 Evaporator Process Piping Y-Strainer  
The process piping Y-strainer requires periodic cleaning of its screen to insure the proper  
flow through the evaporator. To clean the strainer screen, remove the access plug and  
retaining cap, and pull out the screen.  
Wipe, brush, or vacuum out any dirt left in the strainer body. Clean the screen and replace it  
in the strainer taking care to fit it squarely into the machined seat provided.  
Caution! Do not forget to re-install the screen after cleaning it. Operating the chiller  
with no strainer screen can potentially plug the evaporator with dirt. The  
warranty does not cover chiller failures from a dirty evaporator.  
5-6 Preventative Maintenance Service  
Follow a systematic preventive maintenance program to help avoid costly down time. Call  
the Service Department to arrange a schedule of inspections. This service can be tailored to  
fit your maintenance requirements. These inspections include, but are not limited to:  
• Checking refrigerant suction and discharge pressures  
• Checking safety and operating conditions  
• Checking voltage and amperage of all motors  
• Checking all electrical connections  
• Checking quantity of refrigerant  
• Checking compressor oil level on units with tandem compressors  
• Checking lubrication of motor and pump bearings  
• Checking circulating pump operation  
• Checking flow through heat exchangers  
• Checking compressor efficiency  
• Checking noise levels  
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Chapter 6: Troubleshooting  
Problem  
Possible cause  
No power.  
Solution  
Check main disconnect, fuses, wiring,  
and power lead to unit.  
Voltage must be within plus or minus  
10% of nameplate rating.  
Replace.  
Wrong voltage supplied to unit.  
Defective display.  
Replace control circuit fuse.  
Check transformer.  
Unit does not run.  
Control circuit fuse blown.  
Check for a short circuit.  
Replace.  
Add water or water/glycol solution as  
required.  
Defective control transformer.  
Piping flow switch circuit open.  
Pump motor off on overload.  
Leaving fluid setpoint set higher  
than temperature of liquid in  
system.  
Reset and test.  
Lower the leaving fluid temperature  
below the leaving temperature you  
desire.  
Allow time to cool and reset, then check  
for high/low volt-age. It must be within  
plus or minus 10% of the nameplate  
rating.  
Compressor internal overload or  
fuses are open.  
Check for open fuses and loose  
compressor electrical connections.  
Compressor contactor holding coil  
open.  
Defective compressor auxiliary  
contact.  
Pump runs; compressor does not.  
Repair or replace.  
Repair or replace.  
Broken wire in the compressor  
control circuit.  
Locate and repair.  
Plugged Y-strainer  
Clean  
Check hot gas analog output value  
through status screen. Contact Service  
if output value remains at 0%  
throughout compressor cycle.  
Install bypass between to-and-from  
process line  
Pump runs, compressor cycles at  
short intervals.  
Hot gas not coming on  
Low water flow  
Make sure that the water/glycol mixture  
protection is right for the process.  
Water/glycol mixture inadequate  
for process.  
Improperly set leaving fluid  
temperature, warning, or fault set  
point  
Water temperature is too high.  
Adjust.  
Call service to find and repair the leak,  
then have refrigerant added.  
Refrigerant charge is low.  
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Problem  
Possible cause  
Solution  
Verify rotation; if running in reverse  
rotation, reverse any two main power  
leads. Re-verify for correct pump  
rotation.  
Clean the system strainer.  
Check for partially closed valves etc.  
Make sure that all lines are properly  
sized.  
Pump process pressure low (refer  
to curves for normal pressure for  
various pumps).  
Pump running in reverse.  
Check for foreign matter.  
Pump process pressure is too high. Restricted water flow.  
Restricted condenser air flow.  
Clean filters.  
Clean condenser.  
Check the refrigerant charge by viewing  
sight glass on liquid line upstream of the  
expansion valve.  
Unit runs continuously, but not  
enough cooling power.  
Unit low on refrigerant.  
Compressor not operating  
efficiently.  
Call service.  
Unit under-sized for application.  
Call sales rep.  
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Chapter 7: Appendix  
7-1 Returned Material Policy  
Credit Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMA number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returned Material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking  
charge.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new  
and unused condition, suitable for resale.  
Warranty Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMA number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if  
the item is found to be defective in materials or workmanship. Purchased components are covered  
under their specific warranty terms.  
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7-2 Technical Assistance  
Parts Department  
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call [262] 641-8610, Fax [262] 641-8653  
The ACS Customer Service Group will provide your company with genuine OEM quality parts  
manufactured to engineering design specifications, which will maximize your equipment’s performance  
and efficiency. To assist in expediting your phone or fax order, please have the model and serial  
number of your unit when you contact us. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
[
]
Call toll-free 8am–5pm CST 800 423-3183 or call [262] 641-8610  
Emergencies after 5pm CST, call [847] 439-5655  
We have a qualified service department ready to help. Service contracts are available for most  
products.  
Sales Department  
[
Call 262] 641-8610 Monday–Friday, 8am–5pm CST  
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales  
Department for the name of the sales representative nearest you.  
Contract Department  
[
Call 262] 641-8610 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services:  
project planning; system packages including drawings; equipment, labor, and construction  
materials; and union or non-union installations.  
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7-3 Specifications  
Air-Cooled Portable Chillers  
Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4  
gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply  
capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.  
G-PAC-20  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
COOLANT  
4.65  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
WATTS  
BTU/WATT  
CFM  
50  
COMPRESSOR POWER  
EER  
4936  
11.31  
4230  
86  
95  
WATER  
11  
°F  
CONDENSER AIR FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1 METER  
COOLANT FLOW  
GPM  
PSID  
dBA  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
20-80  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
GPM  
60-115  
0.944  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
20 MESH  
NON-FERROUS  
STAINLESS STEEL  
CENTRIFUGAL  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
ALUMINUM  
CAPACITY CONTROL  
REFRIGERANT  
HOT GAS BYPASS  
3 LBS R-410A  
24 INCH  
AXIAL  
CONDENSER FANS  
FRAME  
GALVANIZED STEEL  
CONDENSER FAN MOTOR  
RESERVOIR  
1/2 HP OAO, 1140 RPM  
20 GALLON POLYETHYLENE  
460V/3PH/60HZ  
PANELS  
POWDER COATED STEEL  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
690  
520  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
VDC  
NEMA 12  
MICROPROCESSOR  
10.7  
AMPS  
G-PAC-30  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
COOLANT  
7.30  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
50  
COMPRESSOR POWER  
EER  
7579  
11.56  
6343  
92  
WATTS  
BTU/WATT  
CFM  
95  
WATER  
18  
°F  
CONDENSER AIR FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1 METER  
COOLANT FLOW  
GPM  
PSID  
dBA  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
20-80  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
GPM  
60-115  
1.504  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
20 MESH  
NON-FERROUS  
STAINLESS STEEL  
CENTRIFUGAL  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
ALUMINUM  
CAPACITY CONTROL  
REFRIGERANT  
HOT GAS BYPASS  
4 LBS R-410A  
24 INCH  
AXIAL  
CONDENSER FANS  
FRAME  
GALVANIZED STEEL  
CONDENSER FAN MOTOR  
RESERVOIR  
1 HP OAO, 1140 RPM  
20 GALLON POLYETHYLENE  
460V/3PH/60HZ  
PANELS  
POWDER COATED STEEL  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
870  
700  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
VDC  
NEMA 12  
16.4  
AMPS  
MICROPROCESSOR  
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G-PAC-40  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
COOLANT  
9.91  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
WATTS  
BTU/WATT  
CFM  
50  
COMPRESSOR POWER  
EER  
10070  
11.81  
8458  
87  
95  
WATER  
24  
°F  
CONDENSER AIR FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1 METER  
COOLANT FLOW  
GPM  
PSID  
dBA  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
20-80  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
GPM  
60-115  
2.022  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
20 MESH  
NON-FERROUS  
STAINLESS STEEL  
CENTRIFUGAL  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
ALUMINUM  
CAPACITY CONTROL  
REFRIGERANT  
HOT GAS BYPASS  
6 LBS R-410A  
32 INCH  
AXIAL  
CONDENSER FANS  
FRAME  
GALVANIZED STEEL  
CONDENSER FAN MOTOR  
RESERVOIR  
1 HP OAO, 1140 RPM  
40 GALLON POLYETHYLENE  
460V/3PH/60HZ  
PANELS  
POWDER COATED STEEL  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
1090  
760  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
20  
VDC  
NEMA 12  
MICROPROCESSOR  
AMPS  
G-PAC-50  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
COOLANT  
15.19  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
50  
COMPRESSOR POWER  
EER  
14882  
12.25  
12687  
93  
WATTS  
BTU/WATT  
CFM  
95  
WATER  
36  
°F  
CONDENSER AIR FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1 METER  
COOLANT FLOW  
GPM  
PSID  
dBA  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
AMBIENT AIR TEMPERATURE  
20-80  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
GPM  
60-115  
3.016  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
20 MESH  
NON-FERROUS  
STAINLESS STEEL  
CENTRIFUGAL  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
ALUMINUM  
CAPACITY CONTROL  
REFRIGERANT  
HOT GAS BYPASS  
8 LBS R-410A  
32 INCH  
AXIAL  
CONDENSER FANS  
FRAME  
GALVANIZED STEEL  
CONDENSER FAN MOTOR  
RESERVOIR  
2 HP OAO, 1140 RPM  
40 GALLON POLYETHYLENE  
460V/3PH/60HZ  
PANELS  
POWDER COATED STEEL  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
1290  
950  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
30  
VDC  
NEMA 12  
AMPS  
MICROPROCESSOR  
GP Series Portable Chillers  
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Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
G-PWC-20  
PERFORMANCE (NOMINAL DESIGN CONDITIONS, 60 HZ)  
COOLING CAPACITY  
5.12  
50  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
4064  
COOLANT SUPPLY TEMPERATURE  
COMPRESSOR POWER  
WATTS  
CONDENSER INLET WATER  
TEMPERATURE  
COOLANT  
85  
°F  
EER  
15.13  
15.9  
BTU/WATT  
WATER  
CONDENSER WATER FLOW  
SOUND POWER LEVEL  
GPM  
dBA  
dBA  
COOLANT FLOW  
UNIT PRESSURE DROP  
13  
7
GPM  
PSID  
SOUND PRESSURE LEVEL @ 1 METER  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
20-80  
50-90  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
15  
GPM  
1.06  
TONS  
SPECIFICATIONS  
COMPRESSOR  
SCROLL  
STAINLESS STEEL  
CENTRIFUGAL  
EVAPORATOR FILTER  
COOLANT CIRCUIT  
20 MESH  
COOLANT PUMP  
NON-FERROUS  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
TUBE IN TUBE  
CAPACITY CONTROL  
REFRIGERANT  
FRAME  
HOT GAS BYPASS  
3 LBS R-410A  
GALVANIZED STEEL  
POWDER COATED STEEL  
PANELS  
RESERVOIR  
20 GALLON POLYETHYLENE  
460V/3PH/60HZ  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
690  
520  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
VDC  
NEMA 12  
MICROPROCESSOR  
10.7  
AMPS  
G-PWC-30  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
7.98  
50  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
COMPRESSOR POWER  
6416  
14.92  
25.08  
WATTS  
85  
°F  
EER  
BTU/WATT  
COOLANT  
WATER  
20  
CONDENSER WATER FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1  
METER  
GPM  
dBA  
COOLANT FLOW  
GPM  
PSID  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
20-80  
50-90  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
22.5  
GPM  
1.672  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
STAINLESS STEEL  
CENTRIFUGAL  
20 MESH  
NON-FERROUS  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
TUBE IN TUBE  
CAPACITY CONTROL  
REFRIGERANT  
FRAME  
HOT GAS BYPASS  
4 LBS R-410A  
GALVANIZED STEEL  
POWDER COATED STEEL  
PANELS  
RESERVOIR  
20 GALLON POLYETHYLENE  
460V/3PH/60HZ  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
870  
700  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
VDC  
NEMA 12  
16.4  
AMPS  
MICROPROCESSOR  
GP Series Portable Chillers  
Chapter 7: Appendix  
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G-PWC-40  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
10.94  
50  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
WATTS  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
COMPRESSOR POWER  
8450  
15.53  
33.93  
85  
°F  
EER  
BTU/WATT  
COOLANT  
WATER  
27  
CONDENSER WATER FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1  
METER  
GPM  
dBA  
COOLANT FLOW  
GPM  
PSID  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
20-80  
50-90  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
30  
GPM  
2.262  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
STAINLESS STEEL  
CENTRIFUGAL  
20 MESH  
NON-FERROUS  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
TUBE IN TUBE  
CAPACITY CONTROL  
REFRIGERANT  
FRAME  
HOT GAS BYPASS  
6 LBS R-410A  
GALVANIZED STEEL  
POWDER COATED STEEL  
PANELS  
RESERVOIR  
40 GALLON POLYETHYLENE  
460V/3PH/60HZ  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
1090  
760  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
20  
VDC  
NEMA 12  
MICROPROCESSOR  
AMPS  
G-PWC-50  
PERFORMANCE (NOMINAL DESIGN CONDITIONS)  
COOLING CAPACITY  
16.66  
50  
TONS  
°F  
ALTITUDE  
SEA LEVEL  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
COMPRESSOR POWER  
12778  
15.65  
50.28  
WATTS  
85  
°F  
EER  
BTU/WATT  
COOLANT  
WATER  
40  
CONDENSER WATER FLOW  
SOUND POWER LEVEL  
SOUND PRESSURE LEVEL @ 1  
METER  
GPM  
dBA  
COOLANT FLOW  
GPM  
PSID  
UNIT PRESSURE DROP  
7
dBA  
OPERATING PARAMETERS  
COOLANT SUPPLY TEMPERATURE  
CONDENSER INLET WATER  
TEMPERATURE  
20-80  
50-90  
°F  
°F  
COOLANT FLOW  
MINIMUM LOAD  
45  
GPM  
3.352  
TONS  
SPECIFICATIONS  
EVAPORATOR FILTER  
COMPRESSOR  
SCROLL  
STAINLESS STEEL  
CENTRIFUGAL  
20 MESH  
NON-FERROUS  
COOLANT PUMP  
COOLANT CIRCUIT  
EVAPORATOR  
CONDENSER  
BRAZED PLATE  
TUBE IN TUBE  
CAPACITY CONTROL  
REFRIGERANT  
FRAME  
HOT GAS BYPASS  
8 LBS R-410A  
GALVANIZED STEEL  
POWDER COATED STEEL  
PANELS  
RESERVOIR  
40 GALLON POLYETHYLENE  
460V/3PH/60HZ  
WEIGHT (OPERATING)  
WEIGHT (SHIPPING)  
ELECTRICAL ENCLOSURE  
CONTROL  
1290  
950  
LBS  
LBS  
POWER  
CONTROL CIRCUIT  
COMPRESSOR FULL LOAD AMPS  
120  
30  
VDC  
NEMA 12  
AMPS  
MICROPROCESSOR  
GP Series Portable Chillers  
Chapter 7: Appendix  
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7-4 Pump Curves, Flow, and Pressure Considerations  
60 Hertz Pump Curves  
September 8, 2009  
ACS CHILLER PUMPS  
5-15 ALL 60 Hz  
300  
120  
250  
200  
150  
100  
50  
100  
10 HP 3U 32-200-1100D3G  
5 HP 2CDU 200/506  
80  
60  
40  
20  
0
3 HP 2CDU 70/306  
2 HP CDU 70/520D3G  
1.5 HP CDU 70/315D3G  
3 HP CDU120/530D3G  
0
0
10  
20  
30  
40  
50  
60  
70  
80  
Capacity [Gal/min]  
HP  
Model  
GP 20 GP 30 GP 40 GP 50  
STD  
1.5 CDU 70/315D3G  
2
3
3
5
CDU 70/520D3G  
CDU 120/530D3G  
2CDU 70/306  
STD STD  
OPT OPT OPT STD  
OPT  
2CDU 200/506  
OPT OPT OPT OPT  
OPT OPT  
10 3U 32-200-1100D3G  
GP Series Portable Chillers  
Chapter 7: Appendix  
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50 Hertz Pump Curves  
September 8, 2009  
ACS CHILLER PUMPS  
5-15 ALL 50 Hz  
70  
60  
50  
40  
30  
20  
10  
0
6
10 HP 3U 32-200-1100D3G  
5
4
5 HP 2CDU 200/506  
3 HP 2CDU 70/306  
3
2
1
0
3 HP CDU120/530D3G  
2 HP CDU 70/520D3G  
1.5 HP CDU 70/315D3G  
0
50  
100  
150  
200  
250  
300  
Capacity [liter/min]  
HP  
Model  
GP 20 GP 30 GP 40 GP 50  
STD  
1.5 CDU 70/315D3G  
2
3
3
5
CDU 70/520D3G  
CDU 120/530D3G  
2CDU 70/306  
STD STD  
OPT OPT OPT STD  
OPT  
2CDU 200/506  
OPT OPT OPT OPT  
OPT OPT  
10 3U 32-200-1100D3G  
GP Series Portable Chillers  
Chapter 7: Appendix  
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Pure Water at >40°F  
GPXC-20  
GPXC-30  
GPXC-40  
GPXC-50  
GPM  
DP (PSI)  
GPM  
DP (PSI)  
GPM  
DP (PSI)  
GPM  
DP (PSI)  
0.5X Nominal  
1.0X Nominal  
2.0X Nominal  
6
1.7  
5.9  
9
1.7  
6.1  
12  
24  
48  
1.6  
5.8  
18  
36  
72  
1.8  
6.4  
12  
24  
18  
36  
21.4  
21.9  
20.7  
23.3  
Calculating Chiller Nominal Flow and Pressure to Process  
• Flow rate: Obtain the flow reading from the appropriate pump curve.  
• Pressure: Obtain a corresponding pressure reading from the pump curve you selected,  
then subtract the one-pump pressure drop listed in the above table using the  
appropriate chiller hp and flow rate.  
GP Series Portable Chillers  
Chapter 7: Appendix  
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7-5 Remote Air-Cooled Chiller Configurations  
GP Series Portable Chillers  
Chapter 7: Appendix  
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7-6 Typical Ductwork for Air-Cooled Chillers  
60 Hz Discharge  
air volume  
CFM  
4230  
50 Hz Discharge  
Fan  
air volume  
Model  
HP  
0.5  
1.0  
1.0  
2.0  
kW  
0.4  
0.7  
0.7  
1.5  
m3/min  
120  
CFM  
m3/min  
100  
150  
200  
GPAC-20  
GPAC-30  
GPAC-40  
GPAC-50  
3525  
5286  
7048  
10573  
6343  
8458  
180  
240  
12687  
360  
300  
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: • Customer use of ductwork requires the high pressure fan option. • Allow 30” (77 cm) minimum  
clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility •  
Size the ductwork for maximum capacity • Support ductwork from the building structure, not off of the  
chiller • Back draft damper to outside must be closed at all times when fan/blower is not operating •  
GP Series Portable Chillers  
Chapter 7: Appendix  
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Chillers with dual fans/blower must have a back draft damper on the cycling fan/blower to prevent  
recirculation of hot discharge air • Chillers are designed to operate at a condensing entering air  
temperature of 60ºF (16ºC) minimum without optional Variable Frequency Drive • Maximum total static  
pressure drop external to the chiller must not exceed 0.30” WG (75 Pa)  
GP Series Portable Chillers  
Chapter 7: Appendix  
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7-7  
GP Series Portable Chillers  
Chapter 7: Appendix  
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7-8 Piping Diagrams  
GP Series Portable Chillers  
Chapter 7: Appendix  
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Chapter 7: Appendix  
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Chapter 7: Appendix  
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