Instruction/ maintenance manual of the product GP Series Sterling
Go to page of 44
GP Series Portable Chillers Part Number: 882.93092.0 0 Bulletin Number: SC2-620 Effective: 5/1/2009 Write Down Your Serial Numbers Here For Future Reference: _________________________ ________________.
GP Series Portable Chillers ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughl y check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.
GP Series Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual .........................................................................................
GP Series Portable Chillers iv 4-1 Panel Buttons, Indicator Lights, and Switches .......................................................... 22 Microprocessor Controller ..................................................................................
GP Series Portable Chillers Chapter 1: Safety 5 of 44 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 a pplying efficient, proven techniques that enhance equipment productivity.
GP Series Portable Chillers Chapter 1: Safety 6 of 44 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.
GP Series Portable Chillers Chapter 2: Functional Description 7 of 44 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for air-, water-and remote air-cooled portable chillers.
GP Series Portable Chillers Chapter 2: Functional Description 8 of 44 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.
GP Series Portable Chillers Chapter 2: Functional Description 9 of 44 Refrigeration Features • HFC-410a refrigerant • Electronic hot gas bypass capacity control • High refrigerant pressure cutout switches • Suction and discharge pressure transducers.
GP Series Portable Chillers Chapter 2: Functional Description 10 of 44 High Pressure Cutout This electro-mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 575 psi.
GP Series Portable Chillers Chapter 2: Functional Description 11 of 44 interlock. The alarm signals anytime that a fa ult is recognized during the o peration of the chiller. Communications Options. RS-485 serial Modbus communications. High Pressure Fans.
GP Series Portable Chillers Chapter 2: Functional Description 12 of 44 Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps 460/3/60 SS 1 1.
GP Series Portable Chillers Chapter 3: Installation 13 of 44 Chapter 3: Inst allation 3-1 Uncrating All models are are shipped mounted on a skid, en closed in a plastic wrapper, and open-crated on all four sides and top. 1. Pry the crating away from the skid.
GP Series Portable Chillers Chapter 3: Installation 14 of 44 3-3 Process Water Connections All of our portable chillers have two chille d water connections. The chilled water supply, labeled “To Process” is the outlet for the chille d water leading to the process being cooled.
GP Series Portable Chillers Chapter 3: Installation 15 of 44 3-7 Condenser Considerations Water-Cooled Chiller Condensers Water-cooled portable chillers can use city wate r or tower water as a cooling medium. Make sure that all external piping and connections suppl ying and discharging water to and from the condenser are full size.
GP Series Portable Chillers Chapter 3: Installation 16 of 44 3-8 Checking Motor Direction All of our portable chillers have their moto r rotations properly phased at the factory.
GP Series Portable Chillers Chapter 3: Installation 17 of 44 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 fr eezing.
GP Series Portable Chillers Chapter 3: Installation 18 of 44 Figure 2: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G ly c ol C u r v e s f or Fr e e ze P r ot e c tio n -60.0 -50.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 0.0 10.0 20.
GP Series Portable Chillers Chapter 3: Installation 19 of 44 3-10 Automatic Water Make-Up Option The chiller may be connected to an automatic make-up sy stem if the optional package (pipe fittings, solenoid valve and 1/2” NPT city wate r make-up connection) is factory installed.
GP Series Portable Chillers Chapter 3: Installation 20 of 44 Operator Password. If you define a password for ope rators, then a password will be required to carry out any fuction (other than reviewing the status screens).
GP Series Portable Chillers Chapter 3: Installation 21 of 44 6. Press to acce pt the Password and m ove to the next line. 7. For either Operator or Supervisor passwor d the time that the password will allow the controller to be active can be set by the Operat or or Supervisor Password Time.
GP Series Portable Chillers Chapter 4: Operation 22 of 44 Chapter 4: Operation 4-1 Panel Buttons, Indicator Lights, and Switches Microprocessor Controller The standard chillers use a mi croprocessor-based PID controller.
GP Series Portable Chillers Chapter 4: Operation 23 of 44 4-2 Initial Start-up 1. Verify the initial start-up checklist from Chapter 3, Section 3-11. 2. With the main supply pow er switch in the ON position, the screen will display the version of the software fo r a period of 5 seconds, and then display the main status screen.
GP Series Portable Chillers Chapter 4: Operation 24 of 44 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 num bers have been entered depress the to accept the password.
GP Series Portable Chillers Chapter 4: Operation 25 of 44 Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of opera tion, the compressor internal protector trips. 4-3 Status Screens The controller has eight (8) preconfigured status screens.
GP Series Portable Chillers Chapter 4: Operation 26 of 44 4-4 Access Levels The controller is setup to allow access to three distinct password groups: operator, supervisor, and service.
GP Series Portable Chillers Chapter 4: Operation 27 of 44 Warning, and Hi Temp Fault setpoints. Supervis or access allows the supervisor to modify the above plus Selecting any of the menus in the Menu Screen will display the Password Screen.
GP Series Portable Chillers Chapter 4: Operation 28 of 44 4-5 Controller Setpoints Access Level Variable Description Operator Supervisor Leaving Temp Temperature of fluid out to process x x Hi Temp Wa.
GP Series Portable Chillers Chapter 4: Operation 29 of 44 1. Set the Leaving Fluid temperature by depressing the button to display the menu. Figure 8 - 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.
GP Series Portable Chillers Chapter 4: Operation 30 of 44 the to accept the password. The following screen will appear. Figure 9 - Operator Setpoints Screen 3. Depress to move the cursor to the Leaving Temp line. Use the or button to increment or decrement the value.
GP Series Portable Chillers Chapter 4: Operation 31 of 44.
GP Series Portable Chillers Chapter 5: Maintenance 32 of 44 Chapter 5: Maintenance 5-1 Lubrication Grease all blower bearings, fan and blower m otors, 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).
GP Series Portable Chillers Chapter 5: Maintenance 33 of 44 Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you are monitoring the refrigeration circu it for excessive pressure with gauges. Only a trained technician should use this method.
GP Series Portable Chillers Chapter 6: Troubleshooting 34 of 44 Chapter 6: T roubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage m ust be wit hin plus or minus 10% of nameplat e rating.
GP Series Portable Chillers Chapter 6: Troubleshooting 35 of 44 Problem Possible cause Solution Pump running in reverse. Verify rotation; if running in reverse rotation, reverse any two main power leads. Re-verify for c orrect pump rotation. Pump pressure low (refer to c urves for norm al pressure for vario us pumps).
GP Series Portable Chillers Chapter 7: Appendix 36 of 44 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 RMS number will be assigned for the equipment to be returned.
GP Series Portable Chillers Chapter 7: Appendix 37 of 44 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [262] 641-8610, Fax [262] 641-865 3 The ACS Cu.
GP Series Portable Chillers Chapter 7: Appendix 38 of 44 7-3 Specifications Air-Cooled Portable Chillers Nominal operating paramet ers for air-co oled models are 50ºF (10º C) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35º C) a mbient air.
GP Series Portable Chillers Chapter 7: Appendix 39 of 44 G-PAC-40 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 10.11 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 9944 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 12.
GP Series Portable Chillers Chapter 7: Appendix 40 of 44 Water-Cooled Portable Chillers Nominal operating parameters for w ater-cooled models are 50ºF (10ºC) leaving w ater tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
GP Series Portable Chillers Chapter 7: Appendix 41 of 44 COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POW ER 8323 WATTS CONDENSER INLET WATER TEMPERATURE 85 °F EER 16.
GP Series Portable Chillers Chapter 7: Appendix 42 of 44 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves 1 H P C D X 70/106 1.5 H P C D X 70/156 3 H P 2C D X 120/306 5 H P 2C D X 200/506 2 H P C D X 120/206 3U 32- 200-1- 10H P 2C D X 120/206 2C D X 120/406 3U 32- 200- 1-7.
GP Series Portable Chillers Chapter 7: Appendix 43 of 44 Calculating Chiller Nominal Flow and Pressure to Process • Flow rate: Obtain the flow reading from the appropriate pum p curve.
GP Series Portable Chillers Chapter 7: Appendix 44 of 44 7-5 Electrical Schematic Please refer to your owner’s information packet for more details regarding your specific unit .
An important point after buying a device Sterling GP Series (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling GP Series yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling GP Series - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling GP Series you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling GP Series will certainly help you make a decision on the purchase.
If you already are a holder of Sterling GP Series, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling GP Series.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling GP Series. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling GP Series along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
