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Summary of Contents for ACS GP Series
- Page 1 Operation and Installation Manual GP Series Portable Chillers Part Number: 882.12047.00 Bulletin Number: WTR3-600 Effective: 10/1/2013...
- Page 2 _________________________ _________________________ _________________________ 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 2013 All rights reserved. GP Series Portable Chillers...
- Page 3 If the shipment is not what you ordered, contact the shipping department immediately. For immediate assistance, please contact the correct facility located in the technical assistance section of this manual. Have the order number and item number available. Hold the items until you receive shipping instructions. GP Series Portable Chillers...
- Page 4 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, and it was manufactured by our company, purchased components are covered under their specific warranty terms. GP Series Portable Chillers...
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Page 5: Table Of Contents
Finishing Setup: Setting Up Passwords ..............37 CHAPTER 4: OPERATION ............39 Panel Buttons, Indicator Lights, and Switches ............39 Microprocessor Controller ................... 39 Initial Start-up ......................40 Status Screens ......................42 GP Series Portable Chillers... - Page 6 60 Hertz Pump Curves ..................73 50 Hertz Pump Curves ..................75 Remote Air-Cooled Chiller Configurations ..............78 Typical Ductwork for Air-Cooled Chillers ..............80 Piping Diagrams ......................82 GP Series Portable Chillers...
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Page 7: Chapter 1: Safety
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 7 of 93... - Page 8 Wear Safety Gloves. This equipment operates above 212F (100C) and its surfaces may reach excessive temperatures. We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these hot surfaces. GP Series Portable Chillers Chapter 1: Safety 8 of 93...
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Page 9: Warnings And Precautions
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 9 of 93... -
Page 10: Chapter 2: Functional Description
These packaged chillers should be chosen using the following criteria: Process heat load – Choose the size of the chiller so that rated capacity is no greater than 10% more than the process heat load. GP Series Portable Chillers Chapter 2: Functional Description 10 of 93... -
Page 12: Refrigeration Circuit
Upon flow verification the controller uses the leaving fluid temperature and the setpoint temperature to determine the operation of the compressor(s). When the leaving fluid temperature is greater than the setpoint plus the “compressor on GP Series Portable Chillers Chapter 2: Functional Description 12 of 93... -
Page 13: Standard Features
PID control. There is also a setting to control the discharge pressure to the most efficient value. Standard Features Mechanical Features Compressor – Hermetic scroll compressors. Evaporator – Stainless steel copper brazed plate evaporators. GP Series Portable Chillers Chapter 2: Functional Description 13 of 93... -
Page 14: Electrical Features
• Electronic modulating hot gas bypass capacity control • High refrigerant pressure cutout switch (manual reset) • Suction and discharge pressure transducers. • High refrigerant pressure spring actuated relief valve GP Series Portable Chillers Chapter 2: Functional Description 14 of 93... -
Page 15: Controller Features
If unit is mounted outdoors, power to the unit (and the main power switch) must remain on 24 hours per day, 7 days per week to prevent liquid migration to the compressor. GP Series Portable Chillers Chapter 2: Functional Description 15 of 93... -
Page 17: Flow Switch
75ºF (24ºC). This option will also reduce fan noise in lower ambient temperatures and low loads. GP Series Portable Chillers Chapter 2: Functional Description 17 of 93... -
Page 20: Chapter 3: Installation
The bypass valve is not intended to provide continuous full bypass flow. Do not attempt to adjust or otherwise tamper with the internal bypass. Your warranty will be voided. GP Series Portable Chillers Chapter 3: Installation 20 of 93... -
Page 21: Galvanic Corrosion Considerations
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. GP Series Portable Chillers Chapter 3: Installation 21 of 93... -
Page 22: Air-Cooled Chiller Condensers
VFD and the motor without output chokes is 30 m (100 ft). With output chokes the motor cable length may be extended to 65 m (195 ft). GP Series Portable Chillers Chapter 3: Installation 22 of 93... -
Page 23: Remote Air-Cooled Chiller Condensers
• Discharge line risers cannot exceed an elevation difference greater than 100 feet without a 2% efficiency decrease. • Refer to page 78 of the Appendix for the location of traps. GP Series Portable Chillers Chapter 3: Installation 23 of 93... - Page 24 Horizontal Horizontal Total Equiv. Total Equiv. Upflow Upflow Upflow Upflow Upflow Upflow Length (Ft) Length (Ft) Downflow 1-5 Ft 6-10 Ft 11-15 Ft Downflow 1-5 Ft 6-10 Ft 11-15 Ft GP Series Portable Chillers Chapter 3: Installation 24 of 93...
- Page 25 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 GP Series Portable Chillers Chapter 3: Installation 25 of 93...
- Page 26 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 GP Series Portable Chillers Chapter 3: Installation 26 of 93...
- Page 27 A-3/4 GPRC-175 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 B-1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 A-3/4 GPRC-210 B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8 B-1-5/8 GP Series Portable Chillers Chapter 3: Installation 27 of 93...
- Page 28 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. GP Series Portable Chillers Chapter 3: Installation 28 of 93...
- Page 29 GP Series Portable Chillers Chapter 3: Installation 29 of 93...
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Page 30: Checking Motor Direction
For chillers with optional pumps, check the appropriate pump curve in the Appendix. Do not run pump dry. Doing so will result in seal damage. Condenser Fan Air should be drawn through the condenser and discharged vertically from the chiller. GP Series Portable Chillers Chapter 3: Installation 30 of 93... -
Page 37: 3-12 Finishing Setup: Setting Up Passwords
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. GP Series Portable Chillers Chapter 3: Installation 37 of 93... - Page 38 Operator or Supervisor Password Time. With the PW Time value highlighted, press to increment or decrement the time. The password time for either setup can be from 0 to 99 minutes. GP Series Portable Chillers Chapter 3: Installation 38 of 93...
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Page 39: Chapter 4: Operation
Operating the chiller setpoint below 45°F (7°C) without the proper amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances. Figure 12: Controller Display... - Page 41 10. Operate the chiller, looking for any leaks and listening for unusual noises or vibrations that could indicate improper operation. Elevated sound level and substantially reduced current draw indicate reverse rotation. After several minutes of operation, the compressor internal protector trips. GP Series Portable Chillers Chapter 4: Operation 41 of 93...
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Page 42: Status Screens
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. GP Series Portable Chillers Chapter 4: Operation 42 of 93... - Page 43 GP Series Portable Chillers Chapter 4: Operation 43 of 93...
- Page 44 The chiller can be equipped with a tempered fluid loop inside of the chiller. If this option is installed, the main screen changes to the following. GP Series Portable Chillers Chapter 4: Operation 44 of 93...
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Page 45: Gp Series Portable Chillers
Temperature difference above process setpoint Proc Off Diff before process heater turns off Time (in seconds) Process High Temperature alarm Proc Hi Temp Dly is ignored before activating GP Series Portable Chillers Chapter 4: Operation 45 of 93... - Page 46 Minimum tank level. Used to set the default low Tank Min Lvl tank lefvel alarm setpoints as well as the auto-water makeup on setpoint. GP Series Portable Chillers Chapter 4: Operation 46 of 93...
- Page 47 Figure 17: Menu Screen 2. Depress the button to highlight SETTINGS and press . If passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear. GP Series Portable Chillers Chapter 4: Operation 47 of 93...
- Page 48 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. GP Series Portable Chillers Chapter 4: Operation 48 of 93...
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Page 49: Configuration Settings
CHIL OUT (retransmission of the chiller out temperature), FROM PROC Analog Out 2 (retransmission of the from process temperature), TO PROC (retransmission of the to process temperature) or COOL VLV (process loop cooling valve). GP Series Portable Chillers Chapter 4: Operation 49 of 93... - Page 50 WEB. Network Baudrate Determines the baudrate for communications. Determines the network address of the chiller on the Network Address network. Determines if STANDARD (English) or METRIC Units units are used. GP Series Portable Chillers Chapter 4: Operation 50 of 93...
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Page 51: Alarms
Network communications use a RJ-45 hardware interface using the basic Ethernet TCP/IP layer stack. Protocols available are BACNet (Ethernet, IP, or MS/TP) and ModBus IP. See Appendix for the controller data that is available through these protocols. GP Series Portable Chillers Chapter 4: Operation 51 of 93... -
Page 52: Chapter 5: Maintenance
Follow the directions on the container. Shell & Tube Condensers (GPWC70-210). Remove dirt and slime in the condenser tube water side by cleaning with a nylon tube brush. Remove mineral deposits by reverse GP Series Portable Chillers Chapter 5: Maintenance 52 of 93... -
Page 53: Maintaining The Evaporator
• Checking compressor oil level on units with tandem compressors • Checking lubrication of motor and pump bearings • Checking circulating pump operation • Checking flow through heat exchangers • Checking compressor efficiency • Checking noise levels GP Series Portable Chillers Chapter 5: Maintenance 53 of 93... -
Page 54: Chapter 6: Troubleshooting
The display will show the cause the alarm and will indicate a possible solution. To accept the , and follow the suggested solution to correct the alarm condition. alarm press following table shows the possible alarm messages that could appear on the display. GP Series Portable Chillers Chapter 6: Troubleshooting 54 of 93... -
Page 62: Chapter 7: Appendix
India +91 21 35329112 • Asia/Australia +86 512 8717 1919 • Facilities: ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com United States: Asia/Australia: India ACS Schaumburg-Corporate Offices... -
Page 63: Specifications
1 HP OAO, 1140 RPM PANELS POWDER COATED STEEL RESERVOIR 20 GALLON POLYETHYLENE WEIGHT (OPERATING) POWER 460V/3PH/60HZ WEIGHT (SHIPPING) CONTROL CIRCUIT ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 16.4 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 63 of 93... - Page 64 2 HP OAO, 1140 RPM PANELS POWDER COATED STEEL RESERVOIR 40 GALLON POLYETHYLENE WEIGHT (OPERATING) 1290 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) CONTROL CIRCUIT ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 64 of 93...
- Page 65 RESERVOIR 70 GALLON POLYETHYLENE WEIGHT (OPERATING) 2580 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 1900 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 23.1 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 65 of 93...
- Page 66 RESERVOIR 140 GALLON POLYETHYLENE WEIGHT (OPERATING) 3870 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 2850 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 30.4 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 66 of 93...
- Page 67 RESERVOIR 140 GALLON POLYETHYLENE WEIGHT (OPERATING) 5160 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 3800 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 54.5 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 67 of 93...
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Page 68: Water-Cooled Portable Chillers
GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 20 GALLON POLYETHYLENE WEIGHT (OPERATING) POWER 460V/3PH/60HZ WEIGHT (SHIPPING) CONTROL CIRCUIT ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS 16.4 AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 68 of 93... - Page 69 GALVANIZED STEEL PANELS POWDER COATED STEEL RESERVOIR 40 GALLON POLYETHYLENE WEIGHT (OPERATING) 1290 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) CONTROL CIRCUIT ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR FULL LOAD AMPS AMPS CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 69 of 93...
- Page 70 RESERVOIR 70 GALLON POLYETHYLENE WEIGHT (OPERATING) 2580 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 1900 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 23.1 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 70 of 93...
- Page 71 RESERVOIR 140 GALLON POLYETHYLENE WEIGHT (OPERATING) 3870 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 2850 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 30.4 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 71 of 93...
- Page 72 RESERVOIR 140 GALLON POLYETHYLENE WEIGHT (OPERATING) 5160 POWER 460V/3PH/60HZ WEIGHT (SHIPPING) 3800 CONTROL CIRCUIT 24/120 ELECTRICAL ENCLOSURE NEMA 12 COMPRESSOR RATED LOAD AMPS (2) @ 54.5 AMPS EACH CONTROL MICROPROCESSOR GP Series Portable Chillers Chapter 7: Appendix 72 of 93...
- Page 77 • 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 77 of 93...
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Page 78: Remote Air-Cooled Chiller Configurations
Remote Air-Cooled Chiller Configurations GP Series Portable Chillers Chapter 7: Appendix 78 of 93... - Page 79 Figure 19: Double Riser Detail GP Series Portable Chillers Chapter 7: Appendix 79 of 93...
- Page 81 0.003 28 / 70 0.001 0.003 0.002 30 / 75 0.002 0.002 32 / 80 0.002 0.001 36 / 90 0.001 Note: 1 inch of water column = 250 Pascal GP Series Portable Chillers Chapter 7: Appendix 81 of 93...
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Page 82: Piping Diagrams
Piping Diagrams GP Series Portable Chillers Chapter 7: Appendix 82 of 93... - Page 83 GP Series Portable Chillers Chapter 7: Appendix 83 of 93...
- Page 84 GP Series Portable Chillers Chapter 7: Appendix 84 of 93...
- Page 85 GP Series Portable Chillers Chapter 7: Appendix 85 of 93...
- Page 86 GP Series Portable Chillers Chapter 7: Appendix 86 of 93...
- Page 87 GP Series Portable Chillers Chapter 7: Appendix 87 of 93...
- Page 88 GP Series Portable Chillers Chapter 7: Appendix 88 of 93...
- Page 89 GP Series Portable Chillers Chapter 7: Appendix 89 of 93...
- Page 90 GP Series Portable Chillers Chapter 7: Appendix 90 of 93...
- Page 91 GP Series Portable Chillers Chapter 7: Appendix 91 of 93...
- Page 92 GP Series Portable Chillers Chapter 7: Appendix 92 of 93...
- Page 93 GP Series Portable Chillers Chapter 7: Appendix 93 of 93...
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