Table of Contents
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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.
GP Series
Portable Chillers
Part Number: 882.93092.00
Bulletin Number: SC2-620
Effective: 5/1/2009
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_________________________
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Table of Contents
Related Manuals for Sterling GP Series
Summary of Contents for Sterling GP Series
- Page 1 GP Series Portable Chillers Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.
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Page 2: Shipping Information
(262) 641-8610. Have the order number and item number available. Hold the items until you receive shipping instructions. Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. GP Series Portable Chillers... -
Page 3: Table Of Contents
Checking Motor Direction ... 16 Three-Phase Compressors ...16 Water Pumps...16 Condenser Fan...16 Water Reservoir ... 17 3-10 Automatic Water Make-Up Option... 19 3-11 Initial Start-Up... 19 3-12 Finishing Setup: Setting Up Passwords ... 19 CHAPTER 4: OPERATION... 22 GP Series Portable Chillers... - Page 4 Parts Department ...37 Service Department...37 Sales Department...37 Contract Department ...37 Specifications ... 38 Air-Cooled Portable Chillers ...38 Water-Cooled Portable Chillers ...40 Pump Curves, Flow, and Pressure Considerations... 42 60 Hertz Pump Curves ...42 Electrical Schematic ... 44 GP Series Portable Chillers...
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Page 5: 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 5 of 44... -
Page 6: 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 6 of 44... -
Page 7: Chapter 2: Functional Description
(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 7 of 44... -
Page 8: Standard 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 Chapter 2: Functional Description 8 of 44... -
Page 9: Refrigeration Features
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 Chapter 2: Functional Description 9 of 44... -
Page 10: High Pressure Cutout
(1 gpm/3.8lpm). General Fault Indicator Audible/Visual Alarm*. Includes a 100 dB audible alarm horn/ visual alarm strobe and silence button with provisions for customer wiring indication GP Series Portable Chillers Chapter 2: Functional Description 10 of 44... -
Page 11: Mounting Features
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 Chapter 2: Functional Description 11 of 44... - Page 12 Figure 1: Optional Pump Amperages Voltage Construction 460/3/60 GP Series Portable Chillers Chapter 2: Functional Description Full Load Amps 12.0 12 of 44...
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Page 13: Chapter 3: Installation
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 GP Series Portable Chillers Important! 310.15(B)(2)(a) Chapter 3: Installation... -
Page 14: Process Water Connections
Consult a qualified water treatment specialist to determine whether treatment is needed. We offer a complete line of water treatment equipment. Contact your sales representative for water testing and treatment options. GP Series Portable Chillers Chapter 3: Installation 14 of 44... -
Page 15: Condenser Considerations
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. GP Series Portable Chillers Chapter 3: Installation 15 of 44... -
Page 16: Checking Motor Direction
Appendix. Caution! Do not run pump dry. Doing so will result in seal damage. Condenser Fan Air should be drawn through the condenser and discharged vertically from the chiller. GP Series Portable Chillers Chapter 3: Installation 16 of 44... -
Page 17: Water Reservoir
To prevent this, a vacuum breaker should be installed at the high point of the “To Process” and “From Process” lines. GP Series Portable Chillers Chapter 3: Installation 17 of 44... - Page 18 Example: 45°F set point minus 20°F = 25°F. From Figure 28, 25°F equates to 10% by volume of glycol required. GP Series Portable Chillers Pe rce n t G lyc o l Cu rves fo r F ree ze P ro tec tion 20.0...
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Page 19: 3-10 Automatic Water Make-Up Option
You can establish passwords for two levels of security: operators and supervisors. The controller comes from the factory with neither password set. This allows every user access to all functions. GP Series Portable Chillers Chapter 3: Installation 19 of 44... - Page 20 Password line is highlighted. 5. Press 0 and 9999. GP Series Portable Chillers to highlight SETPOINTS, and press until the following screen appears for the Operator Password to increment or decrement the number. The password can be between...
- Page 21 Operator or Supervisor Password Time. With the PW Time value highlighted, press password time for either setup can be from 0 to 99 minutes. GP Series Portable Chillers to increment or decrement the time. The Chapter 3: Installation...
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Page 22: Chapter 4: Operation
Back Button Up Arrow Button Enter Button Down Arrow Button GP Series Portable Chillers Detailed description 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. -
Page 23: Initial Start-Up
Figure 5 - Menu Screen 4. Depress the passwords were setup (See Section 3-12 for information on the controller passwords) the password screen will appear. GP Series Portable Chillers button to highlight SETPOINTS and press Chapter 4: Operation button to display . - Page 24 10. Operate the chiller, looking for any leaks and listening for unusual noises or vibrations that could indicate improper operation. GP Series Portable Chillers to accept the password. The following screen will to move the cursor to the Leaving Temp line. Use the button to increment or decrement the value.
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Page 25: 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 tank fluid level (depth) -
Page 26: Access Levels
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 GP Series Portable Chillers Chapter 4: Operation 26 of 44... - Page 27 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. GP Series Portable Chillers Chapter 4: Operation 27 of 44...
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Page 28: Controller Setpoints
Alarm Silence Time Operator Password Time Supervisor Password Time GP Series Portable Chillers Description Temperature of fluid out to process Setpoint for alarm to warn when leaving fluid temperature is too high Setpoint to shut down pump and compressor based on... - Page 29 Enter the Operator Password by depressing the the cursor, and then depressing the decrement the number. Once all of the numbers have been entered depress GP Series Portable Chillers button to highlight SETPOINTS and press Chapter 4: Operation button to display .
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Page 30: Alarms
The communications function allows you to read/write parameters, do operating instructions, and select the setting level. GP Series Portable Chillers to accept the password. The following screen will appear. to move the cursor to the Leaving Temp line. Use the button to increment or decrement the value. - Page 31 GP Series Portable Chillers Chapter 4: Operation 31 of 44...
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Page 32: Chapter 5: Maintenance
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. GP Series Portable Chillers Chapter 5: Maintenance 32 of 44... -
Page 33: Maintaining The Evaporator
• Checking compressor oil level • 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 33 of 44... -
Page 34: Chapter 6: Troubleshooting
Unit does not run. Pump runs; compressor does not. Pump runs, compressor cycles at short intervals. Water temperature is too high. GP Series Portable Chillers Possible cause No power. Wrong voltage supplied to unit. Defective on/off switch. Control circuit fuse blown. - Page 35 Pump pressure is too high. Unit runs continuously, but not enough cooling power. GP Series Portable Chillers Possible cause Pump running in reverse. Check for foreign matter. Restricted water flow. Restricted condenser air flow.
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Page 36: Chapter 7: Appendix
After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if the item is found to be defective in materials or workmanship. Purchased components are covered under their specific warranty terms. GP Series Portable Chillers Chapter 7: Appendix 36 of 44... -
Page 37: Technical Assistance
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. Sterling, Inc 2900 S. 160 Street New Berlin, WI 53151 www.sterlco.com GP Series Portable Chillers Chapter 7: Appendix 37 of 44... -
Page 38: Specifications
CONDENSER FANS AXIAL CONDENSER FAN MOTOR 1 HP OAO, 1140 RPM RESERVOIR 20 GALLON POLYETHYLENE POWER 460V/3PH/60HZ CONTROL CIRCUIT COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers 4.72 TONS ALTITUDE °F COMPRESSOR POWER °F WATER CONDENSER AIR FLOW SOUND POWER LEVEL... - Page 39 CONDENSER FANS AXIAL CONDENSER FAN MOTOR 2 HP OAO, 1140 RPM RESERVOIR 40 GALLON POLYETHYLENE POWER 460V/3PH/60HZ CONTROL CIRCUIT COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers 10.11 TONS ALTITUDE °F COMPRESSOR POWER °F WATER CONDENSER AIR FLOW SOUND POWER LEVEL...
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Page 40: Water-Cooled Portable Chillers
CONDENSER TUBE IN TUBE RESERVOIR 20 GALLON POLYETHYLENE POWER 460V/3PH/60HZ CONTROL CIRCUIT COMPRESSOR FULL LOAD AMPS G-PWC-40 COOLING CAPACITY GP Series Portable Chillers TONS ALTITUDE °F COMPRESSOR POWER °F WATER CONDENSER WATER FLOW SOUND POWER LEVEL PSID SOUND PRESSURE LEVEL @ 1 METER 20-80 °F... - Page 41 BRAZED PLATE CONDENSER TUBE IN TUBE RESERVOIR 40 GALLON POLYETHYLENE POWER 460V/3PH/60HZ CONTROL CIRCUIT COMPRESSOR FULL LOAD AMPS GP Series Portable Chillers °F COMPRESSOR POWER °F WATER CONDENSER WATER FLOW SOUND POWER LEVEL SOUND PRESSURE LEVEL @ 1 PSID METER...
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Page 42: Pump Curves, Flow, And Pressure Considerations
Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves GP Series Portable Chillers design 3 2CDX 120/406 3 HP 2CDX 120/306 design 2 1.5 HP CDX 70/156 2 HP CDX 120/206 2CDX 120/206 design 1 1 HP CDX 70/106... - Page 43 • For two-pump (Process/Recirc) chillers, do not subtract pressure drop from table above for process pump. GP Series Portable Chillers Chapter 7: Appendix 43 of 44...
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Page 44: Electrical Schematic
Electrical Schematic Please refer to your owner’s information packet for more details regarding your specific unit. GP Series Portable Chillers Chapter 7: Appendix 44 of 44...
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