Related Manuals for G&D VERTICAL AIR Series
Summary of Contents for G&D VERTICAL AIR Series
- Page 1 CHILLER INSTALLATION GUIDE & USER MANUAL - VERTICAL AIR SERIES - INFO@GDCHILLERS.COM 1.800.555.0973 GDCHILLERS.COM/INSTALLATION-VIDEOS...
- Page 2 VERTICAL AIR SERIES CHILLER MANUAL ©2022 G&D CHILLERS, INC. ALL RIGHTS RESERVED...
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Page 3: Table Of Contents
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES CONTENTS CONTACT INFORMATION & AFTERHOURS SUPPORT ............ 5 INSTALLATION VIDEO LINKS .................... 5 RECEIVING YOUR CHILLER .................... 6 WARNINGS AND NOTICES .................... 6 PACKAGE CHILLER DESCRIPTION .................. 7 INSALLATION OVERVIEW .................... 8 INSTALLATION REQUIREMENTS AND CONTRACTOR RESPONSIBILITIES ...... 9 INSTALLER‐SUPPLIED COMPONENTS .................. 9 CHILLER INSTALLATION ‐ MECHANICAL ................ 9 PIPING RECOMMENDATIONS ................... 11 ELECTRICAL INSTALLATION .................... 13 SEQUENCE OF OPERATION .................... 13 CHILLER OPERATING PRINCIPLES .................. 14 REFRIGERANT CYCLE ...................... 14 CONTROLLER AND NAVIGATION .................. 15 CONTROLS INTERFACE ...................... 18 UNIT START‐UP PROCEDURES ................... 18 ... - Page 4 NORMAL SHUTDOWN ....................... 20 START‐UP INSTRUCTIONS (9 EASY STEPS)................. 21 WARRANTY START‐UP CHECKLIST .................. 22 TERA .......................... 23 MODEL INFORMATION ..................... 24 UNIT NAMEPLATE ...................... 24 COMPRESSOR NAMEPLATE.................... 25 COMPRESSOR INFORMATION ................... 25 COMPRESSOR REPLACEMENT ................... 26 POWER SUPPLY WIRING .................... 28 MAINTENANCE ........................ 30 MAINTENANCE CHECKLIST .................... 33 TROUBLESHOOTING ...................... 36 CAREL ALARMS ........................ 39 PROPYLENE GLYCOL CHART .................... 41 WARRANTY STATEMENT .................... 42 ...
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Page 5: Contact Information & Afterhours Support
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES CONTACT INFORMATION & AFTERHOURS SUPPORT CONTACT INFORMATION G&D Chillers, Inc. 760 Bailey Hill Rd. Eugene, Oregon 97402 1.800.555.0973 info@gdchillers.com Office Hours: 8 AM – 5 PM PST AFTERHOURS TECHNICAL SUPPORT G&D Chillers offers 24/7 technical support. For emergency assistance after normal business hours, call the main office at 1.800.555.0973. -
Page 6: Receiving Your Chiller
RECEIVING YOUR CHILLER INSPECTION CHECKLIST When the unit is delivered, verify that it is the correct unit and that it is properly equipped. Compare the information which appears on the unit nameplate with the ordering and submittal information. Inspect all exterior components for visible damage. Report any apparent damage or material shortage to the carrier and make a "unit damage"... -
Page 7: Package Chiller Description
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES PACKAGE CHILLER DESCRIPTION CONDENSER REFRIGERANT PIPING – Standard configuration. Copper tube Type L ACR copper. Liquid line-filter drier, sight AIR COOLED glass/moisture indicator, solenoid valve aluminum fin vertical air flow condenser coil. Direct drive propeller type fans with DDP motors and built- electronic expansion valve. -
Page 8: Insallation Overview
INSTALLATION OVERVIEW LOCATION Air cooled units must sit outside and be anchored to a solid level surface. A concrete pad is recommended. Location should be free of grass and other debris that could plug condenser fins. Ensure minimum clearance* between condenser intake side and any buildings, walls, etc. -
Page 9: Installation Requirements And Contractor Responsibilities
I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES INSTALLATION REQUIREMENTS AND CONTRACTOR RESPONSIBILITIES A list of the contractor responsibilities typically associated with the unit installation process is provided. FOUNDATION FLUID PIPING • Meet foundation requirements • Fluid strainer Solid level surface •... - Page 10 CLEARANCES Provide enough space around the unit to allow the installation and maintenance personnel unrestricted access to all service points. Observe all applicable local and national codes. Refer to submittal drawings for the unit dimensions, to provide sufficient clearance for the opening of control panel doors and unit service. All sides should have clearance not less one full width of the condenser to any obstruction.
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Page 11: Piping Recommendations
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES PIPING RECOMMENDATIONS The drawing on the next page shows features that should be included in the piping system. Supplemental details and additional recommendations are listed here: Insulate supply and return piping •... -
Page 13: Electrical Installation
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES ELECTRICAL INSTALLATION GENERAL RECOMMENDATIONS All wiring must comply with local codes and the National Electric Code. Minimum circuit ampacities and other unit electrical data are on the unit nameplate. Specific electrical schematics and connection diagrams are shipped with the unit. -
Page 14: Chiller Operating Principles
CHILLER OPERATING PRINCIPLES This section contains an overview of the operation of air-cooled liquid chillers equipped with thermostatic control systems. Note: To ensure proper diagnosis and repair, contact a qualified service organization if a problem should occur. GENERAL The large capacity chiller unit is a reciprocating type compressor air-cooled liquid chiller. This unit is equipped with unit-mounted starter/control panels and operates with R404A or R448A refrigerant. -
Page 15: Controller And Navigation
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES CONTROLLER AND NAVIGATION ALARM :SET :ENTER :PROGRAM :INFO :DOWN :ESCAPE :POWER Set Screens: 1. Glycol set point: Ensure you see in the bottom right of the display screen. a. You can change options from SET, INFO and POWER by using the UP and DOWN buttons. - Page 16 1234 25 4 6 ÿ 8 9 2 ÿ 5 21 ÿ G3 9 2 ÿ 5 21 ÿ ÿ ÿ ! ÿ " # ÿ $ % & O ÿ...
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Page 18: Controls Interface
CONTROLS INTERFACE MAIN SCREEN The Main screen is the "dashboard" of the chiller. High level status information is presented so that a user can quickly understand the operating status of the chiller. Controller use and navigation is discussed in depth in the CONTROLLER AND NAVIGATION section. -
Page 19: Pre-Start Checkout
I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES PRE-START CHECKOUT When installation is complete, but prior to putting the unit into service, the following prestart procedures must be reviewed and verified correct: CAUTION: COMPRESSOR DAMAGE! Do not operate the unit with the compressor, oil discharge, liquid line service valves and the manual shutoff on the refrigerant supply to the condenser "CLOSED". Failure to "OPEN" all valves prior to starting the compressor may cause serious damage. Check the power supply voltage to the unit at the main power distribution block. Voltage must be within the voltage utilization range stamped on the unit nameplate. Voltage imbalance must not exceed 2 percent. Check the unit power phasing to be sure that it has been installed in phase with the phase monitor. Fill the chiller reservoir with the proper solution of freeze inhibitor. Vent the system while it is being filled. CAUTION: PROPER WATER TREATMENT! The use of untreated or improperly treated water in the chiller may result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required. G&D assumes no responsibility for equipment failures which result from ... -
Page 20: Freeze Protection
CAUTION: REFRIGERANT! If both suction and discharge pressures are low but sub‐cooling is normal, a problem other than refrigerant shortage exists. Do not add refrigerant, as this may result in overcharging the circuit. Use only the refrigerant specified on the unit nameplate. Contact G&D for the recommended oil type or refer to the data plate on the compressor for your specific chiller. Failure to do so may cause compressor damage and improper unit operation. WARNING: HAZARDOUS VOLTAGE! Disconnect all electric power, including remote disconnects before servicing. Follow proper lock‐ out/tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. FREEZE PROTECTION The chiller system must be protected from freezing by use of a freeze inhibitor. The solution must be strong enough to provide protection against ice formation at the lowest anticipated ambient temperature, and at least 20° cooler than the lowest set point. A minimum of 35% Propylene Glycol is required. Do not exceed 40%. NOTICE: Equipment Damage! In order to provide freeze protection in the event of a power loss you MUST use sufficient freeze inhibitor in the chiller. NORMAL SHUTDOWN 1. - Page 21 9 Easy Steps to Start-up Your New G&D Chiller Please view install videos online at www.gdchillers.com/installation-videos Vertical Air Chillers 1. Chiller positioning: Clearance on all 4 sides of the chiller needs to be equal to one full width of the condenser.
- Page 22 Jobsite: Tech Company: Chiller Model: Technician: Chiller Serial #: Start-Up Date: FOLLOWING START-UP OF CHILLER, PLEASE SEND A COPY OF COMPELTED FORM TO G&D TECH SUPPORT CLEARANCE AROUND CHILLER FRONT: BACK: LEFT: RIGHT: (Include photos for warranty) CHILLER MOUNTING (Anchor required) GLYCOL/DYNALENE MIXTURE % GLYCOL/DYNALENE...
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Page 23: Tera
I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES TERA SERVICE We have chosen to partner with Carel, the largest refrigeration controls manufacturer. They are a robust, global partner that specializes in remote monitoring communications with the latest technology. Unlike other chiller manufacturers, we’re committed to build chillers with no proprietary parts. -
Page 24: Model Information
UNIT NAMEPLATE OVERVIEW This manual covers the installation, operation and maintenance of the Vertical Air series package chillers. NAMEPLATES The chiller nameplate is applied to the exterior surface of the control panel door. A compressor nameplate is located on each compressor. -
Page 25: Compressor Nameplate
INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES COMPRESSOR NAMEPLATE The compressor nameplate provides the following information: Unit model and size descriptor • • Unit serial number • Identifies unit electrical COMPRESSOR INFORMATION OIL LEVEL To check compressor oil level, refer to the label near the compressor sight glass. The compressor(s) must be off. Wait three minutes. -
Page 26: Compressor Replacement
REFRIGERANT PIPING The compressor suction and discharge lines are copper. In most instances, piping may be reused. If piping is not reusable, order the correct service parts. Cut all tubing with a tubing cutter to prevent copper filings from entering the system. Cut the tubing in a straight length of pipe after the compressor connection has been un‐sweated. The line can then be reinstalled using a slip coupling and brazing. NOTICE: The compressor suction line configuration must not be changed in any way. Changing compressor suction line configuration will compromise proper oil return to the compressor(s). COMPRESSOR ELECTRICAL TERMINAL BOX Be sure to protect the terminal box and all wiring when un‐brazing or brazing compressor refrigerant piping connections COMPRESSOR REPLACEMENT If the chiller suffers a failed compressor, use these steps for replacement: Each compressor has lifting eyes. Use proper lifting techniques. After a mechanical failure of a compressor, it is necessary replace the liquid line filter drier. After an electrical failure of a compressor, it will also be necessary to replace the liquid line filter drier and add a suction filter drier with clean‐ up cores. Note: Do not alter the refrigerant piping in any way as this can affect compressor lubrication. ... - Page 27 INT69 TML All Frascold compressors used in G&D Chillers vertical air series of chillers feature a red alarm button (depicted below). If the light in this button is lit, do not press the alarm button. Please call G&D Chillers technical support for assistance with INT69 TML flash code sequence diagnosis (located in box on top of compressor).
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Page 28: Power Supply Wiring
REFRIGERANT CYCLE DESCRIPTION The chiller refrigeration cycle is described below. Refrigerant evaporation occurs in the brazed plate evaporator. Metered refrigerant vaporizes as it cools the chilled liquid flowing through the evaporator passages. The refrigerant vapor leaves the evaporator as superheated gas. Refrigerant vapor generated in the evaporator flows to the compressor suction manifold where it enters and flows across the compressor motor windings to provide cooling. - Page 29 INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES WARNING: HAZARDOUS VOLTAGE! Disconnect all electric power, including remote disconnects before servicing. Follow proper lock- out/tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
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Page 30: Maintenance
MAINTENANCE GENERAL Perform all maintenance procedures and inspection at the recommended intervals. This will prolong the life of the chiller and minimize the possibility of malfunctions. Use an "Operator's Log" to record the unit's operating history. The log serves as a valuable diagnostic tool for service personnel. - Page 31 INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES Clean the condenser coils. Refer to "Coil Cleaning" in this manual. Please refer to preventative maintenance (next page) for items to verify the chiller is in perfect working order. Note that the fields highlighted in yellow are things the owner/operator can perform.
- Page 32 NOTICE: ENVIRONMENTAL CONCERNS! Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain chlorine, fluorine and carbon (CFCs) and those containing hydrogen, chlorine, fluorine and carbon (HCFCs).
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Page 33: Maintenance Checklist
Company:_____________________________________________ Date:________________________ Tech:________________________ Contact Name:_________________________________________ Phone:_______________________ Address:______________________________________________ ______________________________________________ Email:________________________ MAINTENANCE CHECKLIST (PERFORM EVERY 3 MONTHS) Glycol Pressure Glycol Pressure Glycol Level Glycol Level Glycol Mixture Glycol Mixture Fan Function Fan Amps Pump Function Pump Function Pump Amps Pump Rotation Compressor Function Compressor Amps Condenser Integrity Condenser Integrity... - Page 34 CHECKLIST T-Stat Function T-Stat Function Time Delay Function Alt-Relay/Sequencer Function Oil Level Oil Level Refrigerant Charge Grease Motors Grease Motors Contactor Function Breaker Function SuperHeat SubCooling Inspect All Terminations (Tightness/Burns) Check TXV Bulbs Insulation Integrity Insulation Integrity Cosmetic Integrity: Cosmetic Integrity: Skin,Screws,Knobs Skin,Screws,Knobs Check All Capacitors...
- Page 35 PARTS LIST : Quantity Additional Comments:...
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Page 36: Troubleshooting
TROUBLESHOOTING COMPLAINT SYMPTOMS CAUSE SOLUTION Lower than expected suction Low refrigerant charge Check for leaks, repair, and System short of and discharge pressures recharge. See item 5 capacity Higher than expected Dirty condenser Clean. See item 2 head pressure Lower than normal suction Incorrect superheat - Adjust superheat too high... - Page 37 I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES TROUBLESHOOTING COMPLAINT SYMPTOMS CAUSE SOLUTION Minimal difference in pressure Broken suction valves Change compressor Compressor does between high side and low side Broken discharge line Change compressor not pump of system, when compressor...
- Page 38 TROUBLESHOOTING COMPLAINT SYMPTOMS CAUSE SOLUTION Check for leaks, repair, and Compressor starts Internal overload tripping Loss of charge causing recharge but cycles on insufficient motor cooling overload MUST WAIT 2-3 HOURS TO 1-ph fix undervoltage CHECK IF IT WILL RESET Voltage is low or protection, 3-ph correct unbalanced if 3-ph...
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Page 39: Carel Alarms
I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES CAREL ALARMS CODE DESCRIPTION RESET ACTION DELAY AL004 Unit – User inlet water temperature probe Switch the unit off AL005 Unit – User outlet water temperature probe Switch the unit off AL008 Unit –... - Page 40 AL176 Circuit 1 – Overload compressor 2 Stop compr.2 Circ.1 AL178 Circuit 1 – Pump-Down end for maximum time Stop circuit 1 Parameter B035 AL200 Circuit 2 – Alarm discharge probe pressure Stop circuit 2 AL201 Circuit 2 – Alarm suction probe pressure Stop circuit 2 AL202 Circuit 2 –...
- Page 41 INSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES 3 4 53 67 8 98 ÿ 7 6 57 ÿ 4 ÿ 3 ÿ ÿ 3 ÿ ÿ ! ÿ " ÿ...
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Page 42: Warranty Statement
**TO ACTIVATE WARRANTY, FILL OUT STARTUP CHECKLIST AND RETURN WITHIN 30 DAYS** WARRANTY STATEMENT TWO-YEAR LIMITED WARRANTY ON PARTS, ONE-YEAR LIMITED WARRANTY ON LABOR G&D CHILLERS, INC. provides a limited warranty to the original purchaser of new products against defects in materials and workmanship for a period of one (1) year of normal commercial usage. - Page 43 I NSTALLATION GUIDE • USER MANUAL VERTICAL AIR SERIES TO THE EXTENT THAT ANY OF THE SAME CANNOT BE EXCLUDED, SUCH IMPLIED CONDITION, REPRESENTATION AND/OR WARRANTY IS LIMITED IN DURATION TO THE EXPRESS WARRANTY PERIOD REFERRED TO IN THE "LIMITED WARRANTY"...
- Page 44 INSTALLATION GUIDE • USER MANUAL SINGLE & DUAL STAGE MODELS G&D Chillers welcomes any and all questions or concerns We can be reached at 800-555-0973 or 541-345-3903...
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