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GP SERIES PORTABLE CHILLERS AIR AND WATER COOLED PACKAGED UNITS OPERATIONS AND INSTRUCTION MANUAL GPL05, GPL07, GPL10, GPL15, GPL20, GPL25, GPL30, GPL40, GPL50, GPL60 Part Number: 882.04368.00 Revision: 06/2024 <<Insert name of product>><< insert part number>> • << 9/11/2018>>...
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Hold the items un l you receive shipping instruc ons. Returns Do not return any damaged or incorrect items un<l you receive shipping instruc<ons from the shipping department. GPL Series Portable Chillers 882.04368.00 • 06/2024...
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ACS Group. Manufacturer reserves the right to change specifications, design without notification or obligation. ACS Group does not assume any responsibility for any errors that may appear in this manual. In no event will ACS Group be liable for technical or editorial omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual.
Water Reservoir ....................... 27 Automatic Water Make-Up Option................29 3-10 Initial Start-Up ......................30 3-11 Finishing Setup: Setting Up Passwords ..............33 3-12 Unit Information ....................... 34 3-13 Cold Weather Installation ..................34 GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Evaporator Process Piping Y-Strainer ..............61 Preventative Maintenance Service ................61 A2L refrigerant handling and safety ................. 62 Refrigerant Service Change Log Card ...............62 Room size requirements ..................63 Service ports ......................64 Alarms/leak sensor ....................64 GPL Series Portable Chillers 882.04368.00 • 06/2024...
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TECHNICAL SPECIFICATIONS ................78 Pumps, Curves, Flow, and Pressure Considerations ..........78 Pump and System Curves Per Model Number and Utility Frequency ....79 Double Riser Detail ....................89 Typical Ductwork for Air-Cooled Chillers ..............90 GPL Series Portable Chillers 882.04368.00 • 06/2024...
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. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Each individual must take responsibility for observing the prescribed safety rules as outlined. All cau<on, warning and danger signs must be observed and obeyed. Any actual or poten<ally dangerous condi<ons must be reported to your immediate supervisor. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Sec(on 5-7. If the leak for Opteon™ XL41 and consult any detector sets off an alarm, follow relevant local codes for more detailed guidelines set forth by state and federal informa(on. regula(on to mi(gate. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Lock out. This equipment is operated with 3-phase electrical power. Therefore, when performing any maintenance opera(ons, we recommend following the local standards for performing a lock-out/tag-out procedure. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Upon comple<on of any machine maintenance, be certain ALL SAFETY GUARDS AND COVERS are securely and properly fastened prior to resuming machine opera<on. All fasteners must be in place and properly <ghtened. ANY SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. GPL Series Portable Chillers 882.04368.00 • 06/2024...
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We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime considera<on. We expect you, as a user, to abide by the foregoing recommenda<ons in order to make operator safety a reality. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Chapter as well as Chapters 3 and 4. Standard range of opera<on is 20ºF to 80ºF (-7ºC to 27ºC) for applica<ons using a water/glycol mix and 45ºF to 80ºF (7º to 27ºC) for water only applica<ons. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
(by volume) to protect the system. See Chapter 3 for a further discussion regarding the use of glycol within the system for these applica<ons. ACS Group does not warrant the freeze up of the evaporator under any circumstances.
The second compressor will be enabled if the leaving fluid temperature remains above the setpoint plus the “compressor on differen<al” value for more than 60 seconds. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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“discharge pressure start” % for a given <me delay (discharge pressure hold). AHer the <me delay, it will control to the discharge pressure setpoint via the PID control. There is also a seJng to control the discharge pressure to the most efficient value. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Internal process water bypass valve for system protec<on Fully insulated refrigera<on and process water piping 20 mesh Y strainer on process water piping into the evaporator Tank level indica<on via operator interface Pump pressure indica<on via operator interface GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Low refrigerant pressure <me delay for low ambient start-up on air-cooled chillers with the variable- speed fan op<on 103 dB audible/visual General Fault Indicator Audible/Visual Alarm Other Features One year labor warranty One year compressor warranty Two year parts warranty Three year limited controller warranty GPL Series Portable Chillers 882.04368.00 • 06/2024...
Failure to do so will damage the compressor. 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 migra on to the compressor. GPL Series Portable Chillers 882.04368.00 • 06/2024...
4 and 23. Refer to the electrical schema<c supplied in the control enclosure. Once the wiring is complete the controller will need to be reconfigured within the supervisor seJngs screen. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Op onal Pumps. Pump op<ons are available for greater pressure and flow rates. A recircula<on pump is required whenever process water flow is less than 1.2 gpm per ton or greater than 4.8 gpm per ton. See Appendix for op<onal pump curves. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
3%. If the input voltage does have an imbalance from phase to phase greater than 3% then a line reactor must be installed to prevent faults within the VFD. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
This ac<on allows the chiller to keep func<oning while the flow is stopped to process. The bypass valve is not intended to provide con<nuous full bypass flow. Do not a<empt to adjust or otherwise tamper with the internal bypass. Your warranty will be voided. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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 GPL Series Portable Chillers 882.04368.00 • 06/2024...
It is connected to the tower water return line, or to a sewer or other approved discharge receiver. A water-regula<ng valve is a standard feature in the condenser water out line. Figure 6 - Typical Water-Cooled Condenser Connec ons GPL Series Portable Chillers 882.04368.00 • 06/2024...
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. GPL Series Portable Chillers 882.04368.00 • 06/2024...
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 warranty the freeze up of the evaporator under any circumstances. The following glycol products are available from ACS:...
Damage from freeze-up is not covered by the warranty. To prevent system freeze-up in automa<c make-up applica<ons, we recommend using either a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for more informa<on about these configura<ons. GPL Series Portable Chillers 882.04368.00 • 06/2024...
The voltage at the main power connec<on must read within plus or minus ten percent (±10%) of the voltage listed on the serial tag. Electrical connec<ons must conform to all applicable codes. Figure 9 - GPL Serial Tag Loca on GPL Series Portable Chillers 882.04368.00 • 06/2024...
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.
Note: For further informa on and details on the electrical demands from the GPL chiller units, please see the technical data sheets that can be supplied by your sales representa ve or found online. GPL Series Portable Chillers 882.04368.00 • 06/2024...
0 equa<ng to no password necessary to access the corresponding access level. Dura<on for each passworded mode to be ac<ve can be defined from 2 to 99 minutes, aHer which access will <me out. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Solenoid valves that rely on pressure drops to close may be affected by cold temperatures. Failure to insulate or heat the liquid lines may result in flooded starts, cycling of equipment or damaged equipment. GPL Series Portable Chillers 882.04368.00 • 06/2024...
20ºF to 80ºF (-7ºC to 27ºC). 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.
Note: elevated sound level and substantially reduced current draw indicate reversed pump rotation. After several minutes of operation, the compressor’s internal protection circuit will trip. GPL Series Portable Chillers 882.04368.00 • 06/2024...
If no ac<ve alarms exist at the <me is pressed, an alarm history will be displayed instead. See Sec on 5-7 for more details on A2L leak sensor triggers and warnings. GPL Series Portable Chillers 882.04368.00 • 06/2024...
“Next” and “Back” buAons at the top right and leH of the status screens, respec<vely. You can return to the home screen at any <me by touching Alarm SeJngs 1 Screen Alarm SeJngs 2 Screen Alarm SeJngs 3 Screen Alarm SeJngs 4 Screen GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Setpoint for alarm to warn when op<onal process loop fluid Process Low Tmp Fault temperature is too low Flow/P Pres Alarm Delay Flow / pump pressure alarm delay from the <me the pump starts GPL Series Portable Chillers 882.04368.00 • 06/2024...
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High suc<on pressure warning alarm setpoint High Suc<on Fault High suc<on pressure fault alarm setpoint Amount of <me the compressor must be ac<ve before the high High Suc<on Delay suc<on alarms are monitored GPL Series Portable Chillers 882.04368.00 • 06/2024...
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High Cabinet Refrig Hys setpoint the cabinet refrigerant level must drop before the alarm can be cleared Set if auxiliary alarm is normally open or closed and whether it is Auxiliary Alarm a warning or fault 882.04368.00 • 06/2024 GPL Series Portable Chillers...
“Next” and “Back” buAons at the top right and leH of the status screens, respec<vely. You can return to the home screen at any <me by touching Loop Setpoints 1 screen Loop Setpoints 2 screen Loop Setpoints 3 screen 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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D parameter of the discharge pressure PID loop Discharge Start Discharge start percent Discharge Prestart Discharge prestart <me Discharge Hold Discharge hold <me Discharge Minimum Discharge minimum percent Discharge Maximum Discharge maximum percent GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Heater Cycle Time PID loop output is checked every ten seconds. If the heater PID loop output is 70% when sampled the heater output will be on for 7 seconds and off for 3 seconds. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Manual mode is only available when the chiller is offline. Manual Mode screen 1 Manual Mode screen 2 Note: While in Manual Mode, all alarms are disabled. The chiller should be monitored at all mes. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Protocols available are BACNet (Ethernet, IP, or MS/TP) and ModBus IP. Network options Local network values can be entered and maintained from the “Network” screen found by naviga<ng through the Main Menu. Tap on the appropriate field and type in the desired value. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Time in minutes for operator password to be ac<ve Operator PW Dura<on Supervisor Password 4-digit password for supervisory interac<on Supervisor PW Dura<on Time in minutes for supervisor password to be ac<ve Service password dura<on Service PW Dura<on GPL Series Portable Chillers 882.04368.00 • 06/2024...
You can return to the home screen at any <me by touching Sensor Setup 1 screen Sensor Setup 2 screen Sensor Setup 3 screen Sensor Setup 4 screen GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Pump Pres Maximum Pump pressure sensor maximum Pump Pres Offset Pump pressure sensor offset Suc<on Pres Minimum Suc<on pressure sensor minimum Suc<on Pres Maximum Suc<on pressure sensor maximum Suc<on Pres Offset Suc<on pressure sensor offset GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Pump flow sensor maximum Pump Flow Offset Pump flow sensor offset Remote SP Min Remote setpoint minimum Remote SP Max Remote setpoint maximum Remote SP Offset Remote setpoint offset Cabinet Refr Offset Cabinet refrigerant sensor offset GPL Series Portable Chillers 882.04368.00 • 06/2024...
Service Info Tapping the “Service Info” buAon shows contact informa<on for ACS group to access technical answers, knowledge, and aHermarket sales. Service Info Screen 4-10 Set Clock Tapping “Set Clock” opens the clock seJngs screen. Set Clock screen – set date and <me.
4-11 Settings Access the seJngs menu by tapping “SeJngs” from the Main Menu. SeJngs 1 Screen SeJngs 2 Screen SeJngs 3 Screen GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Lag Comp On Delay Chilled fluid reaches 2°F (1.1°C) above Chilled Fluid setpoint Time (in minutes) before lag compressor is de-energized once Lag Comp Off Delay chilled fluid reaches 2°F (1.1°C) below Chilled Fluid setpoint GPL Series Portable Chillers 882.04368.00 • 06/2024...
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DP Auto SP Increase Automa<c discharge pressure setpoint increase amount DP Auto SP Increase Automa<c discharge pressure setpoint increase interval DP Auto SP Incr Min HG Automa<c discharge pressure setpoint minimum hot gas percent 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Access the setup menu by tapping “System Setup” from the Main Menu. System Setup 1 Screen System Setup 2 Screen System Setup 3 Screen System Setup 4 Screen GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Ac<vates the op<onal water-cooled condenser differen<al water Condenser Diff Switch pressure switch Chiller Diff Switch Ac<vates the op<onal evaporator differen<al water pressure switch Aux Alarm Sets if Auxiliary alarm installed Heater Ac<vates the op<onal process heater GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Serial # Sets the chiller’s serial number PLC Power Sets whether the PLC is powered by AC or DC power LOG Sample Rate Sets the rate at which data is save to the log GPL Series Portable Chillers 882.04368.00 • 06/2024...
You can return to the home screen at any <me by touching System Status 1 screen System Status 2 screen System Status 3 screen System Status 4 screen GPL Series Portable Chillers 882.04368.00 • 06/2024...
Keep a spare air filter set on hand. Install and use it while cleaning. 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. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt and slime in the evaporator by reverse-circula<ng with a mild detergent and water solu<on. Remove mineral deposits by reverse-circula<ng Non-Acid De-Scaling Solu<on (Part No. 216.00016.00). Follow the direc<ons on the container. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Checking quan<ty of refrigerant Checking compressor oil level on units with tandem compressors Checking lubrica<on of motor and pump bearings Checking circula<ng pump opera<on Checking flow through heat exchangers Checking compressor efficiency Checking noise levels 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Upon receipt of the chiller unit, it is advised to calculate and enter the room size and maximum charge allowed on this card for future information, as well as the serial number of the unit associated with the card, if that is not already filled out. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Below is a chart of calculated values to base general sizing on where M is the refrigerant charge, and A the smallest room footprint recommended for that charge size.: Figure 16 - UL Refrigerant Charge Table and Room Size Calcula ons GPL Series Portable Chillers 882.04368.00 • 06/2024...
Refer to supplied schema<cs, or reach out to the sales and service teams for more informa<on on how to u<lize this contact. A2L leak sensor GPL Series Portable Chillers 882.04368.00 • 06/2024...
Protect yourself from hot surfaces when working on the refrigeration or process temperature sections of this equipment. These devices can reach temperatures of 180°F (82°C). Allow the equipment to cool prior to performing any maintenance or service. GPL Series Portable Chillers 882.04368.00 • 06/2024...
Locate the drive and write down the fault code shown on the display VFD Fault Drive has detected internal fault of drive. Contact customer service for assistance. GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Liquid line valves closed on controller See Discharge Pressure Sensor Discharge pressure switch failure Failure From Process fluid temperature too Verify flow through system. Make High Suc<on Pressure Fault high correc<ons as necessary. GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Electrical connec<on at controller open Sensor wires loose from controller Check the wiring connec<on at the terminal block controller terminal block Leaving Water Temp Sensor Failure Sensor wires broke between sensor Replace Sensor and controller terminal block. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Sensor wires loose from controller Verify wiring at terminal block. . terminal block Condenser Inlet Temp Sensor Failure (optional with sensor pack) Sensor wires broke between sensor Replace temperature sensor and controller terminal block. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Verify value in parameter setting. Open drain valve and remove High Level Fault Too much fluid in system some fluid from system so that level is below high level fault. Tank sensor failure Replace sensor GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Low Level Warning Optional Water Makeup valve and makeup valve. Replace failure valve if necessary Tank sensor failure Replace sensor Compressor Differential Pressure Low discharge pressure or high Contact customer service Warning suction pressure GPL Series Portable Chillers 882.04368.00 • 06/2024...
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Make up solenoid failure at valve and at terminal block. Water make-up failure Increase water pressure to be Insufficient water pressure above 5 psig (0.3 bar) Auxilliary Alarm SC/W This alarm is configurable 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Pump 2 Overload SC/W Verify system valves are operational and properly set. Pump flow rate in excess of capacity Contact customer service or sales if pump is sized too small for application. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Replace sensor if necessary. Sensor wires loose from controller Verify wiring at sensor and at terminal block terminal block. Replace sensor if From Proc Sensor Failure Sensor wires broke between sensor necessary and controller terminal block. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Pump runs; compressor does not. Failed compressor motor Compressor contactor holding coil Repair or replace. open. Defective compressor auxiliary Repair or replace. contact. Broken wire in the compressor Locate and repair. control circuit. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
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Unit runs continuously, but not Unit low on refrigerant. sight glass on liquid line upstream of the enough cooling power. expansion valve. Compressor not operating Call service. efficiently. Unit under-sized for application Call sales rep. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Refer to this manual for assistance in installing and maintaining a highly efficient machine. Ques<ons regarding areas that are not covered in the manual should be referred to the customer service manager at the factory at 262.641.8600. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Flow rate: Obtain the flow reading from the appropriate pump curve in the following pages. Pressure: Obtain a corresponding pressure reading from the pump curve you selected, then subtract the one-pump pressure drop listed in Figure 18 using the appropriate chiller and flow rate. GPL Series Portable Chillers 882.04368.00 • 06/2024...
1197 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. 882.04368.00 • 06/2024 GPL Series Portable Chillers...
Technical Assistance PARTS SUPPORT ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service. The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifica<ons, which will maximize your equipment’s performance and efficiency.
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