Manuel d'utilisation / d'entretien du produit 882.93092.01 du fabricant Sterling
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GP Series Portable C hillers Part Number: 882.9309 2.01 Bulletin Number: SC2 - 620. 4 Effective: 10/10/2011 Write Down Your Serial Numbers Here For Fut ure Reference: _________________________ _______.
GP Series Po rtable Chillers ii Shipp ing Information Unpacking and I nspecti on You should inspe ct your equi pment for pos sible shi pping damage. Thoroughl y check the equipment for any damage that might have oc curred in transi t, such as broken or loose wiring and components, loose hardware and mounti ng screws, etc.
GP Series Po rtable Chillers iii Table of Conte nts CHAP TER 1 : SAFETY ................................................................ 5 1-1 How t o Use T his Manu al ......................................................................
GP Series Po rtable Chillers iv 4-4 Access Levels ................................................................ ............................................ 41 4-5 Controller Set points ..................................................
GP Series Po rtable Chillers Chapter 1: Safety 5 of 90 Chapte r 1: Safe ty 1-1 How to Use This Manual Use this manual as a gui de and reference for insta lling, operat ing, and maintaini ng your equipment. The purpose is t o assist you in appl ying efficient , proven techniques t hat enhance equipment productivit y.
GP Series Po rtable Chillers Chapter 1: Safety 6 of 90 1-2 Warnings and P reca utions Our equipment i s designed t o provide safe and rel iable o peration when instal led and opera ted within desi gn specif icatio ns, foll owing nati onal and l ocal safet y codes.
GP Series Po rtable Chillers Chapter 2: Functional Description 7 of 90 Chapte r 2: Functional De scription 2-1 Models Cove re d i n This Manual This manual provides operat ion, instal lation, and maint enance instructi ons for air -, water - and remote air - cooled portable chi llers.
GP Series Po rtable Chillers Chapter 2: Functional D escription 8 of 90 Process Fluid Temperature – The sta ndard range for the leaving fluid t emperature for thi s series of packaged chi llers is 20° F to 80°F ( - 6.7°C to 26.7°C). When the process requi res fluid temperat ures below 45°F (27.
GP Series Po rtable Chillers Chapter 2: Functional Description 9 of 90 Refrigera tion Circuit Air - , wate r - , and remote air - cool ed refrigerant c ondensing differ only in the way the compressed gas is condensed to a liquid. Shown below is a wat er cooled v ersion.
GP Series Po rtable Chillers Chapter 2: Functional Description 10 of 90 differential” va lue the controller will enable the compressor ; if equipped with two compressors th e controller w ill enable the one with the least a mount of hours.
GP Series Po rtable Chillers Chapter 2: Functional Description 11 of 90 Air - Cooled Condenser – Alum inum fin/ tube with w ashable filter s, package d uni ts only . Variable sp eed fan cont rol stan dard for all remote air cooled condensers and GPAC70 thr ou gh 210.
GP Series Po rtable Chillers Chapter 2: Functional Description 12 of 90 Multiple refrigeration access po rts Liquid line shut - off ball valves Filter - dryer Sight glas s External.
GP Series Po rtable Chillers Chapter 2: Functional Description 13 of 90 High Pressur e Cutout This electro - mechanical cutout devic e opens the compressor contr ol circuit i f the refri geration system compresso r discharge pressure exceeds 575 psi g .
GP Series Po rtable Chillers Chapter 2: Functional Description 14 of 90 Flow Sw itch The thermal dispersion flow swit ch cutout devic e, mounted in the pr ocess piping, shuts dow n the chiller if it senses that t he water/glycol f low rate through the evapor ator has dropped below an acceptable level .
GP Series Po rtable Chillers Chapter 2: Functional Description 15 of 90 Stainless Steel Reservoir. Manufactured fr om 304 stainless st eel. Mounting Features. Moun ting rails w ith feet – GP20 - GP105 indoor units. Standard on GP140 - GP210 and all outdoor packaged units.
GP Series Po rtable Chillers Chapter 3: Installatio n 16 of 90 Chapte r 3: Installation 3-1 Uncrating All models are shipped mounted on a skid, encl osed in a plasti c wrapper, and open - crated on all four sides a nd top. 1. Pry the crati ng away from the skid.
GP Series Po rtable Chillers Chapter 3: Installatio n 17 of 90 3-3 Process W ate r Connections All of our por table c hiller s have two chi lled wate r connecti ons. The chi lled wate r supply, labeled “To Process” is t he outlet for t he chilled water l eading to the proces s being cooled.
GP Series Po rtable Chillers Chapter 3: Installatio n 18 of 90 3-5 Galvanic Cor rosion Consi de rations The materials used in the water circuit piping of these chil lers are non - ferrous and react electro - chemically w ith ferrous metallic ma terials.
GP Series Po rtable Chillers Chapter 3: Installatio n 19 of 90 Figure 3 : Typical GP20 - 50 Water Cooled Condenser Connections Air- Cooled Chill er Condenser s Air - cooled chillers use the s urrounding air t o cool the condenser.
GP Series Po rtable Chillers Chapter 3: Installatio n 20 of 90 Remo te Air - Cooled Chill er Condenser s Remote air - cooled portable c hillers are shipped with nitrogen hol ding charge and a full charge of oil (excl uding the amount needed for fi eld piping).
GP Series Po rtable Chillers Chapter 3: Installatio n 21 of 90 Sizing Refri gerant Lines. To dete rmine field in stalled liquid a nd discharg e line sizes, first establish the e quivalent lengt h of pipe for each line, val ve, and elbow. Chill er capacity and leaving water temperature range is also required.
GP Series Po rtable Chillers Chapter 3: Installatio n 22 of 90 GPRC - 40 GPRC - 50 Total Equiv. Length (Ft) L iquid Line Size (OD") Total Equiv. Length (Ft) Liquid Line Size (OD") Horizontal.
GP Series Po rtable Chillers Chapter 3: Installatio n 23 of 90 GPRC - 105 GPRC - 140 Total Equiv. Length (Ft) Liquid Line Size (OD") Total Equiv. Length (Ft) Liquid Line Size (OD") Horizonta.
GP Series Po rtable Chillers Chapter 3: Installatio n 24 of 90 Figure 6 : Discha rge Line Siz ing Model Horizontal or Downflow Discharge Line Sizes (OD") Total Equivalent Length (Ft) 25 50 75 100.
GP Series Po rtable Chillers Chapter 3: Installatio n 25 of 90 Refrigerant Charge Determination. The approximate amount of refrigera nt charge required by the system varies base d on the total le ngth of the refri gerant lines and t he size of the chiller.
GP Series Po rtable Chillers Chapter 3: Installatio n 26 of 90 Figure 8: R emote Condenser Configurations.
GP Series Po rtable Chillers Chapter 3: Installatio n 27 of 90 Figure 9: D ouble Riser Detail 3-8 Checking Motor Dire ction All of our por table c hiller s have thei r motor rot ations p roperly phas ed at the factory.
GP Series Po rtable Chillers Chapter 3: Installatio n 28 of 90 3-9 Wate r Re se rvoir The standard water reser voir is rotat ionally molded polyet hylene with a removable li d.
GP Series Po rtable Chillers Chapter 3: Installatio n 29 of 90 Figure 10 : Suggested Overhead Piping Configuration.
GP Series Po rtable Chillers Chapter 3: Installatio n 30 of 90 Figure 11 : Ethylene Glycol and Propylene G lycol Curves Percent Glycol Curves for Freeze Protection -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 20.0 30.0 40.0 50.
GP Series Po rtable Chillers Chapter 3: Installatio n 31 of 90 3- 10 Automati c Water Make - Up Option The chiller may be connected to an automatic make - up system if the optional package (pipe fittings , solenoid val ve and 1/ 2” NPT city water make - up connection) is fa ctory instal led.
GP Series Po rtable Chillers Chapter 3: Installatio n 32 of 90 Complete chilled water To Proces s and From Process connections. It is s uggested that shut - off valves are added to unit to cont rol the flow rate to process and for complet ely isolating the chiller from th e process.
GP Series Po rtable Chillers Chapter 3: Installatio n 33 of 90 Warning! Operating t he chill er setpoint be low 45°F (7°C) wi thout the proper amount of glycol for fr eeze protecti on could result in a damaged evaporator. AC S Group does not warrant the f reeze up of the evaporator under any circumstances.
GP Series Po rtable Chillers Chapter 3: Installatio n 34 of 90 Warning! If you choose t o establish passwords st ore them in a secure location because if they are forgot ten there i s no way to reset them without a service call .
GP Series Po rtable Chillers Chapter 4: Operation 35 of 90 Chapte r 4: Ope ration 4-1 Pane l Bu ttons, Indicator Ligh ts, and Sw itche s Microproces sor Contro ller The standard chillers use a microprocessor - based PID controller . The Carel PCO c ontroller is located in the cont rol enclosure.
GP Series Po rtable Chillers Chapter 4: Operation 36 of 90 Butto n Button Descr iption Detailed description Menu Button Used to access the menus structure of the PGD interface On/Off Button U sed to turn the entire chiller On or Off. Th e button is backlit and will turn amber when the chiller is On.
GP Series Po rtable Chillers Chapter 4: Operation 37 of 90 Enter the establi shed Operator Password by depressing the to mo ve the position of the cur sor, and then depres sing the or button to increment or decrement t he number. Once all of the numbers ha ve been entered depress the to accept the password.
GP Series Po rtable Chillers Chapter 4: Operation 38 of 90 Figure 16 : Main C hiller Status Screen Depressing cycles through the following screens (shown below) – Analog I/O, D igital I/O, and Test. The Analog and Digit al I/O screens pr ovide status of al l of the inputs and outputs for the cont roller.
GP Series Po rtable Chillers Chapter 4: Operation 39 of 90.
GP Series Po rtable Chillers Chapter 4: Operation 40 of 90 The chiller can be equi pped with a tempered fluid l oop inside of the chi ller. If this option i s installed, the main screen changes to t he following.
GP Series Po rtable Chillers Chapter 4: Operation 41 of 90 4-4 Access Lev els The con troller is setup to allow access to thr ee distinct password groups: oper ator, supervis or, and service. Operator access allows the user to modify the Leaving Water Temp, Hi Tem p Warning, and Hi Temp Fault setpoints .
GP Series Po rtable Chillers Chapter 4: Operation 42 of 90 Variable Descrip tion Access Level Operator Supervisor Chil Hi Temp Dly Time (in seconds) Chilled High Temperature alarm is ignored be fore activating x Hi Temp Flt T ype When set to CRIT, chiller and process high t emp alarms will deactivate compressors and pumps.
GP Series Po rtable Chillers Chapter 4: Operation 43 of 90 Variable Descrip tion Access Level Operator Supervisor Tank Max Lvl Maximum tank level. Used to set the default high tank level alarm s etpoints as well as the auto - water makeup off setpoint.
GP Series Po rtable Chillers Chapter 4: Operation 44 of 90 Enter the Opera tor Password by depressing t he to move the position of the cursor, and the n depressing the or button to increment or decrement the number. Once all of the numbers have been entered depr ess the to accept the password.
GP Series Po rtable Chillers Chapter 4: Operation 45 of 90 4-6 Configuration Se ttings Within the Supervisor Menu the chi ller can be confi gured if options ar e added in the fiel d.
GP Series Po rtable Chillers Chapter 4: Operation 46 of 90 Variable Descrip tion Access Level Operator Supervisor Analog Out 3 Determines how analog output 3 is used.
GP Series Po rtable Chillers Chapter 4: Operation 47 of 90 4-7 Alarms The controller is setup with multiple alarms, most of them configura ble using the Supervis or password. Section 4 - 5 Controller S etpoints on page 41 gives a list of al arms that the controller i s setup to displ ay.
GP Series Po rtable Chillers Chapter 5: Maintenance 48 of 90 Chapte r 5: Mainte nanc e 5-1 Lubrication Grease all fan motors, and pump motors t hat do not ha ve permanentl y sealed be arings. Be sure to use an all - purpose industrial gr ease with a temperatur e reference of 185 P F (85 P C).
GP Series Po rtable Chillers Chapter 5: Maintenance 49 of 90 Caution! Do not use steam or water over 140º F (60ºC) to clean a condenser unless you are monitoring the refri geration circui t for excessive pr essure with gauges. Only a traine d technici an should use t his method.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 50 of 90 Chapte r 6: Trouble sho oting Many problems that can occur while oper ating the chil ler can be avoided by foll owing the recommended installation, op eration, and maintena nce outlined within t his manual.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 51 of 90 CC = Comp ressor Critical SC = System Critical PC = Process C ritical W = Warning Alarm Name # Type Possible Cause Solution Compressor Fault 1 CC MCP Failure Allow the compressor to cool down.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 52 of 90 Water cooled condenser valve stuck open Verify cooling valve operation. Fan VFD output at 100% Verify VFD is in remote versus manual operation.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 53 of 90 system fault Chiller too sm all for load Verify with sales representative the sizing of the chiller for the application.
GP Series Po rtable Chillers Chapter 6: T roubleshooting 54 of 90 water temperature too low and air flow or condenser inl et water temperature. Too little refrigera nt in system. C ontact customer service for service call Water cooled condenser valve stuck op en Verify cooling valve operation.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 55 of 90 Auxilliary A larm 41 SC/W This alarm is configurable Low Suction Pressure at Startup 42 CC Parameter set too short for remote condenser.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 56 of 90 Problem Possible cause Solution Control circuit fuse blown. Replace control circuit fuse. Check transformer. Check for a short circuit. Defective control transformer. Replace. Piping flow switch circui t open.
GP Series Po rtable Chillers Chapter 6: Troubleshooting 57 of 90 Problem Possible cause Solution Pump runs; compressor does not. Leaving fluid setpoint set higher than temperat ure of liq uid in system. Lower the leaving fluid temperature below the leaving temperatur e you desire.
GP Series Po rtable Chillers Chapter 7: Appendix 58 of 90 Chapte r 7: Appe ndix 7-1 R e turne d Mate rial Policy Credit Re turns Prior to the return of any material, authorizatio n must be given by the manufacturer . A RM A number will be assigned for t he equipment to be returned.
GP Series Po rtable Chillers Chapter 7: Appendix 59 of 90 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering desi gn specifications, which will maximize your equi pment’s performance and efficiency.
GP Series Po rtable Chillers Chapter 7: Appendix 60 of 90 Spe c ifications Air- Cooled Portabl e Chill ers Nominal operating parameters for ai r - cooled models ar e 50ºF (10ºC) leaving wat er temperature at 2. 4 gpm per ton (9.1 lpm per 3.517 kW) wit h 95ºF (35ºC) ambient air.
GP Series Po rtable Chillers Chapter 7: Appendix 61 of 90 G PAC - 40 PERFORMANCE (NOMINAL DESIGN CONDI TIONS) COOLING CAPACITY 9.91 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 10070 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 11.
GP Series Po rtable Chillers Chapter 7: Appendix 62 of 90 GPAC - 70 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 20.16 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 20048 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 12.
GP Series Po rtable Chillers Chapter 7: Appendix 63 of 90 GPAC - 105 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 30.21 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 29731 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 12.
GP Series Po rtable Chillers Chapter 7: Appendix 64 of 90 GPAC - 175 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 49.41 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 48693 WATTS AMBIENT AIR TEMPERATURE 95 °F EER 12.
GP Series Po rtable Chillers Chapter 7: Appendix 65 of 90 Water - Cooled Porta ble Chil lers Nominal operating parameters for wat er - cooled models ar e 50º F (10ºC) leaving water t emperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF ( 29ºC) tower water.
GP Series Po rtable Chillers Chapter 7: Appendix 66 of 90 G PWC - 40 PERFORMANCE (NOMINAL DESIGN CONDITI ONS) COOLING CAPACITY 10.94 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 8450 WATTS CONDENSER INLET WATER TEMPERATURE 85 °F EER 15.
GP Series Po rtable Chillers Chapter 7: Appendix 67 of 90 GPWC - 70 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 22.68 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 16970 WATTS CONDENSER INLET WATER TEMP 85 °F EER 16.
GP Series Po rtable Chillers Chapter 7: Appendix 68 of 90 GPWC - 105 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 33.64 TONS ALTITUDE SEA LEVEL COOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 2550 8 WATTS CONDENSER INLET WATER TEMP 85 °F EER 15.
GP Series Po rtable Chillers Chapter 7: Appendix 69 of 90 GPWC - 175 PERFORMANCE (NOMINAL DESIGN CONDITIONS) COOLING CAPACITY 54.46 TONS ALTITUDE SEA LEVEL C OOLANT SUPPLY TEMPERATURE 50 °F COMPRESSOR POWER 41633 WATTS CONDENSER INLET WATER TEMP 85 °F EER 15.
GP Series Po rtable Chillers Chapter 7: Appendix 70 of 90 7-3 Pump Cur ve s, Flow, and Pre ssure Considerations 60 Hert z Pump Curves ACS CHILLER PUMPS 20-50 A LL 60 Hz HP GP 20 GP 30 GP 40 GP 50 1.
GP Series Po rtable Chillers Chapter 7: Appendix 71 of 90 ACS CHILLER PUMPS 70-210 A LL 60 Hz HP GP70 GP90 GP105 GP 140 GP175 GP210 5 STD STD STD 5 OPT OPT OPT S TD STD 5 STD 5 OPT 7.
GP Series Po rtable Chillers Chapter 7: Appendix 72 of 90 50 Hertz Pump Curves ACS CHILLER PUMPS 20-50 A LL 50 Hz HP GP 20 GP 30 GP 40 GP 50 1.5 CDU 70/315D3G S TD 2 CDU 70/520D3G OPT STD S TD 3 CDU 120/530 D3G OPT OPT STD 3 OPT 5 2CDU 200/506 OPT OPT OPT OPT 10 3U 32-200-1100D3G OPT OPT 2CDU 70/306 Model September 8, 2009 2 HP CDU 70/520D3G 1.
GP Series Po rtable Chillers Chapter 7: Appendix 73 of 90 ACS CHILLER PUMPS 70-210 A LL 50 Hz HP GP70 GP90 GP105 GP 140 GP175 GP210 5 STD STD STD 5 OPT OPT OPT STD S TD 5 STD 5 OPT 7.
GP Series Po rtable Chillers Chapter 7: Appendix 74 of 90 Pure Water at >40°F GPXC - 20 GPXC - 30 GPXC - 40 GPXC - 50 GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) GPM DP (PSI) 0.5X Nominal 6 1.7 9 1.7 12 1.6 18 1.8 1.0X Nominal 12 5.9 18 6.1 24 5.8 36 6.
GP Series Po rtable Chillers Chapter 7: Appendix 75 of 90 7-4 R e mote Air - Coole d Chille r Configurations.
GP Series Po rtable Chillers Chapter 7: Appendix 76 of 90 Figure 19 : Double Riser Detail.
GP Series Po rtable Chillers Chapter 7: Appendix 77 of 90 7-5 Typi cal Ductwo rk for Air - Cooled Chille rs Model Fan 60 Hz Discharge air volume 50 Hz Discharge air volume HP kW CFM m 3 /min CFM m 3 /min GPAC - 20 0.5 0.4 4230 120 3525 100 GPAC - 30 1.
GP Series Po rtable Chillers Chapter 7: Appendix 78 of 90 Notes: Customer use of ductwork requires the high pressure f an option. Allow 30 in. (77 cm) minimum clearance around the chiller footprint to facilit ate free passage of cooling air and service accessibilit y .
GP Series Po rtable Chillers Chapter 7: Appendix 79 of 90 7-6 Piping Diagrams.
GP Series Po rtable Chillers Chapter 7: Appendix 80 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 81 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 82 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 83 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 84 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 85 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 86 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 87 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 88 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 89 of 90.
GP Series Po rtable Chillers Chapter 7: Appendix 90 of 90.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Sterling 882.93092.01 c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Sterling 882.93092.01 - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Sterling 882.93092.01, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Sterling 882.93092.01 va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Sterling 882.93092.01, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Sterling 882.93092.01.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Sterling 882.93092.01. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Sterling 882.93092.01 ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
