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Advantage BG Series, Instruction Manual

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Advantage BG Series Instruction Manual Download Page 85

Glycol Chillers : BC Series with MG Control Instrument

Page: 85

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142 

317-887-0729    Fax: 317-881-1277

Service Department Fax:  317-885-8683

Email: [email protected]

Temperature Setpoint
Reserved
Temperature High Alarm
Temperature Low Alarm
Low Flow Alarm
To Process Temperature
From Process Temperature
Flow
Process Status

Machine Status 1

Machine Status 2

Machine Status 3

Machine Control

Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Status

Reserved
Reserved
Reserved
Reserved
Reserved
Low Refrig Suction Pressure
High Refrig Discharge Pressure
To Process Water
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved

Register

1
2
3
4
5
6
7
8
9

10

11

12

13
14
15
16

17
18
19
20
21
22
23

24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Coil

 
 
 
 
 
 
 
 

1 thru 16

17 thru 32

33 thru 48

49 thru 64

65 thru 80
81 thru 96

97 thru 112

113 thru 128

 
 
 
 
 
 

257 thru 272

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Use

 R/W

 

R/W
R/W
R/W

R
R

R

R

R

R

R
R
R

R/W

R
R
R
R
R
R
R
R
R
R
R
R

Range

 0 - 250

 

0 - 50
0 - 50

0 - 255
0 - 255
0 - 255

Units

 F

 

F
F

GPM

F
F

GPM

F
F
F
F
F
F

 PSI

PSI
PSI

Notes
 
 
Deviation Value
Deviation Value
Absolute Value

* Low water level is defined but not implemented 

  and will never trigger

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Low

Flow

Bit 8

Bit 7

Bit 6

Bit 5

Low

Temp

Bit 4

Hi

Temp

Bit 3

Alarm

Machine

Bit 2

Alarm

Process

Bit 1

Alarm

Bit 0

0

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Phase

Wrong

MOL Evap

Pump

Low Flow

Bit 8

Bit 7

Bit 6

Bit 5

Low Temp

Bit 4

 

Bit 3

Alarm

Machine

Bit 2

Alarm

Process

Bit 1

Alarm

Bit 0

0

Low Ref

Pressure

High Ref

Pressure

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Sensor

Fail

Bit 3

Alarm

Machine

Bit 2

Alarm

Process

Bit 1

Alarm

Bit 0

0

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

MOL Proc

Pump

Bit 4

Low Water

Level

Bit 3

Alarm

Machine

Bit 2

Alarm

Process

Bit 1

Alarm

Bit 0

0

MOL Evap

Pump

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Alarm

Ack.

Bit 0

On/Off

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Reserved

Zone On

Reserved

1

Output 4

Output 3 Output 2 Output 1

Reserve

D

Bit 8

Bit 7

Bit 6

Bit 5

Comp.

Overload

Bit 4

Low Oil

Pressure

Bit 3

Reserved

Bit 2

High Ref.

Pressure

Bit 1

Low Ref.

Pressure

Bit 0

Low Water

Flow

1

Reserved

Running

8.9  MODBUS REGISTERS

Summary of Contents for BG Series

Page 1: ...dvantageEngineering com Covering Models 1 to 30 Horsepower MG Instruments Scroll Compressors Model Serial Number Stop If running at a fluid temperature below 48 F you must use a water and glycol mixture at a ratio that protects the fluid from freezing to approximately 25 F below the lowest expected set point temperature For 25 F fluid use a mixture of 30 35 glycol See Section 8 1 and 8 2 of this m...

Page 2: ......

Page 3: ...OVERING INSTALLATION OPERATION MAINTENANCE G L Y C O L C H I L L E R ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 Website www AdvantageEngineering com E mail service AdvantageEngineering com ...

Page 4: ...2 3 2 Start up operations procedure 22 3 3 Instrument operation 27 3 4 Shut down procedure 32 4 0 TROUBLESHOOTING 33 4 1 Unit Will Not Start 34 4 2 Compressor Hums But Will Not Start 34 4 3 Shuts Off On High Pressure 34 4 4 Shuts Off On Low Pressure 35 4 5 Compressor Shuts Off On Internal Overload 36 4 6 Low Or No Process Pressure Or Water Flow 36 4 7 Cooling Capacity Inadequate 36 4 8 Sensor 36 4...

Page 5: ...g com 7 0 RELATED DRAWINGS 55 7 1 Mechanical Schematic 56 7 2 Typical Physical 5 Horsepower 57 7 3 Typical Physical 7 5 10 Horsepower 58 7 4 Typical Physical 15 20 Horsepower with Fan 59 7 5 Typical Physical 15 30 Horsepower with Blower 60 7 6 Duct Schematic for Air Cooled Chillers 61 8 0 APPENDIX 62 8 1 Operations below 48 F fluid or 38 F ambient 63 8 2 Refrigerant pressure temperature chart 66 8...

Page 6: ...Page 6 THIS PAGE INTENTIONALLY BLANK ...

Page 7: ... 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 1 0 GENERAL 1 1 Introduction 1 2 Safety 1 3 Receiving Instructions 1 4 Efficiency 1 5 Clean Air Act 1 6 Water treatment 1 7 Components ...

Page 8: ...ystem however a system failure will release it Refrigerant gas can cause toxic fumes if exposed to fire Install this unit in a well ventilated area away from open flames Failure to follow these instructions may result in a hazardous condition Recover refrigerant to relieve pressure before opening the system See nameplate for refrigerant type Do not use non approved refrigerants or refrigerant subs...

Page 9: ...erve precautions in literature and on tags stickers and labels located on the equipment Wear work gloves and safety glasses WARNING This equipment contains hazardous voltages that can cause severe injury or death Disconnect and lock out incoming power before installing or servicing the equipment WARNING This equipment contains refrigerant under pressure Accidental release of refrigerant under pres...

Page 10: ...recommendations be followed The Manufacturer accepts no responsibility for inefficient operation or damage caused by foreign materials or failure to use adequate water treatment 1 5 CLEAN AIR ACT A Units manufactured after January 1 2010 may contain refrigerant HFC 410A HFC 407C HFC 404A or HFC 134A Most units manufactured prior to January 1 2010 contain refrigerant HCFC 22 B It is unlawful for an...

Page 11: ...may result in scaling erosion corrosion algae or slime B It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment is required C Advantage assumes no responsibility for equipment failures which result from untreated or improperly treated water D Do not use deionized water in this unit Some customized units may be compatible with deio...

Page 12: ...e panels removed for photo Caster Compressor Liquid Line Solenoid Filter Drier Refrigerant Site Glass Fan Motor Protective Fan Shroud Water Regulator Valve Coolant Pump Water Cooled Condenser Electrical Cabinet Compressor Insulated Reservoir Air Discharge Coolant Pump Expansion Valve Insulated Reservoir Tank Electrical Cabinet Air Cooled Condenser Optional Low Water Flow Bypass Valve Depending on ...

Page 13: ... Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 2 0 INSTALLATION 2 1 General 2 2 Unit Location 2 3 To and From Process Connections 2 4 Make Up Water Supply Connection 2 5 Air Cooled Condenser Connection 2 6 Electrical Connection ...

Page 14: ...uid leak will not cause damage to the surroundings or install the unit in such a way that an unforeseen fluid leak will not damage its surroundings B For air cooled models 1 These units are designed for indoor use only 2 For most efficient operation locate the chiller in a level clean dry and well ventilated environment 3 The unit has an air cooled refrigerant condenser For air cooled condensers a...

Page 15: ...Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com To Process Typical process connections shown on 2 horsepower indoor unit From Process From Process To Process Typical process connections shown on 10 horsepower indoor unit ...

Page 16: ...d to avoid excessive elbows and or lengths of pipe or hose If using flexible hose avoid tight twists or curls and excessive lengths E Valves and filters may be installed in the process water piping to facilitate service and maintenance provided that such devices maintain the full inside diameter of the process connection If installed all such devices must be open and clean during unit operation F ...

Page 17: ...g to rated CFM at the static pressure of 90 inches of water F On blower units a damper control assembly is required in low ambient temperature areas or when outdoor air make up is used The assembly works in conjunction with refrigerant head pressure to regulate air flow to maintain proper refrigerant head pressure when condenser intake air temperature will be less than 60 F G All air cooled units ...

Page 18: ...ng must comply with local codes and the National Electric Code 2 Electrical power supply requirements for standard units are identified on the equipment data tag Determine that the plant s voltage supply is the same as the unit s voltage requirements taking into account the SSCR Rating Typical data tag WARNING Do not connect the unit to a voltage supply not equal to the unit s voltage requirements...

Page 19: ...disconnect switch There is no power entry hole into the electrical cabinet This allows the matching of the entry hole size and location to the customer supplied fittings 5 A unit specific electrical drawing is shipped with the unit 6 Voltage supplies must be within 10 of the name plate voltage and must be within 2 from leg to leg Extreme voltage imbalance or using the wrong voltage can damage your...

Page 20: ...8683 Email service AdvantageEngineering com C General 1 Make certain all ground connections to the unit are properly affixed 2 Make certain power conductor disconnecting means and fusing are properly sized according to the unit s power supply requirements 3 Follow all local and national codes 4 Make certain that all owner and factory wire connections are tight before applying power to the unit ...

Page 21: ...t Fax 317 885 8683 Email service AdvantageEngineering com 3 0 OPERATIONS 3 1 General 3 2 Start Up Operations Procedure 3 3 Instrument Operation 3 4 Instrument Main Menu 3 5 Instrument Setpoints Menu 3 6 Instrument Utilities Menu 3 7 Instrument Network Menu 3 8 Instrument Flow Menu optional 3 9 Instrument Options Menu 3 10 Instrument Machine Menu 3 11 Low Tank Level 3 12 Shut Down ...

Page 22: ... unit This segment includes information on system shut down electrical power supply precautions and disconnection from system 3 2 START UP OPERATION PROCEDURE A System Fill 1 For operating temperatures from 48 F to 80 F use water to fill the unit For operating temperatures below 48 F a water and propylene glycol mixture must be used An inhibited propylene glycol can be used for operating temperatu...

Page 23: ...ed as process lines are filled and air is purged additional fluid may be required to restore the reservoir to the correct level Verify reservoir level via the coolant sight glass 6 Do not use straight deionized or RO reverse osmosis water in this unit unless your unit was specifically designed for use with deionized water Consult factory if not certain B PROPER ROTATION PHASING OF SCROLL COMPRESSO...

Page 24: ... allowed to cool before it will restart Thermal overload cooling and reset may take substantial time 7 Procedure to set proper rotation a Supply electrical power to the unit Once the correct voltage is supplied to the unit the control instrument will read Standby or Status Ready Adjust the setpoint to 70 F or higher to prevent the compressor from activating during this procedure See Section 3 5 fo...

Page 25: ...ed from the rear of the motor If the shaft does not rotate when the unit is switched on the operator must identify the cause as outlined in the troubleshooting and repair section of this manual f If the motor shaft is phased correctly shaft turns in a clockwise direction continue with step C If the motor shaft is NOT phased correctly shaft turns in a counter clockwise direction correct as outlined...

Page 26: ... 2 4 gpm per ton of rated capacity Low liquid flow can reduce efficiency and in some cases allow ice to develop in the evaporator which can damage the evaporator Excessive liquid flow will trip the motor overload protection circuit 2 Turn the unit on to activate the process pump Wait a few moments to allow air to be purge from system Observe the digital coolant pressure gauge for steady readout Ch...

Page 27: ...pen the valve until the low refrigerant pressure digital display reading is in the normal operating range for the refrigerant type used in the chiller For Automatic Low Flow Bypass Valves A T handle or adjusting stem is located on the top of the valve Turning the T handle or adjusting stem in the clockwise direction puts more pressure on the valve s spring reducing bypass flow Turning the T handle...

Page 28: ...tton that pops out if the overloads are tripper Simply push the button in until the overloads are reset Other overload relays have a switch This switch will be positioned with the indicator pointing up when in normal operation The indicator will be pointing to the left when the overloads are tripped To reset simply turn the switch to where the indicator points up If a motor overload situation pers...

Page 29: ... the motor name plate g If the amp draw is excessive higher than the listed name plate amp rating a throttling valve must be installed in the from process water line The throttling valve can be a gate valve or a ball valve h With the throttling valve installed fully close the valve and then engage the pump motor Slowly open the throttling valve and monitor the motor amps as displayed on the amp me...

Page 30: ...ystem 2 R134A and R407C models operating above 65 F and R404A models operating above 60 F require the addition of a refrigerant crankcase pressure regulating CPR valve The CPR valve is necessary to lower the temperature of the gas returning to the compressor so that the compressor is cooled properly R410A models may be operated up to 80 F without a CPR valve 3 R410A models please note then operati...

Page 31: ...re is displayed in the display window The default range for the setpoint temperature is 48 F 90 F or 9 32 C 5 Press the Home button to view Outputs Suction Discharge and To Process values 6 Outputs Status indicators that show the state of the chiller s refrigeration system a When the four control status indicators are small the refrigeration system is off and doing no cooling The units pump will s...

Page 32: ... When the compressor is turned off the instrument will wait 3 minutes before turning it back on regardless of the To Process temperature or Setpoint If a low pressure or optional low flow fault has occurred the control will attempt to turn the compressor back on after 3 minutes If the fault condition remains the compressor will not restart and the control will retry after 1 minute The sequence wil...

Page 33: ...ooling 3 Pressing the stop button twice will immediately shut down the entire chiller including the process pump 4 If the compressor is not running when the off button is pressed the chiller and pump will shut down 3 4 Instrument Main menu A The Main Menu offers the ability to set and change values in the following areas Setpoints Utilities Network Flow Options Machine B The Main Menu is accessibl...

Page 34: ...Deviation setting should be no more than 100 F minus set point For example with a 70 F set point the High Deviation should not be set more than 30 F 3 Once acknowledged press the Back button repeatedly to return to the Setpoints screen or press the home button to return to the Home screen To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Main Menu Setpoints Utilit...

Page 35: ...the purchase of the optional flow meter 1 The factory default is 0 GPM The range for the Low Flow is from 0 to 100 GPM 2 Once acknowledged press the Back button repeatedly to return to the Setpoints screen or press the home button to return to the Home screen 3 6 Instrument Utilities menu A Items in the Utilities menu include the operations for the Software Version Display Test and Sensor Display ...

Page 36: ...ayed in Fahrenheit and Celsius Head Pressure displayed in PSI and kPa Suction Pressure displayed in PSI and kPa Process Probe Pressure displayed in PSI and kPa Board Temperature displayed in Fahrenheit and Celsius Flow display in GPM and dl min optional Flow Switch indicates on or off optional Water Make Up Switch indicates on or off optional To Process Setpoint 50 F Circulating 50 F To Process Se...

Page 37: ...00 2400 9600 19200 and 38400 3 Press the Select button to save the selection and confirm success D Address This is the number assigned to the unit in a network 1 Press the Select button to select Address To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Baud Rate Cancel Adjust OK Network Protocol Baud Rate Address Back Pick Go 2400 9600 19200 38400 115200 To Proce...

Page 38: ...o input the value and then press the Select button to save and confirm success To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Main Menu Setpoints Utilities Network Flow Options Machine Back Pick Go To Process Setpoint 50 F Circulating 50 F Main Menu Setpoints Utilities Network Flow Options Machine Back Pick Go FLow Enable Offset Calibration Back Pick Go To Proc...

Page 39: ...Out Secondary Pump Chiller Type Cooling Source To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Remote Start Enable Disable Back Pick Go To Process Setpoint 50 F Circulating 50 F Flow Enable Offset Calibration Back Pick Go FLow Enable Offset Calibration Back Pick Go To Process Setpoint 50 F Circulating 50 F Change Setting Remote Start Success Acknowledge Options ...

Page 40: ... is selected a caution display will appear when reducing the operating setpoint below 48 F The warning must be acknowledged before the change is made by pressing the Select button 3 For Minimum Setpoints 48 F and above From the Machine Menu advance to the Minimum Setpoint screen to enter the minimum setpoint Confirm the selection with the Select Button To Process Setpoint 50 F Circulating 50 F Mai...

Page 41: ...d then press the Select button to save and confirm success 2 The factory default value is English G Pressure and Timer Screens These parameters are factory set and should not be adjusted without consulting the factory Changes are recorded in the instrument memory and adjusting these parameters could void the Factory warranty Pressure Related LP Cut Out LP Cut In HP Cut Out Timer Related LP Start U...

Page 42: ...ent display The usual home screen will not be visible The setpoint can be checked and changed through the menu system and the To Process Temp is available in the sensor section The compressor will activate and provide cooling if needed after its 3 minute delay but the fault screen will still be on the home screen until the water level satisfies the level switch 3 12 SHUT DOWN DISCONNECT SEQUENCE A...

Page 43: ...n system will turn off but the pump will continue to run for about 30 seconds to carry away residual cooling that could damage the unit c Pressing the stop button twice shut down the entire chiller including the process pump at once d If the compressor is not running when the off button is pressed the chiller and pump will shut down º2 To shut down the unit and disconnect from the process a Press ...

Page 44: ...Page 44 THIS PAGE INTENTIONALLY BLANK ...

Page 45: ...artment Fax 317 885 8683 Email service AdvantageEngineering com 4 0 TROUBLESHOOTING 4 1 Unit Will Not Start 4 2 Compressor Hums But Will Not Start 4 3 Shuts Off On High Pressure 4 4 Shuts Off On Low Pressure 4 5 Compressor Shuts Off On Internal Overload 4 6 Low or No Process Pressure or Water Flow 4 7 Cooling Capacity Inadequate 4 8 Sensor 4 9 Pumps 4 10 Chiller Controller ...

Page 46: ...wiring If the problem is with the main power supply coming into the plant call the local power company D Loose terminals Power off and follow all company lock out tag out procedure before tightening terminals 4 3 SHUTS OFF ON HIGH PRESSURE LIMIT A Air cooled units 1 Insufficient condenser air flow Check condenser filter for dirt fins may be plugged with dirt or foreign material Also check for prop...

Page 47: ...he unit low pressure limit is activated three 3 consecutive times during start up the unit will lock out and will not be allowed to start When the chiller control locks out due to low pressure after three 3 attempts there is a problem that must be resolved before the unit should be restarted To re start the unit must be powered down and back on This should only be attempted after the cause of the ...

Page 48: ...an 2 Liquid line valve or suction valve on compressor is partially closed Open fully 3 Liquid line solenoid not opening fully or leaking during off cycle Have the solenoid repaired or replaced if defective by a refrigeration serviceman 4 Expansion valve plugged or inoperative Check thermal bulb and capillary tube for damage Have bulb and or tube repaired or replaced if defective by a refrigeration...

Page 49: ...ic flow and pressure at the maximum run load amp draw of the motor Too much flow can overload the motor and cause the overload circuit to open and stop the pump B If the overload trips check for electrical shorts loose wires or blown fuses If these check OK reset the overload circuit and restart the chiller 4 10 CHILLER CONTROLLER A The control instrument is used for all normal set ups diagnostics...

Page 50: ...trument is determined to be at fault you will be referred to the instrument manufacturer you have 3 options a Purchase a new instrument as a replacement b Send your instrument back for repair freight prepaid For a nominal fee contact factory for current fees your instrument will be repaired and returned c Purchase a new instrument and repair the old one as a back up F OTHER INFORMATION 1 Repair Wa...

Page 51: ...9 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 5 0 MAINTENANCE 5 1 Warranty Service Procedure 5 2 Periodic Preventative Maintenance 5 3 Special Maintenance 5 4 Solenoid Valve Service 5 5 Pump Seal Service 5 6 Checking the Refrigerant Charge 5 7 Proper Cleaning Procedure for Brazed Plate Evaporator ...

Page 52: ...the Manufacturer will advise on the repair and recommend available service contractors C It is of the utmost importance that you provide the correct model number and serial number of the machine in question This will allow the Service Department to obtain the correct manufacturing records which will help to properly troubleshoot the problem and obtain the proper replacement parts when they are req...

Page 53: ...ment Fax 317 885 8683 Email service AdvantageEngineering com 5 3 Special Maintenance A Any service of the refrigeration system must be accomplished by a certified refrigeration technician 1 Addition of compressor oil 2 Addition of refrigerant 3 Repair of a refrigerant leak 4 Adjustment of super heat 5 Changing of filter drier or drier core 6 Repair of a refrigeration solenoid ...

Page 54: ...for a failed coil or more often it will not fully close because debris from poor make up water quality is in the valve mechanism 2 To replace the coil disengage power from the unit following all lock out tag out procedures Remove the wires from the failed coil and remove the coil from the valve stem Install the new coil on the stem and reconnect the wires 3 To service the solenoid valve follow the...

Page 55: ...RING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com Coil and solenoid base sub assembly Body Gasket Valve body Core assembly Core spring Diaphragm spring Diaphragm assembly ...

Page 56: ...e up flow is shut off and all pressure relieved 2 Disengage main power supply The operator must verify the proper lockout procedures are followed 3 Access the pump motor by opening or removing any cover panels as necessary figure 5 5B 4 Drain machine The machine can be drained by using the drain valve located on the pump case Drain fluid into a suitable container for reuse or disposal according to...

Page 57: ...readed from the motor shaft to expose the pump seal assembly 10 Remove all seal parts Figure 5 5H Note seal component arrangement to facilitate reassembly 11 Clean motor shaft and lubricate with a mild soap solution 12 Install new stationary seal member in pump casing cavity figure 5 5I The operator must be certain the stationary seal member is fully squared and seated in cavity 13 Slide the rotat...

Page 58: ...d Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com E When the pump seal replacement procedure is complete the operator may restart the unit according the section 3 Stationary member Figure 5 5J Seal members Figure 5 5K Stationary member Figure 5 5I ...

Page 59: ... qualified refrigeration technician 5 7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATORS A The brazed plate evaporator is made of stamped stainless steel plates furnace brazed together with copper based joints The complex geometry of the flow passages promotes turbulent flow which gives high efficiency and reduces fouling by mineral deposits Large solids such as plastic pellets or chunks of ...

Page 60: ...ution reservoir tank Dispose of all back flush fluid according to local codes 4 The cleaning fluid source should have at least 20 psi available If acid cleaning follow the instructions supplied with the acid solution carefully 5 When the procedure is complete reinstall all water lines to original factory orientation Restart the unit and check for proper operation 6 Note This procedure is not norma...

Page 61: ... Page 61 ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 6 0 Components 6 1 Water System 6 2 Refrigeration System 6 3 Options ...

Page 62: ...om the compressed refrigerant gas The action causes the gas to condense into a liquid state still under high pressure Air flow across the condenser is achieved via a motor driven fan assembly or centrifugal blower C WATER COOLED CONDENSER The water cooled condenser removes heat from the compressed refrigerant gas As the heat is removed the gas condenses into a liquid state still under high pressur...

Page 63: ...short cycling of the compressor Units with digital scroll compressors MGD use a solenoid valve to unload the compressor to as low as about 20 capacity Units without a digital scroll compressor use a hot gas bypass solenoid valve to reduce the chiller capacity to about 50 I Liquid receiver optional feature located after the condenser this component receives and stores liquid refrigerant leaving the...

Page 64: ...ng all electric power to the chiller F AUDIBLE AND OR VISUAL ALARM Alarms indicate out of spec operating conditions There are two types of alarms Audible Alarm A simple buzzer alarm emits a loud alarm Visual Alarm Emits an audible sound and flashes a beacon G CONDENSER SCREEN Optional for air cooled models only The condenser screen is a filter for the air cooled condenser to prevent air borne soli...

Page 65: ...7 0 RELATED DRAWINGS 7 1 Mechanical Schematic Water Cooled 5 10 tons 7 2 Mechanical Schematic Water Cooled 15 40 tons 7 3 Mechanical Schematic Air Cooled 5 10 tons with Propeller Fans 7 4 Mechanical Schematic Air Cooled 15 30 tons and 5 20 ton Models with Optional Centrifugal Blower 7 5 Electrical Drawing Air Cooled 7 6 Electrical Drawing Water Cooled 7 7 Physical Drawing Water Cooled 5 10 Ton 7 8...

Page 66: ...SOR PROBE TO PROCESS PORT CONNECTION MAKE UP PORT CONNECTION MAKE UP SOLENOID VALVE LEVEL SWITCH FROM PROCESS PORT CONNECTION CONDENSER WATER IN PORT CONNECTION CONDENSER WATER OUT PORT CONNECTION RESERVOIR TANK EXPANSION VALVE EVAPORATOR SERVICE LID AND FILL PORT REFRIGERANT SIGHT GLASS LIQUID LINE SOLENOID VALVE FILTER DRIER SERVICE VALVE HOT GAS BYPASS VALVE not included onmodels with Digital S...

Page 67: ...SOR PROBE TO PROCESS PORT CONNECTION MAKE UP PORT CONNECTION MAKE UP SOLENOID VALVE LEVEL SWITCH FROM PROCESS PORT CONNECTION CONDENSER WATER IN PORT CONNECTION CONDENSER WATER OUT PORT CONNECTION RESERVOIR TANK EXPANSION VALVE EVAPORATOR SERVICE LID AND FILL PORT REFRIGERANT SIGHT GLASS FILTER DRIER SERVICE VALVE HOT GAS BYPASS VALVE not included onmodels with Digital Scroll Compressors COMPRESSO...

Page 68: ... CONDENSER w FANS 5 ton model uses single fan COOLANT PUMP TO PROCESS SENSOR PROBE TO PROCESS PORT CONNECTION MAKE UP PORT CONNECTION MAKE UP SOLENOID VALVE LEVEL SWITCH FROM PROCESS PORT CONNECTION RESERVOIR TANK EXPANSION VALVE EVAPORATOR SERVICE LID AND FILL PORT REFRIGERANT SIGHT GLASS LIQUID LINE SOLENOID VALVE FILTER DRIER SERVICE VALVE HOT GAS BYPASS VALVE not included onmodels with Digital...

Page 69: ... CENTRIFUGAL BLOWER AIR COOLED CONDENSER w blower COOLANT PUMP TO PROCESS SENSOR PROBE TO PROCESS PORT CONNECTION MAKE UP PORT CONNECTION MAKE UP SOLENOID VALVE LEVEL SWITCH FROM PROCESS PORT CONNECTION RESERVOIR TANK EXPANSION VALVE EVAPORATOR SERVICE LID AND FILL PORT REFRIGERANT SIGHT GLASS LIQUID LINE SOLENOID VALVE FILTER DRIER SERVICE VALVE HOT GAS BYPASS VALVE not included onmodels with Dig...

Page 70: ...ol Instrument Page 70 ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 7 5 TYPICAL ELECTRICAL DRAWING AIR COOLED ...

Page 71: ...C 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 7 6 TYPICAL ELECTRICAL DRAWING WATER COOLED This electrical is shown with optional UL panel components The GFCI would not be standard ...

Page 72: ...st Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 7 7 TYPICAL PHYSICAL WATER COOLED 5 10 TON The Physical Drawing is presented for illustration purposes only For exact details consult the Manufacturer ...

Page 73: ... Description Weather cap Screen Flashing to suit Roof curb Plant roof Butterfly with counterbalance Separate duct support from roof Gate control for exhaust air flow Manual chain control Duct to plant heating system Mating collar Chiller air exhaust port Air cooled chiller with blower NOTE THIS DRAWING IS FOR EXPLANATION PURPOSES ONLY NOT FOR CONSTRUCTION PURPOSES 7 8 DUCT SCHEMATIC FOR AIR COOLED...

Page 74: ...Page 74 THIS PAGE INTENTIONALLY BLANK ...

Page 75: ...3 Email service AdvantageEngineering com 8 0 APPENDIX 8 1 Operations Below 48 F 8 2 Operating Below 48 F Fluid or 38 F Ambient 8 3 Refrigerant Pressure Temperature Chart 8 4 Inhibited Propylene Glycol 8 5 Chiller Capacity and Derate Chart 8 6 Probe Calibration MG Instrument 8 7 Status Indicators MG Instrument 8 8 Water Quality 8 9 Modbus Registers 8 10 Remote and Auto Start Feature Configuration ...

Page 76: ... Machine LP Cut In to adjust the low pressure switch according to the specifications in the chart below Never lower the cut out setting on the adjustable low pressure switch without adding glycol to the circulating system Evaporator damage will result and this damage is not covered by the factory warranty G Once all safety provisions are made the temperature control set point may now be lowered to...

Page 77: ...ol Instrument Page 77 ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 8 2 REFRIGERANT PRESSURE TEMPERATURE CHART ...

Page 78: ...e is more than 2 5 times faster than plain water On steel it is 4 5 times faster D MAINTENANCE RESPONSIBILITY A refractometer shown below should be used on a regular basis to determine the mixture strength according to freeze point The freeze point temperature should be 25 F below the lowest required setpoint see chart Water may evaporate from the mixture and if you continue to add a premixed solu...

Page 79: ...onditions affect air cooled chiller operation and capacity Standard rating is at 95 F entering air temperature For ambient air conditions greater than 95 F chiller derating will occur For ambients over 95 F consult factory Standard chiller rating is at 50 F For all other temperature settings output tonnage is altered as follows 60 50 45 40 35 30 25 20 105 100 90 80 70 60 50 40 OUTPUT TEMPERATURE F...

Page 80: ...ater with lots of ice You should place a digital thermometer in the ice bath to read the temperature of the bath Place the probe in the ice bath C Procedure 1 Restart the instrument according to the procedures outlined in the unit manual 2 Reduce the unit s setpoint to its lowest setting 3 The to process temperature on the display should equal the temperature of the ice bath as indicated by the di...

Page 81: ...f this probe is required repeat the setup and calibration procedure with the from process probe A from process probe may not be included with your chiller 8 Stop the unit following the shutdown procedure described in the manual and place all process probes back in the unit to return to normal operation From Process Calibration Potentiometer From Process Calibration Potentiometer To Process Calibra...

Page 82: ...ompressor On Scroll Compressor or Digital Scroll Compressor 2nd Compressor On Scroll Compressor or Digital Scroll Compressor Unloading On Hot Gas Bypass or Digital Unloading Setpoint 50 F Outputs Compressor On Discus Compressor Unloader On Setpoint 50 F Outputs Compressor On Screw Compressor Compressor at 50 Capacity Compressor at 75 Capacity Pulse Typical display for chillers with a single compre...

Page 83: ...wfrost Dow Chemical 1 800 447 4369 B The following are guidelines specific to chillers with an internal circulation pump and fluid reservoirs C Long term performance of your chiller will be adversely affect by poor water conditions The three major problems water treatment must address are 1 Scaling a Scaling of the heat transfer surfaces due to minerals can be minimized by proper treatment and fil...

Page 84: ...VANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 3 Algae 1 Algae organism growth can be controlled by the proper use of chemical treatment ...

Page 85: ... F F F F F F PSI PSI PSI Notes Deviation Value Deviation Value Absolute Value Low water level is defined but not implemented and will never trigger Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Low Flow Bit 8 Bit 7 Bit 6 Bit 5 Low Temp Bit 4 Hi Temp Bit 3 Alarm Machine Bit 2 Alarm Process Bit 1 Alarm Bit 0 0 Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Phase Wrong MOL Evap Pump Low Flow Bit 8...

Page 86: ...he unit is ordered with this option or it can be configured in the field C Caution When configured with auto start as described here the normal on off button will no longer function to turn the unit on and off The unit must be turned off using the installed remote on off switch D Factory installed remote or auto start feature 1 If MG Series control instrument has been factory configured with the r...

Page 87: ...cknowledge and save the selection To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Remote Start Enable Disable Back Pick Go To Process Setpoint 50 F Circulating 50 F Flow Enable Offset Calibration Back Pick Go FLow Enable Offset Calibration Back Pick Go To Process Setpoint 50 F Circulating 50 F Change Setting Remote Start Success Acknowledge Options Remote Start ...

Page 88: ...END 2021 Advantage Engineering Inc RE 20210216 ...

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