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Advantage OACS Series Instruction Manual Download Page 71

OACS Central Chillers : with MG Series Control Instrument 

Page: 71

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]

7.7  TYPICAL PANEL CONTROL STATION DRAWING

ITEM

PC-1187

3

7

6

5

4

2

1

DESCRIPTION

PRESSURE GAUGE:  PRES. TO PROCESS

MASTER SWITCH OFF/ON

EMERGENCY STOP

POWER ON
ALARM INACTIVE/ACTIVE

PANEL

PRESSURE GAUGE:  LOW PRES., ZONE #1

PRESSURE GAUGE:  HEAD PRES., ZONE #1

OACS-80AD 42SFX

10

14

13

12

11

9

8

15

PROCESS PUMP ON
PROCESS PUMP OVERLOAD
EVAPORATOR PUMP OFF/ON
EVAPORATOR PUMP ON

PROCESS PUMP OFF/ON

FAULT

SUMP HEATER ON

EVAPORATOR PUMP OVERLOAD

LIGHTS & OPER

AT

OR

S

17

16

PRESSURE GAUGE:  LOW PRES., ZONE #2

PRESSURE GAUGE:  HEAD PRES., ZONE #2

TERMINAL STRIP

REFRIGERANT LOW PRES. SWITCH, ZONE #1

REFRIGERANT HIGH PRES. SWITCH, ZONE #1

INSTRUMENT:  MZC-3

BUS BAR

GROUND LUG

SOLID STATE TIME DELAY RELAY:  TANK LEVEL

CONTROL TRANSFORMER

FUSE BLOCK:  FU-19,20

INSTRUMENT TRANSFORMER

INSTRUMENT:  MZC-3 ZONE BOARD, ZONE #1

RELAY:  LOW LEVEL  (R1)

J

Q

O
P

N

M

L

K

C

H

I

G

E
F

D

B

ITEM

A

PC-1187

OACS-80AD 42SFX

PANEL

DESCRIPTION

S

W

U
V

T

R

FUSE BLOCK:  FU-13,14,15

FUSE BLOCK:  FU-16,17,18

OIL PRESSURE SAFETY SWITCH, ZONE #1

POWER DISTRIBUTION BLOCK

RELAY:  ALARM/FAULT  (R2)

FUSE BLOCK:  FU-10,11,12

SOLID STATE TIME DELAY RELAY:  HEATER

REFRIGERANT LOW PRES. SWITCH, ZONE #2

REFRIGERANT HIGH PRES. SWITCH, ZONE #2

INSTRUMENT:  MZC-3 ZONE BOARD, ZONE #2

OIL PRESSURE SAFETY SWITCH, ZONE #2

ITEM

PC-1187

OACS-80AD 42SFX

PANEL

DESCRIPTION

Z

Y

X

FUSE BLOCK:  FU-4,5,6

FUSE BLOCK:  FU-7,8,9

FUSE BLOCK:  FU-1,2,3

ITEM

PC-1187

OACS-80AD 42SFX

PANEL

DESCRIPTION

MOTOR STARTER:  M2

HEATER CONTACTOR:  H1

BB

AA

MOTOR STARTER:  M1

CC
DD
EE

COMPRESSOR CONTACTOR:  M4
COMPRESSOR CONTACTOR:  M3

6

7

11

14

16

13

9

10

17

15

12

8

1

2

3

4

5

STOP

'E'

EMERGENCY

STOP

W

W

W

W

A

A

R

A

B

C

D

F

E

G

F

H

I

J

K

L

M

N

P

O

Q

R

S

T

U

V

W

X

Y

Z

AA

BB

CC

DD

EE

CONTROL BOARDS

12V TRANSFORMER

CR306B002

CR306B002

9T58K0050

CR305E0

3030APS120VAC

CONTROL BOARDS

CR305E0

Summary of Contents for OACS Series

Page 1: ...NTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEngineering com E mail service AdvantageEngineering com Covering Models From 20 210 Tons Air Cooled with MG Control Instrument Model Serial Number ...

Page 2: ......

Page 3: ...ument COVERING INSTALLATION OPERATION MAINTENANCE 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: ...n Typical 20 3 0 OPERATIONS 21 3 1 General 22 3 2 Start Up Operation Procedure 23 3 3 MG Instrument Operations 27 3 4 Instrument Main Menu 30 3 5 Instrument Setpoints Menu 30 3 6 Instrument Utilities Menu 32 3 7 Instrument Network Menu 33 3 8 Instrument Flow Menu optional 34 3 9 Instrument Options Menu 35 3 10 Instrument Machine Menu 36 3 11 Controls 39 3 12 Pressure Gauges Alarm Beacon 40 3 13 Di...

Page 5: ...zed Plate Evaporators 59 6 0 COMPONENTS 61 6 1 Refrigeration Components 62 6 2 Coolant System 64 7 0 RELATED DRAWINGS 65 7 1 Typical Circuit Schematic 66 7 2 Typical Physical Drawing 67 7 3 Typical Press Drip 68 7 4 Typical Vacuum Breaker Anti Siphon System 69 7 5 Typical Label Placement Drawing 70 7 6 Typical Panel Control Station Drawing 71 8 0 APPENDIX 73 8 1 Operations Below 48 F Fluid or 38 F...

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

Page 7: ... 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 Model Designation 1 8 Components ...

Page 8: ... 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 substitutes D Custo...

Page 9: ...t WARNING This equipment contains refrigerant under pressure Accidential release of refrigerant under pressure can cause personal injury and or property damage Exercise care while working on or around this equipment WARNING Vent all refrigerant relief valves in accordance to ANSI ASHRAE Standard 15 Safety Code for Mechanical Refrigeration This equipment should be located within a well ventilated a...

Page 10: ...ir 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...

Page 11: ... E If the chiller is installed in an environment where ambient temperatures could be under 35 F and or if the unit operating set point will be 48 F or lower a glycol and water solution must be used instead of water See section 8 1 for glycol ratio recommendations and proper unit setting 1 7 MODEL DESIGNATION A The Serial Number identifies the exact configuration of your unit and should be availabl...

Page 12: ...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 1 8 COMPONENTS To Process Connection Process Pump From Process Connection Evaporator Pump ...

Page 13: ...wood 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 Chilled Water Piping Installation 2 4 Air Cooled Condenser 2 5 Make Up Water Supply Connection 2 6 Electrical Connection 2 7 Piping installation ...

Page 14: ... of water See section 8 1 for glycol ratio recommendations and proper unit setting 2 2 UNIT LOCATION A Before placing the unit into position a review of the most suitable location must be made This unit is designed for outdoor installation B Factors to consider when selecting a suitable installation location 1 Provision for adequate ambient air supply to the condenser 2 Loading capacity of roof or...

Page 15: ...t to the from process supply header C TO PROCESS Connect the to process port to the process supply header D Install a high volume basket strainer in the From Process line with isolation valves A basket strainer or bag filter with a 20 mesh 400 micron or finer screen will protect the unit Installing a filter that is too fine may be unnecessary and may result in frequent filter maintenance A wye typ...

Page 16: ... above the top of the pit and a minimum of 8 feet is required between the unit and the pit walls E Lovers fences must have a minimum of 80 free area and 4 feet minimum clearance between the unit and the lovers fence Height of the louver fence must not exceed the top of the unit F If the chiller is installed in an environment where ambient temperatures could be under 35 F and or if the unit operati...

Page 17: ... Units are constructed with a weather resistant electrical enclosure and branch circuit fusing Electrical power supply requirements are identified on the equipment data plate Determine the plant s voltage supply is the same as the unit s voltage requirements 2 All electrical wiring must comply with local codes and the National Electric Code 3 Electrical power supply requirements for standard units...

Page 18: ...ed fittings 6 A unit specific electrical drawing is shipped with the unit 7 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 chiller and cause premature unit failure as well as a safety risk 8 A proper ground is required for the unit B CONTROL CIRCUIT WIRING 1 The unit s supplied c...

Page 19: ...d Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com Zone Board 3 Phase Monitor Transformer Power Entry Compressor Starters Pump Starters Fuse Block Typical electrical panel show Refer to the electrical drawing provided for details to the particular unit ...

Page 20: ...header service or during use of alternate source of cooling water 13 Alternate Source of Cooling Water On Off Valve for system emergency back up 14 Alternate Water Supply Source for system emergency back up 15 System Multi Use Open Drain reservoir overflow reservoir drain system emergency back up 16 Process Water Drops From Header To Use Point valved for servie shut off 17 Pressure Gauge and Therm...

Page 21: ...1 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 3 0 OPERATIONS 3 1 General 3 2 Start Up Operations Procedure 3 3 M1 Control Instrument 3 4 LE Control Instrument 3 5 MZC Control Instrument 3 6 MZC Zone Board 3 7 Configuration Switch Adjustment MZC only 3 8 Controls 3 9 Pressure Gauges and Alarm Beacon 3 10 Shut Down Procedure ...

Page 22: ...CH If the power has been disconnected more than two hours the power should be applied for six hours before restarting Power should be applied to the unit continuously except for service purposes The crankcase heater should be checked for proper operation on a regular basis C The OPERATIONS segment of this manual is divided into the following sections 3 2 Start up operations follow this segment to ...

Page 23: ...treatment specialist should be obtained and their recommendations followed It is the equipment owner s responsibility to prevent damage from foreign material or inadequate water treatment See water treatment section in section 1 6 of this manual for more information 4 FOR AUTOMATIC FILL Always install a manual shut off valve on the make up water supply on the outside of the unit When electrical po...

Page 24: ...pressor may make a loud rattling noise when rotating in the wrong direction 7 Operating the scroll compressor in the wrong direction will cause the unit to trip on it s internal temperature limit and may cause unit damage When the temperature limit trips the compressor must be allowed to cool before it will restart This many take substantial time 8 Procedure to set proper rotation a Supply electri...

Page 25: ...r supplied main power disconnect C PROCESS FLOW ADJUSTMENTS 1 The operator must determine and set proper water flow rate for the most efficient and trouble free operation a Water flow rate through the process is determined by the pressure losses in the process loop Generally higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance Since the evaporator ...

Page 26: ...ncrease as the flow increases until you reach the run load amp rating listed on the motor data tag 4 Please note On initial start up the water use points may not be sufficient to fully load the motor Recheck the amp draw on the motor and adjust the discharge valve as needed to prevent overloading of the motor as use points are added 5 Place an amp meter on one leg of the and start the motor Slowly...

Page 27: ...ycol and modification of the limit control settings are required These adjustments are done from the chiller controller screen Diligent monitoring of the water glycol solution is mandatory to prevent freezing of the evaporator Freezing may cause the evaporator to rupture allowing water and freon to mix which will cause major damage to the refrigeration system R134A and R407C models operating above...

Page 28: ...or Down Arrow keys until the desired setpoint temperature is displayed in the display window The default range for the setpoint temperature is 48 F 70 F or 9 21 C C Press the Home button to view Outputs Suction Discharge and To Process values Outputs indicate the state of the chiller s refrigerations system When four small dots are shown the refrigeration system is off When the first dot is larger...

Page 29: ...t the unit If a high pressure fault occurs the fault must be acknowledged by pressing the start button before the system will attempt to restart E Under normal conditions no fault conditions compressor has been off for 3 minutes the instrument will turn on the compressor when the To Process temperature is above the Setpoint The instrument will engage the capacity control system digital unloading o...

Page 30: ... flow rate display is an option and may not be included on your machine B Process Setpoint Use the Up or Down buttons to change the process setpoint 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 Setpoint Status Ready 50 F Standby To Process Setpoin...

Page 31: ...atedly to return to the Setpoints screen or press the home button to return to the Home screen D Low Flow optional feature not included on all units The Low Flow value programs the controller to sound an alarm if the process flow goes below the low flow set value For example if the flow set value is 3 GPM and if the flow goes below 3 GPM an alarm condition is indicated Note the low flow alarm feat...

Page 32: ...Sensor Display item from the Utilities Menu to advance to the first Sensor Display screen 2 Scrolling through the Sensor Display reveals data for the sensor To Process displayed in Fahrenheit and Celsius From Process displayed in Fahrenheit and Celsius Process Probe Temperature displayed in Fahrenheit and Celsius optional MCU Temperature displayed in Fahrenheit and Celsius Head Pressure displayed ...

Page 33: ...selection and confirm success To Process Setpoint 50 F Circulating 50 F To Process Setpoint 50 F Circulating 50 F Sensor Display Setpoints Process Setpoint Hi Deviation Lo Deviation Low Flow Back Pick Go To Process 52 F 10 9 C From Process 54 F 12 1 C Process Probe Temp 39 F 39 8 C Utilities Software Version Display Test Sensor Display Back Pick Go To Process Setpoint 50 F Circulating 50 F Sensor ...

Page 34: ...e Flow Enable Disable screen Select Enabled to enable the flow option 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 Process Setpoint 50 F Circulating 50 F Change Setting Baud Rate Success Acknowledge To Process Setpoint 50 F Circulating 50 F To Process Se...

Page 35: ...eatedly to return to the Options 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 Offset 3 GPM 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 Offset Su...

Page 36: ... F Machine Set Date Set Time Min Setpoint Hi Temp Shutdown Units Back Pick Go To Process Setpoint 50 F Circulating 50 F Main Menu Setpoints Utilities Network Flow Options Machine Back Pick Go Main Menu Setpoints Utilities Network Flow Options Machine Back Pick Go To Process Setpoint 50 F Circulating 50 F Machine Secondary Pump Chiller Type Cooling Source Back Pick Go To Process Setpoint 50 F Circu...

Page 37: ...esired Select button to save and confirm success 2 The factory default value is 100 F The range is from 65 F 110 F F Units This screen controls how the temperature is displayed The options are English F or Metric C Also when the optional flow meter is installed the flow will display in GPM if English is selected or LPM if Metric is selected 1 Use the Up or Down arrow keys to select the Unit displa...

Page 38: ... 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 Up Delay LP Run Delay H Unit Screens These parameters are factory set and should not be adjusted without consulting the factory Changes are recorded...

Page 39: ...gh Pressure Factory set or fixed cut out manual or automatic reset required Opens due to high pressures associated with improper refrigerant condensing or high fluid temperature overloading the compressor D Low Pressure Factory or fixed cut out and cut in points based on refrigeration type automatic reset Opens due to low pressures associated with improper refrigerant evaporating temperatures NEVE...

Page 40: ...essure being delivered by the process pump to the load B The refrigerant head pressure gauge indicates the pressure of the refrigerant as it is being condensed in the condenser C The refrigerant low pressure gauge indicates the compressor suction pressure and is directly related to the temperature setting on the temperature control D The optional alarm beacon is visual and audible The alarm will a...

Page 41: ...ge the system will reactivate automatically after the pressure rises above the differential value 3 13 DIGITAL PRESSURESTAT SET UP A Some models of this central chiller provide optional digital pressurestats for refrigerant high and low pressure monitoring and display in lieu of traditional analog gauges B The digital refrigerant pressurestat is a dual pressure safety switch as well as a current v...

Page 42: ...g chilled otherwise severe damage to the evaporator could occur 4 Press and release the Toggle Display button again to save the value and move to the next value 5 You will see spDif XXX the suction pressure differential This value indicates the number of PSI the suction pressure must rise above the cut out value before the system will restart 10 PSI is usually a good number for this value and is t...

Page 43: ...ecisely all procedures outlined in this manual an unsafe condition can develop resulting in damage to the unit or personal injury B UNIT SHUT DOWN 1 To shut down the unit without disconnecting from the process a Turn off the unit b Maintain electrical power to the unit at all times except for service purposes 2 To shut down the unit and disconnect from the process a Turn off the unit b Disengage t...

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

Page 45: ...83 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 Coolant Pumps 4 10 Oil Pressure 4 11 Crankcase Heater 4 12 Chiller Controlle...

Page 46: ...he 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 Note Units may be equipped with either an adjustable or non adjustable fixed high pressure switch If the refrigerant pressure exceeds the setting of the adjustable switch it must be manually reset when the discharge pressure falls to ...

Page 47: ...sure rises above the cut in pressure a three minute time delay will occur before the compressor restarts This will protect the evaporator and compressor from damage should a problem occur in the refrigeration system or if the chiller is operated under circumstances which could cause damage to the refrigeration system A Low or no water flow through the evaporator Adjust the flow per sections 3 2 C ...

Page 48: ...ectrician check the fuses and wiring 4 7 COOLING CAPACITY INADEQUATE A Low refrigerant charge Check for adequate refrigerant charge bubbles or misty sight glass indicates low charge If charge is low have system checked for leaks and recharged by a refrigeration serviceman B Hot gas bypass valve stuck open Have repaired or replace if defective by a refrigeration serviceman C Expansion valve plugged...

Page 49: ...een in compressor oil sump Note Only semi hermetic compressors 15 30 tons have an oil pressure safety switch 4 11 CRANKCASE HEATER not on all models A If the crankcase heater is not drawing current during the compressor off cycle check for a defective crankcase heater defective fuses or defective interlock on the compressor starter B Scroll compressors do not have crankcase heaters 4 12 CHILLER CO...

Page 50: ...tance 2 If a control instrument is determined to be at fault 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 3 If you are sending your instrument back for repair do not...

Page 51: ...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 Evaporators 5 8 Configuration Switch Adjustment MZC Instruments Only ...

Page 52: ...ller is not covered by the warranty 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...

Page 53: ...rtment 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: ...or 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: ...ERING 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: ...s under 100 F and pressure is relieved COOLANT pressure gauge reads 0 and water make 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...

Page 57: ...ing screw can be removed Once the retaining screw is removed the impeller can be unthreaded 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 certai...

Page 58: ... 16 Clean pump casing cavities impeller and O ring before reassembly 17 Mate the motor and motor adapter to the pump casing Reinstall the pump casing bolts 18 Reconnect the motor power cord and leads 19 Restore all cover panels as were removed E When the pump seal replacement procedure is complete the operator may restart the unit according the section 3 Stationary member Figure 5 5I Stationary me...

Page 59: ...er drier should be replaced by a 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 ...

Page 60: ...he evaporator water inlet port to an acid solution 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...

Page 61: ...trument 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 Refrigerant System 6 2 Coolant system ...

Page 62: ...ge and moisture content Refrigerant charge is determined by a clear liquid flow Bubbles indicate low refrigerant Moisture content is indicated by the color of the element Element color is normally green If the color of the element is chartreuse or yellow the system has been contaminated with moisture In such case the filter drier must be replaced The replacement of the filter drier must be complet...

Page 63: ...DING GLYCOL TO THE CIRCULATING SYSTEM EVAPORATOR DAMAGE WILL RESULT AND WILL NOT BE COVERED BY THE WARRANTY J Liquid receiver Located after the air cooled condenser this component receives and stores liquid refrigerant leaving the condenser Air cooled models only K Service valves Have been provided throughout the system Only a qualified refrigeration service technician shall operate these valves L...

Page 64: ...depending on refrigerant type 6 2 COOLANT SYSTEM A Reservoir Provides coolant storage during non operating periods An internal baffle separates from process and to process fluid flows during operating periods B Process Pump Provides fluid to the central system C Standby Pump Optional pump to provide backup for the process or evaporator pump D Evaporator pump Provides consistent flow through the br...

Page 65: ...42 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 Email service AdvantageEngineering com 7 0 RELATED DRAWINGS 7 1 Typical Circuit Schematic 7 2 Typical Physical Drawing 7 3 Typical Press Drop 7 4 Typical Vacuum Breaker Anti Siphon System 7 5 Typical Label Placement Drawing 7 6 Typical Panel Control Station Drawing ...

Page 66: ...pply pressure gauge 16 Alarm pressure switch 17 To process connection 18 Standby pump 19 Pump discharge valve 20 Flow safety switch 21 Factory adjusted flow control valve 22 Evaporator 23 Freezestat 24 Compressor suction valve 25 Compressor 26 Low pressure safety switch 27 Low pressure gauge Item 28 Compressor discharge valve 29 Condenser 30 Service valve 31 Head pressure gauge 32 Filter drier 33 ...

Page 67: ...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 2 TYPICAL PHYSICAL DRAWING 97 OUT IN 1 1 4 NOM REF IN 3 WATER OUT OUT IN CENTRAL CHILLER HIGH VOLTAGE WARNING HIGH PRESSURE WARNING MADE IN AMERICA ...

Page 68: ...E SIZES ARE BASED ON FLOW RATES AND PRESSURE REQUIREMENTS SEE SCHEDULE 5 SEE VALVE POSITION SCHEDULE FOR OPEN REQUIREMENTS ALL OTHER VALVES ARE CLOSED MORE THAN ONE CONDITION MAY EXIST AT ONE TIME WITH THE EXCEPTION OF MIXING TOWER AND CHILLED WATER SYSTEMS V CHILLED WATER TO PROCESS CHILLED WATER FROM PROCESS CHILLED WATER FROM PROCESS CHILLED WATER TO PROCESS ON TO AND FROM PROCESS LINES CHILLED...

Page 69: ...called a drain back dam is to retain water in the header system during shut down and to eliminate air purge and shock to plumbing during start up 2 It is necessary to duplicate this arrangement on both the supply and return lines 3 The drain down valve allows header drainage for system maintenance and is closed during normal operation 4 The vacuum breaker must be located at the highest point in th...

Page 70: ...RT DRAIN HIGH VOLTAGE WARNING MADE IN AMERICA OACS 80AD 2 42SF EVAP PUMP OVERLOAD 1 CC DD 1 SUMP HEATER ON BB 1 AA 1 EVAP PUMP ON EVAP PUMP OFF ON X 1 PROCESS PUMP OFF ON Y 1 Z 1 PROCESS PUMP ON PROCESS PUMP OVERLOAD R 1 S 1 T 1 U 1 V 1 W 1 FROM PROCESS EMERGENCY STOP MASTER SWITCH OFF ON POWER ON ALARM INACTIVE ACTIVE FAULT ITEM QTY LP 1452 LABELS DESCRIPTION OACS 80AD 2 42SF EVAP PUMP OVERLOAD 1...

Page 71: ... TIME DELAY RELAY TANK LEVEL CONTROL TRANSFORMER FUSE BLOCK FU 19 20 INSTRUMENT TRANSFORMER INSTRUMENT MZC 3 ZONE BOARD ZONE 1 RELAY LOW LEVEL R1 J Q O P N M L K C H I G E F D B ITEM A PC 1187 OACS 80AD 42SFX PANEL DESCRIPTION S W U V T R FUSE BLOCK FU 13 14 15 FUSE BLOCK FU 16 17 18 OIL PRESSURE SAFETY SWITCH ZONE 1 POWER DISTRIBUTION BLOCK RELAY ALARM FAULT R2 FUSE BLOCK FU 10 11 12 SOLID STATE ...

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Page 73: ...tment Fax 317 885 8683 Email service AdvantageEngineering com 8 0 APPENDIX 8 1 Operating Below 48 F Fluid or 38 F Ambient 8 2 Refrigerant Pressure Temperature Chart 8 3 Inhibited Propylene Glycol 8 4 Chiller Capacity and Derate Chart 8 5 Standard MG Instrument Settings 8 6 Probe Calibration MG Instrument 8 7 Status Indicators MG Instrument 8 8 Water Quality 8 9 Modbus Registers ...

Page 74: ...according to the specifications in the chart on the next page 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 If your unit is equipped with a non adjustable fixed pressure switch with a factory low limit of 48 F this switch must be replaced wi...

Page 75: ...now be lowered to the desired operating temperature L WARNING do not use any type or brand of automotive antifreeze Automotive antifreeze contains corrosion inhibitors silicates designed for compatibility with the materials in automotive engines Unfortunately silicates can gel and cause deposits to foul and insulate heat exchanger surfaces In your chilling system that can mean higher energy costs ...

Page 76: ...rol Instrument Page 76 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 77: ...d in industrial heat transfer applications Automotive anti freeze contains silicate type corrosion inhibitors designed to be compatible with automotive components In an industrial application the silicates will form a gel on the heat transfer surface which will result in substantial reduction in cooling capacity and is virtually impossible to remove 8 4 CHILLER CAPACITY AND DERATE CHART A Standard...

Page 78: ... Service Department Fax 317 885 8683 Email service AdvantageEngineering com 8 5 STANDARD MG INSTRUMENT SETTINGS A Caution See section 8 1 for proper settings based on your fluid set point temperature Adjustable Low Pressure Cut Out Range 9 PSI to 150 PSI Adjustable Low Pressure Cut In Range 19 PSI to 150 PSI Adjustable High Pressure Cut Out Range 225 PSI to 580 PSI ...

Page 79: ... water 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 ...

Page 80: ... of 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 Calib...

Page 81: ... Compressor 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 comp...

Page 82: ...Dowfrost 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 f...

Page 83: ...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 3 Algae 1 Algae organism growth can be controlled by the proper use of chemical treatment ...

Page 84: ...3 Bit 14 Bit 15 Process Status No Alarm 12 49 64 R Pump On Bit 0 Alarm Bit 1 Alarm Process Bit 2 Alarm Machine Bit 3 High Temp Bit 4 Low Temp Bit 5 Bit 6 Bit 7 Bit 8 Lo Flow Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15 Machine Status 1 No Alarm 13 65 80 R Pump On Bit 0 Alarm Bit 1 Alarm Process Bit 2 Alarm Machine Bit 3 HTL Switch Bit 4 Lo Temp Bit 5 Bit 6 Bit 7 Bit 8 Lo Flow Bit 9 Bit 10 Bit 1...

Page 85: ...END 2019 ADVANTAGE ENGINEERING INC RE 20190822 ...

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