Advantage Engineering Maximum User manual

I.O.M. #058 1/03
INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE
Covering
Air-Cooled models
from 5 to 30 tons
with ‘HE’ Instruments
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, IN 46142
317-887-0729 fax: [phone]
Service Department fax: [phone]
www.AdvantageEngineering.com
e-mail: [email protected]

INSTRUCTION MANUAL
MAXIMUM ‘MK’
HE INSTRUMENT
AIR-COOLED MODELS
COVERING
INSTALLATION
OPERATION
MAINTENANCE
ADVANTAGE ENGINEERING, INC. 525 East Stop 18 Road Greenwood, IN 46142
317-887-0729 fax: [phone] Service Department fax: [phone]
website: www.AdvantageEngineering.com e-mail: [email protected]

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 4
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
TABLE OF CONTENTS
1.0 GENERAL 7
1.1 Introduction 8
1.2 Unit location for air cooled models 8
1.3 Unit location for water cooled models 8
1.4 Efficiency 8
1.5 Safety 9
1.6 Clean air act 9
1.7 Miscellaneous 9
2.0 INSTALLATION 11
2.1 General 12
2.2 To and From process connections 12
2.3 Water supply connection 13
2.4 Air cooled condenser 13
2.5 Electrical connection 14
3.0 OPERATIONS 17
3.1 General 18
3.2 Start up/operations procedure 19
3.3 Instrument/operation 24
3.4 Shut down procedure 31
4.0 TROUBLESHOOTING 33
4.1 Sensors 34
4.2 Process/evaporator pump 34
4.3 Compressor 34
4.4 Low flow 34
4.5 Blower/fan 34
4.6 High pressure 35
4.7 Low pressure 35
4.8 Water level 35
4.9 Freezestat 36
4.10 Oil pressure 36
4.11 Crankcase heater 36
4.12 Electronics 36
5.0 MAINTENANCE 37
5.1 Warranty service procedure 38
5.2 Periodic preventative maintenance 38
5.3 Special maintenance 39
5.4 Solenoid valve service 40
5.5 Pump seal service 42
5.6 Checking the refrigerant charge 45
5.7 Proper cleaning procedure for brazed plate evaporators 45
5.8 DIP switch adjustment 47
5.9 Display / Keyboard Operation 49

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 5
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
6.0 COMPONENTS 51
6.1 Water system 52
6.2 Refrigeration system 52
7.0 RELATED DRAWINGS 55
7.1 Mechanical schematic - 5 / 7.5 / 10 tons 56
7.2 Mechanical schematic - 15 / 20 /25 / 30 57
7.3 Physical - 5 tons 58
7.4 Physical - 7.5 / 10 tons 59
7.5 Physical - 15 / 20 / 25 / 30 tons 60
7.6 Duct schematic for air cooled chillers 61
7.7 Electrical 62
8.0 APPENDIX 63
8.1 Specifications 64
8.2 Model # and suffix coding 65
8.3 Operations below 48°F 66
8.4 Water quality control 67
8.5 Inhibited propylene glycol 68
8.6 Sensor current vs temperature 68
8.7 Pressure-temperature chart for R-22 refrigerant 69
8.8 Chiller capacity and derate chart 70

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THIS PAGE INTENTIONALLY BLANK

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
1.0 GENERAL
1.1 INTRODUCTION
1.2 UNIT LOCATION
1.3 EFFICIENCY
1.4 SAFETY
1.5 CLEAN AIR ACT
1.6 MISCELLANEOUS

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 8
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
1.1 INTRODUCTION
A. This manual covers most ‘MK’ series portable chillers with air-cooled
condensers, from 5 to 30 tons.
B. When calling for assistance from the ADVANTAGE Service
Department, it is important to know the model and serial number
of the particular unit. The model number encodes critical unit
information which is helpful in any attempt to troubleshoot
operating difficulties. The serial number allows the service team to
locate manufacturing and testing records which can have additional
information relating to a particular unit.
1.2 UNIT LOCATION
A. The unit is designed for indoor use only. For most efficient
operation, locate the chiller in a clean, dry and well ventilated
environment.
B. The unit has an air cooled refrigerant condenser. For air cooled
condensers, a motor driven fan (on models from 5 to 15 tons) or a
centrifugal blower (on models from 15 to 30 tons) generates air
flow through the condenser to remove heat from the refrigerant
system. The air cooled condenser on the unit will discharge a
maximum of 15,000 BTU’s per hour per ton of cooling.
C. The unit must have a minimum entering air temperature of 60°F
and a maximum entering air temperature of 95°F for efficient
operation.
D. The unit must have a minimum of two feet clearance at the air
intake and six feet at the vertical exhaust air discharge.
E.The unit must have all enclosure panels in place before operating
compressor. Air will not be drawn through the condenser coil if
they are not in place. This will cause the compressor to lockout on
the high pressure safety fault.
1.3 EFFICIENCY
A. Long term efficiency of operation is largely determined by proper
maintenance of the mechanical parts of the unit and the water
quality. ADVANTAGE recommends filtering where required to
prevent solids from plugging critical parts (pumps, heaters, seals for
example). ADVANTAGE highly recommends the services of a
competent water treatment specialist be obtained and his
recommendations followed. ADVANTAGE accepts no responsibility
for inefficient operation, or damage caused by foreign materials or
failure to use adequate water treatment.

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 9
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
1.4 SAFETY
A. It is important to become thoroughly familiar with this manual and
the operating characteristics of the unit.
B. It is the owner’s responsibility to assure proper operator training,
installation, operation, and maintenance of the unit.
C. Observe all warning and safety placards applied to the chiller.
Failure to observe all warnings can result in serious injury or death
to the operator and severe mechanical damage to the unit.
1.5 CLEAN AIR ACT
A. The unit contains HCFC-22 (chlorodifloromethane). This is a class 2
substance.
B. Effective July 1, 1992, it is unlawful for any person in the course of
maintaining, servicing, repairing, or disposing of refrigeration
equipment to knowingly vent or otherwise dispose of any class 2
substance used as a refrigerant in the manner which permits such
substance to enter the atmosphere.
C. De minimis releases associated with good faith attempts to
recapture, reclaim or recycle such substance shall not be subject to
the prohibition set forth in the preceding paragraph.
1.6 MISCELLANEOUS
A. The unit is designed to circulate temperature stabilized fluid
through the process resulting in process temperature control.
B. The ability of the unit to maintain process temperature control is
significantly affected by the method of installation as outline in
section 2 of this manual.
C. If the operator has any questions concerning the location and
operation of the unit, contact the ADVANTAGE Service Department
at 317-887-0729.

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
MK-10A shown
Air Cooled Condenser
Caster
Stainless Steel Frame
Electrical Cabinet
Instrument (LE shown)
Pressure Gauges
Protective Fan Shroud
Caster
Liquid Receiver
Compressor
Liquid Line Solenoid
Refrigerant Site Glass
Flow Switch
Fan Motor
Protective Fan Shroud
Air Discharge
Pressure Gauges (not visible)
Instrument (not visible)
Hot Gas Bypass Valve
Pump
Expansion Valve
Insulated Reservoir Tank

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
2.0 INSTALLATION
2.1 GENERAL
2.2 TO AND FROM PROCESS CONNECTIONS
2.3 WATER SUPPLY CONNECTION
2.4 AIR COOLED CONDENSER
2.5 ELECTRICAL CONNECTION

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
2.1 GENERAL
A. All process piping materials (such as hose, rigid piping, valves or
filters) used in process water piping circuitry must be rated for
100°F minimum temperature and 100 PSI minimum pressure.
B. All such materials must have the equivalent or larger diameter of
the particular process connection that length of process water
piping is connected to.
2.2 TO AND FROM PROCESS CONNECTIONS
A. Connect the ‘TO PROCESS’ to the ‘water in’ manifold on the mold
or process.
B. Connect the ‘FROM PROCESS’ port to the ‘water out’ port on the
process manifold.
C. Process water piping circuitry should be designed to avoid an
excessive use of elbows and/or lengths of pipe or hose. If hose is
the material of choice, avoid tight twists or curls and excessive
lengths.
D. Valves and filters may be installed in the process water piping
circuitry 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.
MK-10A shown
To Process :
Connect to ‘Water In’ port
on process manifold Water Supply :
Connect to plant’s city
water source.
From Process :
Connect to ‘Water Out’
port on process manifold

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 13
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
2.3 WATER SUPPLY CONNECTION
A. The automatic water supply make-up system continually monitors
the reservoir tank and fills it when needed. Connect as follows:
1. Connect the chiller’s ‘WATER SUPPLY’ port to the plant’s
city water source.
2. Minimum water supply pressure requirement is identified
on the equipment data plate. This is normally 20 psi.
3. Be certain to use a water supply line equipped with a back
flow prevention device to prevent contamination of potable
water.
2.4 AIR COOLED CONDENSER
A. Air cooled condensers require
ambient air temperatures between
60°F and 95°F for efficient
operation. Operating above above
95°F may result in elevated
condensing pressures and eventual
shut-down on the high pressure
safety switch. In such cases, a water
assist unit may be necessary for
operations. Air temperatures below
60°F may result in below normal
condensing pressures and poor
condensing. In such cases, a low-
ambient damper assembly is
required. Check with the
ADVANTAGE service department for
more information on operating with
ambients air temperatures above
95°F or below 60°F.
B. Air flow is generated by the motor
mounted fans (figure 2.4A) or
centrifugal blowers (figure 2.4B). Air
flow is from the outside of the
chiller, through the condenser and
exhausted through the top of the
unit. On centrifugal blowers models, exhaust air can be ducted
outside of the plant’s interior environment. Special duct work is
required and a HVAC contractor should be consulted for sizing and
material specifications. Exhaust air can not be ducted on motor
mounted fan models.
C. A free air space of at least two (2) feet is required at the condenser
intake and six (6) feet at the condenser discharge to allow for
proper air flow.
Figure 2.4A
Typical fan assembly
Figure 2.4B
Typical blower assembly

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 14
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
D. At full load, the chiller will
discharge approximately
15,000 BTU’s per hour per ton
of cooling.
E. On blower units, air discharge
duct work should be sized by
a qualified HVAC engineer.
Sizing shall be according to
rated CFM at the static
pressure of .90 inches of
water. See figure 2.4C
at right.
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. See figure 2.4D to the right.
G. All air cooled units must have all enclosure panels in place before
operating compressor. Air will not be drawn through the condenser
coil if they are not in place. This will cause the compressor to
lockout on the high pressure safety fault.
2.5 ELECTRICAL CONNECTION
A. NEMA 1 MODELS
1. Electrical power supply requirements for Nema 1 units are
identified on the equipment data plate. Determine the
plant’s voltage supply is the same as the unit’s voltage
requirements.
WARNING: Do not connect the unit to a voltage supply
not equal to the unit’s voltage requirements as specified
on the unit’s data plate. Use of incorrect voltage will
void the unit’s warranty and cause a significant hazard
that may result in serious personal injury and unit
damage.
Figure 2.4C
Damper assembly
Punch hole 
in top panel
1/4" Copper line
Liquid receiver
(located inside 
chiller on base)
Angle valve and cap
1/4" copper line connection
Figure 2.4D

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
Figure 2.5A Typical electrical panel
2. A customer supplied, four conductor cable is required for
connection to a customer supplied fused disconnecting
means. The fused disconnecting means shall be sized and
installed according to the unit’s power supply requirements
and local electrical codes.
3. Connect the four conductor power cable to power entry
terminal block on the unit’s electrical panel. Then connect
the power cable to the fused disconnect switch.
B. NEMA 12 MODELS
1. NEMA 12 units are constructed with a dust tight 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.
WARNING: Do not connect the unit to a voltage supply
source not equal to the unit’s voltage requirements as
specified on the unit’s data plate. Use of incorrect
voltage will void the unit’s warranty and cause a
significant hazard that may result in serious personal
injury and unit damage.
2. Appropriate conduit and fittings should be selected which
will maintain the integrity of the cabinet.
3. Supply a power conductor sized according to the unit’s
power supply requirements. Connect the power conductor
to the unit’s power supply entry terminal block or the fused
disconnect switch. Some Nema 12 models may be supplied
Refrigerant High Pressure Limit
(protects from excessive condensing pressures)
Refrigerant Low Pressure Limit
(protects from low suction pressures)
Freezestat
(protects against low coolant temperatures) Motor Contractor
(supplies voltage to coolant pump motor)
Motor Overload Relay
(protects motor from excessive amperage)
Transformer
(provides different voltages
to instrument and other components)
Power Entry
(connect to power cord -
grounding lug on panel)
Compressor Contactor
(supplies voltage to compressor)

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
with an optional disconnect switch. The owner supplied
fused disconnecting means shall be sized and installed
according to the unit’s power supply requirements and
local electrical codes.
C. CONTROL CIRCUIT WIRING
1. The unit’s supplied control circuit is 110 volt, 1 phase, 60
cycle. The control circuit is supplied by the factory installed
transformer. An inline control circuit fuse is provided.
D. 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.
E. INFORMATION REGARDING ‘PHASING’ OF SCROLL
COMPRESSORS
1. All portable chillers that have pumps, the compressor(s) will
be set in phase with the pump during the testing process at
the factory.
2. After installation, on units with an ‘LE’ controller, the phase
status must be checked by observing the pump motor shaft
on the end of the pump and comparing its rotation to the
directional arrow on the motor. In either case, if the phase
needs to be altered, it should be done at the main power
entry.

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 17
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
3.0 OPERATIONS
3.1 GENERAL
3.2 START UP/OPERATIONS PROCEDURE
3.3 INSTRUMENT/OPERATION
3.4 SHUT DOWN

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 18
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
3.1 GENERAL
A. Failure to follow the factory required operations procedure may
adversely affect the unit’s ability to adequately control process
temperature and may create a hazardous operating condition
which may result in serious operator injury and/or unit damage.
B. IMPORTANT: if this unit contains a hermetic or semi-hermetic
reciprocating compressor it is equipped with a crankcase heater on
the compressor. While the compressor is idle, the crankcase heater
prevents freon vapor from migrating to and condensing in the
compressor crankcase. If freon is allowed to condense in the
crankcase, it can be drawn into the cylinders upon start up. This
can cause catastrophic damage to the connecting rods, pistons,
and valve plates.
To avoid this, BEFORE THE UNIT IS STARTED, THE POWER
SUPPLY SHOULD BE APPLIED TO THE UNIT FOR AT LEAST 12
HOURS, OR UNTIL THE BOTTOM OF THE COMPRESSOR IS
WARM TO THE TOUCH.
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.
UNITS WITH SCROLL COMPRESSORS DO NOT HAVE A
CRANKCASE HEATER AND THIS PROCEDURE IS NOT
NECESSARY.
C. The OPERATIONS segment of this manual is divided into the
following sections:
3.2 Start up/operations - follow this segment to start the unit
after the initial install to the process system or to restart the
unit after reinstallation to the same or different process
system. This section includes information on system fill,
electric motor phasing (pump rotation) and process flow
adjustments.
3.3 Instrument - follow this segment to start up and operate
the instrument. This section includes information on
setpoint selection and adjustment, and feature
explanations.
3.4 Shut down procedure - follow this segment to shut down
the unit. This segment includes information on system shut
down, electrical power supply precautions, and
disconnection from system.

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
Page: 19
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
3.2 START UP / OPERATION PROCEDURE
A. SYSTEM FILL
1. The unit has an internal reservoir which must be filled and
maintained for proper operation. The unit has a level switch
mounted at the proper water level in the reservoir.
2. WATER QUALITY CONTROL. Lack of, as well as, improper
water treatment can damage the chilling unit. The services
of competent water 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 8 of this manual for more
information.
3. FOR AUTOMATIC FILL:
engage the water supply to
unit. The level switch will
activate the make-up
solenoid (figure 3.2A),
which will open and the
water supply will fill the
reservoir tank. The WATER
LEVEL light (figure 3.2B) on
the instrument will flash red
while the make-up solenoid
valve is open. When the
reservoir tank is filled, the
WATER LEVEL light will
illuminate green. During
operations, with the water
supply source “on”, the unit
will automatically maintain
the correct reservoir level.
4. MANUAL FILL: disconnect
the electrical power supply
and remove all necessary
cover panels to access the
reservoir. Add fluid directly
to the reservoir. When the
pump is first started, as
process lines are filled and
air is purged, additional fluid
may be required to restore
the reservoir to the correct
level as indicated by a
flashing red RESERVOIR
LEVEL light. During
operations, when the
Figure 3.2AMake-up solenoid valve
Figure 3.2B
Water level light - LE instruments
Figure 3.2C
Typical reservoir sight glass

MK Series Portable Chiller : Air-Cooled : HE INSTRUMENT
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ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
RESERVOIR LEVEL light flashes red, the operator must add
fluid to the reservoir. Verify reservoir level via the coolant
sight glass (figure 3.2C).
B. ELECTRIC MOTOR PHASING (PUMP ROTATION)
1. The operator must determine the unit is phased correctly
by visually inspecting the rotation of the pump motor shaft.
The procedure is outlined below. Incorrect phasing results
in poor operation and eventual damage to the unit.
a. Supply electrical power to the unit. Once the
correct voltage is supplied to the unit, the POWER
light on the unit’s control panel will illuminate.
Adjust the setpoint to 70°F to prevent the
compressor from activating during this procedure.
b. Remove all necessary cover panels to access the
pump motor. Note that the electrical power is
engaged at this point and caution must be
observed while the electrical supply is engaged
and cabinet panels are removed and opened.
c. Locate the electric
motor (figure 3.2D).
The electric motor
can be identified
when the electrical
panel cover is open.
The operator must
identify the motor
shaft inside the
electric motor
housing. The motor
shaft can be seen
through the vent
slots in the motor
housing or by
removing the shaft
cover.
d. Toggle the unit’s
START and STOP
keys (figure 3.2E).
This will quickly
cycle the pump
motor “on” and
then “off”.
e. Observe the motor shaft. When the START key is
pressed, the motor shaft will rotate. When the
STOP key is pressed, the shaft will slowly “coast” to
a stop. As the shaft slows, the operator can identify
Figure 3.2D
Electric motor
Figure 3.2E
Start/Stop push buttons -
LE instrument