Advantage BG Series User manual

GLYCOL CHILLER
I.O.M. #180 updated 02/16/2021
INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE
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]
Covering Models :
• 1 to 30 Horsepower
• ‘MG’ Instruments
• Scroll Compressors
Model:
Serial Number :
Stop: If running at a uid temperature below 48°F you must use a water and glycol mixture at a
ratio that protects the uid from freezing to approximately 25°F below the lowest expected set
point temperature. For 25°F uid use a mixture of 30-35% glycol. See Section 8.1 and 8.2 of this
manual before operating your chiller. Regular testing of your glycol protection is critical.

INSTRUCTION MANUAL
With MG INSTRUMENT
& SCROLL COMPRESSORS
AIR-COOLED MODELS
COVERING
INSTALLATION
OPERATION
MAINTENANCE
GLYCOL CHILLER
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]

Glycol Chillers : BC Series with MG Control 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]
TABLE OF CONTENTS
1.0 GENERAL 7
1.1 Introduction 8
1.2 Safety 8
1.3 Receiving instructions 10
  1.4 Efciency 10
1.5 Clean air act 11
1.6 Water Treatment 11
1.7 Components 11
2.0 INSTALLATION 13
2.1 General 14
2.2 To and From process connections 14
2.3 Water supply connection 16
2.4 Air-cooled condenser 16
2.5 Electrical connection 18
3.0 OPERATIONS 21
3.1 General 22
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
4.9 Coolant Pump 37
4.10 Chiller Controller 37
5.0 MAINTENANCE 39
5.1 Warranty service procedure 40
5.2 Periodic preventative maintenance 40
5.3 Special maintenance 41
5.4 Level Switch Maintenance 42
5.5 Pump seal service 44
5.6 Checking the refrigerant charge 47
5.7 Proper cleaning procedure for brazed plate evaporators 47
6.0 COMPONENTS 49
6.1 Water system 50
6.2 Refrigeration system 50
6.3 Options 52

Glycol Chillers : BC Series with MG Control 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]
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uidor38°Fambient 63
8.2 Refrigerant pressure-temperature chart 66
8.3 Inhibited propylene glycol 67

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Glycol Chillers : BC Series with MG Control 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 Safety
1.3 Receiving Instructions
1.4 Efciency
1.5 Clean Air Act
1.6 Water treatment
1.7 Components

Glycol Chillers : BC Series with MG Control 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]
1.1 INTRODUCTION
A. This manual covers glycol chillers with ¼ to 40 horsepower compressors using the
AdvantageMGmicroprocessorcontrolinstrumentandxeddisplacementscroll
compressorsanddigitalscrollcompressors.Thestandarduidoperatingtemperature
range for this chiller is 20°F to 80°F for units using R410A refrigerant. Units using other
refrigerantshavedifferentstandardoperatingranges.Unitsoperatingbelow48°Fuid
require the use of a water/propylene glycol to prevent freezing. Customized units may
have different operating ranges. Consult the factory if you have questions about the
operating range of your chiller.
B. The intent of this manual is to serve as a guide in the installation, operation and
maintenance of your chiller. Improper installation can lead to equipment damage
and poor performance. Failure to follow the installation, operation and maintenance
instructions may result in damage to the unit that is not covered under the limited
warranty. This manual is for standard products. The information contained in this manual
is intended to be general in nature. The information is typical only and may not represent
the actual unit purchased.
C. Chemical refrigerants are used in this unit. The refrigerant is sealed and tested in a
pressurized system however a system failure will release it. Refrigerant gas can cause
toxicfumesifexposedtore.Installthisunitinawell-ventilatedareaawayfromopen
ames.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. Customers should implement a refrigerant management program to document the type
and quantity of refrigerant in each chiller. All refrigeration service technicians performing
workonthischillermustbelicensedandcertied.
E. WhencallingforassistancefromtheManufacturer’sServiceDepartment,itisimportant
to know the model and serial number of the particular unit. The model number includes
criticalunitinformationwhichishelpfulwhentroubleshootingoperatingdifculties.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 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.
D. Observe all safety precautions during installation, startup and service of this equipment
duetothepresenceofhighvoltageandrefrigerantcharge.Onlyqualiedpersonnel
should install, startup and service this equipment.

Glycol Chillers : BC Series with MG Control 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]
Samples of Warning Labels applied to
typical chillers.
1. Alerts users to the danger of high
voltage.
2. Alerts user to the danger of the rotating
condenser fans on air condensed units.
3. Alerts user to the danger of belt drive
systems on unit with blowers.
4. This symbol is seen on all chillers
to alert user to the danger of the
refrigeration system under pressure.
System should only be serviced by a
licensed technician.
E. When working on this equipment, observe 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 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 area. Inhalation of refrigerant can be hazardous to your health and the accumulation
of refrigerant within an enclosed space can displace oxygen and cause suffocation
WARNING
J5318-BF 1
WARNING
2
3
4

Glycol Chillers : BC Series with MG Control 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]
1.3 RECEIVING INSTRUCTIONS
A. Chillers are shipped skid mounted and wrapped in plastic prior to shipment. Check the
overall condition of the equipment prior to accepting delivery.
B. Check for visible damage and document any evident damage on the delivery receipt.
Check the refrigerant gauges to be sure the system charge is intact. See the chart
in section 8.4 for proper pressure readings based on the ambient temperature and
refrigerant type used in the chiller. Shipping damage is the responsibility of the carrier.
C. In order to expedite payment for damages, should they occur, follow proper procedures
and keep detailed records. Take photographs of any suspected damage.
1.4 EFFICIENCY
A. Longtermefciencyofoperationislargelydeterminedbypropermaintenanceofthe
mechanical parts of the unit and the water quality. The Manufacturer recommends
lteringtheprocesswatertopreventsolidsfrompluggingcriticalparts.TheManufacturer
highlyrecommendsthattheservicesofaqualiedwatertreatmentspecialistbeobtained
and their recommendations be followed. The Manufacturer accepts no responsibility for
inefcient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 any person in the course of maintaining, servicing, repairing, or disposing
of refrigeration equipment to knowingly vent or otherwise dispose of any substance used
as a refrigerant in the manner which permits such substance to enter the atmosphere.
C. Very small 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.
D. Customers should implement a refrigerant management program to document the type
and quantity of refrigerant in each chiller. All refrigeration service technicians performing
workonthischillermustbelicensedandcertied.
E. Vent all refrigerant relief valves in accordance to ANSI/ASHRAE Standard 15.
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 area. Inhalation of refrigerant can be hazardous to your health and the accumulation
of refrigerant within an enclosed space can displace oxygen and cause suffocation.

Glycol Chillers : BC Series with MG Control 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]
1.6 WATER TREATMENT
A. The use of untreated or improperly treated water in a portable chiller may result in
scaling, erosion, corrosion, algae or slime.
B. Itisrecommendedthattheservicesofaqualied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
deionized water. Consult the factory before using deionized water.
1.7 COMPONENTS
WARNING: Improper water treatment will void unit warranty.

Glycol Chillers : BC Series with MG Control 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]
Air-Cooled Model 10 ton unit shown.
ABS fascia and enclosure panels
removed for photo.
Water-Cooled Model 10 ton unit shown.
ABS fascia, top and enclosure 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unitconguration
this valve may be mounted
internally or externally.
Optional Low Water
Flow Bypass Valve
Dependingonunitconguration
this valve may be mounted
internally or externally.

Glycol Chillers : BC Series with MG Control 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 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

Glycol Chillers : BC Series with MG Control 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. Chillers are shipped skid mounted and wrapped in plastic prior to shipment. Check the
overall condition of the equipment prior to accepting delivery. Check for visible damage
and document any evident damage on the delivery receipt. Shipping damage is the
responsibility of the carrier.
B. Allprocesspipingmaterials(suchashose,rigidpiping,valvesorlters)usedinprocess
water piping circuitry must be rated for 100°F minimum temperature and 100 PSI
minimum pressure.
C. 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 UNIT LOCATION
A. Foundation. The chiller must be installed on a rigid and level mounting surface with
adequate strength to support the operating weight of the chiller including the weight of
water and attached piping.
This unit will contain water or water/glycol when operating. Locate the chiller
where an unforeseen uid leak will not cause damage to the surroundings or
install the unit in such a way that an unforeseen uid leak will not damage its
surroundings.
B. For air-cooled models:
1. These units are designed for indoor use only.
2. Formostefcient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
motordrivenfan(onmodelsfrom5to20tons)oracentrifugalblower(standard
onmodelsfrom25to30tonsandoptionalonothermodels)generatesairow
through the condenser to remove heat from the refrigerant system. The air
cooled condenser on the unit will discharge approximately 15,000 btu per hour
for every 12,000 btu/hr removed from your process. 1,000 cfm per horsepower.
The unit will reject 25% - 35% more heat than it removes from your process.
4. The unit must have a minimum entering air temperature of 60°F and a maximum
enteringairtemperatureof95°Fforefcientoperation.
5. The unit must have a minimum of four feet clearance at the air intake and six
feet at the vertical or horizontal exhaust air discharge and must have adequate
ventilation to dissipate the rejected heat. The unit must not be placed in non-
ventilated areas.
6. The unit must have all enclosure panels in place before operating the
compressor. Air will not be drawn through the condenser coil if the panels are not

Glycol Chillers : BC Series with MG Control 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]
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.

Glycol Chillers : BC Series with MG Control 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]
in place. Starting the unit without all the enclosure panels in place will result in a
high pressure refrigerant fault.
7. Units with a motor-driven fan may not use duct work unless a booster fan of
equal volume rating has been installed in the duct.
2.3 TO AND FROM PROCESS CONNECTIONS
A. Useappropriatelyratedhoseoruidpipingtoconnecttheprocess
piping going to your process to the “to process” connection on the
chiller.
B. Useappropriatelyratedhoseoruidpipingtoconnecttheprocess
piping coming back from your process to the “from process”
connection on the chiller.
C. Install a high volume basket strainer in the From Process line
withisolationvalves.Abasketstrainerorbaglterwithamesh
screen of 20-40 will protect the unit. A “wye” type strainer
is not recommended because it does not have adequate
debris holding capacity.
D. Process water piping should be designed to avoid excessive
elbowsand/orlengthsofpipeorhose.Ifusingexiblehoseavoid
tight twists or curls and excessive lengths.
E. Valvesandlters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. It is important to check all external process connections for leaks prior to starting the unit.
It is also important to check external connections for leaks and internal hose clamps and
connections for leaks after servicing the
unit.
2.4 AIR COOLED CONDENSER
A. Air-cooled condensers require ambient
air temperatures between 60°F and
95°Fforefcientoperation.Operating
above 95°F may result in elevated
condensing pressures and eventual
shut-down on the high pressure
limit switch. Air temperatures below
60°F may result in over condensing
pressures and cause a low pressure
refrigerant fault. Consult with the
Manufacturer’s service department
for more information on operating with
ambients air temperatures above 95°F
or below 60°F.
From ProcessTo Process
This label marks the To
Process connection
From Process
This label marks the From
Process connection
Typical wye strainer -
Not recommended.
Typical Air-cooled Condenser

Glycol Chillers : BC Series with MG Control 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]
B. Airowisgeneratedbythemotormountedfansorcentrifugalblowers.Airow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specications.Exhaustaircannotbeductedonmotor
mounted fan models.
C. Afreeairspaceofatleastthree(3)feetisrequired
atthecondenserintakeandsix(6)feetatthe
condenserdischargetoallowforproperairow.
D. At full load, the chiller will discharge approximately
15,000 btu per hour for every 12,000 btu/hr removed
from your process 1,000 cfm per horsepower. The
unit will reject 25% - 35% more heat than it removes
from your process.
E. On blower units, air discharge duct
workshouldbesizedbyaqualied
HVAC engineer. Sizing shall be
according 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ow
to maintain proper refrigerant head
pressure when condenser intake air
temperature will be less than 60°F.
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 the panels are not in place.
Starting the unit without the
enclosure panels in place will result
in a refrigerant fault.
CFM RATINGS
Model
5 Horsepower
7.5 Horsepower
10 Horsepower
15 Horsepower
20 Horsepower
25 Horsepower
30 Horsepower
CFM
5,000
7,500
10,000
15,000
20,000
25,000
30,000
Damper assembly
Punch hole
in top panel
1/4" Copper line
Optional
Liquid receiver
(located inside
chiller on base)
Angle valve and cap
1/4" copper line connection
WARNING: Do not attempt to duct exhaust air from a portable chiller using motor driven fans.
Exhaust air can only be ducted from a portable chiller using a blower assembly.
WARNING: Do not attempt to start or operate an air-cooled portable chiller without all cabinetry
panels in place. Air-cooled chillers require air to be drawn through the air-cooled condenser. This
will not occur if the panels are not in place.

Glycol Chillers : BC Series with MG Control 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]
H. Condenser Air Filtering.Usealterthatproducesverylowairowrestrictions.
GenerallyadisposableberglasslterwithaMERVratingof2-3providesadequateair
ltration.Thepurposeofthelteristopreventlargeparticlessuchasdust,lintanddebris
fromfoulingthecondenser.Youshouldbeabletoseethroughtheltermedia.Using
restrictiveltermediacancauselossofchillercapacity,difcultyrunninginwarmweather
and fan motor overheating.
2.5 ELECTRICAL CONNECTION
A. Standard Models
1. All electrical wiring must comply with local codes and the
National Electric Code.
2. Electrical power supply requirements for standard units
areidentied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 as specied on the unit’s data plate. Use of incorrect voltage will void the unit’s
warranty and cause a signicant hazard that may result in serious personal injury and unit
damage.
WARNING: Electric Shock Hazard. High Voltage is present in the electrical cabinet. Disconnect
power before servicing. Follow all facility lock-out tag-out procedures.
WARNING: Check that all electrical connections are tight before starting.
Disconnect power before servicing. Follow all facility lock-out tag-out procedures.
Typical Filter materials.
Typical Filter shown on 10 Horsepower air-cooled unit.

Glycol Chillers : BC Series with MG Control 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. 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. (Some custom units may include a fused or non-fused
disconnectswitch.)
4. Connect the four conductor power cable to the power entry terminal block on
theunit’selectricalpanel.Thenconnectthepowercabletothefused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ttings.
5. Aunitspecic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 chiller and cause premature unit failure as well as a safety risk.
7. A proper ground is required for the unit.
B. Control Circuit Wiring
1. Theunit’ssuppliedcontrolcircuitis110volt,1phase,60cycle.
2. The control circuit is supplied by the factory installed transformer. A control circuit
fuse is provided.
Typical electrical panel.
Terminal Strip
Pump Starter and
Overload Block
Power Entry Terminal Block
Pump & Transformer Fusing
Transformer: Line Voltage
to 115 volts
Grounding Bus Bar
Compressor & Fan Contactor

Glycol Chillers : BC Series with MG Control Instrument
Page: 20
ADVANTAGE ENGINEERING, INC.
525 East Stop 18 Road Greenwood, Indiana 46142
317-887-0729 Fax: [phone]
Service Department Fax: [phone]
Email: [email protected]
C. General
1. Makecertainallgroundconnectionstotheunitareproperlyafxed.
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.