AFFINITY™ CUSTOM CHILLER
Contents
1. Pins 9 and 10 are open when the temperature is within the setpoint range and closed when the temperature is lt or gt than the setpoint range Pins 12 and 13 are closed pins 11 and 12 are open when the unit is operating normally Pins 12 and 13 are open pins 11 and 12 are closed when an alarm condition exists Pins 15 and 16 are closed pins 15 and 14 are open when the chiller is operating normally Pins 15 and 16 are open pins 15 and 16 are closed when an alarm condition exists Pins 18 and 19 are closed and pins 17 and 18 are open when unit is running normally Pins 18 and 19 are open and pins 17 and 18 are closed when an alarm condition exists Pins 21 and 22 control the Local Remote Option Pins 24 and 25 are closed pins 23 and 24 are open when the unit is operating normally Pins 24 and 25 are open pins 23 and 24 are closed when an alarm condition exists PLC Input Table Input Type Description Status OFF StatusON Auxiliary Pump 1 Overload Overload No Overload Contact 1 Auxiliary Pump 2 Overload Overload No Overload Contact Level Switch Refrigerant Low Level gt Setpoint Level lt Setpoint Level 1 7 Level Switch Loop 1 Low Level Level gt Setpoint Level lt Setpoint Level Switch Loop 2 Low Level Level gt Setpoint Level lt Setpoint Pressure High Pressure Pressure lt Setpoint Pressure gt Setpoint Switch Warning Selector Switch Pump 2 ON OFF Pump 2 OFF Pump 2 ON 11 Selector Switch Pump 1 O2. EC 85 EF Alarm 2 setpoint 1 high absolute A21h 1 EC orF Alarm 2 setpoint 1 hysteresis AL22 4 EC 40 EF Alarm 2 setpoint 2 low absolute A22h 1 EC orF Alarm 2 setpoint 2 hysteresis Loop 0 00 Loop break detection time alarms on abnormal input PvT 0410 EC 100 Ohm RTD 50 to 100EC 0 1 degree resolution 0411 EF 100 Ohm RTD 58 to 212EF 0 1 degree resolution TF 4 0 Input Filter time in seconds SFT 0 Process Variable shift Sv h 41 EC 105 EF Setpoint Variable high limit Sv L 3 EC 38 EF Setpoint Variable low limit CTrL Pid Control type dT 0 5 Not supported always 0 5 rEv1 norM Control output 1 action reverse for modulating HGV Mv h 100 0 Manipulated variable control output high limit in percent Mv L 0 0 Manipulated variable control output low limit in percent bUrn 1 Output value when input is abnormal set to 3 when bUrn 1 STno 2 Station number for RS 485 communications Go through the parameters twice then set LoCt to 2 some parameters user changeable Changing the Set Value Temperature Change the Set Value by pressing the gt key on the controller keypad SV will change to a leading zero display Continue pressing the gt key until the appropriate digit flashes Press the v or w key on the controller keypad until the digit changes to the desired value Toggle through using the gt v and W keys to change the appropriate digits until the Set Value reads as desired Continue pressing the
3. RTD 58 to 212EF 0 1 degree resolution Input Filter time in seconds Process Variable shift Setpoint Variable high limit Setpoint Variable low limit Control type Not supported always 0 5 Control output 1 action reverse for modulating HGV Manipulated variable control output high limit in percent Manipulated variable control output low limit in percent Output value when input is abnormal set to 3 when bUrn 1 Station number for RS 485 communications Go through the parameters twice then set LoCt to 2 some parameters user changeable Factory Programming Values for the Loop 2 Controller Press and hold the SEL key to access the parameter menu Use the arrow buttons to change values Display will return to PV SV after about one minute if parameters are not being changed Set the following values LoCt 3 oUT1 Mod AUTo AT OFF P 6 5 i 61 d 0 0 All parameters user changeable Cannot be set anything but 0 0 indicates control output 1 is energized Mode Auto or Manual Normal control not auto tuned Proportional band experimental value for HGMV record actual values Integral time experimental value for HGMV record actual values Derivative time Operation Ar 17 EC 30 EF Anti reset windup limits integral range to control overshoot Man 0 0 Manual resetting value eliminates offset from P only control AL1T 0000 Alarm 1 type none AL2T 0021 Alarm 2 type high amp low absolute AL21 30
4. Wrong phase sequence Refrigeration high pressure cut out tripped Loose wire Defective contactor or coil Loss of refrigerant Compressor damaged Compressor internal thermostat tripped Compressor damaged Evaporator damaged Microprocessor failure Facility Water control valve set too low Microprocessor programmed incorrectly Insufficient flow of Facility Water Verify correct power is applied close breaker after correcting fault Check electrical service to unit Check phase reverse relay or phase monitor If sequence is incorrect switch any 2 wires on the incoming power source Manually reset button on pressure switch after correcting fault Disconnect power then check wiring Repair or replace contactor or coil Locate and repair leak then recharge with type and amount of refrigerant specified on serial tag Replace compressor Call Lydall Allow time for compressor to cool and automatically reset Replace compressor Call Lydall Call Lydall Replace microprocessor Reset Facility Water control valve Call Lydall Reprogram microprocessor Call Lydall Increase flow of Facility Water Problem Unit does not cool continued Pump leaks Excessive noise on Start Up Possible Cause Facility Water too warm Cooling load exceeds capacity of unit Refrigeration solenoid coil failure Loss of refrigerant Solid State Relay failure Solenoid valve stuck shut Defective refri
5. any filters To change the deionizing filter open the bypass H top valve and then close the two bottom valves After changing the filter reverse operation Open lower valves then close top valve The other two micron filters have normal in line isolation valves for changing filters All handles are in horizontal position when bypassing the filter Cooling a Water Cooled Condenser Never hook a water cooled unit to a potable water supply without providing back flow protection A drop in pressure in the water supply could cause back flow resulting in the possible contamination of the potable water supply Water cooled chillers require Facility Water to cool the condenser during operation The amount of flow is controlled automatically by a valve Affinity installs on the condenser This unit requires facility water flow of 10 gallons per minute Facility water temperature should be between 14 and 26 degrees C Facility water pressure must be between 35 and 75 psig Loop 2 will give the best performance be more stable when both loops are in operation Connect the Facility Water supply to the WATER IN fitting at the bottom of the chiller Connect the Facility Water return to the WATER OUT fitting Use connecting lines of the size shown on the coolant diagram inside diameter to reduce pressure loss Note The coolant lines of all water cooled chillers have been blown dry with low pressure air before shipping to protect the units from
6. its factory rated cooling capacity Do not operate damaged or leaking equipment The chiller must not be transported unless properly protected Original factory packaging in good condition or equivalent is required Request air ride trucks if transporting over the road Modifying the chiller without express written consent from Lydall will void the warranty O MANUALS D6624 10 23 2002 Safety Precautions 1 2 7 Heed all warning labels Do not remove Do not operate the chiller with the bonnet removed The bonnet protects personnel from rotating parts and hot surfaces and also protects the chillers components Connect the chiller to a properly fused disconnect box in compliance with the NEC National Electric Code as well as state and local codes for American usage or local and national codes for European usage Maximum fuses must not exceed the maximum rating found on the serial tag on the electrical box The voltage phase and frequency of the power source must also match the requirements specified on the serial tag To reduce the risk of electric shock Do not remove cover of the remote control box if included Refer servicing to properly qualified and licensed personnel Disconnect electrical power before opening the electrical box except for the checking of the phase reverse relay or phase monitor if included with this unit phase reverse relays or phase monitors will never be included in single phase units Pow
7. solid light indicates an alarm COMPRESSOR LOW SUCTION Amber Flashing Activated when the compressor suction pressure is below setpoint The chiller will shut down after a time delay LOW REFRIGERANT LEVEL Amber Solid when a low refrigerant level is sensed in the receiver COMPRESSOR OVERLOAD Amber Flashing Activated after a 2 second delay by the current sensor in one of the leads to the compressor motor when the motor has been shut down due to excessive temperature PHASE LOSS REVERSAL Amber Solid Activated when phases of unit need to be reversed May happen on initial start up of unit If it occurs switch phases exterior to unit and power unit again LOOP 1 LOW LEVEL Amber Solid when a low level condition is sensed by the flow switch in the Loop 1 reservoir Operation LOOP 2 LOW LEVEL Amber LOOP 1 PUMP OVERLOAD Red LOOP 2 PUMP OVERLOAD Red LOOP 1 LOW FLOW Red LOOP 2 LOW FLOW Red ALARM RESET SWITCH Black General Solid when a low level condition is sensed by the flow switch in the Loop 2 reservoir Solid Activated when pump amperage exceeds overload setting Unit shuts down The overload switch will have to be reset to the start position before beginning operation Solid Activated when pump amperage exceeds overload setting Unit shuts down The overload switch will have to be reset to the start position before beginning operation Solid Activated by the flow switch when t
8. the incoming power source Do not change any of the wiring in the electrical box Check again for proper phase sequence before proceeding with these instructions 7 When the previous steps are complete turn the chiller on by placing the ON OFF SET switch in the ON position Immediately check for flow If within five seconds no turbulence is visible in the reservoir or the supply pressure gauge shows no pressure reading shut the chiller off by placing the ON OFF SET switch in the OFF position If flow is established continue filling until the reservoir level rises to within a few inches of the top Do not allow the reservoir to overflow 8 If the pump does not establish prime disconnect the SUPPLY coolant line to vent any trapped air reconnect the line and repeat step 7 9 If the pump still does not prime use the following steps a Disconnect both coolant lines have a container handy to catch any overflow from the RETURN fitting b Force coolant into the SUPPLY fitting The fluid will force the air out of the lines in the chiller and out of the pump head causing it to escape into the reservoir If tap water will be the source of coolant simply connect the tap water line to the SUPPLY fitting and turn on the tap If a source of coolant other than tap water will be used elevate the coolant a few feet above the chiller connect to the SUPPLY fitting and let gravity force the air out into the reservoir Remember to have a container ha
9. the power source must also match the requirements specified on the serial tag Note Affinity models that can operate at either 208 230 volts 60 Hertz or 200 220 volts 50 Hertz have been set at the factory for 200 220 volt operation If the operating voltage will be greater than 220 volts a qualified electrician should remove the red wire from the contactor and replace it with the orange wire taken from the dummy fuse block Attach the red wire to the dummy fuse block as shown in the diagram below See the unit s serial tag for the correct voltage range Warning To reduce the risk of electric shock do NOT remove cover from the electrical box It contains exposed high voltage wires Refer servicing to qualified personnel Disconnect power to the chiller before performing any service Installation TYPICAL CONFIGURATION ELECTRICAL SCHEMATIC CONNECT FOR SYSTEM VOLTAGE Ck Ck 0 RED 208 ORN 240 BLK COM R L S D K INTERCHANGE gt NY PRIMARY CONNECTIONS o KN Us RED AND ORN hi Mg NOT USED MUST BE TO CHANGE VOLTAGE 50 ISOLATED ANDICAPPED g X REMOVED FROM ayer BLU YEL DOWER TERMINAL NOTE IN SOME CASES PRESSURE SCREW TERMINAL BLOCKS ARE USED IN PLACE OF FASTON TERMINATIONS Priming the Pumps and Connecting the Coolant Loop DO NOT RUN THE PUMPS DRY If the pumps do not establish prime the pump shaft seals may overheat and be damaged in less than a minute Use the followin
10. AFFINITY CUSTOM CHILLER FOA SALES AND SERVICE PLEASE CALL PTO SALES y ii 866 392 0600 Boot 626 994 2154 ewer plbsaes can User Manual D6621 Lydall Industrial Thermal Solutions Inc Post Office Box 1000 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 O MANUALS D6622 REV B 02 03 2003 NMT Table of Contents Introduction Equipment Precautions Safety Precautions Installation Transporting Placement Electrical Requirements Priming the Pumps and Connecting the Coolant Loop Pressure Gauges Filters Cooling a Water Cooled Condenser Operation Using the Controllers Programming Values for the Loop 1 Controller Programming Values for the Loop 2 Controller Changing the Set Value Temperature Safety Alarms Temperature Communications Other Lights and Switches on the Control Panel General Preventive Maintenance 25 Pin Interlock Description PLC Tables Table of Contents Trouble Shooting Guide Warranty Refrigeration Diagram Coolant Flow Diagram Electrical Schematic O MANUALS D6623 11 13 2002 Introduction Lydall Affinity Congratulations on your purchase of an Affinity product want to personally welcome you to the Lydall larger family In October of 2001 Lydall purchased Affinity Industries in an effort to expand capability as a Total Thermal Solutions Provider Affinity s chillers and heat exchangers complement Lydall s existing w
11. Lydall Industrial Thermal Solutions Inc O MANUALS D3774 01 11 2002 Equipment Precautions Failure to adhere to these precautions will void the warranty and may damage the chiller 1 This chiller has been shipped without coolant Do not run it without connecting the coolant lines and keeping them filled with appropriate coolant Never run the pump dry because it will be quickly damaged without liquid Never use coolants which are incompatible with the components in this chiller s coolant loop Some coolants may not damage the coolant loop components yet may significantly derate the chillers cooling capacity Never use automotive antifreeze or other antifreeze containing silicates because silicates will cause the pump seals to fail Check with the factory if there are questions about the coolant Maximum storage temperature for the unit is 52EC 125EF This chiller operates on three phase electricity Some components are sensitive to phase sequence The chiller is designed and wired so that all components will operate properly if the phase sequence is correct This unit is protected by a Phase Reverse Relay to prevent it from running if the sequence is incorrect If the chiller fails to start on installation a qualified electrical technician should check the relay in the electrical box If the light on the relay is not brightly lit the phase sequence is incorrect The technician should switch any two wires external to the chill
12. N OFF Pump 1 OFF Pump 1 ON 12 Flow Switch Process Flow Loop Flow lt Setpoint Flow gt Setpoint 3 Spare N A N A N A 4 Pressure Low Suction Pressure lt Setpoint Pressure gt Setpoint Switch Pressure 5 Pressure High Discharge Pressure gt Setpoint Pressure lt Setpoint Switch Pressure 6 Flow Switch Process Flow Loop Flow lt Set point Flow gt Set point 15 Auxiliary Compressor Overload No Overload Contact Overload 16 Relay Phase Reverse Phase Normal Relay Loss Reversal 1 Switch Local Remote Local Remote Switch 7 Reset Switch Alarm Reset Resets Faults O MANUALS D6629 10 03 2002 PLC Output Table O MANUALS D6630 10 03 2002 N A Refrigeration No Alarm Alarm Condition High Pressure Interlock Level gt Setpoint Level lt Setpoint Loop 1 Low Flow Flow gt Setpoint Flow lt Setpoint Light Loop 2 Low Level Flow gt Setpoint Flow lt Setpoint Light Loop 2 Pump Pump OFF Pump ON Contactor Level gt Setpoint Level lt Setpoint No Alarm Flashing Compressor Overload Solid Phase Loss Reversal Combined No Alarm Flash Low Suction Refrigeration Pressure Alarm Solid Low Refrigerant Level Alarm High Discharge No Alarm Flashing Warning Pressure Solid Shutdown Loop 1 Pump Off On Contactor Compressor Contactor Unit does not start Unit does not cool Trouble Shootinc Guide Possible Cause Possible Remedy No power to unit breaker tripped Low voltage
13. are not performed in strict accordance with all applicable city county state and federal laws Further limitations and exclusions This Warranty is in lieu of any other warranties expressed or implied including merchantability or fitness for a particular purpose In no event shall Lydall be liable for any consequential or incidental damages that the Owner may incur resulting from purchase or use of this Lydall product The buyer s sole and exclusive remedy and the liability limit of Lydall for any loss whatever shall not exceed the purchase price paid by the purchaser for the Lydall product on which a claim is made Lydall Industrial Thermal Solutions Inc Post Office Box 1000 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 O MANUALS D3777 05 06 2002
14. elve 12 months from the date of shipment Lydall will repair or at its discretion replace any part found to contain a manufacturing defect in material or workmanship without charge to the Owner for twelve months from date of shipment Shipping costs are excluded from warranty Service labor will be at no charge during the warranty period as long as the labor is supplied at the Lydall plant in Ossipee New Hampshire or by a Lydall approved service provider Replacement or repaired parts will be warranted only for the un expired portion of the original Warranty To obtain prompt warranty service contact Lydall PO Box 1000 Ossipee New Hampshire 03864 USA Before returning any equipment to Lydall for repair it is necessary to contact the Lydall Service Department for a Return Material Authorization number and an authorized service depot location where the repairs will be completed This Warranty does not cover the following Damage or failure of any part caused by accident customer shipping storage misuse customer modification fire flood Acts of God or resulting from failure to properly install operate or maintain the product in accordance with the printed instructions provided in the User Manual As noted in the User Manual any modification of the unit without expressed written consent from Lydall will void the warranty In no event shall Lydall be liable for any repairs or service or any consequence of any repair or service that
15. er Do not modify the wiring inside the electrical box The chiller is designed for indoor use only Do not operate the chiller in ambient temperatures below 7EC 45EF If the chiller has been exposed to ambient temperatures below 7EC allow 24 hours at ambient temperatures above 7EC to warm the oil in the compressor as well as the refrigerant before operating This chiller exhausts the heat it extracts to Facility Water The Facility Water should have a temperature of 30EC 86EF or lower The Facility Water flow will be controlled by the water valve at the chillers condenser At maximum the flow may need to be as high as four liters one gallon per minute for each kilowatt of heat extracted The Facility Water pressure should be at between two and seven bar thirty and one hundred pounds per square inch Routinely inspect the pump inlet strainer located in the reservoir for debris Turn the chiller off then remove and clean the strainer as required to permit free flow of coolant Prevent foreign debris from entering the coolant lines while the strainer is removed Hint A plastic sandwich bag may be used to wrap the strainer to contain most of the debris Failure to keep the strainer clean will reduce the coolant flow and damage the pump Equipment Precautions 8 10 11 12 13 14 15 16 Regularly clean the screen in the assembly at the chiller s inlet for Facility Water To clean shut off the chiller cl
16. er must be applied in order for the phase reverse relay or phase monitor to indicate phase sequence Do not operate equipment with damaged electric power cords Turn off the chiller and disconnect electric power before servicing or moving Coolant lines filters and other components which connect to the chiller must be capable of withstanding the maximum pressure that the pump in the chiller can deliver at the maximum expected temperature The coolant loop has not been designed for potable water applications Do not use the chiller for potable water Never hook the water lines of a water cooled unit to a potable water source or immerse a hose connected to a potable water source in the reservoir without providing back flow protection A loss of pressure in the water source could lead to a back flow of the fluid in the unit resulting in a possible contamination of the potable water source Vapors of some alcohol based antifreezes as well as other coolants may cause explosion if exposed to flame or spark Certain antifreezes may be poisonous if ingested O MANUALS D3799 10 03 2002 Installation Transporting An Affinity chiller rolls easily on four swivel casters The brakes must be off on the two locking casters when moving the unit Roll the chiller gently to its operating location The cushioned casters will help to dampen shock Lock the casters and lower the leveling feet to support the units full weight when the unit is in
17. freezing and subsequent damage This may cause the condenser to be dry which in turn could result in failure to start upon initial start up there could be no water in the condenser to absorb the heat This is easily corrected by pressing the high pressure reset switch a few times to initiate flow through the Facility Water side of the chiller O MANUALS D6625 10 03 2002 Operation Using the Controllers This chiller comes with two FUJI ELECTRIC 1 16 DIN PYX temperature controllers one for each loop These controllers are programmable microprocessors which offers many more features than will need to be mastered at this point Two additional controllers are also provided to display the flow for each loop in gallons per minute These controllers come pre programmed according to the Affinity model selected If some of the controllers additional features become necessary call Lydall service 603 539 5005 for technical assistance or consult the FUJI ELECTRIC Instruction Manual FUJI ELECTRIC To power the controllers without powering the chiller place the ON OFF SET switch in the SET position The digital display will light up The number next to PV is the actual process coolant temperature The number next to SV is the Set Value desired temperature Lights next to OUT1 OUT2 ALM1 and ALM2 may also appear A light on next to OUT1 when the switch is in the ON position indicates that the chiller is cooling Both ALM1 a
18. g instructions when filling and assembling the coolant lines to prevent damage to the pump shaft seals Hint Before turning the chiller on have sufficient clean water or coolant at hand It will be needed immediately to make up the supply necessary to fill the coolant loop The pumps in this unit will usually self prime Follow the instructions below for each loop 1 Close the reservoir drain 2 Fully open the flow control valve if included 3 Have extra coolant to add as the pump primes and the coolant loop fills 4 Fill the reservoir with coolant Do not fill above the height of the coolant loop connection fittings or fluid may leak out 5 Connect the coolant lines from the application to the FPT female pipe thread fittings near the top of the chiller as follows Do not over tighten the insert and do not use a sealant that will lock the male threads to the female threads a Connect the coolant line coming back from the application to the RETURN fitting b Connect the coolant line going to the application to the SUPPLY fitting Installation 6 This chiller is equipped with a Phase Reverse Relay The chiller will not start if the phase sequence is incorrect If the chiller fails to start upon installation have a qualified electrical technician check the Phase Reverse Relay in the electrical box of the chiller If the LED is not brightly lit the phase sequence is incorrect The technician should switch any two of the wires at
19. geration low pressure cut out Malfunctioning thermal expansion valve Pump damaged loss of flow Hot gas bypass valve setting too high Hot gas bypass valve stuck open Faulty pump casing Shaft seal damaged Pump housing O Ring damaged Improper fluid Low voltage Wrong voltage taps used on transformer Contactor or coil failure Possible Remedy Provide cooler Facility Water Reduce cooling load Replace solenoid coil Locate and repair leak then recharge with type and amount of refrigerant specified on serial tag Replace Solid State Relay Repair or replace solenoid valve Repair or replace low pressure cut out Replace thermal expansion valve Replace pump Call Lydall Repair or replace valve Replace pump assembly Replace shaft seal Remove pump and rebuild Call Lydall Check electrical service to unit Connect to proper taps Replace contactor or coil Problem Pump motor overheats Noisy compressor Level light remains on Fault light remains on Level light does not work Possible Cause Pump overload protection set too high Improper voltage supplied Flooding of refrigerant into crankcase Worn compressor Refrigeration high pressure cut out set too high Refrigeration low pressure cut out set too low Low coolant level Reservoir level switch float stuck Time delay relay malfunction when used Level switch failure Low coolant flow No coolant flow Fl
20. gt key until the last digit flashes Press the gt key one more time and all leading zeroes will extinguish This locks in the Set Value temperature Caution Never program in a Set Value temperature of more than 32EC 90EF unless this Affinity model is specifically modified to operate at higher coolant temperatures Never program in a Set Value temperature of less than 5EC 40EF unless a suitable antifreeze is used as coolant AND the unit is designed to operate at below freezing temperatures Operation Safety Alarms Temperature These controllers have ALM1 and ALM2 lights ALM2 may or may not operate depending on the exact model of the PYX controller The alarm s have been preset at the factory to come on when the temperature of the circulating coolant is above or below the temperature the chiller has been set to deliver The OUT1 light on the controller when lit indicates that the refrigerant solenoid valve is open to allow refrigerant to flow to the heat exchanger If the light is on most of the time most of the chillers capacity is being used If the light is on infrequently much less than the chiller s full capacity is being used Communications Pins 2 and 5 on the 9 pin connector provide RS485 Communications from the controllers Other Lights and Switches on the Control Panel HIGH PRESSURE WARNING ALARM Amber Lights when a high pressure condition exists in the compressor A flashing light indicates a warning and a
21. he pump flow falls below setpoint Solid Activated by the flow switch when the pump flow falls below setpoint Use to cancel an reset any alarm when the alarm condition has been corrected This unit requires facility water flow of 10 GPM with facility water temperature between 14 26EC and pressure between 35 and 75 psig The best performance best stability of Loop 2 is achieved when both loops are in operation O MANUALS D6626 02 03 2003 25 Pin Interlock Description Ground AR2 Loop 2 Low Flow CR2 Loop 1 Isolation Valve CR1 Loop 2 Isolation Valve Loop 1 Temperature Alarm Loop 2 Temperature Alarm AR3 Loop 1 Low Level AR1 Loop 1 Low Flow AR5 Refrigerant High Pressure LOCAL REMOTE AR4 Loop 2 Low Level O MANUALS D6627 11 12 2002 Pin 1 is ground Pins 3 and 4 are closed pins 2 and 3 are open when the unit is operating normally Pins 3 and 4 are open pins 2 and 3 are closed when an alarm condition exists Pins 5 and 20 operate a control relay to CR1 With this coil energized via a customer supplied 24 Volts DC signal the Loop 1 isolation valve opens allowing flow out of the unit Pins 6 and 20 operate a control relay CR2 With this coil energized via a customer supplied 24 Volts DC signal the Loop 2 isolation valve opens allowing flow out of the unit Pins 7 and 8 are open when the temperature is within the setpoint range and closed when the temperature is lt or gt than the setpoint range
22. ide array of Passive Thermal Solutions augmenting Lydall s engineered thermal solutions for use in appliance cryogenic building products and automotive markets Our group is market driven as a formidable thermal solution manufacturer Lydall Inc is a New York Stock Exchange listed company NYSE LDL headquartered in Manchester CT Our company with ten operations in the United States France one in Germany and Sales Service Offices in Japan and Singapore is recognized for working with customers to satisfy their unique thermal solution needs and for delivering high quality innovative products and exceptional service Affinity products are high precision specialty temperature controlled equipment The following product manual is designed to help you realize the full value of your purchase We highly recommend that you read this manual in its entirety The manual will assist your company with the installation operation and routine maintenance of your Affinity product Please keep this manual readily accessible to operation and service personnel to ensure you get the most out of our product If you have any questions about this model or have other thermal solution needs do not hesitate to call our Sales department 603 539 3600 or the 24 7 Service department 603 539 5005 Thank you for your confidence in our ability to meet and or exceed your needs and expectations Sincerely John Tattersall Group Vice President
23. nd ALM2 are alarms that are configured differently for different chillers Factory Programming Values for the Loop 1 Controller Press and hold the SEL key to access the parameter menu Use the arrow keys to change values Display will return to PV SV after about one minute if parameters are not being changed Set the following values LoCt 3 All parameters user changeable oUT1 Cannot be set anything but 0 0 indicates control output 1 is energized Mod AUTo Mode Auto or Manual AT OFF Normal control not auto tuned Operation P 8 0 i 32 d 0 0 Ar 17 EC 30 EF Man 0 0 AL1T 0000 AL2T 0021 AL21 30 EC 85 EF A21h 1 EC or F AL22 4 EC 40 EF A22h 1 EC orF Loop 0 00 PvT 0410 EC 0411 EF TF 4 0 SFT 0 Sv h 41 EC 105 EF Sv L 3 EC 38 EF CTrL Pid dT 0 5 rEv1 norM Mv h 100 0 Mv L 0 0 bUrn 1 STno 1 Proportional band experimental value for HGMV record actual values Integral time experimental value for HGMV record actual values Derivative time Anti reset windup limits integral range to control overshoot Manual resetting value eliminates offset from P only control Alarm 1 type none Alarm 2 type high amp low absolute Alarm 2 setpoint 1 high absolute Alarm 2 setpoint 1 hysteresis Alarm 2 setpoint 2 low absolute Alarm 2 setpoint 2 hysteresis Loop break detection time alarms on abnormal input 100 Ohm RTD 50 to 100EC 0 1 degree resolution 100 Ohm
24. ndy to catch any overflow from the RETURN fitting C Reconnect the coolant lines and repeat step 7 Stop filling when the reservoir is full to within a few inches of the top Do not allow the reservoir to overflow A stainless steel mesh strainer attaches to the pump suction port near the bottom of the reservoir It can easily be removed for cleaning First turn the pump off then pull off the strainer rinse it clean and push it back on To protect the pump routinely inspect the strainer to be sure it is clean and properly attached Hint If the strainer is coated with debris wrap it with a plastic sandwich bag before pulling it off to keep most of the debris from escaping into the reservoir Pressure Gauges Two gauges on the unit provide information on the Facility Water Pressure condition One is labeled Facility Water In Pre Strainer one labeled Facility Water In Post Strainer Lydall suggests that the customer takes a sample reading from these gauges soon after installation When the gauge pressure rises well above this sample reading it is time to check and clean the strainer as instructed in the Maintenance section of this manual Installation Date Facility Water In Pre Strainer Facility Water In Post Strainer Filters The Deionizing Filter Is a full flow filter All flow leaving the unit will cycle through the filter All valves are in the vertical position when operating under normal conditions not changing or bypassing
25. ose off the supply of Facility Water to the chiller and remove the screen Clean as necessary and reinstall See Installation for further instructions The compressor in this unit has been charged with a Polyolester lubricant Polyolester lubricants POE will quickly absorb moisture from the ambient surroundings Since moisture levels greater than 100 ppm will result in system corrosion and ultimate failure it is imperative that compressors components containers and the entire system be kept sealed as much as possible Lubricants will be packaged in specially designed sealed containers After opening all the lubricant in a container should be used at once since it will readily absorb moisture if left exposed to ambient air Work on systems and compressors must be carried out with the open time as short as possible Leaving the system or compressor open during breaks or overnight MUST BE AVOIDED Mobil EAL ARCTIC 22 CC is the preferred Polyolester due to unique additives included in this lubricant ICI Emkarate RL 32S is an acceptable substitute if Mobil is not available As received the POE lubricant will be clear or straw colored After use it may acquire a darker color This merely reflects the activity of the lubricant s protective additive Oil level must not fall below 1 4 sight glass Do not operate the chiller at coolant temperatures above or below it was specified to deliver Do not run the chiller with cooling loads that exceed
26. ow switch sticking Time delay relay has not timed out when used Lamp burned out Level switch failure Possible Remedy Reset pump thermal overload relay or replace if faulty Correct voltage Warm crankcase if unit has been off for a long period or has been left in a cool ambient for more than a few hours Replace compressor Call Lydall Adjust setting Adjust setting Check for leaks then fill reservoir Clean reservoir and level switch Replace time delay relay Replace level switch See Problem Low coolant flow See Problem No coolant flow Disassemble flow switch clean and reinstall or replace Wait for time delay relay to time out Replace lamp Replace level switch Problem Low coolant flow No coolant flow Possible Cause Pump suction strainer clogged Flow control valve not fully open Pressure relief valve set too low unless not adjustable Low coolant level in reservoir Restriction in coolant lines external to chiller Frozen evaporator Flow switch clogged Pump not primed Pump suction strainer clogged No coolant in reservoir Pump overload tripped Pump motor shaft bound to seal Pump housing improperly torqued Damaged pump Frozen evaporator Clogged line or closed valve in external piping Leak s in external piping Possible Remedy Remove strainer clean and reinstall or replace Open flow control valve Adjust pressure relief valve to specifica
27. place If a forklift will be used to carry the chiller proceed slowly and carefully to avoid jarring the unit Insert the forks carefully to prevent damage to the casters If the unit will be lifted by crane use lifting strops and do not cinch the strops If the chiller will be shipped protect it from shock and vibration or the warranty will be void The chiller must not be transported unless suitably protected Original factory packaging in good condition or equivalent is required Request air ride trucks when transporting over land Thoroughly drain the coolant lines and blow them dry with low pressure compressed air before shipping or storing Placement Select a level location near the application free from dripping or spraying moisture and excessive dust Keep the coolant lines short to allow the pump to provide maximum pressure and flow to the application If the chiller will be placed more than 25 feet from the application call Lydall to discuss placement and how it might affect performance Electrical Requirements Connect the chiller to a properly fused disconnect box in compliance with the NEC National Electric Code as well as state and local codes for American usage or national and local codes for European usage Maximum fuse sizes in the disconnect box must not exceed the maximum ratings specified on the serial tag of the chiller found on the electrical box near where the power cord connects The voltage phase and frequency of
28. t Adjust and reset refrigeration low pressure cut out Adjust water modulating valve Remove excess refrigerant then charge with type and amount of refrigerated listed on serial tag Adjust and reset pump thermal overload relay to specifications or replace if faulty Determine cause if pump is damaged repair or replace Check electrical service to chiller Throttle flow control valve Adjust pressure relief valve Allow time for compressor to cool and automatically reset Replace module Replace Call Lydall Problem Compressor turns on and off automatically Temperature display reads incorrectly Microprocessor does not work O MANUALS D4207 05 17 2002 Possible Cause Discharge pressure too high Condenser fan s not on Refrigeration high pressure cut out set to automatic Loose wire Broken RTD Microprocessor failure 5 second delay has not timed out Microprocessor programmed incorrectly Microprocessor failure Possible Remedy Check Facility Water for blockage Check motor s and wiring Check settings Disconnect power to unit then check wiring Replace RTD Replace microprocessor Wait at least 5 seconds after turning on Reprogram microprocessor Call Lydall Replace microprocessor Warranty The Lydall Limited Warranty Twelve Month Warranty Parts and Labor Lydall Industrial Thermal Solutions Inc warrants this product to the original Owner for a period of tw
29. tion Fill reservoir to proper level Eliminate restrictions in coolant lines external to chiller Call Lydall Disassemble flow switch clean and reinstall or replace Prime pump Remove and clean strainer then reinstall Repair any leaks then fill reservoir Wait 5 minutes for overload to reset Replace pump or renew seal Remove pump torque to specifications test and reinstall Replace pump Call Lydall Check external piping for dirt or closed valve Repair leaks as needed Problem Chiller cools well below the desired Set Point Chiller shuts down during operation Too much recirculating pressure to process Compressor does not run Possible Cause Microprocessor programmed incorrectly Malfunctioning solenoid valve Solid State Relay failure Microprocessor failure Refrigeration high pressure cut out set too low Refrigeration low pressure cut out set too high Water modulating valve set too high Excess refrigerant charge Pump overload setting too low Pump overload tripped Low voltage Flow control valve set too high Pressure relief valve set too high unless not adjustable Compressor internal thermostat tripped Defective Solid State Motor Overload Motor burned out Possible Remedy Reprogram microprocessor Call Lydall Repair or replace solenoid valve Replace Solid State Relay Replace microprocessor Adjust and reset refrigeration high pressure cut ou
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