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AFFINITY™ CUSTOM CHILLER

User Manual D6621

Lydall Industrial Thermal Solutions Inc.

Post Office Box 1000

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

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Summary of Contents for Affinity

Page 1: ...LLER 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 ...

Page 2: ... 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 ...

Page 3: ...Table of Contents Trouble Shooting Guide Warranty Refrigeration Diagram Coolant Flow Diagram Electrical Schematic O MANUALS D6623 11 13 2002 ...

Page 4: ...g 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 yo...

Page 5: ...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 chiller Do not modify the wiring inside the electrical box 5 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 allo...

Page 6: ...pressors 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 10 As received the POE lubricant will be clear or straw colored After use...

Page 7: ...relays or phase monitors will never be included in single phase units Power 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 4 Coolant lines filters and other components which connect to the chiller must be capable ...

Page 8: ...low 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 fus...

Page 9: ...elf 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...

Page 10: ...orce 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 i...

Page 11: ...l 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 Conn...

Page 12: ...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 and ALM2 are alarms that are configured ...

Page 13: ... 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 1 Station number for RS 485 communications Go throug...

Page 14: ...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 key on the controller keypad SV will change to a leading zero display Continue pressing ...

Page 15: ...s 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 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 Sol...

Page 16: ...witch will have to be reset to the start position before beginning operation LOOP 1 LOW FLOW Red Solid Activated by the flow switch when the pump flow falls below setpoint LOOP 2 LOW FLOW Red Solid Activated by the flow switch when the pump flow falls below setpoint ALARM RESET SWITCH Black Use to cancel an reset any alarm when the alarm condition has been corrected General This unit requires faci...

Page 17: ...emperature Alarm Pins 9 and 10 are open when the temperature is within the setpoint range and closed when the temperature is or than the setpoint range AR3 Loop 1 Low Level 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 AR1 Loop 1 Low Flow Pins 15 and 16 are closed pins 15 and 14...

Page 18: ...low Set point 7 Level Switch Loop 1 Low Level Level Setpoint Level Setpoint 8 Level Switch Loop 2 Low Level Level Setpoint Level Setpoint 9 Pressure Switch High Pressure Warning Pressure Setpoint Pressure Setpoint 10 Selector Switch Pump 2 ON OFF Pump 2 OFF Pump 2 ON 11 Selector Switch Pump 1 ON OFF Pump 1 OFF Pump 1 ON 12 Flow Switch Process Flow Loop 2 Flow Setpoint Flow Setpoint 13 14 Spare N A...

Page 19: ...w Setpoint Flow Setpoint 5 Contactor Loop 2 Pump Contactor Pump OFF Pump ON 6 Lamp Interlock Loop 1 Low Level Light Level Setpoint Level Setpoint 7 Lamp Combined Alarm No Alarm Flashing Compressor Overload Solid Phase Loss Reversal 8 Lamp Combined Refrigeration Alarm No Alarm Flash Low Suction Pressure Solid Low Refrigerant Level Alarm 9 Lamp High Discharge Pressure No Alarm Flashing Warning Solid...

Page 20: ...n 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 Unit does not cool Compressor internal thermostat tripped Compressor damaged Evaporator damaged Microprocessor failure Facility Water control valve set too low ...

Page 21: ...ng 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 Pump leaks Faulty pump casing Shaft seal damaged Pump housing O Ring damaged Improper fluid Re...

Page 22: ...Replace compressor Call Lydall Adjust setting Adjust setting Level light remains on Low coolant level Reservoir level switch float stuck Time delay relay malfunction when used Level switch failure Check for leaks then fill reservoir Clean reservoir and level switch Replace time delay relay Replace level switch Fault light remains on Low coolant flow No coolant flow Flow switch sticking See Problem...

Page 23: ...nt lines external to chiller Call Lydall Disassemble flow switch clean and reinstall or replace No coolant flow 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 Prime pump Remove and clean ...

Page 24: ... reset refrigeration high pressure cut out 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 Too mu...

Page 25: ...nd wiring Check settings Temperature display reads incorrectly Loose wire Broken RTD Microprocessor failure Disconnect power to unit then check wiring Replace RTD Replace microprocessor Microprocessor does not work 5 second delay has not timed out Microprocessor programmed incorrectly Microprocessor failure Wait at least 5 seconds after turning on Reprogram microprocessor Call Lydall Replace micro...

Page 26: ...r 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...

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