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Lydall Affinity User Manual

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AFFINITY™ CUSTOM CHILLER
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

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  • Page 1 AFFINITY™ CUSTOM CHILLER 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: Table Of Contents

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

  • Page 4: Introduction

    Introduction Congratulations on your purchase of an Affinity™ product. I 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 wide array of Passive Thermal Solutions, augmenting Lydall’s engineered thermal solutions for use in...

  • Page 5: Equipment Precautions

    Equipment Precautions Failure to adhere to these precautions will void the warranty and may damage the chiller. 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.
  • Page 6 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)

  • Page 7: Safety Precautions

    Safety Precautions 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 chiller’s 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.

  • Page 8: Installation

    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 place.

  • Page 9: Priming The Pumps And Connecting The Coolant Loop

    Installation 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 following instructions when filling and assembling the coolant lines to prevent damage to the pump shaft seals.

  • Page 10: 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.

  • Page 11: Filters

    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.

  • Page 12: Operation

    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.
  • Page 13 Operation Proportional band - experimental value for HGMV - record actual values Integral time - experimental value for HGMV - record actual values Derivative time 17 (EC), 30 (EF) Anti-reset windup - limits integral range to control overshoot Manual resetting value (eliminates offset from P-only control) AL1T 0000 Alarm 1 type (none) AL2T 0021...

  • Page 14: Changing 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...

  • Page 15: Safety Alarms (Temperature)

    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.

  • Page 16: General

    Operation LOOP 2 LOW LEVEL: Amber Solid when a low level condition is sensed by the flow switch in the Loop 2 reservoir. LOOP 1 PUMP OVERLOAD: Red Solid. Activated when pump amperage exceeds overload setting. Unit shuts down. The overload switch will have to be reset to the “start”...

  • Page 17: 25-Pin Interlock Description

    25-Pin Interlock Description Ground Pin 1 is ground AR2 Loop 2 Low Flow 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. CR2 Loop 1 Isolation Valve Pins 5 and 20 operate a control relay to CR1.
  • Page 18 PLC Input Table Input Type Description Status OFF Status ON Auxiliary Pump 1 Overload Overload No Overload Contact Auxiliary Pump 2 Overload Overload No Overload Contact Level Switch Refrigerant Low Level > Setpoint Level < Setpoint Level Spare Pressure Low Suction Pressure <...
  • Page 19 PLC Output Table Output Type Description Status OFF Status ON Spare Interlock Refrigeration No Alarm Alarm Condition High Pressure Interlock Lamp/Interlock Loop 2 Low Level Level > Setpoint Level < Setpoint Light Lamp Loop 1 Low Flow Flow > Setpoint Flow <...
  • Page 20 Loss of refrigerant Locate and repair leak, then recharge with type and amount of refrigerant specified on serial tag Compressor damaged Replace compressor - Call Lydall Unit does not Compressor internal thermostat Allow time for compressor to cool cool tripped...
  • Page 21 Malfunctioning thermal expansion Replace thermal expansion valve valve Pump damaged, loss of flow Replace pump Hot gas bypass valve setting too Call Lydall high Hot gas bypass valve stuck open Repair or replace valve Pump leaks Faulty pump casing Replace pump assembly...
  • Page 22 Worn compressor Replace compressor - Call Lydall Refrigeration high pressure cut-out Adjust setting set too high Refrigeration low pressure cut-out Adjust setting...
  • Page 23 Fill reservoir to proper level Restriction in coolant lines external Eliminate restrictions in coolant to chiller lines external to chiller Frozen evaporator Call Lydall Flow switch clogged Disassemble flow switch, clean and reinstall, or replace No coolant flow Pump not primed...
  • Page 24 Pressure relief valve set too high Adjust pressure relief valve process (unless not adjustable) Compressor Compressor internal thermostat Allow time for compressor to cool does not run tripped and automatically reset Defective Solid State Motor Replace module Overload Motor burned out Replace - Call Lydall...
  • Page 25 Broken RTD Replace RTD Microprocessor failure Replace microprocessor Microprocessor 5 second delay has not timed out Wait at least 5 seconds after turning does not work Microprocessor programmed Reprogram microprocessor - Call incorrectly Lydall Microprocessor failure Replace microprocessor O:MANUALS\D4207 (05/17/2002)
  • Page 26 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 are not performed in strict accordance with all applicable city, county, state, and federal laws.

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