Lydall Affinity User Manual

AFFINITY™ CUSTOM CHILLER

User Manual D6621

Lydall Industrial Thermal Solutions Inc.

Post Office Box 1000

775 Route 16

Ossipee NH 03864 USA

Telephone: [phone] (Sales), 603-539-5005 (Service), Fax: [phone]

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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

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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
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
Lydall Industrial Thermal Solutions, Inc.

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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.

2. 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 chiller’s 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.

3. Maximum storage temperature for the unit is 52EC (125EF).

4. 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 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, allow 24 hours at ambient temperatures above 7EC to warm

the oil in the compressor as well as the refrigerant before operating.

6. 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 chiller’s 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).

7. 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. Regularly clean the screen in the assembly at the chiller’s inlet for Facility Water. To
clean, shut off the chiller, close off the supply of Facility Water to the chiller, and remove
the screen. Clean as necessary and reinstall. See Installation for further instructions.

9. 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.

10. 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.

11. Oil level must not fall below ¼ sight glass

12. Do not operate the chiller at coolant temperatures above or below it was specified to
deliver.

13. Do not run the chiller with cooling loads that exceed its factory rated cooling capacity.

14. Do not operate damaged or leaking equipment.

15. 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.

16. Modifying the chiller without express written consent from Lydall will void the warranty.

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Safety Precautions

1. Heed all warning labels. Do not remove.

2. 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.

3. 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). 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
of withstanding the maximum pressure that the pump in the chiller can deliver at the
maximum expected temperature.

5. 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.

6. Vapors of some alcohol based antifreezes as well as other coolants may cause
explosion if exposed to flame or spark.

7. Certain antifreezes may be poisonous if ingested.

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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. 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 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.