O ff: 510-249-9100 cell: 650-759-2438 affinity chiller. model RWA
Contents
1. REMAINS TeE 105 1 LYDALL 2 FAIR CDS 1 INDUSTRIAL THERMAL SOLUTIONS OSSIPEE OPERATION PLATE C 0 0 SC 51 td CIEGA Ter 031 SJAL Fees S3921862. Replace pump Call Lydall Check external piping for dirt or closed valve Check for leaks and repair as needed Adjust and reset refrigeration high pressure cut out Adjust and reset refrigeration low pressure cut out Remove excess refrigerant and recharge to specifications on serial tag Problem Chiller shuts down during operation continued Temperature display reads incorrectly Chiller cools well below the desired Set Point Too much recirculating pressure to process Compressor turns on and off automatically Possible Cause Pump thermal overload setting too low Facility Water too warm Pump overload tripped Low voltage Loose wire Broken RTD Microprocessor failure Microprocessor programmed incorrectly Malfunctioning solenoid valve Solid State Relay failure Microprocessor failure Flow control valve set too high Pressure relief valve set too high unless not adjustable Discharge pressure too high Condenser fan s not on Refrigeration high pressure cut out set to automatic Possible Remedy Adjust and reset thermal overload relay to specifications replace if faulty Provide cooler Facility Water Determine reason for trip if pump is damaged repair or replace Check electrical service to chiller Check wiring after disconnecting power Replace RTD Replace microprocessor Reprogram microprocessor Call Lydall Repair or replace solenoid valve Replace
3. because it will be quickly damaged without liquid Keep the fluid in the reservoir at a satisfactory level to avoid damage to the pump and other components 2 Never use coolants which are incompatible with the components in the 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 they will cause the pump seals to fail Check with Lydall if there are questions about the coolant 3 Maximum storage temperature for the unit is 52 C 125 F 4 Heat generated by motors and electrical components must be dissipated Allow sufficient clearance around the unit to dissipate this heat 5 This chiller is designed for indoor use only If the chiller has been exposed to temperatures below 7 C allow 24 hours at ambient temperatures above 7 C to warm the oil in the compressor as well as the refrigerant before starting 6 If this unit contains refrigerant there is an oxygen depletion risk that should be considered It must be placed in a room with adequate volume based on the amount of refrigerant in the unit If additional refrigeration equipment is in the room additional space must be provided In the Placement section under Installation refer to the Warning Oxygen Depletion Risk for more details T This chiller exhausts the heat it extracts to Facility Water The Facility Water
4. 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 60
5. 3 539 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 OMMANUALSD3774 01 11 2002 Facility Water Requirements o 8 5 a o eo ce e o Facility Water FLow Rate gpm o o A Facility Water Flow Rate gpm e o hi 15 25 35 Facility Water Temperature C Facility Water Temperature C B Recommended Minimum bx A w e N eo LS Facility Water Flow Rate gpm Facility Water Flow Rate gpm e an a Nw o 35 15 25 Facility Water Temperature C Facility Water Temperature C wRecommended Minimum fa Recommended Minimum The model number on the serial tag will indicate which graph references this unit 25psi Minimum Facility Water Pressure Differential 50psi Maximum Facility Water Pressure Differential 75psi Maximum Facility Water Inlet Pressure Operating with Minimum Facility Water Flow reduces system efficiency OAMANUALS D5035 06 25 1999 Equipment Precautions Failure to adhere to these precautions will void the warranty and may damage the chiller 1 The chiller has been shipped without coolant Do not run it without connecting the coolant lines and keeping them filled with the appropriate coolant Never run the pump without prime
6. D 15 mE OL MOTOR OVERLOAD PROTECTION M TC TEMPERATURE CONTROLLER x BLE BLE PLE TI T2 em CONNECT F R 8 E STARTING SYSTEM VOLTAGE NEM hos ERN CAPACITOR PI 1 o8 ar au GAN o gt RED ELE TEL M WHERE USED AL t 5 PUMP E pu 24 VAE nr E Y Qu FF SET COMPRESSOR FLU TEL uw 8A Fol ir CCOUQ SEU RIGH DISCHARGE PRESS PIN AE ext PINES 3LiD y od 83 02 gp an Sh 01 dT EN v RU 74 VO p L o L gt C pnl WHT A 108 HICH Be nnp arc BED 3 UT ARS 1 c 27 RID M REL LOW LEVEL S PES Lm wv V BEN id m oc pem ei LOW LEVEL pip s DE OMA 837 e C 4 tee o TEMPERATURE k s CONTROLLER LOW FLOW E ARI 7 10 3L a gu T anl SR i 1 R ani 4 PIN a3 LOW FL lh HIN BG e 3 ad FED APY c 4 1 98 25 PIN te D suBgiINIA Tusc in JoERA UH ipa lt CEFTAC ARE ST Bad zu LE m SSRI PIN 16 21 aT LEVEL 02 LO 33 yd ox CRM B X er As sil Dp GER i uta NUM S DE Tes gt 3 C LG 30 VOLT AC DC AMP MAX filo ORI TEL a HI IN ds A En uu 19 11 uet PELi x mue eee 4 20 03 DES R 8 I5 Fe 1P SEN 1 t v Affinity DEP FTL THIS
7. Li LZ LA ADJUSTABLE EVAPORATOR PRESSURE BYPASS REFRIGERATION lt 4 lt E lt 4 QuT lt Me TEMPERATURE REFRIGERATION SENSOR N Gm FLOW PRS SWITCH amp ETET PRESSURE RELIEF VALVE 2 A GN gt LOW LEVEL d O SWITCH o FIXED RELIEF PRESSURIZED RESERVOIR E Dus Ett Gal OLS ROS ER PSPF3B 5 26 93 m c QW Affinity Lit LYDALL ide INDUSTRIAL THERMAL SOLUTIONS OSSIPEE OPERATION TTS PLATE 1 PLD 0 OIM DASIPEE Te 6033 533 8203 Fas IELI 539 2126 381 996 LTE 151 DATE JEt A Jin O VOLT SILGLE PHASE 60 Hz VULT SIKSLE PHASE SO Hz LEGEND i WPE COLORS PRIMARY COLOR TRACER OR RHEER COLOR T E E n _ T COMPONENT TERMINAL T TERMINAL BLOCK AR ALARM RELAY V CO L MOTOR CONTACTOR BUR OF ELE CT CONTROL TPA SEFORMEF CR CONTROL RELAY z FU s FUSS 7 81 XE al Lap nee a EN
8. Solid State Relay Replace microprocessor Throttle flow control valve Adjust pressure relief valve Check Facility Water for blockage Check motor s and wiring Check settings Problem Compressor does not run Microprocessor does not work OAMANUALS D3629 07 11 2002 Possible Cause Compressor internal thermostat tripped Motor burned out 5 second delay has not timed out Microprocessor programmed incorrectly Microprocessor failure Possible Remedy Allow time for compressor to cool and automatically reset Replace Call Lydall 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 twelve 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 will be 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 warr
9. all 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 FAMANUALS D3777 04 27 2005 Los PESIC GATES os A ERES 1 15 57 gt E VAFCRATOR ok lt 208 19 COOL Ih COON IH lt gt COMPRESSOR lt gt cM PROCESS AIDS COOLING DUT HIGH DISCHARGE LOW SUCTION PRESSURE SWITCH A 6 27 So sk HIGH Lod ee EXPANSION CONDENSER T T N i IN HOT GAS BYPASS VALVE SOLENOID VALVE A ES ns SIGHT Oy GLASS V eJ Ne DRIER F T R N T 111111 H NENNEN i HH i gt ooo THE em Br gu Cater 71537 T CRS RAA W DUAL PS 57 1 T e Affinity ROTOLOCH LYDALL INDUSTRIAL THERMAL SOLUTIONS i OSSIPEE OPERATION Det zia DS l 0 Ble 1 3 GSSIFES he 02554 Tal TEI BEDA for 25 E39 2186 r Lr 151 ose 5 5 CREATED CD 848 Lobo PROCESS COOLING ur gr RETURN SUPPL
10. anty 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 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 Lyd
11. can be changed to any temperature within the range programmed for this Affinity model Note Pressing PV SV allows toggling the indicator light between PV the actual process coolant temperature and SV the Set Value temperature Changing the Set Value Temperature Change the Set Value temperature by pressing PV SV until the indicator light appears next to SV Then directly under the digit in the display to be changed press and the digit will start blinking To increase the digit value press under the blinking digit as many times as necessary To decrease the digit value press V at the left side of the controller Press under the next digit value to be changed and repeat the process When all the digits are set to the desired value and with one digit still blinking press the red ENT key at the far right of the controller to enter the new Set Value temperature Operation A display of letters or numbers which do not indicate temperature may appear SEL or DATA was probably inadvertently depressed The FUJI Instruction Manual explains the use of SEL and DATA functions which are used solely in setting the basic program of the microprocessor Press PV SV to return to either the PV or SV display The controller comes pre programmed according to the Affinity model selected If the additional features programmed into the controller will be needed consult the FUJI Instruction Manual or call Lydall service for technical assistanc
12. cation and death Never place the chiller in a room that is smaller than the minimum room volume requirement as defined below If the room is ventilated the air distribution system must be analyzed to determine the worst case distribution of leaked refrigerant A leak detector alarm device is always required in a ventilated room that does not meet the minimum room volume given below Assure adequate and sufficient room volume and ventilation before placing a chiller that contains refrigerant in a room Contact Lydall at 1 603 539 5005 if you have any concerns or questions Pounds of refrigerant charge can be read directly from the nameplate on your chiller Remember to include in your calculation any refrigerant that may be stored in any other containers Minimum Room Volume Pounds of refrigerant x 110 cubic feet Example Two chillers are placed in a room each containing 6 pounds of refrigerant The minimum room volume shall be 12 x 110 cubic feet or 1 320 cubic feet Installation Electrical Requirements Connect the chiller to a properly fused disconnect box in compliance with National Electric Code NFPA 70 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 The voltage phase and frequency of the power source must also match the requiremen
13. e The highest and lowest SV programmed into the controller depends upon the model selected Caution Never program in a Set Value temperature of more than 32 C 90 F unless this Affinity model is specially modified to operate at higher coolant temperatures Never program in a Set Value temperature of less than 5 C 40 F unless a suitable antifreeze is used as coolant AND the chiller is set to operate at below freezing temperatures Turn the whole system on by placing the ON OFF SET switch in the ON position The Set Value temperature can be changed with the switch in either the ON or SET position Air bubbles will be visible rising in the reservoir as the pump forces air out of the coolant loop After the air has been purged from the coolant loop a steady turbulence may be seen in the reservoir This turbulence mixes the coolant to deliver more precise temperature stability in the coolant supply than the controller indicates Safety Alarms The LOW LEVEL indicator light and the corresponding audible alarm actuate when the coolant level in the reservoir is low and needs to be replenished This indicator light does not actuate with the ON OFF SET switch in the SET position The FAULT light comes on if too little coolant is circulating through the heat exchanger The FAULT light comes on momentarily upon start up until the pump establishes sufficient flow The FAULT indicator does not actuate with the ON OFF SET switch in the SET p
14. enser 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 OAMANUALS D10685 07 25 2002 Operation Using the Controller This Affinity chiller comes standard with a FUJI 1 16 DIN temperature controller This controller is a programmable microprocessor which offers many more features than are necessary to master at this point If more than the basic instructions provided in this manual will be needed consult the FUJI Instruction Manual or call Lydall service 603 539 5005 for technical assistance ED ED GED PV SV SEL DATA ENT mp gt 07 Place the ON OFF SET switch on the control box if included with this chiller or the chiller s control panel near the Fuji controller in the SET position SET activates the control display but does not turn on the refrigeration and pump systems of the chiller Four dots will appear on the display then in 3 4 seconds the temperature of the coolant will appear plus an indicator light next to PV Indicator lights next to C H or L may also appear The function of these lights will be discussed later in the section on Safety Alarms Press PV SV until the indicator light appears next to SV to display the Set Value temperature The Set Value temperature
15. er 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 prevent most of the debris from escaping into the reservoir Cooling a Water Cooled Condenser Never hook a water cooled unit to a potable water supply without providing back flow protection A pressure drop 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 Lydall installs on the condenser See the Facility Water Requirements section of this manual for the specific flow temperature and pressure needed for this unit Failure to connect Facility Water to the unit and supply the correct amount of flow may severely damage the unit in an extremely short period of time Connect the Facility Water Supply to the WATER IN fitting at the bottom of the chiller and connect the Facility Water Return to the WATER OUT fitting Use connecting lines of the size indicated 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 freezing and subsequent damage This may cause the cond
16. flow Open flow control valve Flow control valve not fully open Adjust pressure relief valve to specification Pressure relief valve set too low unless not adjustable Low coolant level in reservoir Fill reservoir to proper level Eliminate restrictions in coolant lines external to chiller Restriction in coolant lines external to chiller Call Lydall Frozen evaporator Disassemble flow switch clean and reinstall or replace Flow switch clogged Problem Fault light remains on No coolant flow Chiller shuts down during operation Possible Cause Low coolant flow No coolant flow Flow switch stuck 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 Refrigeration high pressure cut out set too low Refrigeration low pressure cut out set too high Excess refrigerant charge Possible Remedy See Problem Low coolant flow See Problem No coolant flow Disassemble flow switch clean and reinstall or replace Prime pump Remove and clean strainer then reinstall Check for leaks then fill reservoir Wait 5 minutes for overload to reset Replace pump or renew seal Remove pump torque to specification test and reinstall
17. ntenance schedule Frequency will be based on the application and the cleanliness of the fluid which can vary greatly Failure to regularly check the strainer may result in poor performance and or unit failure Priming the Pump and Connecting the Coolant Loop DO NOT RUN THE PUMP DRY If the pump does not establish prime the pump shaft seal 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 seal 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 v RETURN SUPPLY 6 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 sho
18. one depleting HFC and poses no hazard to the environment However the refrigerant must be recovered by a qualified refrigeration service technician in accordance with all applicable laws When decommissioning remove all fluids by opening all drains and placing the fluid in appropriate containers After all flow has ceased purge the lines with low pressure air The unit is comprised of metals that may be recycled The significant metals which make up the unit are as follows Cold rolled steel Stainless steel Copper There are no significant amounts of plastics or other materials incorporated into this unit Recycle metals appropriately OAMANUALS D8574 05 16 2002 Problem Unit does not start Unit does not cool Trouble Shooting Guide Possible Cause No power to unit breaker tripped Low voltage High pressure cut out tripped Loose wire Defective contactor or coil Loss of refrigerant Compressor damaged Compressor internal thermostat tripped Compressor damaged Facility Water control valve set too low Facility Water too warm Evaporator damaged Microprocessor failure Cooling load exceeds capacity of unit Microprocessor programmed incorrectly Loss of refrigerant Possible Remedy Verify supply power is on close breaker after correcting fault Check electrical service to unit Will automatically reset after correcting fault Check wiring after disconnecting power Repair or
19. osition If the FAULT light remains on for more than a few seconds the chiller should be turned off and the reason for loss of circulation determined and corrected Caution Although the FAULT light alerts the operator that no coolant is flowing the operator must not assume proper circulation through equipment external to the chiller if the light does not appear A bypass system built into the chiller to protect the pump may satisfy circulation requirements within the chiller even though flow outside the chiller is blocked For example turning the flow control valve on the chiller to no external flow does not actuate the light similarly a wheel of a forklift truck standing on an external cooling line thus stopping the flow to the application will not actuate the fault light Operation The FUJI controller on this chiller has HIGH and LOW TEMPERATURE ALARM LIGHTS H and L appear just under the Affinity logo at the top of the controller At the factory a technician has programmed the alarm light to come on under H if the circulating coolant is above the temperature that this chiller has been set to deliver The alarm light under L is programmed to come on if the circulating coolant is below the temperature the chiller has been set to deliver Consult the factory if it is necessary to operate above or below these limits The light on the FUJI controller next to C when lit indicates that the refrigerant solenoid valve is open to allow
20. refrigerant to flow to the heat exchanger If the light is on most of the time most of the capacity of the chiller is in use If the light is on infrequently much less than the full capacity of the chiller is being used Preventive Maintenance 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 itis clean and properly attached Hint If the strainer is coated with debris wrap it with a plastic sandwich bag before pulling it off to prevent most of the debris from escaping into the reservoir The frequency of checking and cleaning this strainer will depend on the cleanliness of the process and the fluid The Facility Water strainer requires a regular maintenance schedule Frequency will be based on the application and the cleanliness of the fluid which can vary greatly Failure to regularly check the strainer may result in poor performance and or unit failure Check the strainers a week or two after starting the unit then develop your own schedule for checking and cleaning the strainers based on experience Decommissioning Decontamination procedures are not required or applicable as there are no hazardous materials used within this unit The refrigerant used in this unit is environmentally friendly a non oz
21. replace contactor or coil Repair leak recharge with type and amount of refrigerant specified on serial tag Replace Call Lydall Allow time for compressor to cool to automatically reset Replace compressor Call Lydall Reset Facility Water control valve Provide cooler Facility Water Call Lydall Replace microprocessor Reduce cooling load Reprogram microprocessor Call Lydall Locate and repair leak recharge with type and amount of refrigerant specified on serial tag Problem Possible Cause Possible Remedy Check electrical service Excessive Low voltage noise on Start Up Wrong voltage taps used on Connect to proper taps transformer Contactor or coil failure Replace contactor or coil Pump motor Improper voltage supplied Correct voltage overheats Level light Low coolant level in reservoir Check for leaks then fill reservoir remains on Reservoir level switch float stuck Clean reservoir and level switch Time delay relay malfunction when Replace time delay relay used Level switch failure Replace level switch Time delay relay has not timed out Wait for time delay to time out when used Level light does not work Lamp burned out Replace lamp Level switch failure Replace level switch Remove strainer clean and reinstall or replace Low coolant Pump suction strainer clogged
22. should never exceed 30 C 86 F The Facility Water flow will be controlled by the water valve at Lydall s condenser See the Facility Water Requirements section of this manual for the exact flow and pressure necessary for this unit 8 A water cooled unit should never be run without the Facility Water connected and flowing The unit will quickly sustain damage without Facility Water This damage is excluded from warranty 9 Routinely inspect the pump inlet strainer located in the reservoir for debris Turn off the chiller then remove the strainer and clean as required to permit free flow of coolant Prevent foreign debris from entering the coolant line 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 may damage the pump 10 Regularly clean the screen in the assembly at the chiller s inlet for Facility Water To clean turn the chiller off close off the supply of Facility Water to the chiller and remove the screen Clean as needed and reinstall Equipment Precautions 11 12 13 14 15 16 Do not operate damaged or leaking equipment Do not operate the chiller at coolant temperatures above or below the values it was specified to deliver Do not run the chiller with cooling loads that exceed its factory rated cooling capacity The chiller must not be transported unless suitabl
23. t 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 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 Drain all coolant lines and blow them dry with low pressure air before transporting or storing the unit Lydall will not accept any unit containing measurable amounts of fluid Fluid left in the unit during shipping may damage components within the unit Such damage is not covered by warranty 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 Units with non pressurized reservoirs should never be installed more than 25 feet below the process or overflow may occur Distances may vary slightly due to elevations above sea level Call Lydall service 603 539 5005 for more information WARNING Oxygen Depletion Risk In the event of a refrigerant leak refrigerant gas may displace oxygen that could result in suffo
24. th electrical box door open e Refer servicing of electrical box components to qualified certified personnel e Do not operate equipment with damaged electrical power cords e Turn off the unit and disconnect electrical power before servicing or moving e Properly ground the unit 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 OAMANUALS 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 when the unit is in place If a forklif
25. ts specified on the serial tag Note Affinity models that can operate at either 208 230 Volts 60 Hertz or 200 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 see diagram below All voltages may not be compatible with this unit See the unit s serial tag for the proper voltage range ELECTRICAL SCHEMATIC f CONNECTFOR SYSTEM VOLTAGE 2 5 11 Lan As P 75VA INTERCHANGE A sF RED AND ORN PRIMARY CONNECTIONS 40 TO CHANGE VOLTAGE 6 NOT USED MUST BE 24 VAC ISOLATED AND CAPPED A TACTA Mn a NOTE IN SOME CASES PRESSURE SCREW TERMINAL BLOCKS 8 YEL ARE USED IN PLACE OF FASTON TERMINATIONS 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 servicing Installing the External Strainer Accessory The strainer accessory comes with extra fittings to allow arrangement in different configurations Any combinations of these fittings is acceptable Lydall recommends that the strainer be installed on the Facility Water inlet port Installation The strainer requires a regular mai
26. v Lydall Manufacturers of Affinity Chillers affinity chiller Pump Motors for affinity model RWA 005T CE01CBD3 Marthon carbonator Part 900 34785 000 5KH32FN5598X original affinity Serial 102699 5KH33GNA444X in NesLabs Type R 134A 5KH32GNB811X cheap version Chiller Part 34785 8EVC 6SL 0S9 99 001676vC 0IS HO Lydall Industrial Thermal Solutions Inc 775 Route 16 Ossipee NH 03864 USA Telephone Sales 603 539 3600 Service 603 539 5005 Fax 603 539 8484 www lydallaffinity com AFFINITY R SERIES CHILLER User Manual D10731 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 OAMMANUALS1D10731 REV A 08 27 2002 RV Table of Contents Introduction Facility Water Requirements Equipment Precautions Safety Precautions Installation Transporting Placement Electrical Requirements Installing the External Strainer Accessory Priming the Pump and Connecting the Coolant Loop Cooling a Water Cooled Condenser Operation Using the Controller Changing the Set Value Temperature Safety Alarms Preventive Maintenance Trouble Shooting Guide Warranty Refrigeration Diagram Fluid Flow Diagram Electrical Schematic OMMANUALS 03851 08 31 2001 Introduction Lydall v Affinity Congratulations on your purchase of an Affinity product want to personally welcome you to the Lydall
27. ws 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 low level alarm shuts off Do not allow the reservoir to overflow T If the pump does not establish prime disconnect the SUPPLY coolant line to vent any trapped air reconnect the line and repeat step 6 Installation 8 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 handy to catch any overflow from the RETURN fitting D Reconnect the coolant lines and repeat step 6 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 strain
28. y protected Original factory packaging in good condition or equivalent is required Request air ride trucks if transporting over land The chiller should be thoroughly drained and the coolant lines blown dry with low pressure compressed air before shipping or storing Modifying the chiller without express written consent from Lydall will void the warranty OAMANUALS D3796 10 04 2002 Safety Precautions 1 2 T 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 National Electric Code NFPA 70 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 e 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 e Do not operate wi
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