Control/Monitoring - Artisan Technology Group
Contents
1. Control Valve Valve Open Open Valve Interface Control Relay Control Valve Valve Close Close Valve Interface Control Relay N A N A SSR Output _ Heater Control Heater ON Heater OFF spre na NAW Notused na va w Heater Protection Heater Disabled Heater Enabled Reservoir Level Flash High Level Alarm Alarm Solid Low Level Alarm A A Flash Low Refrigeration Warning Solid Low Suction Pressure Fault Combined Lamp Lamp Lamp Fault Alarm mp Flash Warning Solid Fault La High Discharge Pressure Contactor Pump Combined Fault 1 Flash Low Flow Fault 2 Flash Pump Overload 3 Flash Compressor Overload Solid Phase Reversal ON ON Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Trouble Shooting Guide The following trouble shooting guide is limited to faults that are evidenced by lack of machine performance or by panel alarm Of course many other indications of malfunction are possible For example the operator should be alert to unusual sounds vibration or odors Visually the presence of any oil water or fluid leakage should be cause for immediate investigation Although the trouble shooting guide is limited to difficulties that may be encountered with the unit itself the operator should be alert to the reservoir low level alarm because this could be evidence of serious coolant leakage in the piping to the2. Emergency Stop The momentary EMO has two sets of normally closed contacts Both contacts must be closed to energize the master control relay coil Continuity between pins 1 and 2 of the 4 pin Amp connector external to the unit must also be present To start the unit ensure that the EMO is not depressed then momentarily press the red POWER ON button located on the control panel below the EMO The customer s EMO when connected to pins 1 and 2 of the 4 pin Amp connector will provide the same functionality The customer can use pins 3 and 4 of the 4 pin Amp connector to allow the unit s EMO to turn off other equipment when properly connected Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Operation Operating Range This unit has been designed to operate within the temperature range of 40EC to 80EC and should not be operated outside of this range HFE 7500 must be used as a process fluid in this unit Start Up Before Start Up perform electrical and fluid connections as directed in the Installation section of this manual 1 Inspect the unit inside and out to be sure that there is no fluid oil or refrigerant leaks 2 Do not attempt to operate the unit unless the system appears secure and dry 3 All cable connections must be in place and secure 4 Ensure that the proper power voltage breaker and phase is applied 5 Turn the SET OFF ON switch on the local panel to
3. designed to use HFE 7500 as the coolant It was tested at the factory with HFE 7500 Consult Lydall prior to using any other fluid Other coolants may not be compatible with the components in the unit s coolant loop Maximum storage temperature for the unit is 52EC 125EF The chiller is designed for indoor use only Do not operate the chiller in ambient temperatures below 7EC 45EF or above 30EC 86EF Operation above 30EC will derate the chiller s cooling capacity If the chiller has been exposed to temperatures below 7EC allow twenty four hours at ambient temperature above 7EC to warm the oil in the compressor as well as the refrigerant before starting 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 The cabinet of the chiller is designed to vent air Maintain free space for flow of air on the condenser side of the chiller The two sides or the top must have an equal amount of free space Regularly check the air filter located in front of the compressor Remove the filter clean as needed and reinstall or replace When air flow becomes impeded cooling capacity decreases and electrical efficiency dr
4. 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 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 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 prevent most of the debris from escaping into the reservoir Failure to clean a clogged strainer can restrict flow causing the FAULT light to illuminate Turn the chiller off for a few seconds after correcting the condition to reset the alarm Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring Control Panel The various elements on the control panel are described in the sections below Advanced
5. 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 should be dry before shipping or storing Modifying the chiller without express written consent from Lydall will void the warranty Tools required to perform inspection and maintenance on this unit are screwdriver multimeter including AC voltmeter safety glasses gloves Training requirement All information contained in this manual must be read understood and followed before operating or performing maintenance on this chiller Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Safety Precautions a 2 Heed all warning labels No warning label should ever be removed from the unit 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 national and local codes for European usage Maximum fuses must not exceed the maximum rating found on the serial tag on the electrical box To reduce the risk of electric shock Disconnect electric power before opening the electrical box of the unit Do not operate with electrical box door open Refer servicing of electrical box components to qualified certified personnel Do not operate equipment with damaged electrical power cords Turn off the unit and dis
6. process tool or within the process tool itself In all cases where action is required under the Possible Remedy column of the trouble shooting guide it should be understood that ONLY properly qualified technicians are to perform service work in connection with refrigeration or electrical systems Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Problem Does not start Does not cool Trouble Shooting Guide Possible Cause Possible Remedy Faulty electrical service Improper voltage and or phase to the unit Transformer breaker is tripped Circuit breaker in electrical box is tripped Main breaker is tripped Compressor high discharge pressure shutdown Compressor motor internal thermostat tripped Loss of refrigerant low suction pressure shutdown Cooling exceeds capacity of chiller Microprocessor programmed incorrectly Loss of refrigerant Relay or coil failure Thermal expansion valve open too much or malfunctioning Hot gas bypass valve not functioning properly Check secondary side of 24 volt transformer If OK fault is in control circuitry If not OK fault is in power supply Check Phase Reverse Relay or Phase Monitor in Electrical box Correct phase voltage as needed Reset Reset Reset breaker after determining cause of trip Cycle power by closing the main circuit breaker Same as above Repair leak recharge with type and amoun
7. the cable must not exceed one thousand feet in length PXZ Controller A second controller Figure 2 located inside the electrical box is for heater safety It has been programmed at the factory and should not be changed The following values are provided for information purposes only Affinity C CR HE L amp k So Figure 2 To check the program 1 Press and hold the SEL key until the P n1 menu appears 3 5 secs 2 Toggle through the P n1 menu until dSP1 appears 3 Program the following values dSP1 65 Parameter masking used to hide the display of unused parameters dSP2 255 dSP3 251 dSP4 255 dSP5 3 dSP6 186 dSP7 127 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring 4 Push the PV SV key then the SEL key P n2 will appear Set the following C F P n1 2 Direct acting fails to zero output P n2 2 Input type Type J thermocouple P dF 3 0 Input filter constant in seconds P SL 40 40 Lower limit of setpoint range P SU 320 160 Upper limit of setpoint range P AL 12 High and low zone alarm P AH 0 P dP 0 Number of digits to the right of the decimal point P F F C 5 Push and hold the Sel key for 3 5 seconds until P appears Program as follows P 0 0 i 0 d 0 0 AL 32 0 Heater is off below this temp AH 302 150 Heater is off above this temp HYS 0 0 6 Push and hold the SEL key for 3 5 seconds Toggle to dSP1 Set the
8. Looking for more information A Artisan Visit us on the web at http www artisan scientific com for more information QUALITY INSTRUMENTATION GUARANTEED Price Quotations Drivers Technical Specifications Manuals and Documentation Artisan Scientific is Your Source for Quality New and Certified Used Pre owned Equipment e Tens of Thousands of In Stock Items Fast Shipping and Delivery Equipment Demos Hundreds of Manufacturers Supported Leasing Monthly Rentals Consignment Service Center Repairs InstraView Remote Inspection Experienced Engineers and Technicians on staff in our Remotely inspect equipment before purchasing with our State of the art Full Service In House Service Center Facility Innovative InstraView website at http www instraview com We buy used equipment We also offer credit for Buy Backs and Trade Ins Sell your excess underutilized and idle used equipment Contact one of our Customer Service Representatives today Talk to a live person 888 88 SOURCE 888 887 6872 Contact us by email sales artisan scientific com Visit our website http www artisan scientific com AFFINITY P SERIES CHILLER User Manual D50050 Lydall Industrial Thermal Solutions Inc 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Table of Contents I
9. WinChill Communications are available through the 9 pi PYX4 Microprocessor The microprocessor Figure 1 becomes operative when the breaker is closed and five seconds after the SET OFF ON switch is placed in either the ON or SET position FUJI ELECTRIC Figure 1 The microprocessor receives a temperature signal from the RTD Resistance Temperature Detector located in the process cooling line leaving the evaporator This temperature value is displayed in the PV Process Value readout on the controller The SV Setpoint Value readout has two distinct functions To establish the basic program of the microprocessor l To set the control temperature of the fluid out of the evaporator Changing the Process Temperature Setpoint Change the Setpoint Value by pressing the gt key on the controller keypad SV will change to a leading zero display Continue pressing gt until the appropriate digit flashes Press v to increase the value or press W to decrease the value Continue pressing gt until the last digit flashes Press gt one more time and all leading zeroes extinguish This locks in the Setpoint Value Caution Never program in a Setpoint Value of less than 45EC Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring To power the controller without powering the chiller place the SET OFF ON switch in the SET position The digital display
10. connect electrical power before servicing or moving Properly ground the unit The servicing of the refrigeration system or components should be performed only by properly certified refrigeration technicians Coolant lines filters and other components which connect to the unit must be capable of withstanding the maximum pressure that the pump in the chiller can deliver at the maximum expected temperature Do not remove any warning labels When operating a pump with a magnetic coupling pay special attention to the handling of permanent magnetic parts Due to potential interference from magnets keep a safe distance from pace makers and other devices subject to magnetic interference Fluids can be extremely hot or cold Use appropriate precautions when contact with fluids is possible Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Installation Transporting If a forklift will be used to carry the chiller proceed slowly and carefully to avoid jarring the unit 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 Lydall will not accep
11. 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 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Electrical Requirements 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 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 requirements specified on the serial tag Note Affinity models that can operate at either 200 220 Volts 50 Hertz or 208 230 Volts 60 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 above 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 po
12. e determined by the customer as conditions vary from site to site On a continuing basis the unit must be kept clean and dry inside and out Reservoir fluid should be kept at a satisfactory level 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 prevent most of the debris from escaping into the reservoir Failure to clean a clogged strainer can restrict flow causing the FAULT light to illuminate Turn the chiller off for a few seconds after correcting the condition to reset the alarm All warning alarm conditions should be addressed immediately The air filter in front of the condenser should be checked and cleaned regularly Frequency will depend on the cleanliness of the area 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 ozone 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 applicabl
13. e 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 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com PLC Input Table Type Description Status OFF Status ON Alarm nouses WA Pressure Low Suction Pressure Switch Pressure High Discharge Alarm Switch Pressure Alarm 2 Heater Control Heater Off Heater On Alarm Level Switch Reservoir Level Switch Alarm o Normal Pressure High Pressure Warning Normal Switch Spare Input N A No Alarm Temperature Alarm Temperature Heater Temperature Normal Alarm Level Switch Low Level Shutdown Normal Relay Compressor Current No Compressor Normal Contact Sensor Current Contact Low Voltage Phase Low Voltage Normal Reversal Phase Reversal Run ON OFF Relay Chiller OFF Chiller ON Relay Contac t Switch Spare Input N A Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com PLC Output Table Output 0 Type Description Status OFF Status ON
14. eresis 2 Loop break detection time alarms on abnormal input 100 Ohm RTD 100 to 200EC 1 degree resolution 100 Ohm RTD 148 to 392EF 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 may not be used in all cases Go through the parameters twice then set LoCt to 2 some parameters user changeable WinChill Communications For units with WinChill RS232 Communications to meet CE Compliance the external RS232 cable which connects the unit to the customer s equipment must be shielded This is required to meet the EMC immunity requirements of EN61326 for industrial locations The cable must not exceed 30 feet in length The shield construction must be a braid minimum 85 tinned copper over aluminum foil minimum 100 coverage shield with a 360E shield termination at each end of the cable One possible source for cable meeting this requirement is Black Box part number EGM12D Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring For units with WinChill RS485 communications
15. following dSP1 207 dSP5 135 7 Press the PV SV key until SV shows Set SV to 320EF or 160EC 8 Push and hold the SEL key for 3 5 seconds until AH appears Set LOC to 1 all parameters locked Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring Status Lights SET OFF ON HIGH PRESSURE REFRIGERANT FLASH WARNING FLASH LOW LEVEL SOLD ALARM SOLD LOW PRESSURE FLASH HOH LEVEL 2 FLASH BUMP OVERLOAD SOLID LOW LEVEL 3 FLASH COMPRESSOR OVERLOAD SOLID PHASE REVERSAL Figure 3 The various lights are described below Note that a fault light indicates unit shutdown LEVEL Amber Located on the lower left side of the controller Flashing when a high level warning condition exists in the reservoir Remove excess fluid Solid when a low level alarm condition exists More fluid should be added immediately Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring HIGH REFRIGERANT PRESSURE Red REFRIGERANT Red COMPRESSOR OVERLOAD FAULT Red PUMP OVERLOAD FAULT Red PUMP LOW FLOW FAULT Red PHASE REVERSAL FAULT Red Located on the upper left side of the controller Flashing when a high compressor discharge pressure condition exists warning If pressure continues to increase and exceeds the setpoint the light will become solid alarm and
16. ler 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 electrical technician should switch any two of the wires at the incoming power source Do not change any of the wiring in the chillers electrical box Check again for proper phase sequence before proceeding with these instructions Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Installation G 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 fluid rises to within a few inches of the top of the reservoir 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
17. n 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 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com CE CE Declaration of Conformity Lydall Industrial Thermal Solutions declares that the Lydall product referred to in this manual is in conformity with the provisions of Council Directive 2004 108 EC Electromagnetic Compatibility Directive European Standards EN55011 Group 1 Class A EN61326 Industrial Requirements and Council Directive 2006 95 EC Low Voltage Directive European S
18. n the web at http www artisan scientific com for more information QUALITY INSTRUMENTATION GUARANTEED Price Quotations Drivers Technical Specifications Manuals and Documentation Artisan Scientific is Your Source for Quality New and Certified Used Pre owned Equipment e Tens of Thousands of In Stock Items Fast Shipping and Delivery Equipment Demos Hundreds of Manufacturers Supported Leasing Monthly Rentals Consignment Service Center Repairs InstraView Remote Inspection Experienced Engineers and Technicians on staff in our Remotely inspect equipment before purchasing with our State of the art Full Service In House Service Center Facility Innovative InstraView website at http www instraview com We buy used equipment We also offer credit for Buy Backs and Trade Ins Sell your excess underutilized and idle used equipment Contact one of our Customer Service Representatives today Talk to a live person 888 88 SOURCE 888 887 6872 Contact us by email sales artisan scientific com Visit our website http www artisan scientific com
19. ng 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 Lydall product on which a claim is made Lydall Industrial Thermal Solutions Inc 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Looking for more information A Artisan Visit us o
20. ns to change values Display returns 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 Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring AT AL1T AL11 Aith AL12 Ai2h AL2T AL21 A2th AL22 A22h Loop PvT TF SFT Sv h Sv L CTrL dT rEv1 Mv h Mv L bUrn Stno 0 0 15 0 EC 27 0 EF 65 0 0021 81 0 EC or 174 0 EF 1 0 C or F 41 0 EC or 42 0 EF 1 0 EC or F 0041 28 0 EC 100 0 EF 1 5 EC 3 0 EF 5 0 EC 9 0 EF 1 0 EC 2 0 EF 0 0 0500 EC 0501 EF 5 0 0 80 0 EC 176 EF 40 0 EC or F FUZY 0 5 rEv 100 0 0 0 r 1 Normal control not auto tuned Proportional band Integral time Derivative time Anti reset windup limits integral range to control overshoot Manual resetting value eliminates offset from P only control Alarm 1 type high amp low absolute Alarm 1 setpoint 1 high Alarm 1 hysteresis 1 Alarm 1 setpoint 2 low Alarm 1 hysteresis 2 Alarm 2 type high absolute and low deviation used to operate heater Alarm 2 setpoint 1 energizes heater when PV is above this temp Alarm 2 hysteresis Alarm 2 setpoint 2 heater is on when PV gt AL22 below SV Alarm 2 hyst
21. ntroduction Equipment Precautions Safety Precautions Installation Placement Electrical Connection Priming the Pump and Connecting the Coolant Loop Control Monitoring Control Panel PYX4 Microprocessor Changing the Process Temperature Setpoint Fault Display PYX Controller Parameter Values WinChill Communications PXZ Controller Status Lights EMO Operation Operating Range Start up Shutdown Preventive Maintenance PLC Tables Trouble Shooting Guide Warranty Refrigeration Diagram Coolant Flow Diagram Electrical Schematic Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Introduction Lydall Affinity Congratulations on your purchase of an Affinity product We 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 i
22. ops as motor load increases 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 reverse the phase sequence external to the chiller Do not modify the wiring inside the electrical box Routinely inspect the pump inlet strainer located in the reservoir for buildup of debris Turn the chiller off then remove and clean the strainer as required to permit free flow of coolant Prevent foreign debris from entering 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 coolant flow and may damage the pump Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Equipment Precautions 10 11 12 13 14 15 16 17 Do not operate the chiller at coolant temperatures above or below the values it was specified to deliver Do not operate the chiller with cooling loads that exceed its factory rated cooling capacity Do not operate damaged or leaking equipment The chiller must not be transported unless suitably protected Original factory packaging
23. t 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 Keeping coolant lines short allows 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 WARNING Oxygen Depletion Risk In the event of a refrigerant leak refrigerant gas may displace oxygen that could result in suffocation and death Never place the chiller in a room that is smaller than the minimum room volume requirement as defined below Ifthe 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 inaroom 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
24. t of refrigerant specified on serial tag Cycle power by closing the main circuit breaker Reduce cooling load Reprogram microprocessor Repair leak and recharge with type and amount of refrigerant specified on serial tag Replace relay or coil Replace or adjust thermal expansion valve Call Lydall Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Problem Does not cool continued LOW LEVEL LOW SUCTION PRESSURE Possible Cause Possible Remedy Compressor internal thermostat tripped causing compressor to stop running Compressor damaged Evaporator damaged Microprocessor failure Low level in reservoir due to coolant leakage or evaporative loss Low compressor inlet pressure could be caused by insufficient refrigerant restriction in flow of coolant in the evaporator or freezing in the evaporator if the anti freeze concentration is too low Hot gas valve not functioning properly Flashes in response to a signal from the flow switch in the pump discharge line that indicates low less than 1 2 gallon per minute or no flow Allow time for compressor to cool determine cause repair Replace compressor Call Lydall Replace microprocessor Inspect for leakage in chiller repair refill reservoir Check refrigerant flow in sight glass Note Bubbles in sight glass indicate refrigerant is too low Call Lydall Check if the pump is r
25. tandard EN60204 1 A signed declaration of conformity is available from Lydall upon request European Directive 97 23 EC As of May 29 2002 the European pressure equipment directive PED 97 23 EC became mandatory for the CE marking of some pressure equipment Lydall chillers and condensing units are not CE marked to the PED Most Lydall chillers fall into the Category or the Sound Engineering Practice categories as defined by the PED and since chillers fall under the Low Voltage Directive 2006 95 EC they are excluded from the scope of the PED per Article 1 paragraph 3 6 of the PED Some chillers and condensing units using hermetic compressors of 7 5 HP or more that are classified as Category Il are not excluded from the PED In these cases it is the responsibility of the end user to assure that the final installation complies with all of the appropriate European directives including the PED For more information regarding the PED and other European directives go to http wwww newapproach org Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com 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 the unit without the fluid lines connected and filled with the proper fluid Never run the pump dry because it will be quickly damaged without liquid This unit is
26. the OFF position 6 Fill the reservoir with HFE 7500 7 Close the Main Breaker Turn the SET OFF ON switch to the SET position 8 No warning or alarm lights should ke lit 9 Jog the pump by placing the SET OFF ON switch in the ON position for 2 3 seconds This step will need to be repeated seven or eight times If there is difficulty priming the pump call Lydall service at 603 539 5005 for assistance 10 Once the pump is primed the pressure relief cap on the reservoir must be tightened and the sanitary reservoir cap secured 11 Turn the SET OFF ON switch to the SET position 12 Set the Set Value SV to a value higher than the Process Value PV to open the modulating valve 13 Put the SET OFF ON switch in the ON position The unit should begin operation Turn the unit off set the ON OFF SET switch to the ON position cycle the breaker and in approximately 10 seconds the unit will start Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Operation Shutdown Place the SET OFF ON switch and the Main Power breaker to OFF If the unit will be shut down for a long period the fluid should be drained out of the unit and the lines blown dry with low pressure air Always drain and dry the lines before storing or shipping the unit Preventive Maintenance All maintenance should be performed only by qualified technicians The frequency of maintenance checks should b
27. the unit will shut down Located on the upper right side of the controller Flashing when a low refrigerant level is sensed in the receiver The light will become solid when the unit shuts down on low suction pressure after the time delay Located on the lower right side of the controller 3 flash sequence Activated after a 2 second time 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 Located on the lower right side of the controller 2 flash sequence Activated when the pump amperage exceeds the overload setting Located on the lower right side of the controller Single flash Activated when the pump flow falls below setpoint to warn the operator of an impending low flow condition Located on the lower right side of the controller Solid light Activated when phases of the unit need to be reversed This may happen on initial start up of the unit If it occurs switch phases external to the unit and power the unit again To restart the unit after any fault occurs the power must be cycled To cycle the power place the ON OFF SET switch in the OFF position and open the main circuit breaker for a few seconds When power is reapplied and the ON OFF SET switch is placed in the ON position the unit should restart Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Control Monitoring
28. unning or stopped Check if pump is mechanically operable Check if the overload is open or closed Ensure that sufficient liquid is available Start on overload must be depressed for the pump to start after a fault Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com 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 warranty service contact Lydall 775 Route 16 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 followi
29. wer to the chiller before performing any service ELECTRICAL SCHEMATIC CONNECT FOR SYSTEM VOLTAGE INTERCHANGE RED AND ORN PRIMARY CONNECTIONS NOT USED MUST BE TO CHANGE VOLTAGE ISOLATED AND CAPPED PENONTERERON NOTE IN SOME CASES PRESSURE SCREW TERMINAL BLOCKS BLUI ARE USED IN PLACE OF FASTON TERMINATIONS Artisan Scientific Quality Instrumentation Guaranteed 888 88 SOURCE www artisan scientific com Installation 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 2 Close the reservoir drain Fully open the flow control valve if included Have extra HFE7500 to add as the pump primes and the coolant loop fills Fill the reservoir with HFE 7500 Do not fill above the height of the coolant loop connection fittings or fluid may leak out 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 RETURN SUPPLY This chil
30. will light in about 5 seconds The number next to PV is the actual process fluid temperature The number next to SV is the Setpoint Value desired temperature To view the program depress the SEL key until LoCT appears in the PV section of the controller and 0002 appears in the SV section Change 0002 to 0003 Continuing to depress the w key will bring up the remainder of the program Toggle through the program using the gt v and w keys to change the appropriate digits until the display reads as desired To change a parameter value press gt The value in PV will begin flashing While flashing the value may be changed by pressing v to increase the value or by pressing w to decrease the value When the correct value is visible on the display press SEL to lock in the value Return to the PV SV displays will be automatic after a minute or by pressing and holding the SEL key for a few seconds Fault Display If UUUU appears on the PV display one of the following has occurred RTD burnout RTD disconnected Input is more than 5 of the full range above the high limit Sv h see below in program listing If LLLL appears on the PV display one of the following has occurred RTD short circuit RTD disconnected Input is more than 5 of the full range below the low limit Sv L see below in program listing PYX Parameter Values Press and hold the SEL key to get to the PYX controller parameter menu Use arrow butto
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