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Lydall AFFINITY P Series User Manual

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Lydall AFFINITY P Series User Manual

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Summary of Contents for Lydall AFFINITY P Series

  • Page 1 Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT • FAST SHIPPING AND DELIVERY Experienced engineers and technicians on staff Sell your excess, underutilized, and idle used equipment at our full-service, in-house repair center We also offer credit for buy-backs and trade-ins •...
  • Page 2 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 Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 3: Table Of Contents

    Table of Contents Introduction 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 Operation Operating Range...

  • Page 4: Introduction

    Introduction 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...
  • Page 5 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 I or the Sound Engineering Practice categories as defined by the PED and since chillers fall under the Low Voltage Directive ( ), they are excluded from the scope of the PED per Article 1, paragraph 3.6...

  • Page 6: Equipment Precautions

    This unit is 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.
  • Page 7 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:...

  • Page 8: Safety Precautions

    Safety Precautions 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.

  • Page 9: Installation

    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.\...
  • Page 10 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).

  • Page 11: Priming The Pump And Connecting The Coolant Loop

    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.
  • Page 12 Installation 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.

  • Page 13: Control/Monitoring

    Control/Monitoring Control Panel The various elements on the control panel are described in the sections below. Advanced WinChill Communications are available through the 9-pin connector. To run the unit without the software running, set the Station Number (Stno on the controller parameters, see Parameter Values) to 15. 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.

  • Page 14: Fault Display

    Control/Monitoring To power the controller without powering the chiller, place the SET/OFF/ON switch in the SET position. The digital display 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.

  • Page 15: Winchill Communications

    Control/Monitoring Normal control - not auto-tuned Proportional band Integral time Derivative time 15.0 (EC), 27.0 (EF) Anti-reset windup - limits integral range to control overshoot 65.0 Manual resetting value (eliminates offset from P-only control) AL1T 0021 Alarm 1 type - high & low absolute AL11 81.0 (EC),or 174.0 (EF) Alarm 1 setpoint 1 (high) A11h 1.0(C or F)

  • Page 16: Pxz Controller

    Control/Monitoring For units with WinChill RS485 communications, 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.
  • Page 17 Control/Monitoring Push the PV/SV key, then the SEL key. P-n2 will appear. Set the following: P-n1 Direct acting, fails to zero output P-n2 Input type - Type J thermocouple P-dF Input filter constant in seconds P-SL Lower limit of setpoint range P-SU Upper limit of setpoint range P-AL...

  • Page 18: Status Lights

    Control/Monitoring Status Lights FUJI ELECTRIC OUT1 8. 8. 8. 8. OUT2 ALM1 8. 8. 8. 8. ALM2 :::: :::: :::: 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.
  • Page 19 Control/Monitoring HIGH (REFRIGERANT) PRESSURE - 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 the unit will shut down.
  • Page 20 Control/Monitoring 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.

  • Page 21: Operation

    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. Once the pump is primed, the pressure relief cap on the reservoir must be tightened and the sanitary reservoir cap secured.

  • Page 22: Shutdown

    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.
  • Page 23 PLC Input Table Input Type Description Status OFF Status ON Not Used Overload Pump overload Pump Overload Pump Normal Level Switch Refrigerant Low Level Normal Low Level Not Used Pressure Low Suction Pressure Normal Alarm Switch Pressure High Discharge Normal Alarm Switch Pressure...
  • Page 24 PLC Output Table Output Type Description Status OFF Status ON Control Valve Valve Open Open Valve Interface Control Relay Control Valve Valve Close Close Valve Interface Control Relay SSR Output Heater Control Heater ON Heater OFF Spare Not Used Contactor Heater Protection Heater Disabled Heater Enabled...

  • Page 25: Trouble Shooting Guide

    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.
  • Page 26 Replace relay or coil Thermal expansion valve open too Replace or adjust thermal much or malfunctioning expansion valve Hot gas bypass valve not Call Lydall functioning properly Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 27 Compressor damaged Replace compressor Evaporator damaged Call Lydall Microprocessor failure Replace microprocessor LOW LEVEL Low level in reservoir due to coolant Inspect for leakage in chiller, repair, leakage, or evaporative loss...

  • Page 28: Warranty

    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.
  • Page 29 Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT • FAST SHIPPING AND DELIVERY Experienced engineers and technicians on staff Sell your excess, underutilized, and idle used equipment at our full-service, in-house repair center We also offer credit for buy-backs and trade-ins •...

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