AFFINITY E-SERIES CHILLER

User Manual D3736

Affinity Industries Inc.

Post Office Box 1000
Affinity Place - 775 Route 16
Ossipee NH 03864 USA
Telephone: 603-539-3600 (Sales), 603-539-5005 (Service), Fax: 603-539-8484
F:\MANUALS\D3853 REV. A: 9/20/1999 NMT
Table of Contents
Introduction

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-to-Water Heat Exchanger

Operation

Using the Controller

Changing the Set-Value Temperature

Safety Alarms

25-Pin Interlock Description

Remote ON/OFF Switching Option

Trouble Shooting Guide

Warranty

Fluid Flow Diagram

Electrical Schematic

F:\MANUALS\D3854 (1/13/1999)
Introduction

Thank you for purchasing an Affinity product. Affinity chillers and heat exchangers are built to
the highest industry standards. This manual is designed to help our customers realize the full
value of this Affinity product.

This manual will help to guide personnel through the installation and operation of this Affinity
unit. Keep the manual in a location that is easily accessible to operating and service
personnel.

Affinity manufactures a variety of refrigerated and non-refrigerated chillers and heat-

exchangers to provide precise temperature control for lasers, semiconductor manufacturing,
analytical instruments, and industrial equipment, as well as dozens of other tools and
processes.

If there are any questions about this model, or other applications, call the Affinity service
department at 603-539-5005 or the sales department at 603-539-3600 for a fast response.
We look forward to meeting your temperature control requirements for many years to come.

Sincerely,

Fred Piehl, President

Affinity Industries Inc.

F:\MANUALS\D3774 1/7/1999
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 proper coolant. Never run the pump
without prime because it will be quickly damaged without liquid.

2. This chiller is powered by three phase electricity. Verify pump rotation before
operating. Rotation should be in the same direction as the arrow on the pump casing.
Only qualified electrical service technicians should switch legs on three phase power to
change pump rotation. Note: Jog the pump very briefly to observe the rotation. Verify
pump rotation when the chiller is connected to a different circuit.

3. 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 the factory if there are questions about the coolant.

4. Routinely inspect the pump inlet strainer located in the reservoir for buildup of debris.
Turn the unit off, then remove and clean the strainer 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 to wrap the strainer to contain most of the
debris. Failure to keep the strainer clean will reduce coolant flow and damage the
pump.

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

6. Regularly clean the screen in the assembly at the chiller's inlet for Facility Water. To
clean, turn the chiller off, shut off the supply of Facility Water and remove the screen.
Clean as needed and reinstall.

7. Do not operate damaged or leaking equipment.

8. The chiller must not be transported unless suitably protected. Original factory
packaging in good condition or equivalent is required. Request air-ride trucks if
transporting over land.

9. Modifying the chiller without express written consent from Affinity will void the warranty.

F:\MANUALS\D3790 (1/8/1999)
Safety Precautions
1. Heed all warning labels. Do not remove.

2. Do not operate the unit with the bonnet removed. The bonnet protects personnel from
hot surfaces, and also protects the chiller's components.

3. Connect the unit, in compliance with the NEC (National Electric Code) and local codes,
to a properly fused disconnect box. Maximum fuse sizes 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
qualified personnel.

Refer servicing of the electrical box to qualified personnel.

Do not operate equipment with damaged electrical power cords.

Turn off the unit and disconnect electrical power before servicing or moving.

4. Coolant lines, filters, and other components which connect to the unit must be capable
of withstanding the maximum pressure that the pump in the unit can deliver at the
maximum expected temperature.

5. The coolant loop has not been designed for potable water applications.

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.

F:\MANUALS\D3800 (1/8/1999)
Installation
Transporting

An Affinity chiller rolls easily on its four swivel casters. The brakes must be off on the two
locking casters when moving the chiller. Roll the unit gently to its operating location. The
cushioned casters will help to dampen shock. Lock the casters when the unit is in place. If the
chiller will be carried with a forklift, 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.

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 Affinity to discuss placement and how it might affect performance.

Electrical Requirements

Connect the chiller, in compliance with the NEC (National Electric Code) and local codes, to a
fused disconnect box. 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.

This Affinity Chiller has been set at the factory to run at 460 volts, and is configured for 460Y
power service (277 volts maximum to ground).

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.

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. Affinity recommends that the
strainer be installed on the Facility Water inlet port.

The 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.
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. Close the reservoir drain.

2. Fully open the flow control valve.

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 will 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.

RETURN SUPPLY

6. Check for proper pump rotation by “bump”starting the chiller. Bump start by placing
the ON/OFF/SET switch in the ON position for one or two seconds. Pump rotation
should be in the same direction as the arrow on the pump. If the direction of rotation is
incorrect, a qualified electrical technician should exchange any two of the wires in the
incoming power source (DO NOT change any wiring inside the chiller). Check again for
proper pump rotation as above.
Installation
7. 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 leaks out of the fittings or the reservoir
level rises to within a few inches of the top. 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 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.
c. Reconnect the coolant lines and repeat step 7. Stop filling when fluid leaks out
of the RETURN fitting, or 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.

Cooling a Water-to-Water Heat Exchanger

A water-to-water heat exchanger exhausts the heat it removes into a flow of Facility Water,
which is usually cooled by an evaporative cooling tower or a central refrigerated chiller.

Affinity's microprocessor controlled valve regulates the exact flow of Facility Water required to
remove the heat exhausted by the chiller. The customer must supply Facility Water at a high
enough flow and low enough temperature to carry the cooling load.

Install the Facility Water strainer assembly supplied by Affinity, as previously instructed, (note
the flow direction arrow) to the WATER IN fitting at the bottom of the chiller, and connect the
cooling water supply to it. Connect the return for the Facility Water system to the FPT outlet
marked WATER OUT. Use connecting lines of at least one inch inside diameter to minimize
pressure loss.
F:\MANUALS\D3855 (1/13/1999)
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.

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 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 (v) and the digit will start
blinking. To increase the digit value, press (v) under the blinking digit as many times as
necessary. To decrease the digit value, press (w) at the left side of the controller. Press (v)
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 Affinity for technical assistance. The highest and lowest SV programmed into
the controller depends upon the Affinity model selected.

Caution: Never program in a Set-Value temperature of more than 32EC (90EF) unless this
Affinity model is specially modified to operate at higher coolant temperatures. Never program
in a Set-Value temperature of less than 5EC (40EF) unless a suitable antifreeze is used 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 position.

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 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.

F:\MANUALS\D3775 (1/7/1999)
25 Pin Flow, Temperature, and Level Interlock
The 25 pin flow, temperature, and level interlock consists of a 25 pin D-subminiature connector
installed on the electrical box and the wires and alarm relays necessary to provide the desired
functions. This option is not technically an interlock, as it does not stop or prevent operation of
the chiller, but rather provides a remote alarm indication. The flow and level conditions each
control a normally open (NO) and a normally closed (NC) contact on the 25 pin connector. The
temperature condition is programmable to either NO (the standard) or NC, but not both.

A remote run option (Local/Remote or Remote On/Off) is also wired to the 25 pin connector.

The 25 pin connector provides continuity/discontinuity only. No voltage is applied by the chiller
to pins on the connector except that pin 6 is hot (24 VAC) if a remote run option is specified.
All conductors and terminals are rated 30 volts AC or DC, 1 amp maximum. The pin
assignments are as follows:

Remote Run Option: Connect remote switch to pins 5 and 6.

Temperature alarm: Pins 9 and10 closed in the normal state, open in alarm state

Level alarm: Pins 11 and 12 open, pins 12 and13 closed in the normal state
Pins 11 and 12 closed, pins 12 and13 open in the alarm state

Flow alarm (Fault) Pins 15 and 16 open, pins 14 and 15 closed in the normal state
Pins 15 and 16 closed, pins 14 and 15 open in the alarm state

Overload: Pins 24 and 25 are open in the normal state. These pins connect to
overload contacts 97and 98. When the pump overload trips, contacts 24
and 25 (as well as 97 and 98) close.

Note that the flow contacts are in the alarm state when the chiller is off.

F:\MANUALS\D3856 (9/17/1999)
Remote ON/OFF Switching Option
The Remote ON/OFF option consists of a multi-pin connector of the customer’s choice wired
directly to the control power circuitry in the electrical box. If the customer’s remote switch is in
the ON (or RUN) position, the local ON/OFF/SET switch on the unit will function normally. If
the remote switch is in the OFF position, the unit will not run, regardless of the position of the
local ON/OFF/SET switch.

F:\MANUALS\D3857 (1/13/1999)
 Trouble Shooting Guide
Problem Possible Cause Possible Remedy

Unit does not Breaker tripped, no power to unit Close breaker after correcting fault,
start check power source

Low voltage Check electrical service to unit

Loose wire Disconnect power to unit, then

check wiring

Defective contactor or coil Repair or replace contactor or coil

Unit does not Insufficient flow of Facility Water Increase flow of Facility Water
cool
Facility Water too warm Provide cooler Facility Water

Microprocessor programmed Reprogram microprocessor - Call

incorrectly Affinity

Cooling load exceeds capacity of Reduce cooling load

unit

Microprocessor failure Replace microprocessor

Pump leaks Faulty pump casing Replace pump assembly

Shaft seal damaged Replace shaft seal

Pump housing O-Ring damaged Remove pump and rebuild

Excessive Low voltage Check electrical service to unit

noise on Start-
Up Wrong voltage taps used on Connect to proper taps
transformer

Contactor coil failure Replace contactor coil

Level light Low coolant level 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)
 Problem Possible Cause Possible Remedy

Level light Level switch failure Replace level switch

remains on
(continued)
Level light does Time delay relay has not timed out Wait for time delay relay to time out
not work
Lamp burned out Replace lamp

Level switch failure Replace level switch

Pump motor Pump overload protection set too Reset pump thermal overload relay,
overheats high or replace relay if faulty

Improper voltage supplied Correct voltage

Fault light Low coolant flow See Problem; Low coolant flow
remains on
No coolant flow See Problem; No coolant flow

Flow switch sticking Disassemble flow switch, clean and

reinstall, or replace

Low coolant Pump suction strainer clogged Remove strainer, clean and
flow reinstall or replace

Pump rotating backwards Reverse one electrical phase

Flow control valve not fully open Open flow control valve

Restriction in coolant lines external Eliminate restriction in coolant lines

to unit external to unit

Flow switch clogged Disassemble flow switch, clean and

reinstall, or replace

Pressure relief valve set too low Adjust pressure relief valve to
(unless not adjustable) specifications

No coolant flow Pump not primed Prime pump

Pump suction strainer clogged Remove strainer, clean and

reinstall, or replace
 Problem Possible Cause Possible Remedy

No coolant flow No coolant in reservoir Check for leaks, then fill reservoir
(continued)
Pump overload tripped Wait 5 minutes for overload to reset

Pump motor shaft bound to seal Replace pump or renew seal

Pump housing torqued improperly Remove pump, torque to

specifications, test, and reinstall

Damaged pump Replace pump

Clogged line or closed valve in Check external piping for dirt or

external piping closed valve

Leaks in external piping Check for leaks and repair if

needed
Unit shuts Pump thermal overload setting too Adjust and reset pump thermal
down during low overload to specifications, or
operation replace if faulty

Facility Water too warm Provide cooler Facility Water

Pump overload tripped Determine reason for trip, if pump

is damaged, repair and reinstall, or
replace

Low voltage Check electrical service to unit

Temperature Loose wire Disconnect power to unit, then

display reads check wiring
incorrectly
Broken RTD Replace RTD

Microprocessor failure Replace microprocessor

Unit cools well Microprocessor programmed Reprogram microprocessor - Call

below the incorrectly Affinity
desired Set-
Point Solid State Relay failure Replace Solid State Relay

Microprocessor failure Replace microprocessor

 Problem Possible Cause Possible Remedy

Too much Flow control valve set too high Throttle flow control valve
recirculating
pressure to Pressure relief valve set too high Adjust pressure relief valve to
process (unless not adjustable) specifications

Microprocessor 5 second delay has not timed out Wait at least 5 seconds after
does not work turning on

Microprocessor programmed Reprogram microprocessor - Call

incorrectly Affinity

Microprocessor failure Replace microprocessor

F:\MANUALS\D2422 (1/11/1999)
Warranty
The Affinity Limited Warranty

Twelve-Month Warranty
Parts and Labor

Affinity Industries Inc. warrants this product to the original Owner for a period of twelve
(12) months from the date of shipment. Affinity Industries Inc. 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 (12) months from date of
shipment. Shipping costs are excluded from warranty. Service labor will be at no
charge during the warranty period as long as the labor is supplied at the Affinity
Industries Inc. plant in Ossipee, New Hampshire, or by an Affinity Industries Inc.
approved technician. Replacement or repaired parts will be warranted only for the
unexpired portion of the original Warranty. To obtain prompt warranty service, contact
Affinity Industries Inc., PO Box 1000, Ossipee, New Hampshire, 03864, USA.

This Warranty does not cover the following: Damage or failure of any part caused by
accident, 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’s Manual. As noted in the User’s Manual, any
modification of the unit without expressed written consent from Affinity will void the
warranty.

In no event shall Affinity Industries Inc. be liable for any repairs or service or any
consequence of any repair or service which 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 Affinity Industries Inc. be liable for any consequential or incidental
damages that the Owner may incur resulting from purchase or use of this Affinity
product. The buyer's sole and exclusive remedy and the liability limit of Affinity
Industries Inc., for any loss whatever, shall not exceed the purchase price paid by the
purchaser for the Affinity product on which a claim is made.

Affinity Industries Inc.

Post Office Box 1000
Affinity Place - 775 Route 16
Ossipee, NH 03864 USA
Telephone: 603-539-3600 (Sales), 603-539-5005 (Service), Fax: 603-539-8484
F:\MANUALS\D3777 (1/7/1999)