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1. Table C Tubing nominal OD mm Saturated Suction gas temperature C temperature C 12 15 18 22 28 35 42 54 67 79 105 130 5 0 0 39 0 71 1 20 2 04 3 88 6 88 11 11 21 31 36 85 55 86 115 24 199 30 10 0 37 0 68 1 14 1 94 3 68 6 53 10 54 20 20 34 94 52 95 109 25 189 14 5 10 0 47 0 86 1 45 2 47 4 69 8 33 13 44 25 77 44 58 67 56 139 39 241 30 20 0 44 0 81 1 36 2 31 4 39 7 79 12 58 24 13 41 73 63 25 130 49 225 90 Minimum refrigeration capacity in KW for oil entrainments up HOT Gas risers Refrigerant R407C Table D Tubing nominal OD mm Saturated Discharge discharge gas temperature C temperature C 12 15 18 22 28 35 42 54 67 79 105 130 30 70 0 60 1 09 1 84 3 13 5 95 10 55 17 03 32 65 56 47 85 59 176 59 305 70 80 0 58 1 06 1 79 3 04 5 78 10 25 16 55 31 74 54 90 83 21 171 67 297 19 90 0 57 1 04 1 74 2 96 5 64 10 00 16 14 30 95 53 53 81 13 167 39 289 77 40 80 0 62 1 13 1 90 3 24 6 16 10 93 17 65 33 85 58 55 88 73 183 07 316 92 90 0 60 1 10 1 85 3 16 6 00 10 65 17 19 32 96 47 01 86 40 178 26 308 60 100 0 58 1 07 1 80 3 07 5 83 10 34 16 70 32 02 55 38 83 94 173 17 299 79 50 90 0 63 1 16 1 94 3 31 6 29 11 16 18 02 34 55 59 77 90 58 186 88 323 52 10
2. jndur 901 44 8 SML id OSA p1eoq uorsu x 0 0 Jo 1ndur 03 ndur 90144 Pri ui OSA uorsu x C 0 0 Jo 1ndur 03 jndur 901 44 OSA uorsu x 0 0 Jo 1ndur 0 ndur 2914 uonemsuuoo TE vane vray OSA p1eoq uorsu x 0 0 Jo 1ndur ndur 2914 uone yuo 5235 OSA uorsu x 0 0 Jo 0 ndur 2914 uonem3uuoo ME E OSA uorsu x 0 0 Jo 1ndur 0 ndur 2914 uonem3suuoo TT 1955 posae OSHA uorsuojxo dymo 9 0 0 pesrurojsno ndyno 2914 8 TET 54 OSA uorsu x Jo dyno 9 0 0 PAUL pesrurojsno 9214 idi d cosa OSA p1eoq uorsuojxo Jo dymo 9 0 0 01 Jnd no 2914 SAT 6555 OSHA uorsuojxo ndjno 9 0 0 351 posttuojsnd ndmo 9914 uonemsyuo ESI Pene DSHS uondo yeoH ON S9A 785 AIDAODOY 09419 uonemsuuoo 05 a 0 CHBE 10941
3. Regulation on condenser water inlet Condenser pump interlock Filt r on PR ee Unrestricted air flow on condenser coils 2 ELECTRICAL POWER SUPPLY Control circuit voltage Power circuit power supply voltage L1 L2 Power circuit power supply voltage L2 L3 Power circuit power supply voltage L3 L1 1 Depending on the application 2 According to the type of unit LENNOX Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 41 TROUBLESHOOTING REPAIRS 8 5 MANUFACTURER S RECOMMENDED INSPECTIONS 8 5 1 LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR S 8 5 1 1 Number of recommended preventive maintenance visits LENNOX NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500 1000H visit Major technical inspection Inspection visit 15 000 h inspection 30000 h inspection Tube analysis Every year 3 times a year Every 15000 hours Every 30000 hours This table is published for units operating under normal conditions with an average annual runtime of 4000 hours In hostile industrial e
4. 0007 orep orep 1 0001 uue y 17 XV A A10PeA jun poo uondrios q 1034121259 U99 9S 7 39NV3 21901023 3331 0S wIILVINITD NOILVIYAdO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 70 y 6172 eur UNY 6 8170 ssed g 8 1192 dumd H L HOMO 91 9 HOMO SI bz MOT 5 6 HOMO d AS p HOMO Eltbc IPIS MS E ASIT 91815 7 ASIT 1574 8 I duroO I 002 1oss rduroO r BIET c L suruuny g LIET c Kejosr L 9160 I L Suruuny 9 I Avjou HOMO IPIS 5 HOMO EIET MOTT MS E ASIT TIEZ 2 86 9571 8 dumq c 6000 ZA ede9 2 2 q ICcC juroqies T 02 lt lt Do 917 195JJO 9 HOMO SITZ AST AS VITE de Joop de c Do TITZ ds c Do 1002 45 1 OITZ JOJEM T 0055 lIonuoo Z Do YLIT De ELIZ dur r Do 241 c dur r Z De ILIZ duor OLIZ 410510 U xe 10398 jun uondidosoqq uonduosoq uondidosoq 9
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6. Pod r r 4 PEAT o RPM 1000 400 300 101 Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 21 UNIT START UP LENNOX 5 UNIT START UP 5 1 CHECKS TO BE MADE DURING START UP 5 1 1 CHECKS TO BE MADE DURING START UP Before starting the unit fill in the check list sheet on page 48 of this manual and follow the instructions below to be sure that the unit is correctly installed and ready to operate 1 Thermometers and pressure switches installed in the chilled water circuit and the condenser water circuit Check these safety devices in this order high pressure switch differential oil pressure switch low pressure switch fan control pressure switches and thermostats anti short cycle relay Make sure all indicator lights operate correctly 2 Run evaporator pump prior to start the chiller 3 Flow switch installed and wired into the control box operates properly 4 With the compressor running check the oil pressure If there is a fault do not restart the compressor again until the source of the problem has been located 5 Check that there is sufficient cooling load on the day the start up is conducted at least 50 of the nominal load PROCEDURE TO FOLLOW WHEN STARTING THE UNIT 5 a Press the power ON OFF switch The compressor will only start if the ev
7. 6 HOMO 8197 8 195 y Aejowr L 9197 amp e osr 9 S197 C HOMO 7192 I Aeposr y HOMO EIOZ IPIS MS E ASIT 7192 910 S Z ASIT 1192 SguoO 1 0192 I 1 0097 9 EPST uontsoq e ASIT TYST 910 S Z ASIT 178 SguoO 1 0755 T EEST uontsoq ASIT TEST eis c ASIT TEST SguoO 1 0555 I 2 ETST uontsod ASIT TEST 91815 7 ASIT ITST SguoO 1 0555 Z YInortO Z EIST uontsoq e ASIT TIST eis c ASIT SguoO 1 OISZ I gom 0055 Add 397 oun uNY g 1976 997 Kejoy 9 SOPT MOT AS PVC d USTH 8 HOMO COT EIS AS SISTT TOPT 21216 7 SISTT Sys 0977 y du105 9 XEN ATOPIC um 039115551 0115591 109115591 1933435 UEN GANNILNO9 XVWOO3 334 1 NNW OS 2ILVWITO NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E JO uO SILT WIS AS jopno r Do ILT P E PrI TILT 91815 7 ASIT Sguo OILZ KI9A099Y 00 5 uondo 6795 6 HOMO 897 APS HOMO 1797 AOL BOO 9497 Kepay 9 HOMO Z APS HOMO 9 1 HONO troc 2115 MS ASTI 9 19 asi 1790 30000 1 0595 p UB J T 6595 TEMPON 6 HOMO 8595 Av
8. 18 UNIT START UP EEG ERE X PG SERERE eam 22 5 1 Checks to be made during start up 5 2 charge 5 3 Refrigerant charge 6 OPERATION ex ots basa Ie ER t Ea E SER RE mA 23 06 1 CONTON nist cde eae Pee Ue land 24 6 2 Unitoperatloni oe iux pev eee 26 Tic MAINTENANCE 2 YN aoe al a eee 31 7 1 Weekly 31 7 2 Annual 31 7 3 Cleaning the condenser 32 7 4 Compressor drainage 32 ach ete ERE RE redo babu s b Ta 32 8 TROUBLESHOOTING REPAIRS 33 8 1 List of the most common 5 33 8 2 Control 39 8 3 Operation and start up check sheet 40 8 4 Regular checks to be made Chiller unit environment 41 8 5 Manufacturer s recommended inspections 42 ANNEXES Vut cest be 49 LENNOX Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 PREFACE LENNOX 1 PREFACE You must read and be familiar with this operating manual prior
9. XONNTI GANNILNO9 39NV3I 21901023 33341 NNAN 05 2ILVINTTO NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 657 our 6 HONO BST ssed amp g g dung H L SPC Kel xI 0 d MOT AS d Y31H MS p HOMO CSV IS MS 4474 WIS SISTT IST 80109 1 OST T ON duroo oun UNY 6 HONO ssed g g FOTO 1776 dumg H 4 Rejoy 9 HONO SPC d AS HOMO 2244 d Y31H AS p HONO 21815 AS ASTI 101S Z Wi 3guoO I TNO GEVT euim unw 6 SEPT ssed amp g g FOTO dumg H 4 HONO ETC Avjoy 9 SEPT d MOT AS HONO 4344 d Y31H AS p FOTO 3324 IIS MS 91819 8 oere g duro9 g oun UNY 6 444 ssedkg g dundg H L CVT Avjoy 9 SCPC MOT AS 4674 4 FOTO 1444 21215 MS omis c Tere 3100 1 0 XV A 10398 J yun uonduosoq uonduosoq poo uondri9s q 99 198 39NV3H 21901023 39344 NNJN OS 4 9ILVWITO NOILVH3IdO Installation Operation Maintenance manua
10. 1 0086 lt d di 3 OLOPA 102981231 Jo gt PP Sis nun fo 0021150000 T9 0 21517 ZISE ZIS Z uoremsguo e 0 JST 1188 oSuey 0186 pup 008 3guoO 8 00 8 uondo 4 uone1edo uey 1108 35s AjAroea 101084 Ix 05 I 22 719 ADOUOY Z 107 yes mss 1d 45 dH 1 0 IT LI 4 119 puo 46 1 009 uont nuoA 9 1958 SAS 1urod 195 xouue T AAA x 666 I 0 SISE lt 10198 PISO 3utod Jos xouu T AAA 666 0 0 5 m 10798 12000100014 710995 xoUuu T AAA 666 SE 0 EISE 4 6 jurod 195 ATA 66 0 0 2s ZISE ouoz 195 jeoqredng TATA Ts ST B Do TISE yeopiodns 0196 Sugooy 0058 sumos xouu2 Tu 19951 09 06 I Jo Yun eui z 0 8110295 102410 OT V 0 a ununum pun yes Suizoo1 A3oges 9e Tore 504 1 0cvt FST JU UISSEUEUI ATHOLId AJIONd 40107 ST ST T enr 2 1 00 Jossoiduiog mou ze XEN 07987 um jur 10119115594 gt 099195 CXONNIT GANNILNO9 XVWOO3 334 1 NNW OS 2ILVWITO NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E poods o Suts 519430 poods
11. PAYO 45 197941 5 Jod uonedionue 001 0 0 10 soynurpy odors uorounx uonedronuy 9 cece V 9U0Z 10 AUO omendu 0c 01 01 uo Surpuodop dny1e3s poyedionue uonedionuy ue SMO Do ITTE 1 0cct 519 uonounj Jo uoneAnoe JO z edo s Jo uonoun q 1910 19 128 0 01 9 398 7 oum Buys 2007 HE uui cuo 158 vc vc 0 m pem 0 9 195 F 2007 3011835 8 06 2007 uui uo 158 vc 0 0 4 SINE 0 9 195 V 2007 10 oui Sunejs ZUNS 9007 uui U9 198 o 9 JOS 9402 vc vc 0 0055 perdnooup 103 nog oum Zunes 391195 9407 i SUIT JOJUIM Sum Tourums 1001418 onguro ng JIO x SOK ON SOA lt 4 9 IBA 8095 32010 20121 66 gt 6 TON 3010395 DOT 201 cl A I ARG SUMS 3oolO 2010 T EZTIE Keq SIMU SUNOS 22010 590101 65 0 2015 7 OH 801195 32010 tc 0 H IZIE IMOH OZIE xX o 2 c 14104 155 0 0 21511 1591 5 050 JO YIM 195 Aue JIUL UR Jo 897158900 JOJES
12. OZ TT 027 Kazes Surzoo14 KeS de Hs Vers ATrrorrd 4002 ST ST ASIT Ive 2109 1 0156 1 0085 0045 0095 0055 SyU0 8 uondo UODe HU2A 9 AHT S losso1duio CXONNIT GANNILNO9 XVWOO3 334 1 NNW OS w OILVNII19 NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 0 3UIp1022 O22 01 15 0776 yur omje1oduroj mo porno Aeg d Tek bibo 2422 SPOUT SUT OO 10 10106 ATTATOVOY 10106 J 5848 05 I 2 SIEE OS NOI 05 0 01 ed 9894 oos 195 quelqu 45 199244 9o CMO esp 06 NOI 05 cc 01 AE 2880 oos jurod 155 45 1978 Do EIEE TMO 45 6 07 801 022 LI L 01 16 10240 unuu 0 ewo WOT 9584 oos Do ZIEE TM ds c jurod jos PATYO PMO 45 197941 07 8110255 LT L 01 16 005 10240 0 ewo WOT H ased oos Do TIM 46 1 0166 1009 1 jurod es
13. E LET qub ED 67 ease eid EUROS PLE REP REA ra S A Sad 68 CLIMATIC 50 MENU TREES See specific CLIMATIC 50 user manual ECOLOGIG range 70 Z iam tue u oe EE 79 CERTIFICATES MIONS AFAQ ISO 9000 91 PED Z su sawaka i Akin MAS 92 CE CONFORMITY RIT BLA AG qe EU e et 93 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 49 ECOLOGIC HYDRAULIC HYDRONIC DATA LENNOX ONIT WITHOUT HYDRAULIC OR HYDRONIC MODULE 200 gt 370 STD LN HE SLN 90 130 150 HE SLN ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT Groove lock coupling Temperature sensors Unit isolation valve Plate heat exchanger Water inlet filter 22 Flow switch Differential 04a ira In Out manometers without groove lock coupling option in Out manometers mounted on groove lock coupling option Paddle flow switch OPTIONS 5 Flow switch BASIC UNIT Water inlet filter Flow swith paddle differential Unit isolation valve Supplied loose Supplied mounted Add 03 Add 05 Add 22 Add 02 18 46 Kit for groove lock Inlet Outlet coupling manometer manometer KI tor 1
14. LSPT OA VA L HONO 957 Avjoy 9 SOMO d MOT AS HONO PSPC d AS b FOTO ES TT IIS MS avc 2195 Syu0 OST c duroO BPPT eum UNY g SOMO 1776 OA VA L SOMO bbc Aeqay 9 HONO d MOT AS SOMO d USTH MS p FOTO IIS MS 91819 3guoO 1 orre TNO Cduroo p eum unw 8 SOMO OA VA L SOMO OCT Aeqay 9 SOMO SEPT d MOT AS HONO d MS p FOTO 2215 AS 91819 ByuoD oere TNO 8cyc eum unw 8 SOMO SOMO CVT Avjoy 9 SOMO d MOT AS SOMO VCVC AS p FOTO 91215 AS 4444 91819 Tec 8 0 9 XV A 10398 J yun uonduosoq uonduosoq poo uondri9s q 9 GANNILNO9 JONVY XVWOO3 334 1 OS 2ILVWITO NOILVHAdO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 82 6197 6 8797 8 595 Aejowr L 9595 amp e osr 9 S797 C 709 I HOMO EZOZ IPIS MS E ASIT 29 eis c ASIT 1595 SguoO 1 0595 TIMONO ueq p 6197
15. OPERATING LIMITS LENNOX LCH VK LOW NOISE LCH 402V 422VE 442V 452VE 502V Operating limits Min outlet water temperature 5 5 5 5 5 inlet water temperature C 20 20 20 20 20 Min ditterence water 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 51 51 51 51 50 5 LCH 552VE 602V 652VE 702V 752VE Operating limits Min outlet water temperature 5 5 5 5 5 water temperature 2 20 20 20 20 20 difference water 3 3 3 3 3 Max difference water inlet outlet 8 8 8 8 8 Miri outside 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 C 02 55 55 55 a LCH 803V 853VE 953V 1003VE 1053V Operating limits Min outlet water temperature C 5 5 5 5 5 Max inlet water temperature C 20 20 20 20 20 Min dress water 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 45 15 45 Max outside air temperature 2 50 5 50 5 50 5 50 5 19 LCH 1153VE 1254V 1354VE 1404V 1504VE Operating limits Min water temperature 5 5 5 5 5 Max Det water t
16. A Only trained and qualified personnel is authorised to service and maintain this equipment Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E 39 TROUBLESHOOTING REPAIRS LENNOX 8 3 OPERATION AND START UP CHECK SHEET Machine identifications File number Year of manufacture NORMAL CONDITIONS OF USE Leaving chilled water temperature C Outdoor air temperature Power supply voltage ist V Ph Hz Refrigeranttype Date and time measurements were n Outdoor air temperature C Company responsible for measurements usines Nameoftechnicidn Remarks 1 Circuit 2 Circuit 3 Circuit 4 Compr Compr Compr Compr Compr Compr Compr Compr 1 2 3 1 2 3 1 1 Number of hours of operation Compressors in service per circuit Evaporating pressure Bar Suction piping temperature Condensing pressure Bar Discharge piping temperature Oil pump temperature Oil pressure Bar Oil level A Current on phase 1 per compressor Current o
17. Every compressor is fitted with a single phase crankcase heater that is activated when the compressor stops to ensure separation of the refrigerant and the compressor oil It is therefore powered up when the compressor is not running NB Scroll and reciprocating 6 C ambient type compressors are not fitted with a crankcase heater 6 2 1 5 High pressure switch This pressostat initiates unconditional stoppage of the unit if compressor discharge pressure exceeds the operating limits Reset is automatic Screw and reciprocating compressor with R407C high pressure switch equal 26 5 bars Scroll compressor with R407C high pressure switch equal 29 bars 6 2 1 6 Low pressure switch This pressure switch initiates unconditional stoppage of the unit if if evaporating pressure drops below the value P 1 6 C ambient temperature machines standard P 2 4 bars relative 2 optional 20 C ambient temperature machines P 0 8 bars relative 6 2 1 7 Fan control pressure switch and thermostat The function of these devices is to ensure a level of head pressure compatible with proper unit operation An increase in outdoor air temperature increases head pressure and this is maintained at its required value by fan operation 6 2 1 8 Antifreeze function This function only exists on units designed for brine or glycol water chilling for which the freezing temperature de pends on the concentration of the solution Whatever type of d
18. In this event before putting the unit back into service the compressor and the refrigeration circuit will have to be evacuated 7 5 IMPORTANT Before proceeding with any service operations make sure that the power supply to the unit is switched off When the refrigeration circuit has been opened it will have to be evacuated recharged and inspected to ensure that it is perfectly clean filter drier and leaktight Remember that only trained and qualified personnel are authorised to open a refrigeration circuit Regulations stipulate recovery of refrigerants and forbid willful discharge of refrigerants into the atmosphere 432 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A THE COMPRESSOR DOES NOT START Motor control circuits established the compressor does not run No power supply Check main power supply and switch positions Compressor motor burnt out Replace Low voltage reading on voltmeter Voltage too low Contact power company The system does not start up Breaker tripped or fuses blown Determine the cause If the system is in running order close the disconnect Check condition of fuses No water flow in the evaporator Measure flow check th
19. Or normal compressor operation but the low pressure safety switch trips out and resets frequently Low refrigerant charge Check the charge through the sightglass on the liquid line carry out a leak test then top up the refrigerant charge Suction pressure too low Filter drier frozen up Filter drier obstructed Check the state of the drier and replace the filter Solenoid valve closed Check that the valve is operating properly Expansion valve closed Check bulb and capillaries operation of the valve Compressor suction valve Check the filter C THE COMPRESSOR SHORT CYCLES ON HIGH PRESSURE SAFETY SWITCH TRIP OUT High pressure safety switch trip out Check high pressure safety switch differential Low air water flow in condenser or dirty condenser coil poor heat exchange Check that pumps are operating correctly or the state of cleanliness of the coils check fan operation Incondensibles in the refrigeration circuit Bleed from circuit and top up the refrigerant charge Note it is not permitted to discharge refrigerant to atmosphere 34 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION D T
20. q 9tIc 5 d 9 q SEIT Sutsu puoO d do uonong Do EEIT permes oL do TEIT Sursuopuo y c do TEIZ 1Teogodns T T q OTIT PINES 4 9 q STIT Sursuopuo q c do uonong do ETIT PIMPS o L E do Sutsu puoO 1 6 do ITIC yeoHodng OcIc Jepno e do CLIT SPISMO T OTIZ 1 001 0007 Ueqc oum 6 oum oyep c oum 1 0001 uue y 17 Xew jun uondidosoqq 9po uonduosoq uondidosoq 99 198 XONNIT XViWO23 33211 06 wIOILVINITD NOILV iH6ddO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 Do 7616 b dwel p Do 617 dural Do 7617 lt duo 7 Do 1612 I dure 0617 1103310 94 u 6 JO uO v8Ic HIMS JO uO 8IC 6 YOUMS TSIT T YOUMS 7 181 T H HMS T 0816 5 74 8 JO uO YLIT Aepou p JO uO ELIT Aeesr c JO uO CLTC amp ejoor c JO uO ILIZ I 1 OLIC 7 035 0 JO uO 8917 9ou MS 8 1919 39594 MS L JO uO 9917 SIA MS 9 JO uO SOIT O SIC MS PITT TO SIA MS Y JO uO 9Ic 19 TOTT MOLT MS T JO
21. 9 90 9 9 9 g 9 9 3 9 9 Check valve Shell and tube evaporator Thermostat Temperature sensors External temperature sensor Water differential pressure switch Discharge muffler Heating resistance option VARIANTS EXPANSION DEVICES OPTIONS Basic Unit LCH unit Thermostatic HP LP Pressure Suction and Discharge or UDT or Electronic Gauges Oil Isolating valve 01 03a 03c 04a 08 09 10 11 Add Add Add Add 12 13 14 15 16 17 18 19 07a 07b 14a or 14b 05a 05b 05c 06a 06b Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 69 PITT PUMS 7 5916 6 YOUMS SOMO 6916 MS T SOMO IOIT T YMS 091C 103510 u 9 SOMO Sic y Kejost b OO ESIZ Avjou HOMO TSIT c ABIOY T JO O ISIT I Aefor T OSIT 7 035 0 MO S SOMO 720411 MS 9 SOMO SIT 35594 MS SOMO CO SIC MS SOMO EPIT IO MS SOMO CHIT MOLT MS T THIT HO UO S I OIT 0 7 q 9cIc PINES 4 9 SEIT Sutsu opuoO q c do UOHONS Do EEIT PINES o L E do TEIT Sutsu puoO 1 6 IEIZ yeoHodng 0616 T q OTIT 4 9 q STIT Sutsu puoO q c do UOHONS do ETIT PINES o L E do Sutsu puoO 1 6 do ITIT yeaHodng OTIZ Jepno c PUI do PISNO T emereduer 1 OOIT
22. HANDLING LENNOX UNITS WITH REMOTE CONDENSER Unit with remote condenser Unit with remote condenser without capacity control with capacity control 1 Lower trap with single tube 2 Clode coupled trap 3 Lower trap with double tubes 4 Higher trap with double tubes H1 15 m maxi H2 5 maxi 0 3 H4 0 15 maxi WARNING The liquid level between the condenser and the check valve must compensate the check valve pressure drop If receiver option PED declaration class 3 If no receiver option PED declaration class 1 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 13 INSTALLATION TRANSPORT HANDLING LENNOX CONDENSING UNITS Condensing unit Condensing unit without capacity control with capacity control 1 Lower trap with single tube 2 Clode coupled trap 3 Lower trap with double tubes 4 Higher trap with double tubes H1 15 m maxi H2 5 m maxi H4 0 15 m maxi If receiver option PED declaration class 3 If no receiver option PED declaration class 1 14 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT HANDLING Minimum refrigeration capacity kW for oil entrainments up Suction risers Refrigerant R407C LENNOX
23. In particular the shape and dimensions of the hot gas lines must be carefully designed to ensure proper oil return in all cases and prevent liquid from returning into the cylinder heads when the compressor is stopped On units fitted with capacity reducers the piping sizes must be calculated so that gas velocity is sufficiently high when the unit is operating on capacity reduction Non application of these precautions will cancel the compressor warranty We recommend to follow ASHRAE recommendations 3 7 1 Liquid line sizing Determine the size of liquid lines using 1 Operating conditions at full load 2 Maximum pressure drop of 100 kPa 3 Liquid velocity under 2 m s to avoid liquid slugging 4 Forliquid risers make sure that liquid subcooling is sufficient to counteract the loss of static pressure and prevent gas flashing 3 7 2 Discharge lines and suction lines Calculate these to obtain a gas velocity in vertical sections that enables compressor oil migration and steady return to the compressor tables C and D page 15 Determine the dimensions of vertical lines using the following tables Horizontal lines may be bigger in order to compensate pressure drop in vertical lines The total pressure drop in the piping has to be lower or equal to 1 C at saturation pressure on the suction side 12 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT
24. 33 34 35 2 Ts 37 39 36 37 39 35 36 37 gt 7 Z 702 752 VK LCH3 803 853 VK EM Dc 1 33 ne 37 38 140 39 38 37 z s 32 34 36 a 40 38 32 Y 34 36 V 44 43 42 41 1 P gt 54 3 i ui Mi KOC 4 Z LCH3 953 1003 VK LCH3 1053 1153 VK 28 Y T Te DE 33 M Galle 43 42 41 Y TG 36 37 38 39 40 46 44 4 LCH3 1254 1354 VK LCH3 1404 1504 VK 32 33 34 59487447443 62 4 36 37 38 39 40 50 49 48 47 46 Z 30 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 MAINTENANCE LENNOX 7 MAINTENANCE The following maintenance instructions form a part of the operations required for this type of equipment However It is not possible to give fixed and precise rules for permanent maintenance procedures capable of keep
25. HOMO 89Z WIS 5 6 21571 T897 2 6 9151 189 Sguo T 0895 C NNM p ue4 g HOMO YLIT HOMO 19 2781 5 6 9157 196 91815 7 9157 119 BYUOD 0 95 C WMO UBA L HOMO 7995 HOMO E997 NIS 45 6 9157 995 91815 7 9157 1997 Sguo T 0997 C NN 9 6595 HOMO 7595 HOMO ESOT WIS 5 6 9157 595 9115 2 9151 1592 BYUOD 0597 C NNM ueq HOMO 7 90 HOMO 9 NIS 46 6 9151 91815 7 9157 1795 ByUoD 0795 I p ueq p UN jm Spo uopdrrssq Spo Spo uopdrrssq Spo 099155 UIE Installation Operation Maintenance manual CHILLERS ANNEXES 0105 XONNTI GANNILNO9 39NV3 21901023 33341 NNAN 05 M OILVAII19 NOILV3H3dO 74 0 SUIPAODID 10240 05 IWO INOI 11 9899 oos jurod jos PATYO 45 197941 LT 01 15 Jo TTEE 45 01 5140220 LT L 0 6 102410 una 06 IUD WOT 11 98ed oos De ITEE TM dS I 0266 1009 10M 7 jurod 198 PAYI 45 JVM 301195 19 280000 1940 0 TT 01 De Joumung c 80395 JOJUIM 1940 1940 9808 05 61 01 38
26. MOT 0 0 poods l Suts 19410 4 suej 28215 poods 8116 599616 suey ON ON uonemsaguoo ue uonemsuguoo poods o Suts 519430 poods poods MOT 0 0 poods Suts 19410 onuoo 4 P ica ue ANA SAI NOTE suey ON ON uonemsguoo ue uonemsuuoo 9181 poods o Suts 519430 poods poods MOT 0 0 poods Suts 19410 onuoo 4 28215 poods o Sutg 98815 suey ON ON uey uonemsuuoo 9151 TESE T Innoc poods o Suts 519430 poods z poods MOT T 0 0 poods 8 5 19410 onuoo poods uong npolW suej 28215 poods 8 6 599816 Suej ON ON uonemsguoo ue uonemsuuoo SIT 1686 I Ymono 1 058 wuonelnu A suwu jun uondiis q uondriis q uonduosoq 099125 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 XONNTI GANNILNO9 XVWOO3 334 1 NNIN OS 2ILVWITO NOILV3H3dO OSA p1eoq uorsu x 0 0 Jo
27. Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C 8 Minimum outside air temperature C 6 Maximum outside air temperature Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 51 50 49 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded 49 47 46 ECOLOGIC WAH HEATING MODE WAH 150 200 230 Minimum inlet water temperature 10 Maximum outlet water temperature C 50 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C 8 Minimum outside air temperature with water outlet 35 C C 10 Maximum outside air temperature C 30 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 57 ECOLOGIC OPERATING LIMITS WA LENNOX STD LN HE SLN 075 090 100 110 130 150 Water Test pressure bar 10 Refrigerant Test pressure bar 29 Water Max operating pressure bar 6 Refrigerant Max operating pressure bar 29 Water Minimum flow rate m h 8 C AT Water Maximum flow rate m h 3 Safety Low pressure cut out bar 0 7 Safety Interlocking of low pressure bar 2 2 Safety High pressure cut out bar 29 Safety High pressure reset bar 20 WA 200 230 270 300 370 Operating limits for evaporator Water Test pressure bar 10 Refrigerant
28. 38 TE 794 alt 18 24 va 9 om x x N S a x x g o 98 8 a EE eee 28 6 8 6 858888 5606 09098 c w 8896868868868 REY 25 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 OPERATION LENNOX 6 2 UNIT OPERATION 6 2 1 Functions of refrigeration circuit components 6 2 1 1 Thermostatic expansion valve Very important The thermostatic expansion valve fitted on each machine has been selected for a given operating range it must be replaced with a model with the same reference from the same manufacturer 6 2 1 2 Filter drier This is designed to remove all traces of humidity from within the refrigeration circuit since this can impair opera tion of the unit by acidification of the oil which causes slow disintegration of the varnish protecting the compressor motor windings 6 2 1 3 High and low pressure gauges option Enables instantaneous readout of suction and discharge pressures Sightglass humidity indicator optional on units fitted with scroll type or reciprocating compressors Enables visual verification of the state of the liquid refrigerant monophase ou diphasic in the liquid line upstream of the thermostatic expansion valve Enables detection of humidity in the circuit 6 2 1 4 Crankcase heater
29. Min outlet water temperature C 5 5 5 5 5 Max inlet water temperature C 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 C 49 49 48 5 48 5 47 5 LCH 1153VE 1254V 1354VE 1404V 1504VE Operating limits Min outlet water temperature C 5 5 5 5 5 Max inlet water temperature C 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 47 5 48 5 48 5 47 5 47 5 1 With low temperature kit 2 Unloading start up sequence Installation Operation Maintenance manual CHILLERS ANNEXES 0105 59 OPERATING LIMITS LENNOX LCH VK PK HIGH AMBIENT LCH 322P 412P 462P 532P 402V 422VE Operating limits Min outlet water temperature 5 5 5 5 5 5 inlet water temperature FC 20 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 C 50 48 5
30. O Check absence of transport damage O Check for missing items O Availability of suitable lifting gear slings and spacers UNIT PLACEMENT O Shipping crate removed L Clearances checked O Vibration isolators mounted O Unit set in place O Unit levelled CHILLED WATER CIRCUIT All piping checked for leakage Thermometers installed Water pressure regulator installed Balancing valves installed Flow switch installed System rinsed cleand and filled before being connected to the unit Checked presence of filter on unit inlet and state of cleanliness of the filter Checked operation of the pump and evaporator pressure drop 0 000000 CONDENSER WATER CIRCUIT Checked order of power supply phases for scroll and screw compressor units piping checked for leakage Thermometers installed Water pressure regulator installed System balancing valves installed System rinsed cleand and filled before being connected to the unit Checked presence of filter on unit inlet and state of cleanliness of the filter O Checked operation of the pump and condenser pressure drop 000000 ELECTRICAL EQUIPMENT Check the main power supply matches the unit data plate Check that the unit is correctly earthed Checked order of power supply phases for scroll and screw compressor units Checked correct direction of rotation of fan motors and proper operation of the latter Direction of rotation of pump correct Control cabinet wired up Power s
31. Test pressure bar 29 Water Max operating pressure bar 6 Refrigerant Max operating pressure bar 29 Water Minimum flow rate m h 8 AT Water Maximum flow rate m h 3 Operating limits for Safety Low pressure cut out bar 0 7 Safety Interlocking of low pressure bar 2 2 Safety High pressure cut out bar 29 Safety High pressure reset bar 20 58 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 OPERATING LIMITS LENNOX LCH VK STANDARD LCH 402V 422VE 442V 452VE 502V Operating limits Min outlet water temperature 5 5 5 5 5 inlet water temperature C 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 C 49 5 49 5 49 5 49 5 48 5 LCH 552VE 602V 652VE 702V 752VE Operating limits Min outlet water temperature C 5 5 5 5 5 Max inlet water temperature 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 C 48 5 48 5 48 5 49 49 LCH 803V 853VE 953V 1003VE 1053V Operating limits
32. be leveled failure to install unit correctly will void warranty Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 9 INSTALLATION TRANSPORT HANDLING LENNOX CLEARANCES DRAWINGS For more details please consult our Application Guides or the drawings supplied with the unit ECOLOGIC range ECOMAX range OVERHEAD OBSTRUCTIONS ARE NOT PERMITTED gt meters 2 meters Not allowed Not recommended 1 5 meters For any chiller a minimum distance of 1 meter is required for the good opening and servicing of the elec For any air cooled unit it is necessary to have a minimum distance between air coil and any obstacle of trical box 3 4 WATER CONNECTIONS 3 4 1 Water connections Evaporator Condenser The water circulating pump will be preferably installed upstream so that the evaporator condenser will be subjected to positive pressure Entering and leaving water connections are indicated on the certified drawing sent with the unit or shown in the sales brochure For shell and tube heat exchangers a drainage plug is located at the base of the evaporator A drainage pipe may be connected to this to enable drainage of evaporator water for service operations or for seasonal shut down The use of a water filter in the water circuit upstream of the heat exchanger is mandatory These filters must remove all particles with a diameter greater th
33. crankcase Check appearance of the oil in the sightglass Measure temperature of the oil pump measure superheat at the expansion valve check that the valve bulb is tightly attached Poor heat exchange in the evaporator Check water flow Check fouling by measuring the water pressure drop Excessive oil migration in the circuit measure evaporating pressure superheat and the temperature of the oil pump Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 35 TROUBLESHOOTING REPAIRS LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION F THE COMPRESSOR CUTS OUT ON ANTIFREEZE PRESSURE SWITCH Antifreeze pressure switch Check that the pressure switch tripped is operating properly Low water flow in the evaporator Check the water pump Evaporator obstructed Determine the degree of fouling by measuring water pressure drop Evaporator frozen up Measure pressure drop in water circuit keep water circulating until evaporator has thawed completely Low refrigerant charge Check the refrigerant charge and add refrigerant if necessary G THE COMPRESSOR CUTS OUT ON ITS MOTOR PROTECTION THERMAL RELAY Thermal protection Tripped Check operation of thermal protection change it if necessary Motor windings are not being Measure superheat
34. draining and filling of the system under pressure shall be carried out using connections provided for this purpose and suitable equipment To prevent the risk of explosion due to spraying of coolant and oil the relevant circuit shall be drained and at zero pressure before any disassembly or unbrazing of the refrigerating parts takes place There is a residual risk of pressure build up by degassing the oil or by heating the exchangers after the circuit has been drained Zero pressure shall be maintained by venting the drain connection to the atmosphere on the low pressure side The brazing shall be carried out by a qualified brazer The brazing shall comply with the standard NF EN1044 minimum 30 silver Replacing components In order to maintain CE marking compliance replacement of components shall be carried out using spare parts or using parts approved by Lennox Only the coolant shown on the manufacturer s nameplate shall be used to the exclusion of all other products mix of coolants hydrocarbons etc CAUTION In the event of fire refrigerating circuits can cause an explosion and spray coolant gas and oil Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 5 WARRANTY LENNOX 2 WARRANTY The warranty of the chillers is subject to the warranty definitions as agreed upon in the order It is expected that the design and installation of the unit utilises good
35. jug es conformes have been examined and found conform 2002 03 18 ann e mois jour II est valable jusqu au 5 year month day Itis valid until 2005 03 1 4 h D6 X 0998 1 2000 11 S Le Pr sident du Comit de Certification Le Directeur G n ral d AFAQ The President of the Certification Committee The Managing Director of AFAQ C GUERIN O PEYRAT Sauf suspension notifi e entre temps par AFAQ l entreprise d sign e ci dessus Le pr sent document n a donc qu une valeur indicative Seule fait foi la base de donn es des certificats AFAQ accessible l adresse internet http www afaq org L organisation AFAQ est conforme aux normes internationales en vigueur guide ISO IEC 62 norme EN 45012 Les accr ditations d tenues par AFAQ et ses filiales sont disponibles l adresse internet http www afag org accreditations Excepting notification by AFAQ to the above mentioned company of its suspension This document is for information purposes only For up to date information the only official source is the AFAQ certificates database at http www afaq org The AFAQ organization complies with the international standards in force 62 ISO IEC Guide EN 45012 standard Information on the accreditations held by AFAQ and its subsidiaries is available at http www afag org accreditations AFAQ 116 AVENUE ARISTIDE BRIAND 40 F 92224 BAGNEUX CEDEX FRANCE Ins
36. systems Account is taken of technical constraints both in design and manufacturing sound levels cannot be improved much further than specified Sound levels must therefore be accepted for what they are and the area surrounding the chillers should be treated as necessary The quality of installation can either improve or decrease initial sound characteristics it may be neces sary to provide further treatment such as sound proofing or installation of screens around units installed externally The choice of the location for the installation can be of great importance reflection absorption transmission of vibrations The type of unit support is also very important inertia of the room and the structure of the walling interfere with the installation and its behaviour Before taking any other steps first determine whether the sound level is compatible or not with the environment what it is perfectly justifiable and that these measures envisaged will not cause unreasonable cost Determine what level of sound proofing is necessary on the equipment the installation silencer vibration isolators screens and on the building reinforcement of flooring false ceilings wall coverings It may be necessary to contact an engineering office that specialises in sound abatement 3 7 CONNECTION OF SPLIT UNITS Connections between the unit and the condenser must be made by a qualified refrigeration engineer and require several important precautions
37. than the first third of the way up the bullseyes CAUTION Power up the compressor crankcase heaters at least 24 hours before starting the unit This will enable the refrigerant in the crankcases to evaporate off and prevents damage to compressors through lack of lubrication during start up 7 Start the check the flow of liquid to be cooled through the heat exchangers note the inlet and outlet water pressures and using the pressure drop curves calculate liquid flow by applying the following formula actual flow Q Q x P2 P1 2 where 2 pressure drop measured on site 1 pressure drop published by LENNOX for a liquid flow of Q1 Q1 nominal flow Q real flow 8 On units with air cooled condensers check for correct operation of the fans and that the protective grilles are in good condition Make sure that rotation is in the right direction 9 On units with ducted fan check the air flow and duct pressure drop On delivery the drive belts are new and correctly tensioned After the first 50 operating hours check and adjust the tension 80 of the total elongation of belts is generally produced during the first 15 hours of operation Before adjusting the tension make sure that the pulleys are correctly aligned To tension the belt set the height of motor support plate by moving the plate adjustment screws The recommended deflection is 16 mm per metre from centre to centre Check that according to the dia
38. that power supplies from the building to the place where the unit is installed are properly established and that wire gauges are in keeping with the start up and running currents Check tightness of all electrical connections You MUST make absolutely certain that the power supplies applied to the power and control circuits are those for which the electrical panel was manufactured Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 11 INSTALLATION TRANSPORT HANDLING LENNOX A main isolator switch must be inserted between the end of the power supply cable and the unit to enable total iso lation of the latter when necessary Chillers are supplied as standard without a main isolator switch This is available as an option with regulations For the sake of safety install them where they can be seen and in easy reach of the unit Units must have full earthing continuity IMPORTANT Operation of a unit with the wrong power supply or with excessive phase imbalance constitutes abuse and is not covered by the LENNOX warranty If phase imbalance exceeds 2 for voltage and 1 for current contact your local electricity company immediately before powering up the unit WARNING A Wiring must conform to applicable regulations The type and location of fused isolators must also conform 3 6 SOUND LEVELS Liquid chillers are a significant source of noise in refrigeration and air conditioning
39. to commission the chiller Please closely follow the instructions We would like to stress the importance of training with respect to the correct handling of the chiller Please consult Lennox on the options available in this field It is important that this manual be stored in a permanent location in the vicinity of the chiller Text Important general instruction Danger of Injury or damage to the chiller This manual contains important instructions regarding the commissioning of the chiller It also includes important instructions to prevent personal injury and damage to the machine during operation Furthermore in order to promote fault free operation of the chiller maintenance information has been included Please do not hesitate to contact one of our employees should you require further information on specific chiller subjects Order related documentation will be forwarded under separate cover This documentation consists of CE declaration Operating manual for control system Installation Operating manual Wiring diagram Refrigerant flow diagram except for WA RA WAH LCH Unit detail are given on unit nameplate The data published in this manual is based on the most recent information available It is supplied conditional to later modifications We reserve the right to modify the construction and or design of our chillers at any time without prior notification or obligation to adapt previous supplies accordingly Any
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41. valve or irregular fouled water pressure is to high Clean the valve Install and expansion tank upstream of the valve Compressor shuts down through action of the oil pressure safety switch Low oil charge Add oil K DISCHARGE PRESSURE TOO HIGH Water flow to low or water temperature too high in the condenser Water is far too hot at condenser outlet Adjust the pressure operated water valve or the thermostat on the cooling tower Water is far too cold at the Condenser tubes fouled condenser outlet Clean the tubes Presence of air or incondensibles in the circuit or excessive refrigerant charge Condenser abnormally hot Purge incondensibles and or air and recover excess refrigerant Chilled water leaving temperature too high Excessive cooling load Reduce load reduce water flow if necessary L DISCHARGE PRESSURE IS TOO LOW Water is very cold at condenser outlet Condenser water flow too high or water temperature is too low Adjust the pressure operated water valve or the thermostat on the cooling tower Bubbles in sightglass Low refrigerant charge Repair the leak and add refrigerant Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 37 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS
42. work on the Chiller should be carried out by trained and licenced competent technician 1 The following risks are present on the unit risk of electrical shock risk of injury from rotating parts risk of injury from sharp edges and heavy weight risk of injury from high pressure gas risk of injury from high and low temperatures components It is expected that all works on equipment be carried out in accordance with all local standards and norms It is expected that all worls are carried out with good working practices 4 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 PED DECLARATION LENNOX All Units are compliant with the PED directive 97 23 CE The following note must be followed carefully IMPORTANT NOTICE All work on the unit must be carried out by a qualified and authorised employee Non compliance with the following instructions may result in injury or serious accidents Work on the unit The unit shall be isolated from the electrical supply by disconnection and locking using the main isolating switch Workers shall wear the appropriate personal protective equipment helmet gloves glasses etc Work on the electrical system Work on electric components shall be performed with the power off see below by employees having valid electrical qualification and authorisation Work on the refrigerating circuit s Monitoring of the pressures
43. working practices The warranty will be legally null and void if Service and maintenance have not been executed in accordance with the regulations repairs have not been carried out by Lennox personnel or have been implemented without prior written permission by Lennox Modifications have been made to the equipment without prior written permission by Lennox Settings and protections have been modified without prior written permission by Lennox Non original or other than the prescribed refrigerants or lubricants are used The equipment has not been installed and or connected in accordance with the installation instructions The equipment is being used improperly incorrectly negligently or not in accordance with its nature and or purpose A flow protection device is not fitted In these circumstances Lennox is indemnified from any product liability claims from third parties In the event of a warranty claim the machine serial number and Lennox order number must be quoted 2 1 SAFETY The safety information contained in this manual is provided as a guide for the safe handling of this installa tion Lennox does not vouch for the completeness of this information and can therefore not accept liability for any possible omissions In the air cooled chillers heat is being transported by a pressurised refrigerant with changes in pressure and tem perature Fans have been provided to discharge heat into the environment The pr
44. 0 0 61 1 12 1 88 3 21 6 10 10 82 17 47 33 50 57 95 87 83 181 21 313 70 110 0 60 1 09 1 83 3 13 5 94 10 54 17 02 32 63 56 44 85 53 176 47 305 49 3 7 3 Mechanical isolation of refrigerant lines Isolate refrigerant lines from the building to prevent the vibrations normally generated by the lines to the building structure Avoid bypassing the isolation system on the unit by fixing refrigerant lines or electrical conduits too tightly Any vibrations will be transmitted to the building by rigid piping Lack of vibration isolation on refrigerant pipework will lead to early failure of copper pipe and loss of gas 3 7 4 Pressure test To avoid formation of copper oxide during brazing operations blow a little dry nitrogen through the pipes Piping must be made with tubing that is perfectly clean plugged during storage and between connections opera tions During these operations observe the following precautions 1 Do not work in a confined atmosphere refrigerant fluid can cause asphyxiation Make sure there is sufficient ventilation 2 Donotuse oxygen or acetylene instead of refrigerant fluid and nitrogen for leak testing this could cause a violent explosion 3 Always use a regulator valve isolating valves and a pressure gauge to control test pressure in the system Ex cessive pressure can cause lines to burst damage to the unit and or cause an explosion with se
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46. 1 10 0 WOY r R I Hun 10 ssorpe uoneognuop uonemsuuoo 1 e 10 5801395 JO K1039 OU ST s HOT pue 8 re 103 21915304 o qe reA uoym 31195 NS LISE SPYR paepuejs 0j jurod 195 TTY JO 19501 8 SAO V sju urutoo XV A jun uondidosoq 0565 0565 0168 SINE JUTT fe dsiq T uondidosoqq 0065 2p09 0 6 uondiis q 2p09 99 198 GANNILNO9 XVWOO3 334 1 NNW OS 2ILVWITO NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 CERTIFICATES LENNOX CERTIFICATION N QUAL 1993 1009e LGL FRANCE CONCEPTION FABRICATION ET CESSION INTERNE DE BIENS D EQUIPEMENT DESTINES AU CONDITIONNEMENT D AIR ET A LA REFRIGERATION OF EQUIPMENT GOODS DEDICATED TO AIR CONDITIONING DESIGN MANUFACTURING AND INTERNAL TRANSFER AND REFRIGERATION ZI Les Meuri res BP 71 F 69780 MIONS AFAQ certifie que pour les activit s et les sites r f renc s ci dessus toutes les dispositions mises en oeuvre pour r pondre aux exigences requises par la norme internationale AFAQ certifies that all the arrangements covering the above mentioned activities and locations are established to meet the requirements of the international standard ISO 9001 2000 ont t examin es et
47. 2 5 52 53 5 53 5 LCH 442V 452VE 502V 552VE 602V 652VE Operating limits Min outlet water temperature 5 5 5 5 5 5 inlet water temperature 20 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 C 53 5 53 5 52 52 52 52 LCH 702V 752VE 803V 853VE 953V 1003VE Operating limits Min outlet water temperature C 5 5 5 5 5 5 Max inlet water temperature C 20 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 C 52 5 52 5 52 5 52 5 52 52 LCH 1053V 1153VE 1254V 1354VE 1404V 1504VE Operating limits Min outlet water temperature C 5 5 5 5 5 5 Max inlet water temperature C 20 20 20 20 20 20 Min difference water inlet outlet C 3 3 3 3 3 3 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 C 51 5 51 5 52 52 51 5 51 5 1 With low temperature kit 2 Unloading start up sequence 60 Installation Operation Maintenance manual CHILLERS ANNEXES 0105
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49. 23 CE BUREAU VERITAS 92077 Paris La D fense d agr ment CE 0062 References to Standards that are Applicable NF EN 60204 1 Safety of machinery Electrical equipment of machines References to Other Standards a Directive 98 37 Relating to machinery Directive 93 68 Relating to electrical equipment designed for use within certain voltage limits Directive 89 336 EEC Relating to electromagnetic compatibility Personal Liability for the Manufacture Name Fabrice EXCOFFIER Function Customer Service Manager Date 11 01 2005 Signature LENNOX France Division climatisation de LGL France Si ge social LGL France Zl les Meuri res 68780 Mions France Soci t Anonyme au capital de 37 029 000 RCS LYON 309 528 115 N IDENTIFICATION TVA FR 59 309 528 115 APE 292 F Installation Operation Maintenance manual CHILLERS ANNEXES 0105 93 www lennoxeurope com LENNOX BELGIUM LUXEMBOURG www lennoxbelgium com CZECH REPUBLIC www lennox cz FRANCE www lennoxfrance com GERMANY www lennoxdeutschland com GREAT BRITAIN www lennoxuk com IRELAND www lennoxireland com NETHERLANDS www lennoxnederland com CHILLER_AC IOM 0105 E POLAND www lennoxpolska com PORTUGAL www lennoxportugal com RUSSIA www lennoxrussia com SLOVAKIA www lennoxdistribution com SPAIN www lennoxspain com UKRAINE www lennoxrussia com OTHER COUN
50. 34 vENT2 C2 FR C1 VENT1 C1 FR C1 270D WAJRA 3700 WAIRA 3000 x 200D 230D VENT2 C1 VENT2 C2 VENT2 C1 VENT2 C2 VENT1 C2 VENT1 C1 FR C2 VENT1 C1 VENT1 C2 FRC FR C1 FR C2 VENT1 C1 FR C1 VENT1 C2 FR C2 28 lt 3 Q EX 28 9 28 g 2 1 2 2 VENT 3IC1 2 VENT3 C1 VENT3 C2 VENT3 C1 VENT3 C2 VENT4 C1 60 VENT4 C2 5 VENT4 C1 VENT4 C2 WAH 150D 32 VENT2 C1 WAH 200D WAH 230D Cp 1 M31 VENT1 C1 2v 01 2 N VENT1 C2 FR C2 VENT1 C1 34 VENT2 C2 FRSA Cp 1 2 2 VENT1 C2 VENTE VENT2 C2 v J FRc2 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 29 OPERATION LENNOX ECOMAX Fans electrical box labelling LCH3 322 PK LCH3 412 PK LCH3 402 422 VK GE K 36 2 0 36 37 LCH3 442 452 VK LCH3 462 PK LCH3 532 PK LCH3 502 552 VK LCH3 602 652 VK Y 7 32 33 34 31 32 33 34 35 31 32
51. 5a 15b groove lock coupling Add 01 19 Add 04a 17a Add 04b 17b amp 01 19 50 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITH HYDRONIC MODULE LENNOX STD LN HE SLN ITEMS SUPPLIED LOOSE 01 19 Groove lock coupling Unit isolation valve Oo Se Water inlet filter In Out manometers without groove lock coupling option In Out manometers mounted on groove lock coupling option ITEMS MOUNTED INSIDE THE UNIT Paddle flow switch Water tank 200L or 500L Safety valve Air purge Water drain 25L expansion vessel Second 25L expansion vessel for GGG 39 8 CX GG 3 2 9 S Single 50L expansion vessel WA lt 1500 Pump suction isolation valve Single pump Double pump Air purge Temperature sensor return Temperature sensor supply WA gt 150D Plate heat exchanger OPTIONS Flow switch Expansion Expansion BASIC UNIT 200 500L tank paddle Water inlet Expansion vessel 50L for vessel 50L for Pump isolation and single or double pump d filter vessel 25L 075 090 100 110 all other WA valve HE amp SLN units Add 05 Add 03 Add 10 Add 11b Add 10 11a Add 12 18 Inlet Outlet 06 07 08 09 13a Unit isolation Pump Unit Kit for groove Inlet Outlet m
52. 70 a ON S9A 9186 9 uorsuedxo oruodoopq 001150000 5 e ON S9A SISE I 22 0 8 7 91074 Jo 8 PIRE H uoneinaguoo dund 0017180000 T 0 SIT ETSE Jo 00321180000 T9 0 SIT ZISE ZIS Z run 001721180000 8 0 ASIT 1186 oSuew T 0584 um Jun q 0735 0585 0585 0185 2p09 urolsno urr Uojsn ul 71101817 0n0 c uondidosoq 008 9po5 80009 8 uonduosoq 2p09 4 5 CXONNIT GANNILNO9 39NV3I 21901023 333 1 NNAN OS wIILVINITD NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 perdnoouun 220 518 HO HOMO 5666 SWS puooos SI SIUL 0192 0001 0 0 JUIIOJJIP St SIO SI SWE POU 3 ue Jo Aq o1juoo jo SNA 00861 SCIHOOCT poods SWEA 0 pneg SYYOMNOT SNAGOW 0 0 AL XOUU9T 0 SING Jo 2151 uonemsuuoo S SES de sng 005 I I R uo uoneognuop uornemsq
53. 7166 IWIM Z nom r 0 0 ae 0056 Jonuoo dund ATWO ASTI TIEE 9PON I 0186 oSue 0 sun yeay 1940 1940 8991dop 194 001 0 0 Jo SOMUTIA odors uonoun uonedionuy 43 007 21 0c 01 01 uo Surpuodop oq dnjje3s poyedionue uonedionuy MESMO ITTE 004 1 OTTE STUL uonoung Jo r4 ut edo s jo uonoun q uum uut0 u9 198 0 0 9 198 9007 103 oum Buys 9407 prex uui uut0 uo 39 0 0 9 198 2007 our Sunejs 3095 2007 FRE uut0 uo 198 0 0 N 01 0 198 Suoz 103 oum 801115 Buys 9007 SEDE uum 198 0 69 195 9402 c c 0 5 00 8 perdnooup 103 oum Sunes 391195 2007 1 kie cii OUT JOJUIM um NO0 sA E ON SOK 9716 ung utA 9 IBA duros FOI 32019 66 c STIE Ie9X G FOI 32019 T E 1 SUNS ADOT POTD ETIE amp eq MU 8 YTD 4
54. 9 7 8 dung uonemsyuod T 0 STT 178 dung I sju urttuoo 10998 jun uondidosoqq 0 86 0985 0585 0785 urolsno ur 7 ul 9 urolsno 30nO uondO r 1034121259 q 4 5 GANNILNO9 XVWOO3 334 1 NNW OS wILLVWITI NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 perdnoouun oq 220 SWE x HO HOMO 5666 SWS puooos SI SIUL 0192 0001 0 0 JUIIJJIP St STU SI SWE POU 3 ue Jo Aq onuoo Jo SNA 00861 50021 poods uonvorunuruoo SIN 0 pneg SYYOMNOT SNAGOW 0 0 AL XOUU9T 0 SING Jo 2151 uonemsuuoo S SES de sng 005 I I R uo uoneognuop uornemsqguo Teog 9828 oj drusuong ARIS INSEW g T 0 0 557 EZ6E 1 Jojseui SABATR SI uy I I Te 51 oN 85 1 X ZZ65 roquinyy yun SN spun Jo Joquiny 8 1 uoneodo 19158
55. ATOBOY G OS ew WOI 05 0 01 5d 2889 oos Jos oungeroduro juerqury 45 1918 x Do CMO 95 05 9ngurm NOI 05 61 01 mad 2889 oos urod Jos omeroduo juerqury 45 19M EEEE TMO 45 6 OS WOI 5884 0S LT rae 395 juiod 195 1 Jou PMO 45 IWM Jo TELE WA 45 OS oneurp IWOI 5884 0S LT Hi 99s juiod 195 jou PMO 45 IWM Do IEEE THA 1 0558 YEOH SPOUT 8011009 10 10399 AMANOEOY 1019 0 I 22 STEE Hogar OS WOI 05 0 01 2889 oos urod Jos juerqury 45 1918 9o 533 5 05 oneurm WOI 05 cc 01 ud 2889 oos Jos ameroduo juerqury 45 1938 12433 MO 45 6 570900070 XEN AIOE um jun gt uondrosoq gt 0100122594 uondrosoq 4 5 GANNILNO9 39NV3I 21901023 33341 NNAN OS M OILVAII19 NOILVHAIdO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 N OSHA pJeoq O 0 0 Jo 1ndur posruiojsno 03 ndur 29 14 uonemmsuuoo SS I TUER uorsuojxo ot 0 0 JO 1ndur p srtuolsn2 03 jndur 22 14 uonemsuuoo iu ER Pane OSHA uor
56. BP operating pressure BP zo 294 40 3 50 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 7 INSTALLATION TRANSPORT HANDLING 3 1 2 Storage When units are delivered on site they are not always required immediately and are sometimes put into storage In the event of medium to long term storage we recommend the following procedures Ensure that there is no water in the hydraulic systems Keep the heat exchanger covers in position Keep protective plastic film in position Ensure the electrical panels are closed Keep all items and options supplied in a dry and clean place for future assembly before using the equipment It is strongly recommended to store units is a dry sheltered place in particular for units that will be installed indoors 3 2 LIFTING THE UNIT 3 2 1 Safety instructions Installation start up and adjustment of this equipment can be dangerous if certain system specific factors are igno red such as operating pressures electrical components locations roofs terraces and other structures located well above ground level Only highly qualified contractors and technicians with sound knowledge of this type of equipment are authorised to install start up and service it During any service operations observe the recommendations given on labels or instructions sent with the equipment as well as any oth
57. HE COMPRESSOR RUNS IN LONG CYCLES OR RUNS CONTINOUSLY Faulty control thermostat Check operation Temperature too low in the conditioned space Chilled water thermostat set too low Adjust it Bubbles in sightglass Low refrigerant charge Check the refrigerant charge in the sightglass and top up if necessary Filtrer drier partly obstructed Check the drier and replace as required change the filter cartridge Expansion valve partly closed Check expansion valve bulb and capillary measure superheat Liquid line valve not open far enough Open the valve completely Noisy compressor or abnormally high suction pressure or low discharge pressure Leaky compressor valves Check valve gas tightness replace the valve plate if necessary Tighten compressor nuts and bolts E THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH Oil pressure switch tripped Check operation of the oil pressure safety switch Oil level in sightglass is too low Oil pressure too low Check the oil level in the sightglass on the crankcase check the cleanliness of the oil filter check the oil pump Visible oil leak Oil level too low Low oil charge Check that there is no leakage and add oil Leaky oil sump Repair and add oil Suction line unusually cold compressor noisy Liquid refrigerant present in the compressor
58. IT Major technical inspection Inspection of the compressors with replacement of the valves springs seals and gaskets bearings oil discharge valve piston rings Dimensional inspection of the big ends and gudgeon pins replacement of parts as required quotation depending on the type of compressor TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 43 TROUBLESHOOTING REPAIRS LENNOX 8 5 2 LIQUID CHILLERS WITH SCROLL COMPRESSOR S 8 5 2 1 Number of recommended preventive maintenance visits NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up P 2 Inspection visit Tube analysis 1 1 1 2 2 1 3 3 1 3 4 3 5 1 3 10 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 1 10 Every year 3 times a year Every 3 years This table is published for units operating under normal conditions with an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 44 Installation Operation Maintenance manual IOM AIR COO
59. IT START UP LENNOX These verifications should be made as quickly as possible with a stable cooling load i e the cooling load of the installation should be the same as the capacity developed by the unit Measurements taken without heeding this condition will result in unusable and probably wrong values These verifications can only be made once the proper operation of all safety devices and unit controls has been established 5 2 OIL CHARGE Units have a complete operating charge of oil when they are shipped and there is no need to add any oil before start up or afterwards Note that unit shutdowns by the differential oil pressure switch are usually caused by other problems than a lack of oil in the refrigeration circuits Overcharging with oil can cause serious problems on an installation particularly for the compressors The only time any oil might need adding is when a compressor is replaced 5 3 REFRIGERANT CHARGE Self contained units have a complete refrigerant charge at the time they are shipped This charge may need to be topped up when the unit is installed or at other times during the service life of the unit Additional charge can be introduced through the Schrader valves on the suction line Every time fluid is added check the state of the charge with the sightglass provided to that effect on the liquid line and also by the amount of liquid subcooling at the con A denser outlet IMPORTANT Start up and commissioning must
60. LED CHILLERS 8 SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS LENNOX START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system if used Verification of operating parameters and unit performance Transmission of the machine service log 500 1000 H VISITS Post wear in inspection Oil acidity test leak test Replacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges Check up on the microprocessor based management system if used Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 45 TRO
61. LENNOX Installation operating and maintenance AIR COOLED CHILLERS CHILLER_AC IOM 0105 E TABLE OF CONTENTS LENNOX AIR COOLED CHILLERS AND SPLIT UNITS INSTALLATION OPERATION MAI NTENAN CE MAN UAL Ref CHILLERS_IOM 0105 E The present manual applies to the following CHILLERS versions ECOLOGIC range WA WAH RA range LCB MCC range range Our company is a member of the Eurovent Certification Programme all LENNOX chillers are F w tested and rated in accordance with Eurovent certification program Our products comply with the European standards C Product designed and manufactured under a quality management system certified to AFAQ ISO 9001 by AFAQ 150 9001 VERSION 2000 LENNOX have been providing environmental solutions since 1895 our range of air cooled chillers continues to meet the standards that have made LENNOX a household name Flexible design solutions to meet YOUR needs and uncompromising attention to detail Engineered to last simple to maintain and Quality that comes as standard Information on local contacts at www lennoxeurope com All the technical and technological information contained in this manual including any drawing and technical descriptions provided by us remain the property of Lennox and must not be utilised except in operation of this product reproduced issued to or made available to third parties without the prior written agreement of Lenn
62. Max operating pressure Bar 6 0 6 0 6 0 6 0 6 0 6 0 Refrigerant Max operating pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Min flow m3 h 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT Water Max flow m3 h 220 220 220 220 250 250 Operating limits for Pressure gauge control Safety Cut of low pressure Bar 0 7 0 7 0 7 0 7 0 7 0 7 Safety Interlocking of low pressure Bar 2 2 2 2 2 2 2 2 2 2 2 2 Safety Cut of high pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Safety Interlocking of high pressure Bar 20 20 20 20 20 20 62 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 ECOLOGIC REFRIGERATION CIRCUIT LENNOX REFRIGERANT DRAWING STD LN HE SLN 370 STD LN HE SLN Airflow REFRIGERATION CIRCUIT COMPONENTS 1st amp 2nd scroll compressors 3rd scroll compressor on size 370 STD LN HE amp SLN High pressure switch Pressure transducers HP amp BP Low and High pressure mano e 059 meter Suction and discharge isolation valves Safety valve CE or UDT Expansion valve bypass for low Air cooled condenser ambient operations Fan motor Electronic expansion valve Manual isolating valve Evaporator heat echanger Filter drier Suction temperature sensor Soleno d valve External temperature sensor amp G 02 Sight glass Heating resistance option Thermostatic expansion valve GGG VARIANTS EXPANSION DEVICE OPTIO
63. NS Ther Suction Size 370 WA unit Ther mostatic Electronic HP LP and Sight glass BASIC UNIT STD LN CEorUDT mostatic expansion expansion pressure discharge HE SLN expansion valve low valve gauges isolating valve ambient valve 01 03 04a 04b Add 14 amp Add 14 12 Add 16 amp Add 05a amp Add 06a amp 08 09 10 11 17 19 12 815 18 05b 06b Adda Installation Operation Maintenance manual CHILLERS ANNEXES 0105 65 ECOLOGIC REFRIGERATION CIRCUIT LENNOX REFRIGERANT DRAWING 150 200D 230D EFRIGERATION CIRCUIT COMPONENTS 1st amp 2nd scroll compressors Air cooled condenser Evaporator External temperature sensor High pressure switch Fan motor Check valve Pressure transducers HP amp BP Manual isolating valve Restrictor 4 way inverting valve Low and High pressure mano meter 1 Filter drier Suction and discharge isolation Thermostatic expansion valve valves Safety valve CE or UDT 17 Evaporator Condenser heat ex Heating resistance option changer Liquid receiver 8 9 9 9 9 08 BASIC UNIT VARIANT OPTIONS Basic unit CE or UDT HP LP pressure gauges Suction and discharge isolating valves 01 03 04a 04b 19 22 08 07a 07b Add 06a 06b Add 05a 05b 09 10 11 23 20 17 14 21 66 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 REF
64. RIGERATION CIRCUIT REFRIGERANT DRAWING LENNOX STD LN HE SLN 1370 STD LN HE SLN IRFLOW Airflow AIRFLOW 1st amp 2nd scroll compressors Pressure transducers HP amp BP Low and High pressure mano 052 058 meter Suction and discharge isolation valves 3rd scroll compressor on size 370 STD LN HE amp SLN High pressure switch REFRIGERATION CIRCUIT COMPONENTS Safety valve CE or UDT Air cooled condenser Fan motor Manual isolating valve Q Filter drier 12 Soleno d valve 13 Sight glass Suction temperature sensor External temperature sensor TD Heating resistance option VARIANTS OPTIONS Size 370 WA unit Suction and dischar BASIC UNIT HAN TEST GEHE me ge isolating valve Sight glass 01 03 04a 04b 08 09 10 11 12 18 19 Add 02 07a or 07b Add 05a amp 05b Add amp 06b Add 13 67 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 REFRIGERANT DRAWING SCREW COMPRESSOR LENNOX STANDARD HIGH AMBIENT LOW NOISE Refrigeration Circuit Component Screw compressor High pressure switch Pressure transducers HP amp BP Low and High pressure mano es 659 moter Suction and discharge isolation valves Safety valve CE or UDT Air cooled condenser Electronic expansion valve Fan motor Shell and tube evaporator M
65. RS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT HANDLING LENNOX 3 3 LAY OUT AND INSTALLATION REQUIREMENTS The following preparations are important for the installation of the chiller Air cooled chillers such as Ecologic or Ecomax are designed for outdoor installation Please consult Lennox prior to implementing other types of installation Locate the chiller where it is least affected by wind install windbreaks where wind speeds gt 2 2 m s The ground beneath the unit must be flat level and of sufficient strength to support the weight of the unit with its full liquid charge and the occasional presence of the usual service equipment In locations exposed to frost the supporting surface if the unit is installed on the ground must be built on concrete stakes extending downwards beyond the normal depth of frost It is always advisable to build a supporting surface detached from the general building structure to avoid transmission of vibrations On normal applications unit rigidity and point load positions enable installation to minimise vibrations Vibration isolators may be used by contractors on installations requiring particularly low vibration levels Use of vibration isolators MUST be accompanied by installation of flexible connections in the unit water piping Vibration isolators must also be fixed to the unit BEFORE bein
66. SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION M SUCTION PRESSURE IS TOO HIGH The compressor runs continuously Too much cooling demand on the evaporator Check the system Suction line unusually cold Liquid refrigerant returns to compressor a Expansion valve opened to far a Adjust superheat and check that the expansion valve bulb is correctly fitted in place b Expansion valve blocked in open position b Repair or replace N SUCTION PRESSURE IS TOO LOW Bubbles in sightglass Low refrigerant charge Repair the leak and add refrigerant Excessive pressure drop across the filter drier or the solenoid valve Filter drier obstructed Replace the cartridge No refrigerant passing through the expansion valve Expansion valve bulb has lost its charge Replace the bulb Loss of capacity Expansion valve obstructed Clean or replace Conditioned space too cold Compressor short cycling Superheat value too high Control thermostat contacts stuck in closed position Capacity modulation setting too low Excessive pressure drop in the evaporator Repair or replace Adjust Check the external equalizing line on the expansion valve Low pressure drop in the evaporator Low water flow Check water flow Check the condition of the filters look for obstructions in the chilled water c
67. TRIES www lennoxdistribution com Due to Lennox s ongoing commitment to quality he Specifications Ratings and Dimensions are subject to change without notice and without incurring liability mproper installation adjustment alteration Service or maintenance can cause property damage or personal injury nstallation and service must be performed by a qualified installer and servicing agency
68. UBLESHOOTING REPAIRS 8 5 3 LIQUID CHILLERS WITH SCREW COMPRESSOR S 8 5 3 1 Number of recommended preventive maintenance visits LENNOX NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up technical Inspection visit Tube analysis inspection 1 1 1 2 1 3 1 3 3 1 3 19 1 3 3 1 1 1 3 1 3 Every year 3 times a year Every 3 years This table is published for units operating under normal conditions with an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 46 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS LENNOX START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system Verification of operating parameters and unit performance Transmission of the machine service log 500 1000 H VISITS Post wear in inspection Oil acidity test leak test Replacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with rec
69. allation Operation Maintenance manual CHILLERS ANNEXES 0105 CERTIFICATES DECLARATION OD CONFORMITY LENNOX ADV DECONF M001 1 Site industriel de Mions LENNOX Zl Les Meuri res 71 69780 Mions France France T l phone 33 0 4 72 23 20 20 Fax 33 0 4 72 23 04 56 DECLARATION OF CONFORMITY CE The Undersigned Company certifies under its responsibility that the equipment under pressure identified below is in conformity with the requirements of the directive that are applicable EQUIPMENT UNDER PRESSURE N 97 23 CE Description of Equipment Under Pressure and the Procedure of Evaluation to be in Conformity Type of Machine Serial Number Year of Manufacture Cat gorie de la DESP Procedure of Evatuation Module H1 Attestation N Certificat d examen de conception Module H1D Attestation N Description of Components Under Pressure Type of Component Category of Risk COMPRESSEUR SZ 300 EVAPORATOR FILTER DRYER VS489 EXPENSION VALVE TRE 80 TUBE PRESSURE SWITCH P100 SAFETY VALVE 450PSI Name and Address of the Organisation Auditing the Quality Assurance System NF EN ISO 9001 AFAQ F 92224 Bagneux Cedex FRANCE d agr ment QUAL 1993 1009 Name and Address of the Organisation Auditing our Conformity to the Directive of Equipment Under Pressure DI 97
70. an 1 mm and must be positioned within 1 meter of the inlet of the exchanger They may be supplied as an option by the manufacturer LACK OF FILTER AT THE INLET OF A PLATE HEAT EXCHANGER WILL MAKE WARRANTY VOID Hydraulic drawings in Annexes page 50 to 54 or supplied with the unit 3 4 2 Water analysis The water must be analysed the water circuit installed must include all items necessary for treatment of the water filters additives intermediate exchangers bleed valves vents isolating valves etc according to the results of the analysis We do not advise operation of the units with open loops which can cause problems with oxygenation nor operation with untreated ground water Use of untreated or improperly treated water can cause deposits of scale algae and sludge or cause corrosion and erosion It is advisable to call in a qualified water treatment specialist to determine what kind of treatment will be necessary The manufacturer cannot accept liability for damage caused by the use of untreated or improperly treated water salt water or brine 10 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT HANDLING LENNOX 3 4 3 Antifreeze protection 3 4 3 1 Use glycol water solution ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZING The glycol water solution must be sufficiently concentrated to ensure proper protection and pre
71. anometer or valve isolation valve lock coupling manometer kit for groove 13b 14 15a 15b 16 lock coupling Add 02 18 Add 02 12 18 Add 01 16 Add 04a 17a Ada T Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 51 ECOLOGIC HYDRAULIC HYDRONIC DATA LENNOX UNIT WITH HYDRAULIC MODULE STD LN HE SLN lt 99 5 ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT Groove lock coupling Paddle flow switch Single pump Unit isolation valve 25L expansion vessel Double pump Water inlet filter Second 25L expansion vessel for Air purge WA gt 150D In Out manometers without Single 50L expansion vessel Temperature sensor return groove lock coupling option WA lt 150D In Out manometers mounted on Temperature sensor supply groove lock coupling option Plate heat exchanger OPTIONS Expansion vessel Flow sich water inlet filt Expansion vessel other Single or double pump paddle mounted 25L or all other 075 090 100 110 WA units HE amp SLN Add 11b Add 10 amp 11a Inlet Outlet Unit isolation valve Kit for groove lock Inlet Outlet manometer kit 14 15a 15b 16 13a or 13b coupling manometer for groove lock coupling Add 02 18 Add 01 19 Add 04a 17a Ang nr 5 52 Installation Operation Mai
72. anual isolating valve Economiser heat exchanger Filter drier Temperature sensors Solenoid valve External temperature sensor Sight glass Water differential pressure switch Thermostatic expansion valve GG 9 2 9 8 9 3 3 C9 9 9 Heating resistance option VARIANTS EXPANSION DEVICES OPTIONS Basic Unit LCH with Eco LCH Unit Thermostatic Electronic HP LP Pressure Suction Isolating CE or UDT Expansion valve Expansion valve Gauges valve 01 03 04a 04b 08 09 Add 07a Add Add Add Add 10 11 12 16 06a 13 17 14 10 or 07b 14 15 05a or 05b 06b 68 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 REFRIGERANT DRAWING PISTON COMPRESSOR LENNOX STANDARD HIGH AMBIENT LOW NOISE AIRFLOW Refrigeration Circuit Component Screw compressor switch Pressure transducers HP BP oil isolation valves HP BP and oil pressure Pressure indicator HP Suction and discharge Safety valve CE or UDT Air cooled condenser Fan motor Manual isolating valve Filter drier Solenoid valve Sight glass Thermostatic Electronic expan sion valve
73. aporating pressure is greater than the cut in set point of the low pressure switch Check immediately the good rotation of the compressor Evaporating pressure drops steadily the evaporator empties itself of the liquid refrigerant accumulated in it during storage After a few seconds the solenoid valve opens if any 5 b Check on the sightglass upstream of the expansion valve that the bubbles disappear progressively indica ting a correct refrigerant charge and without non condensable gas If the humidity indicator changes colour indicating the presence of humidity replace the filter drier cartridge if the latter is of the replaceable type Even better check the sub cooling after the condenser 5 c Check that when the cooling load has been balanced by the capacity of the unit the chilled liquid is at design temperature 6 Check the current values per phase on each compressor motor 7 Check the current values per phase on each fan motor 8 Check compressor discharge temperature 9 Check compressor oil pump temperatures semi hermetic reciprocating compressors 10 Check suction and discharge pressures and compressor suction and discharge temperatures 11 Check chilled liquid entering and leaving temperatures 12 Check outdoor air temperature 13 Check liquid refrigerant temperature at the condenser outlet 22 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 UN
74. ar 6 0 6 0 6 0 6 0 6 0 6 0 Refrigerant Max operating pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Min flow m3 h 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT Water Max flow m3 h 89 3 89 3 153 5 153 5 153 5 153 5 Operating limits for Pressure gauge control Safety Cut of low pressure Bar 0 7 0 7 0 7 0 7 0 7 0 7 Safety Interlocking of low pressure Bar 2 2 2 2 2 2 2 2 2 2 2 2 Safety Cut of high pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Safety Interlocking of high pressure 20 20 20 20 20 20 LCH 702V 752VE 803V 853VE 953V 1003VE Operating Timits for Evaporator Water Test pressure Bar 10 10 10 10 10 10 Refrigerant Test pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Max operating pressure Bar 6 0 6 0 6 0 6 0 6 0 6 0 Refrigerant Max operating pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Min flow m3 h 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT 8 C AT Water Max flow m3 h 153 5 153 5 153 5 153 5 180 180 Operating limits for Pressure gauge control Safety Cut of low pressure Bar 0 7 0 7 0 7 0 7 0 7 0 7 Safety Interlocking of low pressure Bar 2 2 2 2 22 2 2 2 2 2 2 Safety Cut of high pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Safety Interlocking of high pressure Bar 20 20 20 20 20 20 LCH 1053V 1153VE 1254V 1354VE 1404V 1504VE Operating limits for Evaporator Water Test pressure Bar 10 10 10 10 10 10 Refrigerant Test pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water
75. ay g 1699 Avpoy L HOMO 9595 Kepay 9 895 Z 6 HOMO YEOT 1 Ke oy r 595 21815 AS ISTI CLOT 3WIS Z QUE 1896 guo 0692 mor ueq Z GANNILNO9 XVWOO3 334 1 NNW OS 2ILVWITO NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 84 ATIS ne R 1osso1duroo YIM spun 104 ON S9 ETSE soseis 1 i ON S9A 8 uorsuedxo 00021180007 0 1085530101 N S9A I 1 8 0086 Z 3 9 07 1081981101 Jo 8 S JO Sd T T9 e 0 9513 ZISE ZIS Z pour mr uongemsamuo 0 TISE 8 1 0186 JuN T I TAT dH Ix 05 2 7196 ADOEOY T DR ET A mod 195 ommssord qS dH lx 08 q 1196 puo 46 TAN 155 xouuTT AAA x 666 I 0 s SISE q 3039 218970 Jos XOUUS AAA 1 666 08 0 S VISE Lr 107297 1200110004 rod 195 AWA lx 666 gt 0 EISE dt mod jos xouuoT AAA x 66 0 0 ZISE ouoz peaq c Turod 155 75 5685 AAA ST 2e TISE 1 OISE 80009 1 Do ZA 43 un IW L 7 OF SUIP4052D
76. be conducted by LENNOX authorised engineer Never shut of power to the crankcase heaters except for lengthy service operations or seasonal shu Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E 23 OPERATION LENNOX 6 OPERATION 6 1 CLIMATIC CONTROL cf See the specific CLIMATIC 50 manual cf See the specific Basic CLIMATIC controller manual 6 1 1 Menu Tree ECOLOGIC range See Annexes page 70 to 78 6 1 2 Menu Tree ECOMAX range See Annexes page 79 to 90 6 1 3 Connection diagrams CLIMATIC 30 Aremote controller is offered as an option To install this optional remote controller proceeded as follow Connect exactly as indicated in electrical diagram The wire should not exceed 50 m The three cables for connection from the keypad to the power board must be kept separate from other cables using an individual cable channel and use shielded cables with a cross section of 1 Electrical box at the unit Terminal block Remote controller optional 25 771 N SX p Three lead shielded cable with a cross section of 1mm2 Connection to be made by user MAXIMUM LENGTH 50m 24 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 LENNOX OPERATION 6 1 4 Connection diagrams CLIMATIC 50 Y8 EB
77. cating D8 Copeland Mobil EAL Arctic 22 R407C Maneurop 160 SZ 16 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 LENNOX INSTALLATION TRANSPORT HANDLING LENNOX 3 7 7 Air cooled condensers An air cooled condenser connected to a unit must have the same number of circuits as the unit Selection of the condenser must be made carefully to enable transfer of the heat capacity of the unit even at the highest temperatures expected on an installation It is mandatory to control the head pressure in order to enable the unit to operate properly whatever the season A variety of different systems may be used but the most simple and efficient of these modulates fan operation using a pressure or temperature control For condensers fitted with a small number of fans 1 or 2 it may be necessary to vary the fans speed Head pressure control systems that operate by flooding the condenser with liquid refrigerant should be avoided since they entail very large refrigerant charges and can cause serious problems if they are not correctly controlled 3 8 DUCTED UNITS INSTALLATION Air outlet duct Unit Auxiliary drip tray heat pump unit Air inlet duct Notes carefull of air cycling between inlet and outlet For air outlet it is recommended to duct each fan separately Ins
78. dd heat conducting paste to improve contact Make sure all sensors are correctly fitted and that all capillary tubes are fastened 18 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 PRELIMINARY LENNOX The technical data printed at the top of the wiring diagram should correspond with those indicated on the unit nameplate 3 Make sure that the power supplied to the unit corresponds to its operating voltage and that phase rotation corresponds to the direction of rotation of the compressors screw amp scroll 4 Make sure that the water circuits mentioned in 1 are completely filled with water or brine as the case may be with the air bled out of all high points including the evaporator ensuring they are perfectly clean and leaktight In the case of machines with water cooled condensers the condenser water circuit must be ready to operate filled with water pressure tested bled filter cleaned after 2 hours of operation of the water pump Cooling tower in operating condition water supply and overflow checked fan in operating condition 5 Reset all manually resetting safety devices where necessary Open power circuits to all components compressors fans 6 Power up the unit with the main disconnect switch option Visually check the oil level in the compressor crank cases bullseyes This level may vary from one compressor to another but should never be higher
79. de mark LENNOX Description des quipements Ensemble sous pression Equipment description Identification des quipements concern s liste en annexe le cas ch ant Suivant liste en annexe Identification of equipment concerned list attached where necessary Num ro s d attestation s d examen CE de la conception mise s dans le cadre de l application du module H1 par BUREAU VERITAS organisme notifi n 0062 concern e s par l approbation du syst me de qualit Number s of the EC design examination certificate s Issued under Ihe scope of module H1 by BUREAU VERITAS S A notified body nr 0062 concerned by the approval of he quality system Cette attestation est valable jusqu au 02 09 2005 This certificate is valid until Le maintien de l approbation est soumis la r alisation par le Bureau Veritas des audils essais et v rifications selon le contrat sign par le fabricant et le Bureau Veritas The approval is conditional upon the surveillance audits tests and verifications to be carried out by Bureau Veritas as per the provisions stated in the agreement signed by both the manufacturer and Bureau Veritas Cette attestation est pr sum e nulle et fe fabricant supportera seul les cons quences de son ulilisalion i les assurances donn es par le fabricant lors de la demande d intervention en mati re a d application de son syst me qualit approuv b de conformit de son quipement so
80. e delay between starting the first winding and the second winding cannot exceed 0 8 seconds 6 2 2 6 Chilled liquid pump interlock This interlock is made only if the the pump is supplied with the liquid chiller As soon as the unit is powered up and the remote on off for the unit is validated the pump starts running Prior operation of the pumps is mandatory for compressor operation Note on units with CLIMATIC control control of 1 or 2 water pumps is catered for by the control program 6 2 2 7 Flow switch for the chilled liquid option This control device initiates unconditional unit stoppage as soon as the flow of chilled liquid water brine etc ensured by the pump becomes insufficient since this could cause rapid evaporator freeze up When the contact opens due to a lack of flow the unit must stop immediately If the purchaser installs a flow switch himself electrical connections should be made to the two remote interlock terminals dry contact Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 27 OPERATION LENNOX 6 2 3 Automatic sequences 6 2 3 1 Starting sequence Press the unit start switch the power light will come on The control circuit cannot be energised if there is no power supply to the main power circuit Depending on the demand for cooling the control thermostat authorises start up of the compressor s which takes place in seq
81. e water pump and water circuitry and filters Flow switch contacts open Find the cause of the trip out Check circulation of liquid in the evaporator and the condition of the flow switch Anti short cycle relay action Wait until the anti short cycle time delay has expired Faulty control thermostat Check for proper operation set points contacts Oil pressure switch tripped Check the oil pressure switch and determine the cause of the trip out Antifreeze thermostat or low pressure safety switch tripped Check evaporating pressure the condition of the antifreeze thermostat and the low pressure safety switch Compressor thermal protection relay tripped High pressure safety switch tripped Check for proper operation of the relay Check the condensing pressure and the condition of the high pressure safety switch Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 33 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION B THE COMPRESSOR DOES NOT START Low pressure safety switch trip out Check low pressure safety switch differential Normal operation with too frequent starts and stoppages due to action of the low pressure safety switch Bubbles in sightglass
82. ed on groove lock coupling 12 Water drain option Paddle flow switch 13 Air purge OPTIONS Water Flow Switch Flow Switch Unit Kit for Inlet Outlet Inlet Outlet Basic Unit Inlet Filter Paddle differential Isolation Groove Lock Manometer Manometer kit for 1 2 Valve Coupling Groove LockCoupling Add 06 07 070 Add Add Add Add Add Add 13 12 03 05 08 02 10 01 11 04a 04b 09b 01 11 1 Supplied Loose 2 Supplied Mounted 54 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 ECOLOGIC OPERATING LIMITS LENNOX STANDARD ECOLOGIC WA WA 150 200 230 270 370 Minimum outlet water temperature C 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C 8 Minimum outside air temperature C 6 Minimum outside air temperature with low ambient kit C 10 Maximum outside air temperature Normal operation with CLIMATIC 30 12 C water inlet 7 C water outlet C 43 44 44 44 43 43 Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 51 59 59 51 51 48 Start up with CLIMATIC 30 Thermostatic expansion valve and NO unloading C 37 39 39 38 36 37 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded C 49 46 46 48 48 45 Start up with CLIMATIC 50 Electronic expa
83. emperature Es 20 20 20 20 20 Min difference water 3 3 3 3 3 Max difference water inlet outlet 8 8 8 8 8 Min outside air temperature 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 Max outside air temperature 2 C 55 1 With low temperature kit 2 Unloading start up sequence Installation Operation Maintenance manual CHILLERS ANNEXES 0105 61 OPERATING LIMITS LENNOX LCH VK PK STD LN HA LCH 322P 412P 462P 532P 402V 422VE Operating limits for Evaporator Water Test pressure Bar 10 10 10 10 10 10 Refrigerant Test pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Max operating pressure Bar 6 0 6 0 6 0 6 0 6 0 6 0 Refrigerant Max operating pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Min flow m3 h 8 C AT 8 C AT 8 C AT 8 C AT 8 AT 8 Water flow m3 h 99 3 Tom 1935 1995 399 893 Operating limits for Pressure gauge control Safety Cut of low pressure Bar 07 0 7 07 07 07 07 Safety Interlocking of low pressure Bar 2 2 22 22 22 22 22 Safety Cut of high pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Safety Interlocking of high pressure Bar 20 20 20 20 20 20 LCH 442V 452VE 502V 552VE 602V 652VE Operating Timits for Evaporator Water Test pressure Bar 10 10 10 10 10 10 Refrigerant Test pressure Bar 26 5 26 5 26 5 26 5 26 5 26 5 Water Max operating pressure B
84. er applicable safety procedures Follow all safety rules and regulations Wear protective glasses and work gloves Handle heavy or bulky equipment carefully during lifting and moving operations and when setting it on the ground A CAUTION BEFORE EACH SERVICE OPERATION MAKE SURE THAT THE UNIT POWER SUPPLY IS PROPERLY ISOLATED AND LOCKED OUT NOTE SOME UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPA RATE ISOLATION PLEASE CHECK THE WIRING DIAGRAM 3 2 2 Handling Handling operations must be carried out by qualified personnel Comply strictly with lifting instruction pasted on the unit Unit handling operations must be carried out carefully to avoid jolting the frame the panels the electrical box the condenser coil fins etc NOTE The heat exchangers of the condensers could be protected from damage during transport by plastic plates The machine is also wrapped in packing foil It is recommended to leave this protection in place during any transport and lifting operations and not to remove the plastic plates until commissioning take care that the protecting foil wrapping is not blown away NOTE Rubber anti vibrations mountings AVM amp factory accessories are to be found in the control panel for shipping If the unit is mounted on anti vibration mountings these should be fitted to the unit before final positioning 8 Installation Operation Maintenance manual IOM AIR COOLED CHILLE
85. evice is used see case 1 and 2 cut out by the antifreeze function causes immediate unit stop page CASE 1 Antifreeze thermostat This device monitor chilled liquid temperature at the evaporator outlet It triggers when the temperature goes below the minimum value 4 C for water CASE 2 Antifreeze pressure switch This monitors evaporating pressure of the refrigerant It triggers when the temperature goes below the preset mini mum value Note On units fitted with CLIMATIC control see the appropriate user manual for more specific details 26 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 OPERATION LENNOX 6 2 1 9 Differential oil pressure safety switch only on units with semi hermetic compressors a Reciprocating compressors This pressure switch initiates unconditional unit stoppage if differential oil pressure drops for more than two minutes below a pre established minimum safety value Differential oil pressure is the difference between the oil pump discharge pressure and the gas pressure inside the compressor crankcase suction pressure The differential oil pressure safety switch is factory set and is not modifi able on site b Screw compressors This pressure switch initiates unconditional unit stoppage if differential oil pressure rises above a preset safety value Differential oil pressure in this case is high pressure less the compressor oil injec
86. f bubble free liquid in the sight glass indicating that there is sufficient charge and controlled that sub cooling is correct according to the system design value In all cases do not top up the charge until the unit reaches a stable state of operation It is pointless to overcharge a system this can adversely affect operation Overcharging causes Excessive discharge pressure Arisk of damage to the compressor Excessive power consumption 3 7 6 Oil charge All units are delivered with a complete oil charge In the case of split units it may be necessary due to the length of piping installed to add a certain amount of oil compatible with the type of compressor and refrigerant used Please refer to the following oil table Note This table is valid for self contained chillers only or chillers mounted on receivers on which the leaving water temperature is not lower than 5 C For other cases consult the documentation shipped with the machine Oil recommendation for Lennox chillers Refrigerant Compressor type Brand Oil type R22 Bitzer B320SH R22 Scroll SM Maneurop Maneurop 160 P R22 Scroll ZR Copeland Suniso 3 GS R22 Reciprocating D8 Copeland Suniso 160P R22 Reciprocating MT Maneurop Maneurop 160 P R407C Screw CSH Bitzer BSE170 R407C Scroll SZ Maneurop Maneurop 160 SZ R407C Scroll ZR Copeland Copeland 3MA Mobil EAL Arctic 22CC ICI Emkarate RL32CF R407C Recipro
87. g fixed to the ground Selection of vibration absorbing isolator capacity is not LENNOX s responsibility The unit must be bolted to the vibration isolators and the latter solidly fixed into the concrete slab Check that vibration isolator contact surfaces fit flush to the floor If necessary use spacers or re surface the flooring but in all events make sure that the isolators seat flatly on the supporting surface It is essential that the units be installed with sufficient free space around them to enable proper circulation of air ejected by the condensers and to provide easy access to all unit components for servicing and maintenance If the air rejected by the condenser encounters any obstacles it will tend to be recycled by the fans This will cause an increase in the temperature of the air used to cool the condensers Obstruction of the air outlet will also impair air distribution across the entire heat exchanging surface of the condenser Both of these conditions which reduce the heat exchange capacity of the coils will cause an increase in condensing pressure This will lead to a loss of capacity and an increase in compressor power input To prevent air flow to be reversed due to prevaling winds units cannot be completely shrouded with a higher uninterrupted wind shield If such a configuration cannot be avoided an air ejection duct must be installed at the same height as the surrounding shield It is important that units must
88. gram below figure 14 the following ratio remains the same A mm 20 P mm The belts should always be replaced when the disk is set to maximum the belt rubber is worn or the wire is visible Replacement belts must have the same rated size as the ones they are replacing If a transmis sion system has several belts they must all be from the same manufacturing batch compare serial numbers Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 19 PRELIMINARY LENNOX NOTE An under tensioned belt will slip heat and wear prematurely On the other hand if a belt is over tensioned the pressure on the bearings will cause them to over heat and wear prematurely Incorrect alignment will also cause the belts to wear prematurely 9a PULLEYS ALIGNMENT After adjusting one or both of the pulleys check the transmission alignment using a ruler placed on the inner face of the two pulleys NOTE The warranty may be affected if any major modification is made to the transmission without ob taining our agreement beforehand The actual resistance of ductwork systems is not always identical to the calculated theoretical values To rectify this it may be necessary to modify the pulley and belt setting To this effect the motors are fitted with variable pulleys 9b AIRFLOW BALANCING Measure the absorbed amps If the absorbed amps are greater than the rated val
89. gt Cooling capacity of the chiller in kW N gt Number of capacity stage of the chiller Dt Water temperature Delta T Vt 72 x Q n x dt itres Example for a chiller with 400kW water conditions 12 C 7 C and 4 capacity stages the minimum volume is Vt 72 x 400 5 x 4 1440 This formula will give the minimum water capacity of the installation that will ensure a temperature rise of the water loop of dt n C during anti short cycle of compressors This formula is only applicable for air conditioning installation and must not be used for process cooling where temperature stability is required 3 4 6 Flow switch Aflow switch must be installed on the evaporator water inlet or outlet so as to enable detection of water flow through the heat exchanger before the unit is started up This will protect the compressors against any eventual liquid slugging during the starting phase and prevent accidental ice formation in the evaporator if the flow of water is interrupted Flow switches are available on option The normally open contact of the flow switch should be connected to the terminals provided to that effect in the unit electrical box See the wiring diagram supplied with the unit The normally closed contact can be used as an indication of a lack of flow condition Warranty is void if a flow detection device is not fitted and connected to the LENNOX control panel 3 5 ELECTRICAL CONNECTIONS First of all make sure
90. guo Teog 9828 oj drusuong ARIS INSEW g T 0 0 557 EZ6E 1 Jojseui SABATR SI uy I I Te 51 oN 85 1 X ZZ65 roquinyy yun SN spun Jo Joquiny 8 1 uoneodo 191581 10 0 WOY r R I Hun 10 ssorpe uoneognuop uonemsuuoo 1 e 10 5801395 JO K1039 OU ST s HOT pue 8 re 103 21915304 o qe reA uoym 31195 NS LISE SPYR 0j jurod 195 TTY JO 19501 SAO V gt XV A jun uondidosoq 0565 0565 0168 SINE JUTT fe dsiq T uondidosoqq 0065 2p09 6 uondiis q 2p09 4 5 GANNILNO9 39NV3I 21901023 33311 NNAN 05 M OILVAII19 NOILV3H3dO Installation Operation Maintenance manual CHILLERS ANNEXES 0105 q 951 5 d 9 q SSIT Sursuopuo d S uonong sp do ESTIT permes oL E do TSIT c Do ISIT yeoHodng OSIT q PINES 4 9 q SYIT Sutsu puoO q c do uonons EPIT POLINES L E do CHIT Sutsu puoO 1 6 IvIc 1 071 lt
91. he sightglass with the machine running at full load Let the compressor operate for 3 to 4 heures before adding any oil Check the oil level every 30 minutes If the level does not reach the level indicated above contact a qualified refrigeration mechanic 2 Overcharging with oil can be as dangerous to a compressor as a lack of oil Before topping up contact a qualified technician Only use oils recommended by the manufacturer See page 15 3 Check the oil pressure 4 The flow of liquid refrigerant through the sightglass should be steady and without bubbles Bubbles are a sign of a low charge a possible leak or of a restriction in the liquid line Contact a qualified technician Each sightglass is fitted with a humidity indicator The colour of the element changes according to the level of hu midity in the refrigerant but also according to temperature It should indicate dry refrigerant If it shows wet or CAUTION contact a qualified refrigeration technician CAUTION When starting up the unit run the compressor for at least 2 hours before taking a humidity reading The humidity detector is also sensitive to temperature and as a consequence the system must be at normal operating temperature to give a meaningful reading 5 Check operating pressures If they are higher or lower than those recorded when the machine was put into service see the chapter 8 6 Inspectthe entire system so as to detect any eventual abnormality no
92. in the sufficiently cooled evaporator adjust it if necessary H COMPRESSOR CUTS OUT THROUGH ACTION OF THE MAIN POWER FUSE Power supply on two phases Check power supply voltage only Faulty motor windings Replace the compressor Compressor seized Replace the compressor I THE COMPRESSOR STARTS WITH DIFFICULTY Faulty windings Replace the compressor Mechanical problem Replace the compressor 36 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE LENNOX RECOMMENDED ACTION J THE COMPRESSOR IS NOISY If starting on a single winding on compressors fitted with part winding start or wye delta Check operation of the starter contacts the start up time delay and the condition of the windings Broken mechanical parts inside compressor Compressor knocking Replace the compressor Suction line is unusually cold a Liquid slugging b Expansion valve blocked in open position Broken suction valves a Check superheat and that the expansion valve bulb is correctly installed b Repair or replace Replace broken valves High discharge pressure The water regulating valve or the pressure operated water valve taps or knocks Pressure operated water
93. ing all units in perfect operating condition since too many factors depending on local conditions specific to the installation the way the machine is operated the frequency of operation climatic conditions atmospheric pollution etc Only trai ned experienced personnel can establish strict maintenance procedures adapted to the conditions listed above Nonetheless we recommend a regular maintenance schedule 4times a year for chillers operating all year long 2 times a year for chiller that only operate during the cooling season All operations must be performed in conformity with the maintenance plan this will extend the service life of the unit and reduce the number of serious and costly breakdowns It is essential to keep a service log for weekly records of operating conditions of the machine This log will serve as an excellent diagnostic tool for maintenance personnel likewise the machine operator by noting down changes in machine operating conditions will often be able to anticipate and avoid problems before they actually occur or worsen The manufacturer cannot be held responsible for any malfunctioning of any equipment it provides if it is caused by a lack of maintenance or by operating conditions beyond those recommended in this manual Shown below and as an illustration only are some of the most common rules applied for maintenance 7 1 WEEKLY MAINTENANCE 1 Check the compressor oil level This should be half way up t
94. ircuit piping 38 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS LENNOX 8 2 CONTROL DEVICES Operation By reacting to compressor discharge pressure the high pressure switch monitors efficiency of the condenser Poor efficiency the result of an excessive condensing pressure is usually caused by Adirty condenser Low water flow Low air flow The low pressure switch monitors the pressure at which the refrigerant evaporates in the evaporator tubes Low evaporating pressure is usually caused by Low refrigerant charge A faulty expansion valve An obstructed liquid line filter drier Adamaged compressor cylinder bank unloader The control thermostat monitors chilled water temperature at the evaporator inlet The most common causes of subnormal temperatures in this zone are Low water flow Thermostat setting too low The oil pressure switch monitors oil injection pressure on the compressor Low oil pressure is usually caused by Low oil charge Aworn or faulty oil pump Adefective crankcase heater causing condensation of refrigerant in the oil sump The above information does not represent a complete analysis of the refrigeration system It is intended to familiarise the operator with unit operation and to provide him with the technical data required to enable him to recognise correct or report a fault
95. is not responsible for off loading and positioning 3 1 1 1 Unit Nameplate The rating plate provides a complete reference for the model and ensures that the unit corresponds to the model ordered It states the electrical power consumption of the unit on start up its rated power and its supply voltage The supply voltage must not deviate beyond 10 10 The start up power is the maximum value likely to be achieved for the specified operational voltage The customer must have a suitable electrical supply It is therefore important to check whether the supply voltage stated on the unit s rating plate is compatible with that of the mains electrical supply The rating plate also states the year of manufacture as well as the type of refrigerant used and the required charge for each compressor circuit LENNOX 04 72 23 20 20 69780 MIONS FRANCE Unit type WA 230DKLN N Serie Serial N R 125995 01 tse You 0272004 Refrigerant Fluide Nombre de circuits Circuits N R 2 Kg Cireuit Pression Max service HP Max operating pressure HP bar frigo nominale Ke Ee 400 3 50 230 1 50 Valeur alim principalelauxiliaire w Temp Air ambiant Maxi Air ambiant temp Maxi Poids nit weight Type compresseur Clinpresser type Pression d eprouve Test pressure Pression d Br rd I Pression service HP Max operating pressure HP Pression Max service
96. isy compressor loose casing panels leaky pipes or juddering contacts 7 Record temperatures pressures dates et times and any other observations in the service log 8 Leak detection is recommended 7 2 ANNUAL MAINTENANCE On units with water cooled condensers it is important that the unit be serviced regularly by a qualified technican at least once every year or every 1000 hours of operation Failure to observe this rule can lead to cancellation of the warranty and will clear LENNOX of whatever responsibility A service visit by a qualified technician is also recommended after the first 500 hours of operation after the unit is first put into service 1 Inspect valves and piping Clean the filters if necessary clean the condenser tubes see cleaning the condenser 87 3 2 Clean the chilled water piping filters CAUTION The chilled water circuit may be pressurised Observe the usual precautions when depressurising the circuit before opening it Failure to observe these rules could lead to accidents and cause injury to service personnel 3 Clean any corroded surfaces and repaint them Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 31 MAINTENANCE LENNOX 4 Inspect the chilled water circuit for any signs of leakage Check operation of the water circulating pump and its ancillaries Check the percentage of antifreeze in the chilled water circuit top up as neces
97. it entrance The components are located inside the units and must be installed by qualified engineer These filters must remove all particles with a diameter greater than 1 mm 4 5 CHECK LIST BEFORE START UP Before proceeding with start up even for a test of short duration check the following points after having made sure that all the valves on the refrigeration circuit are fully open discharge valves and liquid valves Starting up a compressor with the discharge valve closed will either trip the HP safety switch or blow the cylinder head gasket or the internal pressure safety disc 1 The liquid pump s and other apparatus interlocked with the unit coils air handling units dry coolers cooling towers terminals such as fan coil units etc are in working order as required by the installation and according to their own specific requirements Place all water valves and refrigerant valves in their operating positions and start the water circulating pumps Ensure main power supply is isolated before any work is started Ensure unit is correctly earthed and that earth continuity is correctly done Check that anti vibration mountings are installated and set 2 Check the cleanliness and the tightness of all electrical connections both the connections made at the factory and the connections made on site Also make sure that all thermostat bulbs are correctly inserted and tightened in the various wells if necessary a
98. ith the compressor crankcase heaters activated for as long as it takes to bring oil back up to temperature then restart the unit 6 2 3 5 Pressostatic water valve This device is available as an option for low capacity water cooled condensing units MCW The pressostatic water valve should be installed on the condenser outlet It enables water flow through the heat exchanger to be varied so as to maintain condensing pressure at an appropriate value 6 2 3 6 Fan motor control ECOLOGIC Fans electrical box labelling 1500 WAIRA 2700 WAIRA 3000 2000 VENT1 C1 WAIRA 2300 VENT1 C2 VENT1 C1 ve p FRIC2 VENT1 C1 1 2 except EAJ except LN c1 c2 VENT C1 C2 except PR except LN v FR C1 except LN VENT2 C1 VENT2IC2 VENT2IC1 5 VENT2 C2 e VENT1 C2 VENT3 C1 use VENT3 C2 28 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 WAIRA 3700 VENT1 C1 FRIC1 except LN VENT1 C2 FRIC2 except LN 9 BOR VENT2 C1 VENT2 C2 VENT3 C1 VENT3 C2 100E WAJRA 110E WAIRA 75E 90D 1300 150D VENT3 C1 VENT2 C1 i VENT1 C1 M33 VENT1 C2 FR C1 2V FR C2 VENT2 C1 VENT1 C1 Cp 1 VENT2 C1 2 M
99. l CHILLERS ANNEXES 0105 72 73 HOMO 595 fejost HOMO 92 2781 S c ASIT ZEIT 9J01S Z ASIT 1595 ByuoD 0595 I ueq c HOMO 7595 AB Y HOMO 5595 2781 S c ASIT 9 9J01S Z ASIT 1797 34u09 0595 I ueq Z 195 JENPOIN S HOMO 7192 HOMO 195 2781 MS ASIT Z19Z 9J01S Z ASIT 1192 3 105 1 0197 UBJ T 0097 9 ETST uonisoq c SIT TEST 9J01S Z ASIT 12 lt lt ByuoD 092 C WNOIID Z EISZ uonisoq c TIST 9J01S Z ASIT Sguo I 0155 2 1 0055 GOT QUIL unw 6 897 ssed amp g g LOFT 99 Kejo 9 MOT MS S FOTO vovc d MS t HOMO IS AS COVE 91819 Sguo5 1 0972 TONO 9 XEN ATOPEN um 034115551 12551 09115591 099195 MEN f XONNTI 39NV3 21901023 33441 NNJN OS 4 9ILVWITO NOILVH3Id0O Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E HOMO SILT IIS MS Do Jepno r Do ILT IUT SIT cuc 9101S Z 5511 8yu0 OILZ AIOAODOY 0042 uondO HOMO 7897
100. mum outside air temperature with low ambient kit 10 Maximum outside air temperature Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 53 51 51 54 53 53 51 51 52 53 49 Start up with CLIMATIC 50 Electronic expansion valve and ONE compressor unloaded C 52 49 49 53 52 52 49 49 50 52 46 SUPER LOW NOISE ECOLOGIC WA WA 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C 8 Minimum outside air temperature C 6 Minimum outside air temperature with low ambient kit 10 Maximum outside air temperature Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 52 49 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded C 50 46 46 51 50 49 47 46 48 49 43 Start up with CLIMATIC 50 Electronic expansion valve and one compressor unloaded 51 47 48 52 51 50 48 47 49 50 44 47 1 56 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 ECOLOGIC OPERATING LIMITS LENNOX ECOLOGIC WAH COOLING MODE WAH 150 200 230 Minimum outlet water temperature 5 Maximum inlet water temperature C 20
101. n approbation CE de la canceplion et d inspeclion et d essais des produits finis se r v lent inexactes et de mani re g n rale si le fabricant ne respecte pas l une ou l autre des obligalions mises sa charge par la directive n 97 23 CE du 29 mal 1997 telle que transpos e dans le s droit s nationat aux applicabfe s This certificate shall be deemed to be void and the manufacturer shall alone bear any consequences pursuant to its use where the manufacturer fails fo comply with his undertakings as per he agreement in respect of a implementalion of the approved quality system b conformity of the equipment with the EC design approval conditions and inspection and tests on the final product and generally where the manufacturer faits In particular to comply with any of his obligations under directive nr 97 23 EC of 29 may 1997 as transposed in the applicable lavi s Le Sign par Signed b sie a 3 2 02 SEPTEMBRE 2002 P BERIOU p _ Y LE Code d enregistrement Registration code 2002 3948 Etabli Made at LYON DARDILLY La pr sente altestalion esi soumise aux Conditions G n rales de Service de Bureau Veritas jointes la d intervention sign e demandeur This certificate is subject to the terms of Bureau Veritas General Conditions of Service attached to the agreement signed by the applicant PRTPV112 2 Page 1 2 bttp www bureauventas com ped Inst
102. n phase 2 per compressor A Current on phase 3 per compressor Liquid line temperature Bar Evaporator pressure drop C Chilled water temperature C Leaving chilled water temperature Bar Condenser pressure drop Condenser entering water Condenser leaving water temperature pressure switch cut out Bar H P pressure switch cut in Bar Low pressure switch cut in Bar Oil pressure switch cut out Bar Antifreeze pressure switch cut out Bar Fan 2 3 Fan 4 40 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS 8 4 REGULAR CHECKS TO BE MADE CHILLER UNIT ENVIRONMENT CHILLED WATER CIRCUIT VALUE Inlet Outlet pressure guages for pressure drop Evaporator inlet temperature Evaporator outlet temperature Glycol concentration 1 Flow switch Chilled water pump interlock Filter On water uu n s Da Pace e Tr NEP rd CONDENSER WATER CIRCUIT Inlet Outlet pressure guages for pressure drop Condenser inlet temperature Condenser outlet temperature
103. ng Sharp voltage parts parts Check regularly that the warning labels are still in the correct positions on the machine and replace them if neces sary Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT HANDLING LENNOX 3 INSTALLATION 3 1 Transport Handling 3 1 1 Controls and delivery checks On receipt of a new equipment please check the following points It is the customer s responsibility to ensure that the products are in good working order fill the check list page 48 The exterior has not been damaged in any way The lifting and handling equipment are suitable for the equipment and comply with the specifications of the handling instructions enclosed here in Accessories ordered for on site installation have been delivered and are in good working order If the unit is delivered with its operating charge of refrigerant that there has been no leakage use an electronic detector The equipment supplied corresponds to the order and matches the delivery note If the product is damaged exact details must be confirmed in writing by registered post to the shipping company within 48 hours of delivery working days A copy of the letter must be addressed to LENNOX and the supplier or distributor for information purpo ses Failure to comply will invalidate any claim against the shipping company Please be reminded that LENNOX
104. nsion valve and ONE compressor unloaded C 49 47 47 49 49 46 ECOLOGIC WA 150 200 230 270 370 Minimum outlet water temperature 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C 8 Minimum outside air temperature C 6 Minimum outside air temperature with low ambient kit C 10 Maximum outside air temperature Normal operation with CLIMATIC 30 12 C water inlet 7 C water outlet C 41 43 42 42 41 41 Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 50 48 47 50 50 47 Start up with CLIMATIC 30 Thermostatic expansion valve and NO unloading C 35 37 36 36 33 33 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded C 47 45 44 47 47 43 Start up with CLIMATIC 50 Electronic expansion valve and ONE compressor unloaded C 48 46 45 48 48 44 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 55 ECOLOGIC OPERATING LIMITS LENNOX HIGH EFFICIENCY ECOLOGIC WA WA 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet C Minimum outside air temperature C 6 Mini
105. ntenance manual CHILLERS ANNEXES 0105 ECOLOGIC HYDRAULIC DRAWING UNIT WITH FREE COOLING OPTION WA 150 STD LN LENNOX STD LN HE SLN ITEMS SUPPLIED LOOSE Groove lock coupling Unit isolation valve In Out manometers without 04a ira groove lock coupling option Paddle flow switch mounted on tube Water inlet filter ITEMS MOUNTED INSIDE THE UNIT Plate heat exchanger Temperature sensors Flow switch differential 06000 Free cooling coil Isolating valves Three way valve Drain OPTIONS Paddle flow switch Differential flow BASIC UNIT Water inlet filter switch Unit isolation valve Supplied loose Supplied mounted Add 03 Add 05 Add 22 Add 02 18 Inlet outlet 16 Kit for groove lock Inlet Outlet manometer kit 15a 15b coupling manometer for groove lock coupling Add 01 19 Add 04a 17a pad eo and Installation Operation Maintenance manual CHILLERS ANNEXES 0105 53 HYDRAULIC DRAWING LENNOX STANDARD HIGH AMBIENT LOW NOISE ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT Groove lock coupling Heat exchanger Unit isolation valve Temperature sensors Water inlet filter Differential Flow switch In Out manometers without groove lock coupling option In Out manometers mount
106. nvironments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 42 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS LENNOX START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system if used Verification of operating parameters and unit performance Transmission of the machine service log 500 H 1000 VISITS Post wear in inspection Oil acidity test leak test Replacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges if necessary Check up on the microprocessor based management system if used Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary 15 000 H VISIT Major technical inspection Inspection of the compressor and replacement of valves springs and seals depending on the type of compres sor 30 000 H VIS
107. ord of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges Check up on the microprocessor based management system Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary 30000 H VISIT Replacement of the compressor and return the old one for revision with replacement of bearing and inspection of compressor geometry Major technical inspection Start up of the installation again TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 47 CHECK LIST LENNOX This check list should be filled in by the contractor to make sure that unit installation takes place according to ap propriate industry practices WARNING Disconnect the power supply before carrying out any inspections on the unit If the unit must be left powered up proceed with precaution to avoid risk of electrocution Note some units have a separate control circuit supply that is not isolated when the main power supply is OFF This must be isolated separately RECEPTION
108. otection of operating and main tenance personnel was central in the design of the air cooled chiller Safety features have been included to prevent excessive pressure in the system Sheet metal parts have been fitted to prevent inadvertent contact with hot pipes The fans are equipped with protective grids and the electrical control panel is completely touch proof This excludes some parts operating at a safe voltage lt 50 Volt The service panels can only be opened using tools Notwithstanding that the air cooled chillers are equipped with extensive safety and protection features the utmost care and attention is needed when carrying out operations on the machine Furthermore ear protection should be worn when working on or in the vicinity of the air cooled chillers Operations on the cooling circuit or electrical equipment should be carried out by authorised personnel 2 1 1 Safety Definition The air cooled chillers meet the following safety definitions Pr EN 378 1 EU Directive 89 392 EG Machine Directive EN 60204 1 EMC Directive Pressure Equipment Directive 97 23 CE And is provided with CE markings on the condition that the necessary options are present for further information see declaration 2 1 2 Warning labels The chiller is marked with the following warning labels to alert to potential hazards on or near the potentially haz ardous part A A A High temperatures Electrical Rotati
109. ox Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 1 LENNOX 2 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 TABLE OF CONTENTS PREFACE nm ee uie IRE SUPERO EUR RR EE 4 PED Declaration I eee EET 5 WARRANTY Eve gene 6 2217 Safely v b ups Lp s Blk ra i ber r nr V a Agi d d ed 6 INSTAEEATION eel MAIER ILL EMILE Ue 7 3 1 Transport d DR B 7 3 2 Lifting s o Poe r arb ubed e bes 8 3 3 Lay out and installation requirements 9 3 4 Water connections 10 3 5 Electrical connections 11 3 6 Sound levels 4 uude Ga em RARE FRAME 12 3 7 Connections of split units 12 3 8 Ducted units installation 17 PRELIMINARY CHECKS 18 4 1 EMMIS sis de AERA Esca a As 18 4 2 Refrigeration circuit checks and recommendations 18 4 3 Hydraulic system installation 18 4 4 Installation of external hydraulic components supplied loose by LENNOX 18 4 5 Check list before start up
110. sary if antifreeze is used 5 Carry out all weekly maintenance duties The first and last inspection will include the seasonal shutdown procedure or the restarting procedure depending on the case These inspections should include the following operations Check the contacts of motor contactors and control devices Check the adjustment and operation of each control device Conduct an oil analysis to determine the acidity Record the results Chanage the oil if necessary WARNING Oil analyses should be carried out by a qualified technician Misinterpretation of the results could cause damage to the equipment Also analysis operations should be conducted according to the right procedures so as to avoid accidents and potential injury of service personnel Follow the recommendations given by LENNOX as concerns compressor oil see the appropriate table Conduct a refrigerant leak test Check motor winding isolation Other operations may be necessary depending on the age and the number of hours of operation of the installa tion 7 3 CLEANING THE CONDENSER 7 3 1 Air cooled condensers Clean the coils either with a vacuum cleaner cold water compressed air or with a soft brush non metallic On units installed in a corrosive atmosphere coil cleaning should be part of the regular maintenance program On this type of installation all dust gathered on the coils should be quickly removed by regular cleaning Caution do no
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112. t use high pressure cleaners that could cause permanent damage to the aluminium coil fins 7 3 2 Multitube water cooled condensers Use a cylindrical brush to remove sludge and other substances in suspension inside the condenser tubes Use a non corrosive solvent to remove scale deposits The water circuit in the condenser is manufactured in steel and copper A water treatment specialist given the right information will be able to recommend the right solvent for removing scale The equipment to be used for external water circulation the quantity of solvent and the safety measures to be taken must be approved by the company supplying the cleaning products or by the company conducting these operations 7 4 COMPRESSORS OIL DRAINAGE Oil for refrigeration equipment is clear and transparent It keeps its colour over a long period of operation Given that a correctly designed and installed refrigeration system will operate without any problems there is no need to replace the compressor oil even after a very long period of operation Oil that has become dark in colour has been exposed to impurities in the refrigeration piping system or to excessive temperatures on the discharge side of the compressor and this inevitably impairs the quality of the oil Darkening of the colour of the oil or degradation of its qualities can also be caused by the presence of humidity in the system When the oil has changed colour or has been degraded it must be changed
113. tallation Operation Maintenance manual CHILLERS ANNEXES 0105 E 91 CERTIFICATES PED LENNOX 92 BUREAU VERITAS S A 2001 Bureau Veritas S A is a Notified Body under the number 0062 BUREAU VERITAS ATTESTATION D APPROBATION DE SYSTEME DE QUALITE module H1 CERTIFICATE OF QUALITY SYSTEM APPROVAL module H1 CE PED H1 LEN001 02 FRA BUREAU VERITAS agissant dans le cadre de sa notification num ro d organisme notifi 0062 atteste que le syst me de qualit appliqu par le fabricant pour la conception fa fabrication l inspection finale et les essais des quipements sous pression identifi s ci apr s a t examin selon les prescriptions du module H1 de l annexe III de la directive Equipements sous pression N 97 23 CE et est conforme aux dispositions correspondantes de la directive BUREAU VERITAS S A acting within the scope of its notilication notified body number 0062 attests that the quality system operated by the manufacturer for design manufacture final inspection and testing of the pressure equipment identified hereunder has been examined against the provisions of annex Hi module H1 of the Pressure Equipment directive n 97 23 EC and found to satisfy the provisions of the directive which apply to it Fabricant nom Manufacturer narne LENNOX France Usine de MIONS Adresse Address 2 1 Les Meuri res BP 71 F 69780 MIONS Marque commerciale Tra
114. tallation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 17 PRELIMINARY CHECKS LENNOX 4 PRELIMINARY CHECKS Check that all drain and purge plugs are in place and well tightened prior to fill the installation with water 4 1 LIMITS Prior to any operation please checks the operation limits of the unit given in the ANNEXES at the end of the page 55 to 62 These tables will give you all necessary information concerning the operating envelop of the unit Please consult the Risk analysis and hazardous situations according to 97 123 directive given in the ANNEXES at the end of the IOM pages 63 amp 64 or supplied with the unit 4 2 REFRIGERATION CIRCUIT CHECKS AND RECOMMENDATIONS In case of split units check the installation has been made according to the recommendation described S Installa tion The unit refrigeration circuit sketch is given in the ANNEXES at the end of the page 65 to 69 or supplied with the unit 4 3 HYDRAULIC SYSTEM INSTALLATION CHECKS The unit hydraulic sketch is given in the ANNEXES at the end of the IOM See page 50 to 54 4 4 INSTALLATION OF EXTERNAL HYDRAULIC COMPONENTS supplied loose by Lennox Some hydraulic components may be supplied loose by Lennox Filters Expansion vessels Valves Manometers Note In case of plate heat exchangers it is mandatory that a filter is installed at exchanger un
115. tion pressure 6 2 2 Functions of electrical components 6 2 2 1 Electronic or cam type anti short cycle relay This device limits the number of compressor start ups Compressor motor thermal protection This device stops the motor if winding temperature rises too high and enables it to start up again when temperature drops back to a normal value 6 2 2 2 Fan over current protection Circuit breaker designed to stop the fan motors in the event of phase over current in relation to the permitted value 6 2 2 3 Compressor motor over current protection Circuit breaker designed to protect each motor winding against accidental over current 6 2 2 4 Indicator lights The electrical control box is fitted with indicator lights enabling visualisation of the state of operation or non operation of a function or given circuit There is also an indicator to show that the unit is powered up an emergency stoppage indicator for each compres sor an indicator to show stoppage of the compressor via the regulating system through the main control thermostat which is sensitive to chilled water temperature a run light per compressor and a general fan default stoppage indicator on air cooled units On units with CLIMATIC control see the appropriate manual 6 2 2 5 Time delay relay for starting compressor motors one winding at a time option This optional relay is supplied on units ordered with the part winding start system The tim
116. uence The compressor run indicating lights come on 6 2 3 2 Regulator stoppage sequence When the cooling load starts decreasing from its maximum value the multi stage control thermostat shuts down successive stages depending on the progressive reduction in return chilled liquid temperature Depending on machine equipment staged reduction consists either in shutting down a compressor or activation of a compressor capacity reducer This continues until the unit shuts down completely through action of the regulator The compressor regulation stoppage lights come on 6 2 3 3 Safety shutdown sequence If a default occurs on a circuit it is detected by the appropriate safety device high pressure overshoot loss of oil pressure motor protection etc The relay in question initiates unconditional stoppage of the compressor on that circuit and the safety stoppage indicating light comes on Some defaults give rise to immediate stoppage of the entire unit Tripped flow switch Tripped antifreeze thermostat etc In cases other than that of manually reset safety devices starting up of the circuit or the machine takes place auto matically once the default has been cleared 6 2 3 4 Loss of power supply There are no problems restarting the machine after a loss of power supply of short duration up to about one hour loss of power supply lasts longer than this when power supply is resumed set the unit to OFF w
117. ues the ventilation system has a lower pressure drop than anticipated Reduce the flow by reducing the rpm If the system resistance is significantly lower than design there is a risk that the motor will overheat resulting in an emergency cut out If the absorbed amps are lower than the rated values your system has a higher pressure drop than anticipated Increase the flow by increasing the rpm At the same time you will increase the absorbed power which may result in having to increase the motor size 9c CHECKING AIRFLOW AND ESP Using the following fan curve the airflow the total pressure available 97 the corresponding dynamic pressure Pd can be estimated for a specific operating point 10 Before making any electrical connections check that insulation resistance between power supply connection terminals is in keeping with applicable regulations Check the insulation of all electrical motors using a DC 500V megohmeter following the manufacturer s instructions CAUTION Do not start any motor whose insulation resistance is lower than 2 m gaohms Never start any motor while the system is under a vacuum 20 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS 8 SPLIT UNITS 0105 PRELIMINARY 18 18 CURVE LENNOX CC T m ER wld lt fer Se SA ad bot ZA SR PX NN T 2
118. upply conforms with unit nameplate indications Pump starter and flow switch circuits complete and in working order Pipe heaters installed on all piping exposed to freezing temperatures All unions tightenend with a torque wrench 0000000000 GENERAL O Cooling load available minimum 50 O Coordination between different professions for final commissioning CUSTOMER ORDER NUMBER LENNOX REFERENCE DESIGNATION 5 RANA athe A e APRI SU PA a Sila QE MES COMMENTS be Be nate idee bd Ria Shee oder bind date uki en ds NAME un ns wa eR an as eed ba eee eee SIGNATURE i i e ker gera ae ur 48 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 LENNOX AIR COOLED CHILLERS AND SPLIT UNITS INSTALLATION OPERATION MAI NTENAN CE MAN UAL Ref CHILLERS_IOM 0105 E ANNEXES HYDRAULIC CIRCUIT DRAWINGS ECOLOGIC rang wee pates 50 eX eer RE enn 54 OPERATING LIMITS ECOLOGIC rang rx CERA a RR RC areata waters 55 ECOMAXTahge Er hide wae NE Ne AR 59 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE 63 REFRIGERATION CIRCUIT DRAWINGS ECOLOGIC range uu Pinte nd Blase eiu BE di 65 SA range
119. vent formation of ice at the lowest outdoor air temperatures expected on an installation Take precautions when using passivated MEG antifreeze solutions Mono Ethylene Glycol or MPG Mono Propylene Glycol Corrosion can occur with these antifreeze solutions with oxygen 3 4 3 2 Drain the installation is important to make sure that manual or automatic air bleeders are installed at all the high points of the water circuit To enable drainage of the circuit make sure that drain cocks are installed at all the low points of the circuit To drain the circuit the drain cocks must be opened and an air inlet ensured Note air bleeders are not designed to admit air FREEZING OF AN EVAPORATOR DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX WARRANTY 3 4 4 Electrolytic corrosion We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an imba lance between earthing points AN EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT WARRANTY 3 4 5 Minimum water capacit The minimum volume of the chilled water circuit must be calculated with the formula here under If necessary ins tall a buffer tank Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formula hereafter
120. vere personal injury Ensure conduct liquid line and gas line pressure tests are in conformity with applicable legislation Before starting up a unit on a receiver the piping and the condenser must be dehydrated Dehydration should be carried out using a double stage vacuum pump capable of drawing 600Pa absolute pressure vacuum Best results are obtained with a vacuum down to 100 Pa To get down to this level at normal temperatures i e 15 C it is often necessary to leave the pump running for 10 to 20 hours The duration of pump operation is not a factor of efficiency The pressure level must be checked before the unit is put into service Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 15 INSTALLATION TRANSPORT HANDLING 3 7 5 Refrigerant charge Chillers with R407C must be filled in the liquid phase Never charge a machine operating on R407C in the vapour phase vapour the composition of the mixture could be modified In liquid phase connect either to a liquid isolating valve or to the quick connector on the liquid line at the valve outlet For unit using R22 the charging may be done in vapour phase in that case connection will be made to the suction valve Note Splits units are supplied with a refrigerant or nitrogen holding charge Before pulling down the vacuum for dehydra tion completely purge the unit Charge the unit until there is a constant flow o

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