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INSTALLATION - OPERATING & MAINTENANCE MANUAL

1. 5 CLIMATIC 50 Menu Tree ECOMAX range continued Screen Description Code Description code Description code unt 1 Display 3910 1 Standard Sp 3911 Yes No 9 Com 3900 Off 1 N 22 Se EI Comments Allows a reset of ALL set point to standard factory settings when available No possible for configurations and clock as there is no factory settings for these Configuration Identification adress for the unit from 1 to 4 for master slave operation Configuration Number of units on the BUS Unit with address N 1 is always the master Master Slave relationship refer to page 7 for details 1 4 Watchdog 3934 1000 Configuration Identification number on the 485 Bus Configuration Type of BMS 0 Mode Lennox Climatic 1 MODBUS 2 LONWORKS BMS communication speed between 1200BDS and 19800 BMS Activation of the control by a computer or an automat mode BMS is activated if this value is different from zero This value is decreased every second BMS Cancel the override unnocupied mode XVINOO3 NU N OS NOILVH3dO CERTIFICATES CERTIFICATION N QUAL 1993 1009e LGL FRANCE CONCEPTION FABRICATION ET CESSION INTERNE DE BIENS D EQUIPEMENT DESTINES AU CONDITIONNEMENT D AIR ETALA REFRIGERATION OF EQUIPMENT GOODS DED
2. Air outlet x Z Air outlet duct Es Air inlet Unit we UA ES B f Auxiliary drip tray heat pump unit Air inlet duct Notes Be carefull of air cycling between inlet and outlet For air outlet it is recommended to duct each fan separately Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E e 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 IOM 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 8 Installation 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 a
3. 5 CLIMATIC 50 Menu Tree ECOLOGIC range continued screen Description Code Description Code Description _ Code Unt Factory max commems 8 Config 3800 1 3810 Range Jaen lite 8 Configuration Unit model 2Sze 92 Configuration Type of unit Pump 394 Configuration Pump configuration Configuration Electronic expansion valve Configuration All season control amp Glyc 348 1 o 50 Configuration Glycol persentage Configuration Heat recovery option 2 Out Configuration Free output to be customised Configuration Free output to be customised Configuration Free output to be customised 3 In Configuration Free input to be customised Configuration Free input to be customised Configuration Free input to be customised Configuration Free input to be customised LConfiguration Fan control type Configuration Free output to be customised 4 In Configuration Free input to be customised Custom SEM 2 input of the extension board BE50 Configuration Free input to be customised 2 input of the extension board BE50 21 Configuration Free input to be customised 2 input of the extension board 50 Configuration Free input to be customised pem Je ILL 0 rm gt
4. 18 5 WNT SIARTUP aan here ee E EE EE E 22 5 1 Checks to be made during start up 5 2 Oil charge 5 3 Refrigerant charge 6 OPERATIONS eege CERN ORC CC SCENE OR Ra 23 6 1 CLIMATICTM control 24 6 2 ok bd was Roa Qa cde bs a pa a 26 7 MAINTENANCE AER ER RE dEr cw ag toe wea x08 EE ENEE 31 7 1 Weekly 31 7 2 Annual maintenance 31 7 3 Cleaning the 92 7 4 Compressor oil 32 Ted ut e EEN 32 8 TROUBLESHOOTING REPAIRS 33 8 1 List of the most common problems 33 8 2 Control devices 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 EE 49 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 to commission the chill
5. VENT1 C2 FR C2 VENT2 C2 29 OPERATION ny LENNOX ECOMAX Fans electrical box labelling LCH3 322 PK LCH3 412 PK LCH3 402 422 VK U 32 94 LCH3 442 452 VK LCH3 462 PK LCH3 532 PK LCH3 502 552 VK LCH3 602 652 VK deeem LCH3 702 752 LCH3 803 853 VK Gs 38 C Cae sn 31 35 40 37 a2 36 42 40 38 32 34 44 a2 4 S LCH3 953 1003 VK LCH3 1053 1153 VK d SU Ce 42 41 se Cer 40 46 46 46 y LCHS 1254 1354 VK LCHS 1404 1504 VK LSU CS se S6 Cae Cas se 40 48 Cer ue 7 30 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E MAINTENANCE mu EVW X 7 MAINTENANCE The following maintenance instructions form a part of the operations required for this type of equipment
6. z temperature temperature Bar Bar Antireeze pressure swich orou o Fan pressure switch 1 cut out bar Bar Bar Bar Bar Bar ar Fan pressure switch cout out C 40 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E TROUBLESHOOTING REPAIRS wy LENNOX 8 4 REGULAR CHECKS TO BE MADE CHILLER UNIT ENVIRONMENT CHILLED WATER CIRCUIT VALUE Inlet Outlet pressure guages for pressure drop DkPa Evaporator inlet temperature C Evaporator outlet temperature C Glycol eet CC e SR EE Flow Switch operational d bit Chilled water pump Fiter on Water GCUID anu eee bade CONDENSER WATER CIRCUIT Inlet Outlet pressure guages for pressure drop DkPa Condenser inlet temperature C Condenser outlet temperature Regulation on condenser water inlet Condenser pump interlock Filler on water CIICU 22 v acea yew tarrag mae EE Sure PE Ws Unrestricted air flow on
7. DESIGNATION ea COMME NY Ses a a once Sey EE Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E 5 LENNOX AIR COOLED CHILLERS AND SPLIT UNITS INSTALLATION OPERATION MAINTENANCE MANUAL Ref CHILLERS_IOM 0105 E ANNEXES HYDRAULIC CIRCUIT DRAWINGS EC OLOGIG Talde EEN 50 ECOMAXrange 54 OPERATING LIMITS ECOLOGIS EE 59 range a EE EE ER EE 59 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE 63 REFRIGERATION CIRCUIT DRAWINGS ECOLOGIC TANGO esca oo one end 65 5255 sS 67 ECOMAX range 52 52 68 CLIMATIC 50 MENU TREES See specific 50 user manual ECOLOGIC TOU mx dep a Palme e q ses 70 79 CERTIFICATES MIONS AFAQ ISO 9000 91 el KEE 92 CE GONFORMITY 93 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 49 ECOLOGIC HYDRAULIC HYDRONIC DATA LENNOX UNIT WITHOUT HYDRAULIC OR HYDRONIC MODULE ITEMS SUPPLIED LOOSE or 19 Groove lock coupling 02 18 Unit isolation valve Water inlekfilter 150 std In Well 75 100 110he sln ITEMS MOUNTED INSIDE THE UNIT 15 155 Te
8. Ac N receiver option eclaration 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 Gil Minimum refrigeration capacity in kW for oil entrainments up Suction risers Refrigerant R407C Table C Tubing nominal OD mm Saturated Suction gas temperature temperature 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 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
9. Low refrigerant charge A faulty expansion valve An obstructed liquid line filter drier A damaged 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 A worn or faulty oil pump A defective 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 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 39 TROUBLESHOOTING REPAIRS my LENNOX 8 3 OPERATION AND START UP CHECK SHEET NORMAL CONDITIONS OF USE Power supply voltage Refrigerant type Date and time measurements were taken Outdoor air temperature Company responsible for measurements Name of technician Circuit 1 Compr 2 Compr Compr Compr Compr Compr 1 2 3 1 1 Compr 3 Compr 1
10. 0105 E ECOLOGIC OPERATING LIMITS n LENNOX STANDARD ECOLOGIC WAH COOLING MODE WAH 150 200 230 Minimum outlet water temperature S 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet ue 8 Minimum outside air temperature C 6 Maximum outside air temperature e Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded K 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 50 Minimum difference water inlet outlet 3 Maximum difference water inlet outlet 8 Minimum outside air temperature with water outlet 35 C 10 Maximum outside air temperature 30 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 5f ECOLOGIC OPERATINGLIMITS muy LENNOX WA 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 C AT Safety Low pressure cut out bar 0 7 Safety Interlocking of low pressure bar 2 2 Safet
11. C to 50 during operation 30 to 65 during storage Do not expose any part of the machine to a naked flame Maximum chilled water return temperature 45 Maximum hot return water Indications in the technical IOM temperature 50 C supplied with the unit Install a temperature limitation device An Get EE destruction o Provide an appropriate protection Indications in the technical IOM the circuit liquid gas metal parts Get could be thrown out of the unit g g 9 Indications on general mechanical drawings in the technical guide and the supplied with the unit Indications of the Min and Max outdoor temperature on the unit nameplate Partial or complete destruction of the circuit liquid gas could be thrown out of the unit Partial or complete destruction of the circuit liquid gas metal parts could be thrown out of the unit 63 RISK ANALYSIS ANDHAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE LENNOX Event Actions to Eliminate the Risk ee ee Occurrence of a risk Modification of the mechanical and chemical properties of certain Partial or complete destruction of Unit exposed to extremely Protect the units against these types of Indications in the technical corrosive materials the circuit liquid gas metal parts could be thrown out of the unit materials with a risk or corrosion rupture pipe bursting leaks and cracks P
12. However It is not possible to give fixed and precise rules for permanent maintenance procedures capable of keeping 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 trained experienced personnel can establish strict maintenance procedures adapted to the conditions listed above Nonetheless we recommend a regular maintenance schedule 4 times 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 a
13. Liste On Off On Off On Off On Off h XvINOO3 nue OS NOILVH3dO X0NNTTESE 2 9010 S3X3NNV e SHATTIIHD 15 e CLIMATIC 50 Menu Tree ECOMAX range continued Main screen Code Description Code Description Code Description Code Unit Min 6 Comp 4 2460 5 EEV 2500 1 Circuit 1 2510 4 Circuit 2 2540 1 Config 2541 6 Ventilation 2600 1 Fan Circuit 1 2610 5 Relay 2 2625 On Off XvINOO3 9341 OS NOILVH3dO XONNI THES 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOMAX range continued Main screen Code Description Code Description Code Description Code Unt Min Factory Max EE rom fra fe NU N OS NOILVH3dO XONNJ 78888 CLIMATIC 50 Menu Tree ECOMAX range continued st fete M RR 3400 I Circuit An be Comp priority Circuit priority management Safety limit Freezing safety limit minimum with 3422 Safety limit Lennox setting 5 EEV 3500 1 Cooling 3510 1 SuperHeat 3511 5 1 Im e EEV Superheat set point 3512 C 0 o o9 EEV Lennoxset point 35
14. RUSSIA SLOVAKIA UKRAINE UNITED KINGDOM OTHER EUROPEAN COUNTRIES AFRICA CHILLER AC OM 0105 E LENNOX BENELUX N V S A t l 32 3 633 30 45 fax 32 3 633 00 89 e mail info be lennoxbenelux com LENNOX JANKA t l 4202 510 88 111 fax 420 2 579 10 393 e mail janka janka cz LENNOX FRANCE t l 33 1 64 76 23 23 fax 331 64 76 35 75 e mail marketing france lennoxfrance com LENNOX DEUTSCHLAND GmbH t l 49 69 42 09 790 fax 49 69 42 09 79 40 e mail info deglennoxdeutschland com LENNOX DISTRIBUTION t l 971 4 262 9309 fax 971 4 266 7082 e fax 1 240 368 73 62 Mobile 971 50 4510669 e mail mmrifai emirates net ae LENNOX BENELUX B V t l 31 33 2471 800 fax 31 33 2459 220 e mail info lennoxbenelux com LENNOX POLSKA Sp z o o t l 48 22 832 26 61 fax 48 22 832 26 62 e mail info lennoxpolska pl LENNOX PORTUGAL t l 351 22 998 33 70 fax 351 22 998 33 79 e mail info lennoxportugal com LENNOX DISTRIBUTION MOSCOW t l 7 095 246 07 46 fax 7 502 933 29 55 e mail lennox dist moscow mtu net ru LENNOX SLOVENSKO t l 421 2 44 87 19 27 fax 421 2 44 88 64 72 e mail lennox slovensko lennox sk LENNOX REFAC S A t l 34 915 40 18 10 fax 34 915 42 84 04 e mail marketing lennox efac com LENNOX DISTRIBUTION KIEV t l 380 44 213 14 21 fax 380 44 213 14 21 e mail jankauk uct kiev ua
15. Water Test pressure Bar 10 10 10 10 10 10 Refrigerant Test pressure Bar 25 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 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 22 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 E RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE GE LENNOX Unusual stress in the frame leading to possible and strains vibrations and cracks Unit not installed properly or leveled to the ground Unsuited hydraulic or Unusual stress on the pipe work SM leading to possible and strains 3 i refrigeration pipe work vibrations and cracks N 4 Modification of the mechanical Circuits exposed to an unusual properties of certain materials with heat source a risk or rupture or pipe bursting leaks or cracks appearing gt Increase of the refrigerant pressure in the heat exchanger with a risk of exceeding the working pressure leading to possible strains vibrations cracks and pi
16. mma mm rt end automatic switch summer time winter ISO 1003 SUL NU N OS WOLLWWID 0 Zone Setting Starting time for Zone B set Zone Setting Starting time for Zone C set Anticipation Function Bottom of the slope in 2 o 3220 1 Foot 3221 Limit of activation of the function This allows an Anticipation anticipated startup in the morning depending on 20 the outdoor temperature Only for the Zone A 2 Gradient arr Anticipation Function Slope in Minutes of 100 anticipation per degrees 1 Change Change over Change over mode for heat pump Over 3310 1 Mode 3311 Liste units 0 chiller only 1 HP only 2 automatic with pump 3300 3 automatic without pump operation 3312 beis Change over Change over winter setting 3313 st 10 IChange over Change over summer setting 000 Change over IChange over Change over summer setting 000 over summer setting 2 Water tse SP Outlet chilled water temperature set point Cool 3320 1 Sp Wat 1 3321 see page 11 Climatic 50 minimum with 5 10 7 Glycol according to 96 Water SP Outlet chilled water temperature set point 2 Sp Wat 2 3322 see page 11 IOM Climatic 50 minimum with 5 10 7 17 Glycol according to XONNI 3 S010 S3X3NNV SH3TIIHO enuew eoueuejureyy CLIMATIC 50 Menu Tree ECOLOGIC range continued m Description D
17. 0105 7 INSTALLATION TRANSPORT HANDLING LENNOX 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 Itis 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 ignored 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 other 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
18. 2 except LN VENT C1 C2 except LN c2 except LN FR C1 FR C2 1 except LN VENT2 C1 VENT2 C2 VENT2 C1 VENT2 C2 e VENT3 C2 VENT3 C1 VENT1 C2 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 OPERATION WA RA 370D y Cp 1 C1 VENT1 C1 VENT1 C2 FR C1 FR C2 except LN except LN VENT2 C1 VENT2 C2 VENT3 C1 VENT3 C2 Cp 2 Cp 3 1 2 3 E WA RA 100E WA RA 110E WA RA 75E WA RA 90D WA RA 130D WA RA 150D VENT3 C1 2 yw 8 8 VENT2 C1 UN SC Ki VENTI C2 FR C1 FR C2 VENT2 C1 C1 es 2 p VENT1 C1 VENT2 C1 we 2 fsa VENT2 C2 FR C1 Cp 2 VENT1 C1 FR C1 WA RA 270D WA RA 3000 WA RA 370D WA RA 200D m WA RA 2300 S VENT2 C1 VENT2 C2 VENT2 C1 VENT2 C2 VENT1 C1 vente FR C1 VENT1 C1 Genres VENT1 C1 MENTIS FR C1 FR C2 VENT2 C1 VENT2 C2 VENT3 C1 VENT3 C2 VENT3 C1 wes VENT3 C2 VENT3 C1 VENT3 C2 C2 C2 VENTA C1 4 2 ZE VENTA C2 WAH 1500 VENT2 C1 VENT1 C1 VENT1 C1 FR C1 VENT2 C1 VENT2 C2 VENT1 C2 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 WAH 200D WAH 230D
19. 2 Data 2000 1 General 2100 1 Temperature 2110 1 Outside 2 Inlet 3 Outlet date 2 Circuit 1 2120 1 SuperHeat 2 T Condensing 3 T Saturated 4 T Suction 5 P Condensing 6 P Saturated 3 Circuit 2 2130 1 SuperHeat 2 T Condensing 3 Saturated 4 T Suction 5 P Condensing 6 Saturated 4 Circuit 3 2140 1 SuperHeat 2 Condensing 3 T Saturated 4 T Suction 5 P Condensing 6 P Saturated 5 Circuit 4 2150 1 SuperHeat 2 T Condensing 3 T Saturated 4 T Suction 5 P Condensing 6 P Saturated 2111 2112 2113 2121 2122 2123 2124 2125 2126 2131 2132 2133 2134 2135 2136 2141 2142 2143 2144 2145 2146 2151 2152 2153 2154 2155 2156 C 980998 SIS O 2 pul __ Je 3 o ___ 32 JC B JC 0 35 5 326 b ___ Le 33 0 34 _ 35 b _ 6 Jb an 10 Oo 0 0 Le 0 245 b 46 b _ 25 20 0 25 C 25 _ C 355 b 56 b XvINOO3 9341 nue 06 NOILVH3dO XONNI 3 S010 SJX3NNV SH3TTIHO 5 CLIMATIC 50 Menu Tree ECOMAX range continued Code Description Code 6 Other 2160 9 In Custom 2190 Description
20. 2410 3 9010 S3X3NNV 5 jenueui 5 ebuei ISO 1003 SUL NU N OS NOILYY3dO LI XONN 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOLOGIC range continued screen Code Description Code Description _ 2 Comp 2 Circ 1 3 3 Circ 1 4 Comp 1 Circ 2 5 Comp 2 Circ 2 Code 2420 2430 2440 2450 Description 1 Config 2 State 3 Sw State 4 Sw High P 5 Sw Low P 6 Relay 7 H Pump 8 Bypass 9 Run Time 1 Config 2 State 3 Sw State 4 Sw High P 5 Sw Low P 6 Relay 7 H Pump 8 Bypass 9 Run Time 1 Config 2 State 3 Sw State 4 Sw High P 5 Sw Low P 6 Relay 7 H Pump 8 Bypass 9 Run Time 1 Config 2 State 3 Sw State 4 Sw High P 5 Sw Low P 6 Relay 7 H Pump 8 Bypass 9 Run Time Liste Liste On Off On Off On Off On Off On Off On Off h Liste Liste On Off On Off On Off On Off On Off On Off h Liste Liste On Off On Off On Off On Off On Off On Off h Liste Liste On Off On Off On Off On Off On Off On Off h ebuei 5 50 1003 SUL nuew OS WOLLVWID NOIL Vu3dO X0NNTTESE 2 9010 S3X3NNV e SHQ3TIIHO uOonej E su e CLIMATIC 50 Menu Tree ECOLOGIC rang
21. 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 crankcases bullseyes This level may vary from one compressor to another but should never be higher than A 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 pump s 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 Qix4 P2 where 2 pressure drop measured on site pressure drop published by LENNOX for a liquid flow of Q1 1 nominal flow Q realflow 8 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 8096 of the total elongation of belts is
22. 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 52 100 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 operations 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 Donotus
23. Description Code 7 Out Custom 2170 8 In Custom 2180 Description Description Code Min Factoy XVINOO3 NU N OS NOILVH3dO XONNJ 78888 3 S010 S3X3NNV SH3TIIHO eoueuejureyy e 9 CLIMATIC 50 Menu Tree ECOMAX range continued III 3 Sw SES On Off 1 Water 2210 1 Sp Cool 2211 2 Ventilation 2220 1 Comp 1 Circ 1 2410 za Je aen Je e Us Tu Feto XvINOO3 9341 nue OS NOILVH3dO XONNI 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOMAX range continued screen Code Description Code Description Description Code ___ Unt Factory _ 2 Comp 2 Circ 1 2420 3 Comp 1 Circ 2 2430 4 Comp 2 Circ 2 2440 5 Comp 3 2450 2 State 2422 4 Sw High P 2424 5 Sw Low P 2425 2 State 2432 2434 2435 2436 2437 8 Run Time 2438 244 2442 2443 2444 2445 lie 244 ____ 2425 Onon 2427 Onon 2408 2432 Liste 2434 2435 Onon 246 2437 amp RunTme Loes hn 24431 Liste 242 244 ____ ___ 2445 onon 247 ____ Las tse MRuTme ms n
24. E lt gt Ul lt D c Q O o XUNN TI 3 S010 SJX3NNV SH3TTIHO 5 CLIMATIC 50 Menu Tree ECOLOGIC range continued Yes No Allows a reset of ALL set point to standard factory settings when available No possible for configurations and clock as there is no factor settings for these 9 Com 3900 0 Configuration Number of units on the BUS Number L Unit ee the master mm m m Master Slave relationship refer to page 7 for 2 details ME un m Configuration Identification number the 485 1 1 200 Bus Configuration Type of BMS 0 Mode Lennox qe fo T MODBUS 2 LONWORKS BMS communication speed between 1200BDS __ 999 ms fa 29 1080 mode BMS is activated if this value is different from zero This value is decreased every second BMS Activation of the control by a computer 4 Watchdog 3934 or an automat 5 BMS Unoc 3935 On Off ebuei 5150 1003 SUL nuew OS 2IVIWID NOIL Vu3dO XONNT 788 2 9010 S3X3NNV e SHQ3TIIHO enuew uOnej E su e 6 e CLIMATIC 50 Menu Tree ECOMAX range Main screen Code Description Code Description Code Description Code Unit Min Factory Max 1 Alarm 1000 1 date time
25. be avoided an air ejection duct must be installed at the same height as the surrounding shield A It is important that units must be leveled failure to install unit correctly will void warranty Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 gs 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 3 meters vi ly ri P d E COSE Mae eene Sure rs E GEN SE EE L RA SETS UTE EE TELE 7 GE e E H SSS e Not allowed Not recommended For any air cooled unit itis necessary to have a minimum distance between air coil and any obstacle of 1 5 meters N Forany chiller a minimum distance of 1 meter is required for the good opening and servicing of the electrical 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 c
26. compressor THE COMPRESSOR STARTS WITH DIFFICULTY Mechanical problem Replace the compressor 36 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION J THE COMPRESSOR IS NOISY If starting on a single winding on Check operation of the starter compressors fitted with part contacts the start up time delay winding start or wye delta and the condition of the windings Compressor knocking Broken mechanical parts inside Replace the compressor compressor Suction line is unusually cold a Liquid slugging a Check superheat and that the expansion valve bulb is correctly installed b Expansion valve blocked in b Repair or replace open position Broken suction valves Replace broken valves High discharge pressure The Pressure operated water valve Clean the valve Install and water regulating valve or the fouled water pressure is to high expansion tank upstream of the pressure operated water valve or irregular valve taps or knocks Compressor shuts down through Low oil charge action of the oil pressure safety switch K DISCHARGE PRESSURE TOO HIGH Water is far too hot at condenser Water flow to low or water Adjust the pressure operated outlet temperature too high in the water valve or the
27. condenser coils 2 ELECTRICAL POWER SUPPLY Control circuit voltage V Power circuit power supply voltage L1 L2 V Power circuit power supply voltage L2 L3 V Power circuit power supply voltage L3 L1 V 1 Depending on the application 2 According to the type of unit Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 41 TROUBLESHOOTING REPAIRS LENNOX 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 NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS 500 1000H Major Inspection 15 000 30000 h Tube Start up visit technical visit inspection inspection analysis inspection 2 s j i a _ 8 _ _ j LL LLL 3 1 1 3 times a Every Every Every 3 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 42 Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REP
28. design manufacture final inspection and sting of the pressure equipment identified hereunder has been examined against Ihe provisions of annex module H1 of iha Pressure Equipment directive n B7 23 E C and found fo satisfy provisions of the directive which apply to it Fabricant nom Manufacturer name LENNOX France Usine de MIONS Adressa Address 2 1 Les Meuri res BP 71 F 69780 MONS Marque commerciale Trade mark LENNOX Description des quipements Ensemble sous pression Equipment description Identification des quipements concernes liste annexe fe cas ch ant Suivant liste en annexe identiicaton of equipment concerned ist attached where necessary ATTESTATION D APPROBATION DE SYSTEME DE QUALITE module H1 x x d attestation s d examen da la conception mise s dans le cadre de l application du module par BUREAU VERITAS S A organisme n 0062 par l approbation du systame de qualit Number s of EC design examinatian certificate s issued under the scope of module by BUREAU VERITAS S A notified body nr 0052 concerned by the approval of ihe quality system Cette attestation est valable jusqu au 02 09 2005 This certificate valid until Le maintien de l approbation est soumis la r alisation par le Bureau Veritas des audits essais et v rifications selon le contrat sign par
29. 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 values 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 P and 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
30. should be carried out by trained and licenced competent technician 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 E PED DECLARATION mu ENNOX 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 he 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 draining and fil
31. thermostat on condenser the cooling tower Water is far too cold at the Condenser tubes fouled Clean the tubes condenser outlet Condenser abnormally hot Presence of air or Purge incondensibles and or air incondensibles in the circuit or and recover excess refrigerant excessive refrigerant charge Chilled water leaving Excessive cooling load Reduce load reduce water flow temperature too high if necessary L DISCHARGE PRESSURE IS TOO LOW Water is very cold at condenser Condenser water flow too high Adjust the pressure operated outlet or water temperature is too low 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 E 37 TROUBLESHOOTING REPAIRS LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION M SUCTION PRESSURE IS TOO HIGH The compressor runs Too much cooling demand on Check the system the evaporator continuously Suction line unusually cold a Expansion valve opened to far a Adjust superheat and check that the expansion valve bulb is Liquid refrigerant returns to correctly fitted in place compressor b Expansion valve blocked in b Repair or replace open position N SUCTION PRESSURE IS TOO LOW Bubbles in
32. 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 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 necessary 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 wh
33. 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 compressor 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 time 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 cou
34. 0 200 230 270 300 370 Minimum outlet water temperature C 5 Maximum inlet water temperature 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 M 50 12 C 7 C water one compressor unloaded 3 53 5 51 54 53 5 Start up with CLIMATIC 50 Electronic expansion valve and ONE compressor unloaded S 52 49 49 53 52 5 49 46 N Super W ek dk low noise ECOLOGIC WA WA 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature C 5 Maximum inlet water temperature ue 20 Minimum difference water inlet outlet C 3 Maximum difference water inlet outlet 8 Minimum outside air temperature 6 Minimum outside air temperature with low ambient kit 10 O ho Maximum outside air temperature e Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded 9 52 49 49 53 52 5 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded 1 50 46 46 51 50 4 Start up with CLIMATIC 50 Electronic expansion valve and one compressor unloaded 51 47 48 52 51 5 47 1 43 44 56 Installation Operation Maintenance manual CHILLERS ANNEXES
35. 1 web Juse o Comments Configuration Pump configuration EE Configuration persentag Yee 1 BE50 1 sme mm ue a lee de qum x le de EES Configuration Heat recovery option Configuration Free output to be customised First output of the extension board BE50 Configuration Free output to be customised Second output of the extension board 5 Configuration Free output to be customised Third output of the extension board 50 Configuration Free output to be customised Fourth output of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 Configuration Free input to be customised input of the extension board BE50 XvINOO3 9311 9 OS NOILVH3dO XONNI 3 S010 S3X3NNV SH3TTIHO
36. 13 C 35 999 EEV Lennox set point Proportional factor 3514 s 0 999 EEV Lennox set point Integral factor 3516 o J 999 EEV Lennox set point Derivate factor 6 Ventilation 3600 Wees SEN DENM 17 11 HP SP High pressure set point for R134a unit 3612 C i es 50 Factor Reactivity set point for fan operation 3700 2 2 8 Config 3800 1 Unit 3810 3811 L Configuration Unit model 3812 et __ Configuration Type of unit Configuration Type of refrigerant R407C SS R134a R22 2 Compressor 3920 Ve SE Configuration Electronic expansion valve 2 LAK 3822 Configuration All season contro DS Yes No Configuration For units with reciprocating compressor extra capacity reduction 42 3 9010 S3X3NNV 5 5 o XvINOO3 9311 9 OS NOILVH3dO e XONNI 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOMAX range continued 3 Setting 3000 1 General 3100 1 Order 3110 2 Clock 3120 1 Time 3210 2 Schedule 3200 2 Anticipation 3220 3310 3 Control 3300 2 Safety 3320 Description 1 On Off 2 Pompe 3 Reset Al 4 Resume 5 Test 1 Hour
37. 2 Minute 3 Day 4 Month 5 Year 6 Win Sum 1 Start Uno 3 Start z A 5 Start z B 7 Start z C 1 Foot 2 Gradient 1 Sp Wat 1 2 5 Wat 2 3 Sp Out 1 4 Sp Out 2 5 Reactiv 1 Wat Low code _ 3111 On Off 3311 C 5 10 7 3312 5 10 7 3313 C 1 SE 3 10 5 10 12 minimum with Glycol according to Leen fo O ff ff ff 4 4 4 10 0 2 2 10 He Je 0 24 6 3 to 6h30mn modulo 10mn 5 4 Off Unit pump operation mode set up see Pump operation description page 11 Climatic 50 Reset Discharges the safety measures of the unit Override Cancel any override action set with the DC50 Lennox set point 3 Clock Clock setting Hour Clock Clock setting minute Clock Clock setting Month Clock Clock setting Year Clock automatic switch summer time winter time Zone Setting Starting time Hour for Unocupied zone set 6 3 to get eh30mn modulo 10mn Zone Setting Starting time for Zone A set 6 3 to get 6h30mn modulo 10mn Zone Setting Starting time for Zone B set 6 3 to get 6h30mn modulo 10mn Zone Setting Starting time for Zone C set XVINOO3 nue OS NOILVH3dO JN CO gt N Anticipation Function Bottom of the slope in C Limit of
38. 51 59 59 51 51 48 e Start up with CLIMATIC 30 Thermostatic expansion valve and NO unloading C 37 39 39 38 36 37 e Start up with CLIMATICTM 50 Thermostatic expansion valve and ONE compressor unloaded C 49 46 46 48 48 45 e Start up with CLIMATIC 50 Electronic expansion valve and ONE compressor unloaded C 49 47 47 49 49 46 W a ek dk low noise ECOLOGIC WA WA 150 200 230 270 300 370 Minimum outlet water temperature S 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet S 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 e Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 50 48 47 50 50 47 e Start up with CLIMATIC 30 Thermostatic expansion valve and NO unloading C 35 37 36 36 33 33 e Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor unloaded S 47 45 44 47 47 43 e 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 595 ECOLOGIC OPERATINGLIMITS EEENNLENWUX HIGH ek dk EFFICIEN CY ECOLOGIC WA WA 075 090 100 110 130 15
39. 6 2 1 2 Filter drier This is designed to remove all traces of humidity from within the refrigeration circuit since this can impair operation ofthe 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 ofthe 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 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 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 un
40. 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 C 50 48 52 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 Max inlet water temperature 20 20 20 20 20 20 Min difference water inlet outlet 3 3 9 9 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 K 5 5 5 5 5 Max inlet water temperature 20 20 20 20 20 20 Min difference water inlet outlet 9 3 3 3 2 5 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature 6 6 6 6 6 6 Min outside air temperature 1 C 15 15 15 15 15 15 Max outside air temperature 2 52 5 52 5 525 52 5 52 52 LCH 1053V 1153VE 1254V 1354VE 1404V 1504VE Operating limits Min outlet water temperature 5 5 5 5 5 5 Max inlet water temperature 20 20 20 20 20 20 Min difference water inlet outlet S 3 3 3 3 gt 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 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 temperatu
41. AIR COOLED CHILLERS English 01 2005 __ lt Wh gt z lt LLI BO 4 lt e lt g lt lt ea u Wo z gt TABLE CONTENTS LENNOX AIR COOLED CHILLERS AND SPLIT UNITS INSIALLATION OPERATION MAINTENANCE MANUAL Ref CHILLERS IOM 0105 E The present manual applies to the following CHILLERs versions ECOLOGIC range WA WAH RA ECOMAX range LCH LCB MCC range MCB range Our company is a member of the Eurovent Certification Programme all LENNOX chillers are tested and rated in accordance with Eurovent certification program Our products comply with the European standards Product designed and manufactured under a quality management system certified to AFAQ ISO 9001 by AFAQ 150 9001 YERSION 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 exc
42. AIRS LENNOX 8 5 1 2 Description of inspection duties Liquid chiller with reciprocating compressor s 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 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 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 compressor 30 000 H VISIT Major technical inspection Inspection of the compressors with replacement of the valves springs seals and gaskets bearings oil discharge valve piston rings Dimension
43. AQ to the above mentioned company of its suspension This document ix jor informetion purposes only For up to date informotian the only official source is the cerrificstes dotabese at was he anganizatiar complies with Che international stondonds in fore Guide Eh 25012 information op the acrredintapns held by iit subsidiaries 15 avaiable ot hip ang AFAQ 116 AVENUE ARISTIDE BF 40 F 92224 BAGNEUX CEDEX FRANCE Installation Operation Maintenance manual CHILLERS ANNEXES 0105 91 e CERTIFICATES PED wy LENNOX Bureau Veritas A A is a Notified Body under the number 0062 VERITAS CERTIFICATE OF QUALITY SYSTEM APPROVAL module H1 N CE PED H1 LEN001 02 FRA BUREAU VERITAS GA agissant dans le cadre de sa notification num ro d organisme notifi 0062 atteste que le syst me de qualit appliqu par fabricant pour la conception la fabrication l nspaction finale et les essais des quipements sous pression identifi s ci apr s a t examin selon les prescriptions du module de l annexe III de la direcbve Equipements sous pression N 97 23 CE et est conforme aux disposilions carrespondantes de la directive BUREAU VERITAS GA within the scope of its notification notified body number 0052 atestas that quality system operated by the manufacturer for
44. AWING all UNITS high ambient est J ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT QO Groove lock coupling Heat exchanger Unit isolation valve Water inlet filter Differential Flow switch In Out manometers without groove lock coupling option In Out manometers mounted on groove lock coupling 12 Water drain option Paddle flow switch 13 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 06 07a 07b Add Add Add Add Add Add Add 13 12 03 05 08 02 10 01 11 04a 09a 04b 09b 01 11 1 Supplied Loose 2 Supplied Mounted 54 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 ECOLOGIC OPERATINGLIMITS __ LENNOX W a dk STANDar d ECOLOGIC WA WA 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 e Normal operation with CLIMATIC 30 12 C water inlet 7 C water outlet C 43 44 44 44 43 43 Normal operation with CLIMATICTM 50 12 7 water one compressor unloaded C
45. Dead zone 1 Sp Cond 2 Reactiv Safety limit Hot water outlet temperature limit Comp priority Circuit priority management Safety limit Freezing safety limit minimum with 5 Glycol according to 96 Function Defrost Choice of defrost 1 cycling or 0 dynamic Function Defrost Authorization of defrost 0 Threshold of outside temperature in c Function Defrost Authorization of defrost Threshold of coil temperature in c Function Defrost Time limit for icing in minute For the dynamic defrost the unit will run this minimum amount of time If cycling defrost this is the time delay to start the defrost once the temperature conditions are met Function Defrost Running time of fans after 00 defrost cycle in order dry the outside coil 5 EEV Superheat set point 3421 C le 1 20 3431 3432 3433 C M 10 m 3434 3 oo usa 3435 3511 3512 3513 3514 3515 3611 3612 EEV Lennox set point EEV Lennox set point Proportional factor 2 4 3 EEV Lennox set point Integral factor Lennox set point Derivate factor 17 11 30 HP SP High pressure set point for R134a unit Ventilation 3600 7 Option 3700 10 5 5 0 5 HP Factor Reactivity set point for fan operation 3 9010 S3X3NNV SH3TTIHO
46. Evaluation Module Attestation N Certificat d examen CE de la conception Module HID Attestation 9 Description of Components Under Pressure ART 3 3 Category of Risk and Address of the Organisation Auditing the Quality Assurance System NF EN 150 5001 AFAQ F 92224 Bagneux Cedex FRANCE N d agr ment QUAL 1993 1009 Name and Address of the Organisation Auditing our Conformity to the Directive of Equipment Under Pressure DI 97 23 CE BUREAU VERITAS F 92077 Paris La D fense N d agr ment CE 0062 References to Standards that are Applicable a NF EN 60204 1 Safety of machinery Electrical equipment of machines References to Other Standards Directive 98 37 EC Relating to machinery Directive 93 68 EEC Relating to electrical equipment designed for use within certain voltage limits Directive 88 336 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 siege social LGL France 21 les Meuri res 69780 Mons France Societe Anonyme au capital 37 029 000 RCS LYON B 309 528 115 N IDENTIFICATION FR 59 309 528 115 APE 292 F Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E 93 BELGIUM CZECH REPUBLIC GERMANY MIDDLE EAST NETHERLANDS
47. ICATED TO AIR CONDITIONING AND REFRIGERATION wawww DESIGN MANUFACTURING AND INTERNAL TRANSFER Zl 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 above mentioned activities and locations are established to meet the requirements of the international standard ISO 9001 2000 ont t examin es et jug es conformes have been examined and found conform It is valid until 2002 03 18 ann a mois jour est valable jusqu au 2005 03 14 year month day 4 o RS rr Le President du Comite de Certification Le Directeur G n ral The President of the Certification Committee The Managing Director of AFAQ C GUERIN O PEYRAT JP suspension notifi e entre temps par AFAQ l entreprise d sign e ci dessus Le pr sent document ao donc qu une valeur indicative Seule fait foi la base de donn es des certificats AFAQ accessible l adresse internet Corganication est conforme aux normes internationales en vigueur quide ISO IEC 52 norme EN 45012 Les acereditakiore d tenues aar et ses filiales sort disporibles l adresse irternet httpc vww afag org accreditations Fxcembing notification by AF
48. 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 install 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 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 litres Example for a chiller with 400kW water conditions 12 7 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 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 A flow 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 switc
49. Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 PRELIMINARY CHECKS ENN oX 18 18 FAN CURVE V mh 3 4 pee 4 d d B pd dj F TT C Im s 3 4 D 7 BM 8 10 20 40 Hd imm on 4 o an on an an Sp aee Pac UNITSTART UP mu ENNOX 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 Checkthatthere is sufficient cooling load on the day the start up is conducted at least 50 96 of the nominal load PROCEDURE TO FOLLOW WHEN
50. LENNOX INDUSTRIES Ltd t l 44 1604 599400 fax 44 1604 594200 e mail ukmarketing lennoxind com LENNOX DISTRIBUTION t l 334 72 23 20 14 fax 33 4 72 23 20 28 e mail marketing glennoxdist com LENNOX www ennoxeurope com
51. N Air cooled condenser Fan motor Manual isolating valve Filter drier Solenoid valve Sight glass Thermostatic expansion valve EXPANSION DEVICE Thermostatic expansion valve low ambient Thermostatic expansion valve Add 14 amp Add 14 12 v Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E Expansion valve bypass for low ambient operations Electronic expansion valve Evaporator heat echanger Suction temperature sensor External temperature sensor 8 GGG 9 Heating resistance option OPTIONS Suction Electronic HP LP and Sight expansion pressure discharge glass valve gauges isolating valve Add16 amp Add05a amp Add 06a amp 18 05b 06b GES e 65 e ECOLOGIC REFRIGERATION CIRCUIT REFRIGERANT DRAWING 1st amp 2nd scroll compressors High pressure switch 04a 04b Pressure transducers HP amp BP Low and High pressure manometer 06a 06b Suction and discharge isolation valves Safety valve CE UDT BASIC UNIT Basic unit 01 03 04a 04b 1 9 22 08 09 10 11 23 20 1 7 14 21 e 66 muy LENNOX OR 150 200D 230D Air cooled condenser Evaporator External temperature sensor Fan motor Check valve Manual isolating valve Restrictor Filter drier 4 way inverting valve Thermostatic expansion valve Liquid receiver 27 e 2 Evaporator Condenser heat exchanger Heating resistance opt
52. NS Flow switch paddle mounted Water inlet filter BASIC UNIT 200 500L tank Expansion and single or double pump vessel 25L 06 07 08 09 13a or 13b 14 15a 15b 16 Kit for groove lock coupling Unit isolation Pump Unit isolation valve valve Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E vessel 50L for 075 090 100 1 10 manometer Expansion Expansion vessel 50L for all other WA units Pump isolation valve HE amp SLN Add 05 Add 03 Add 10 Add 11b Add 10 11a Add 12 18 Inlet Outlet manometer kit for groove lock coupling Inlet Outlet 02 18 02 12 18 Addot t6 9 020170 e 51 ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITH HYDRAULIC MODULE ITEMS SUPPLIED LOOSE or 19 Groove lock coupling Unit isolation valve Water inlet filter In Out manometers without groove lock coupling option In Out manometers mounted on groove lock coupling option BASIC UNIT Single or double pump 14 15a 15b 16 13a or 13b 52 ITEMS MOUNTED INSIDE THE UNIT Flow switch paddle mounted 25L Unit isolation valve muy ENNOX std In he sin Paddle flow switch 25L expansion vessel Second 25L expansion vessel for WA 150D Single 50L expansion vessel WA lt 150D OPTIONS Expansion vessel Water inlet filter Add 05 Add 03 Add 10 Add 11b Add 10 amp 11
53. STARTING THE UNIT 5 a Press the power ON OFF switch The compressor will only start if the evaporating 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 indicating 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 Checkthat 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 These verifications s
54. Sight glass Discharge muffler 8 2 9 G Heating resistance option VARIANTS EXPANSION DEVICES OPTIONS Basic Unit LCH unit Thermostatic HP LP Pressure Suction and Discharge CE or UDT or Electronic Gauges Oil Isolating valve 01 03 03 04 08 09 10 11 12 13 14 15 16 17 18 19 076 14 146 05a 05b 05c 06a 06b Installation Operation Maintenance manual CHILLERS ANNEXES 0105 69 07 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOLOGIC range Main screen Code Description Code Description Code Description Code Unit Min Factory Max 1 Alarm 1000 1 date time edat ime o o o o ra 2100 1 Temperature 2110 TOwsde J Ple PO Jens J J 2 Circuit 1 2120 amp P Condening 2125 ep Saturated 2126 In 2 Data 2000 1 Gene 5P Condensing 295 b _ 6 P Saturated 2136 LN ebuei 5 50 1003 SUL nuew OS WOLLVWID NOILVu3dO CLIMATIC 50 Menu Tree ECOLOGIC range continued mum m Code Dessinion Code pen Ust e rom ps 2 2200 1 Water 2210 2 Ventilation 2220 1 SetPoint 2221 s SRuwm Ti _ ermo em f 4 Compressor 2400 1 Comp 1 Circ 1
55. State 4 Relay 1 Config 2 State 3 Inlet 4 Outlet 5 Sw State Liste Liste On Off On Off Liste Liste On Off On Off Liste Liste On Off On Off Liste Liste On Off On Off Liste Liste On Off On Off Liste Liste C C 2715 On Off ebuei 91507099 SUL nuew OS WOLLWWID NOILVu3dO XONNJ 78888 3 9010 SJX3NNV SH3TTIHO enuew 5 e CLIMATIC 50 Menu Tree ECOLOGIC range continued Screen Description Code Description code Description Code unt Mm Factory Comes 00000 3 Setting 3000 1 General 3 Control Zone Setting Starting time Hour for 1 Time 3210 1 Start Uno 3211 Unocupied zone set 6 3 to get 6h30mn 2 Schedule 3200 24 modulo 10mn Zone Setting Starting time for Zone A set 212 1 3100 1 Order 3110 OvOff 8111 Ion Unit pump operation mode set up see Pump operation 3 Reset Al 3114 Yes No Reset Discharges the safety measures of the S Off unit Override Cancel any override action set with 4 R 11 Yes N 5Test omg Lige 0 Jo Lennoxsetpoint 2Clock 3120 44 0 ClocK Clock setting Hour 93122 fo s9 Clock Clock setting minute Clock Clock setting Day 4 194 11 Clock Clock setting Month 5Year 3 Le 9 Clock setting Year
56. TION TRANSPORT HANDLING mu ENNOX 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 accompa
57. V 1354VE 1404V 1504VE Operating limits Min outlet water temperature 5 5 5 5 5 Max inlet water temperature 6 20 20 20 20 20 Min difference water inlet outlet 3 3 3 3 3 Max difference water inlet outlet 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 50 5 50 5 49 49 1 With low temperature kit 2 Unloading start up sequence Installation Operation Maintenance manual CHILLERS ANNEXES 0105 61 ECOM AX OPERATING LIMITS LENNOX all units L CH 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 25 5 26 5 26 5 Water Max operating pressure Bar 6 0 6 0 6 0 6 0 6 0 6 0 Hefrigerant 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 3 153 5 153 5 153 5 89 3 89 3 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 22 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 442V 452VE 502V 552VE 602V 652VE Operating limits for Evaporator Water T
58. ___ PRIPVII2 A2 Page 1 2 1 1 1 d 1 i Certe altesiation est pr sum e nulle et le fabricant supportera seul les cans quences de son utilisalion zi ies assurances donn es par le fabricant egistrement Registration code 2002 3948 P HIS La attestalon esi soumise aux Conditions G n rales de Service de Bureau Veritas jointes la demande d intervention sign e parle demandeur This certificate is subject to less of Bureau Vanlas General Conditions of Service sitached tha agreement signed by fhe applicant BUREAU VERITAS 5 2001 http www bureamveritas com ped 92 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E CERTIFICATES DECLARATION OD CONFORMITY EN ENNUX 1 Site industriel Mions Les Meuri res BP 71 e France 69780 Mions France T l phone 33 0 4 72 23 20 20 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 7 23 Description of Equipment Under Pressure and the Procedure of Evaluation to be in Conformity Tvpe of Machine serial Number Year of Manufacture Cat gorie de la DESP Procedure of
59. a Kit for groove lock coupling Add 02 18 Add 01 19 04a 17a Expansion vessel Inlet Outlet manometer Single pump Double pump Air purge Temperature sensor return Temperature sensor supply Plate heat exchanger 50L for WA 150 STD amp 075 090 100 110 HE amp SLN Expansion vessel 50L for all other WA units Inlet Outlet manometer kit for groove lock coupling Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E ECOLOGIC HYDRAULIC DRAWING UNIT WITH FREE COOLING OPTION WA 150 STD LN ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT o9 Groove lock coupling Plate heat exchanger o2 18 Unit isolation valve sb Temperature sensors Water inlet filter In Out manometers without itch diff ial groove lock coupling option ow Switch aiTerena Paddle flow switch mounted on tube Differential flow switch Supplied mounted Paddle flow switch BASIC UNIT Water inlet filter Supplied loose 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 Add Installation Operation Maintenance manual CHILLERS ANNEXES 0105 OPTIONS Add 03 Add 05 Add 02 18 sy LENNOX Std In he sin Free cooling coil Isolating valves Three way valve Drain Unit isolation valve 53 HYDRAULIC DR
60. a 06b Suction and discharge isolation valves 67 076 Safety valve CE or UDT Air cooled condenser Electronic expansion valve Fan motor Shell and tube evaporator Manual isolating valve Economiser heat exchanger Filter drier Temperature sensors Solenoid valve External temperature sensor Sight glass Water differential pressure switch Thermostatic expansion valve GGG 9 8 9 9 2 9 2 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 E ECOM AX REFRIGERANT DRAWING PISTON COM PRESSOR all UNITS high ambient AIRFLOW Refrigeration Circuit Component Screw compressor HP BP and oil pressure switch Pressure transducers HP amp BP Pressure indicator HP BP oil Suction and discharge iso lation valves Safety valve CE or UDT Air cooled condenser Thermostatic Electronic expan sion valve Fan motor Check valve Shell and tube evaporator Manual isolating valve Thermostat Filter drier Temperature sensors External temperature sensor Solenoid valve Water differential pressure switch 9 9
61. activation of the function This allows an anticipated startup in the morning depending on the outdoor temperature Only for the Zone A Anticipation Function Slope in Minutes of anticipation per degrees Water SP Outlet chilled water temperature set point see page 11 Climatic 50 minimum with 17 Glycol according to Water SP Outlet chilled water temperature set point see page 11 IOM Climatic 50 minimum with Glycol according to SP Ambiant air temperature set point see page 13 IOM Climatic 50 SP Ambiant air temperature set point see 0 page 13 IOM Climatic 50 7888 Capacity Factor Reactivity factor for cooling mode Safety limit Chilled water outlet temperature limit CLIMATIC 50 Menu Tree ECOMAX range continued Main perse coe quen co D emie 4 um Enean fo fo _ o ss s EEN f s o 6 m tSpCond 3611 E E PE 000 3700 8 Confg 3800 1 Uni 3810 p 42 T Lr 3820 1 um oS ss e pe ee 3 i B 2 Circuit 2 3832 Liste 2 3 9010 S3X3NNV SH3TTIHO eoueuejure y 5 Sen pressor e 8 Comments IComp priority Circ
62. al 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 AIR COOLED CHILLERS amp SPLIT UNITS 0105 43 TROUBLESHOOTING REPAIRS E 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 500 1000H Major technical visit inspection Inspection visit Tube analysis 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 COOLED CHILLERS amp SPLIT UNITS 0105 E 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 performanc
63. artial or complete destruction of 9A Unit exposed to explosive Risk of explosion or pipe bursting the circuit liquid gas metal parts Protect the units against these types of Indications in the technical materials U products supplied could be thrown out of the unit Inappropriate Heat Transfer Partial or complete destruction of Usual fluids are Water or Water with Indications in the technical IOM Fluid the circuit Leaks Glycol supplied Inappropriate refrigerant fluid in Corrosion excessive heat Pate comp ele GN Only use the fluid specified on the Indications of the refrigerant fluid 11A the circuit liquid gas metal parts ue the circuit combustion or explosion unit s nameplate on the unit nameplate could be thrown out of the unit EN Authorized oils Refer to the Indication on the compressor 12A Inappropriate in the Corrosion excessive heat Partial M complete destruction of compressor nameplate or the nameplate or the manufacturer compressor the circuit Leaks documentation documentation Isolate the section of the circuit to be worked on and recover the refrigerant before any work Always wear protection goggles and gloves Parts to be brazed using best Partial or complete destruction of engineering practices Use brazing the circuit liquid gas metal parts materials approved by Lennox Ensure could be thrown out of the unit the circuit is leak free before refilling with refrigeran
64. arts Check regularly that the warning labels are still in the correct positions on the machine and replace them if necessary 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 he 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 purposes Failure to comply will invalidate any claim against the shipping company Please be reminded that LENNOX is not responsible for off loading an
65. at 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 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 Maximum pressure drop of 100 kPa 3 Liquid velocity under 2 m s to avoid liquid slugging For liquid 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 retur
66. conditional stoppage of the unit if if evaporating pressure drops below the value 1 6 ambient temperature machines standard 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 depends on the concentration of the solution Whatever type of device is used see case 1 and 2 cut out by the antifreeze function causes immediate unit stoppage 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 for water CASE 2 Antifreeze pressure switch This monitors evaporating pressure of the refrigerant It triggers when the temperature goes below the preset minimum value 26 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E OPERATION mu ENNOX Note On units fitted with CLIMATIC control see the appropriate user manual for more specific details 6 2 1 9 Differential oil pressu
67. d 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 9 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 3 1 2 Storage WR Tel 04 72 23 20 20 69780 MIONS FRANCE Type Unit type WA 230DELN Serie Serial N R Annee Year 02 2004 Refrigerant Fluide Nombre de circuits Circuits N R Lei ar WE pressure HP 27 ber Pression Max service BP t SR TT SS vm Air ambiant temp Maxi foit tt TEN Pression d epreuve Test pressure Pression d a Test pressure BP Pression service Max operating pressure HP Pression service BP operating preseure BP Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS
68. e Transmission of the machine service log 500 H 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 E 45 TROUBLESHOOTING REPAIRS 1 8 5 3 LIQUID CHILLERS WITH SCREW COMPRESSOR S 8 5 3 1 Number of recommended preventive maintenance visits NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Major Start up a 2 technical Inspection visit SC Tube analysis inspection 2 L3 _ T This table is published for units operating
69. e continued screen Code Description Code Description Code 5 EEV 2500 1 Circuit 1 2510 2 Circuit 2 2520 2610 Description 1 Config Liste 2 State Liste 3 Sw State On Off 4 Sw High P On Off 5 Sw Low P On Off 6 Relay On Off 7 8 Bypass On Off 9 Run Time h 1 Config Liste 2 State Liste 3 Position 1 Config Liste 2 State Liste 3 Position 1 Config Liste 2 State Liste 3 Sw State On Off 4 Relay On Off 5 Modulat 1 Config Liste 2 State Liste 3 Sw State On Off 4 Relay On Off 1 Config Liste 2 State Liste 3 Sw State On Off 4 Relay On Off 6 Ventilation 2600 1 Fan 1 Circuit 1 2 Fan 2 Circuit 1 2620 2630 3 Fan 3 Circuit 1 5150 1003 SUL NU N OS 2IIVWID XONNI THES 3 S010 SJX3NNV SH3TTIHO eoueuejureyy 5 CLIMATIC 50 Menu Tree ECOLOGIC range continued Main screen Code Description Code Description 4 Fan 4 Circuit 1 5 1 Circuit 2 6 Fan 2 Circuit 2 7 3 Circuit 2 8 Fan 4 Circuit 2 7 Option 2700 1 Recovery Code 2640 2650 2660 2670 2680 2710 Description 1 Config 2641 2 State 3 Sw State 4 Relay 1 Config 2 State 3 Sw State 4 Relay 5 Modulat 1 Config 2 State 3 Sw State 4 Relay 1 Config 2 State 3 Sw State 4 Relay 1 Config 2 State 3 Sw
70. e 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 flow switch ripped antifreeze thermostat In cases other than that of manually reset safety devices starting up of the circuit or the machine takes place automatically 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 If loss of power supply lasts longer than this when power supply is resumed set the unit to OFF with the compressor crankcase heaters activated for as long as it takes to bring sump 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 WA RA 150D WA RA 270D WA RA 300D WA RA 200D WA RA 230D e e 5 VENT 1 C1 uo y C1 VENT1 C1 Cp VENT1 C2 S 1 FR C2 VENT1 C1 VENT1 C2 except LN c
71. e oxygenor acetylene instead of refrigerant fluid and nitrogen for leaktesting 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 Excessive pressure can cause lines to burst damage to the unit and or cause an explosion with severe 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 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 15 INSTALLATION TRANSPORT HANDLING wy LENNOX 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 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 outle
72. ed or improperly treated water salt water or brine 10 Installation Operation Maintenance manual 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 prevent formation of A ice atthe lowest outdoor airtemperatures expected on installation Take precautions when using non 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 It 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 imbalance between earthing points AN EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION
73. ept in operation of this product reproduced issued to or made available to third parties without the prior written agreement of Lennox Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 1 O 7 Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 E TABLE OF CONTENTS wy LENNOX le PREFACE EE 4 PED D cldrdliOll wa NUR HORROR uB PP RUE RE 5 WARRANTY EE 6 EE 6 3 INSTALLATION get eer Re CR RECON Ee E UA CR CUR E NEE e Ce ees 7 MN PERTENECER TT TD TITLE Mu e BEER 8 Lay out and installation requirements 9 3 4 Water connections 10 3 5 Electrical connections 11 36 Soundlevels EEN 12 3 7 Connections of split 12 3 8 Ducted units installation 17 4 PRELIMINARY CHECKS 18 18 4 2 Refrigeration circuit checks and recommendations 18 4 3 Hydraulic system installation ckeckS 18 4 4 Installation of external hydraulic components supplied loose by LENNOX 18 4 5 Check list before start up
74. er 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 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 work on the Chiller
75. er circulating pump and its ancillaries Check the percentage of antifreeze in the chilled water circuit top up as necessary 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 installation 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 th
76. ertified 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 than 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 untreat
77. es 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 Theequipment is being used improperly incorrectly negligently or not in accordance with its nature and or purpose Aflow 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 installation 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 temperature Fans have been provided to discharge heat into the environment The protection of operati
78. escription Description Comments Water SP Ambiant air temperature set point see page 13 IOM Climatic 50 SP Ambiant air temperature set point see page 13 IOM Climatic 50 Capacity Factor Reactivity factor for cooling mode Water SP Outlet hot water temperature set point see page 13 IOM Climatic 50 Water SP Outlet hot water temperature set point see page 13 IOM Climatic 50 Water SP Ambiant air temperature set point see page 13 IOM Climatic 50 Water SP Ambiant air temperature set point see page 13 IOM Climatic 50 Capacity Factor Reactivity factor for heating mode Safety limit Chilled water outlet temperature limit minimum with Glycol according to Code 3323 Factory 3324 ebuei 91507099 SUL nuew OS WOLLVWID 3325 9 2 3 3331 4 3332 C 4 3333 C C C C 3334 C 9 9 is 3 10 5 10 je 1 20 3335 3341 10 10 17 17 10 10 22 CA N jo A 2 0 5 0 0 19 5 53 3342 3411 3 3 Sp Out 1 4 Sp Out 2 5 Reactiv 3 Water Heat 3330 1 Sp Wat 1 2 Sp Wat 2 3 Sp Out 1 4 Sp Out 2 5 Reactiv 4 Safety 3340 1 Wat Low 2 Wat High Compressor 3400 1 Circult 3410 1 Rotat 2 Safety 3420 1 Frost 3 Defrost 3430 1 Mode 2 Outside 3 Coil 4 Time Limit 5 Time Fc 5 EEV 3500 1 Cooling 3510 1 SuperHeat 2
79. est pressure Bar 10 10 10 10 10 10 Hefrigerant 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 Hefrigerant 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 AI 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 Bar 20 20 20 20 20 20 LCH 702V 752VE 803V 853VE 953V 1003VE _Operating limits for Evaporator Water Test pressure Bar 10 10 10 10 10 10 Hefrigerant 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 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 LCH 1053V 1153VE 1254V 1354VE 1404V 1504VE Operating limits for Evaporator
80. 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 CONDENSER WATER CIRCUIT Checked order of power supply phases for scroll and screw compressor units All 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 Checked operation of the pump and condenser pressure drop 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 O 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 supply 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 GENERAL O Cooling load available minimum 50 96 1 Coordination between different professions for final commissioning CUSTOMER ORDER NUMBER LENNOX REFERENCE
81. 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 diagram below figure 14 the following ratio remains the same 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 transmission 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 CHECKS LENNOX A 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 obtaining our agreement beforehand The actual resistance of
82. he low pressure carry out a leak test then top up safety switch Bubbles in the refrigerant charge sightglass Or normal compressor operation but the low pressure safety switch trips out and resets frequently Suction pressure too low Filter Filter drier obstructed Check the state of the drier and drier frozen up 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 Check high pressure safety out switch differential Low air water flow in condenser Check that pumps are operating or dirty condenser coil poor correctly or the state of heat exchange cleanliness of the coils check fan operation Incondensibles in the Bleed from circuit and top up the refrigeration circuit 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 LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION D THE COMPRESSOR RUNS IN LONG CYCLES OR RUNS CONTINOUSLY Faulty control thermostat Check operation Temperature t
83. hes 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 N 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 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 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 isolation 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
84. hnical 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 JOIIASIIFIOIIFCGX I GI GGGV I This check list should be filled in by the contractor to make sure that unit installation takes place according to appropriate 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 1 L1 Check absence of transport damage Check for missing items Availability of suitable lifting gear slings and spacers UNIT PLACEMENT L1 1 L1 Shipping crate removed Clearances checked Vibration isolators mounted Unit set in place Unit levelled CHILLED WATER CIRCUIT 000090 All piping checked for leakage Thermometers installed Water pressure regulator installed Balancing valves installed Flow switch installed System rinsed cleand and
85. hould 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 22 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 UNITSTART UP m ENNOX 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 amou
86. ie fabricant at le Burgau Veritas fhe 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 lors damande dinbtarventian en a d application de son systeme qualit approuv 6 de conformit de son son approbation CE de la canceplion et c d inspection et d essais des produits finis se inaxactes et de mani re g n rale si le fabricant respecte pas l une ou l autre des obligations mises charge par la directive n HIE du 29 mai 1907 telle que lransposee dans le s droits national aux applicables This certificate shail ba deamed to be void and ihe manufacturer shall alone bear any c nseguences pursuant fo ils use where lte manufacturer fats fo comply with his undertakings as agreement in respect of immplementalian gf tha approved quality system b conformity of the equipment EC desim approval conditions and inspection and fests on the produci and generally where tho manufacturer falls partizulsr Fo with any of his obligations under direclive 87 23 EC of 20 may 1997 as transposed im the applicable laws Etabli Made af Sign Signed by SignBthre Signature LYON DARDILLY 02 SEPTEMBRE 2002 P BERIOU STER TA wt LS __
87. ion VARIANT OPTIONS CE or UDT HP LP pressure gauges Suction and discharge isolating valves 07a or 07b Add 06 060 Add 05a 05b Installation Operation Maintenance manual CHILLERS ANNEXES 0105 RA REFRIGERATION CIRCUIT LENNOX HO std In he sin REFRIGERANT DRAWING Text AIRFLOW C Airflow L AIRFLOW REFRIGERATION CIRCUIT COMPONENTS 1st amp 2nd scroll compressors 67 07b Safety valve CE or UDT 3rd scroll compressor on size l 370 STD LN HE amp SLN Air cooled condenser High pressure switch Fan motor Pressure transducers HP amp BP Low and High pressure Manual isolating valve manometer 06a 06b Suction and discharge isolation 11 Filter drier valves Solenoid valve Sight glass Suction temperature sensor External temperature sensor 8 9 9 Heating resistance option VARIANTS OPTIONS Size 370 WA unit suction and BASIC UNIT EHE Ee discharge isolating Sight glass STD LN HE SLN CE or UDT gauges valve 01 03 04a 04b 08 09 10 11 12 18 Add 02 07 070 Add 05a amp 05b Add 06a amp 06b Add 13 19 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 67 ECOM AX REFRIGERANT DRAWING SCREW COMPRESSOR all UNITS high ambient Refrigeration Circuit Component Screw compressor High pressure switch Pressure transducers HP amp BP Low and High pressure manometer 06
88. is type of installation all dust gathered on the coils should be quickly removed by regular cleaning Caution do not 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 b
89. itzer B320SH Maneurop Maneurop 160 P Copeland Suniso 3 GS Copeland Suniso 160P Maneurop Maneurop 160 P Bitzer BSE170 Maneurop Maneurop 160 SZ Scroll ZR Copeland Copeland 3MA Mobil EAL Arctic 22CC ICI Emkarate RL32CF Reciprocating 08 Copeland Mobil EAL Arctic 22 Reciprocating MS Maneurop Maneurop 160 SZ Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 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
90. lation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 OPERATION mu EVW X 6 1 4 Connection diagrams CLIMATIC TM 50 OOO DS 50 INS ID C E Cl ND 05 C TONS C lt 5 2 C XL X 1 8 za D D O ata D g C ca D UNS D D D JA DC 50 DOA 2A vA EDI 49 lt A lt 5DI LJ 50 ZDI 80N BOL 85 1000 SON 18 88 UNS SS SDN ATON DIDL 69 20 640 NTC HEIDE 1 ON diltol OFF Input 5 6 m 1 2 g ld HSIDL eeeegjeeeses eees Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 25 OPERATION mu ENNOX 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
91. ld 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 e 27 OPERATION 28 mu ENNOX 6 2 3 Automatic sequences 6 2 3 1 Starting sequence Press the unit start switch the power light will come 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 sequence 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 pressur
92. ling 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 o 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 working practic
93. mperature 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 Min outlet water temperature 5 5 5 5 2 Max inlet water temperature C 20 20 20 20 20 Min difference water inlet outlet 3 3 3 3 Max difference water inlet outlet S 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 5 5 5 5 5 Max inlet water temperature 6 20 20 20 20 20 Min difference water inlet outlet 3 3 3 3 3 Max difference water inlet outlet 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 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 ECOM AX OPERATING LIMITS wy LENNOX LCH VK PK all units Bug LCH 322P 412P 462P 532 402 422VE Operating limits Min outlet water temperature C 5 5 5 5 5 5 Max inlet water temperature 20 20 20 20 20 20 Min difference water inlet outlet 3 3 9 9 3 3 Max difference water inlet outlet C 8 8 8 8 8 8 Min outside air temperature C 6 6 6
94. mperature sensors Plate heat exchanger 22 Flow switch Differential oa 17 In Out manometers without groove lock coupling option in Out manometers mounted on groove lock coupling option Paddle flow switch BASIC UNIT 16 15a 15b 50 OPTIONS Flow switch differential Unit isolation valve Supplied mounted Add 03 Add 05 Add 22 Add 02 18 Inlet Outlet manometer kit for groove lock coupling Add 01 19 Add 04a 17a Add 04b 17b amp 01 19 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 Flow switch paddle Water inlet filter Supplied loose Kit for groove lock Inlet Outlet coupling manometer ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITH HYDRONIC MODULE ITEMS SUPPLIED LOOSE or 19 Groove lock coupling Unit isolation valve Paddle flow switch Water tank 200L or 500L Water inlet filter Safety valve In Out manometers without Ai groove lock coupling option EE In Out manometers mounted on Water drain groove lock coupling option 25L expansion vessel Second 25L expansion vessel for gt 1500 GG 9 9 ITEMS MOUNTED INSIDE THE UNIT 9939999399 std In he sin D Single 50L expansion vessel WA lt 150D Pump suction isolation valve Single pump Double pump Air purge Temperature sensor return Temperature sensor supply Plate heat exchanger OPTIO
95. n Description 3 1 Circuit 1 2 Circuit 2 3 Circuit 3 4 Circuit 4 Code 3831 3832 3833 3834 Liste Comments Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed O 79 TI AJ gt ES lt E gt lt D 5 3 gt 3 9010 S3X3NNV 5 5 e 68 CLIMATIC 50 Menu Tree ECOMAX range continued em _ code sesion Code pm m Unt Im e 4 Option 5 Out Custom 6 In Custom 7 1 Custom 3840 3850 3860 3870 1
96. n 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 at saturation pressure on the suction side e 12 Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLATION TRANSPORT HANDLING LENNOX UNITS WITH REMOTE CONDENSER Unit with remote condenser Unit with remote condenser without capacity control with capacity control dEr max 1 Lower trap with single tube H2 5m maxi 2 Clode coupled trap H3 0 3 m maxi 3 Lower trap with double tubes H4 0 15 m maxi 4 Higher trap with double tubes WARNING The liquid level between the condenser and the check valve A must compensate the check valve pressure drop receiver option eclaration class 3 If no receiver option PED declaration class 1 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 e 13 INSTALLATION TRANSPORT HANDLING LENNOX CONDENSING UNITS Condensing unit Condensing unit without capacity control with capacity control Min 0 25 gradient Lower trap with single tube Clode coupled trap Lower trap with double tubes Higher trap with double tubes H1 15 m maxi H2 5 m maxi HA 0 15 m maxi
97. n the Check water flow Check fouling evaporator 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 my 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 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 Replace the
98. ne Check that anti vibration mountings are correclty 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 e 18 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 PRELIMINARY CHECKS LENNOX tightened in the various wells if necessary add heat conducting paste to improve contact Make sure all sensors are correctly fitted and that all capillary tubes are fastened 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
99. ng and maintenance 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 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 hazardous part A High temperatures Electrical Rotating Sharp voltage parts p
100. nied by installation of flexible connections in the unit water piping Vibration isolators must also be fixed to the unit BEFORE being 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 A Itis 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
101. nt of liquid subcooling at the condenser outlet IMPORTANT Start up and commissioning must be conducted by LENNOX authorised engineer Never shut of power to the crankcase heaters except for lengthy service operations or seasonal shutdown Remember to power up the crankcase heaters at least 24 hours before the unit is restarted Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 23 OPERATION mu ENNOX 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 A remote 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 mm 2 Electrical box at the unit Terminal block Remote controller optional x 1000 1 IV SY Three lead shielded cable with a cross section of 1mm Connection to be made by user MAXIMUM LENGTH 50m 24 Instal
102. oo low in the Chilled water thermostat set too s Adjust it conditioned space low 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 MEM Liquid line valve not open far Open the valve completely enough Noisy compressor or abnormally Leaky compressor valves Check valve gas tightness high suction pressure or low replace the valve plate if discharge pressure necessary Tighten compressor nuts and bolts E THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH MEM 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 Repair and add oil Suction line unusually cold Liquid refrigerant present in the Check appearance of the oil in compressor noisy compressor crankcase 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 i
103. operations and when setting it on the ground CAUTION BEFORE EACH SERVICE OPERATION MAKE SURE THAT THE UNIT POWER SUPPLY IS PROPERLY ISOLATED AND LOCKED OUT A NOTE 5 UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPARATE 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 s He Installation Operation Maintenance manual AIR COOLED CHILLERS amp SPLIT UNITS 0105 INSTALLA
104. pe or vessel bursting 7 Possibility of a unit being hit by Extreme heat explosion cracks lightning Unusual increase in the temperature of the Chilled water return to the evaporator or the hot return water to the condenser Installation Operation Maintenance manual CHILLERS ANNEXES 0105 Outdoor temperature below Strains vibrations and cracks freezing pipe bursting Event Actions to Eliminate the Risk onto minimise Occurrence of a risk Violent Chocks Static or Appearance of cracks distortions Leaks liquid or gas projections Only handling the units using the Handling procedure shown in the Dynamic Loads applied possibility of rupture Metal parts projections chassis and lifting rings if available supplied with the unit Level the machine during commissioning In the case where the unit is installed on anti vibration Leaks mountings all supporting points must be used and the block hardness must be selected according to the type of units being installed Proper support and fitting of the pipe Indications in the technical Leaks work on site supplied with the unit Partial or complete destruction of Provide anti frost protection ei Water WECKER Indications in the technical IOM the circuit liquid gas could be treated with Glycol or trace heaters thrown out of the unit along the pipe work Recommended minimum and maximum outdoor temperature 20
105. pplied for maintenance 7 1 WEEKLY MAINTENANCE 1 Check the compressor oil level This should be half way up the 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 humidity 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 wa
106. r flow in the evaporator Measure flow check the 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 Check evaporating pressure the pressure safety switch tripped condition of the antifreeze thermostat and the low pressure safety switch Compressor thermal Check for proper operation of protection relay tripped the relay High pressure safety switch Check the condensing pressure tripped and the condition of the high pressure safety switch Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E 33 TROUBLESHOOTING REPAIRS LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION B THE COMPRESSOR DOES NOT START Low pressure safety switch trip Check low pressure safety out switch differential Normal operation with too Low refrigerant charge Check the charge through the frequent starts and stoppages sightglass on the liquid line due to action of t
107. re kit 2 Unloading start up sequence 60 Installation Operation Maintenance manual CHILLERS ANNEXES 0105 E ECOM OPERATINGLIMITS all units my LENNOX LCH VK 402V 422VE 442V 452VE 502V 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 3 3 3 3 3 Max difference water inlet outlet 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 51 51 51 51 50 5 LCH 552VE 602V 652VE 702V 752 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 S 3 3 3 3 3 Max difference water inlet outlet S 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 50 5 50 5 50 5 20 5 50 5 LCH 803V 853VE 953V 1003VE 1053V Operating limits Min outlet water temperature 5 5 5 5 2 Max inlet water temperature C 20 20 20 20 20 Min difference water inlet outlet 3 3 3 3 Max difference water inlet outlet S 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 50 5 50 5 50 5 50 5 49 LCH 1153VE 1254
108. re 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 modifiable 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 injection 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
109. s put into service see the chapter 8 6 Inspect the entire system so as to detect any eventual abnormality noisy 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 7 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 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 31 MAINTENANCE mu ENNOX 3 Clean any corroded surfaces and repaint them 4 Inspect the chilled water circuit for any signs of leakage Check operation of the wat
110. sightglass Low refrigerant charge Repair the leak and add refrigerant Excessive pressure drop across Filter drier obstructed Replace the cartridge the filter drier or the solenoid valve No refrigerant passing through Expansion valve bulb has lost its Replace the bulb the expansion valve charge Loss of capacity Expansion valve obstructed Clean or replace Conditioned space too cold Control thermostat contacts Repair or replace stuck in closed position Compressor short cycling Capacity modulation setting too Adjust low Superheat value too high Excessive pressure drop in the Check the external equalizing evaporator line on the expansion valve Low pressure drop in the Low water flow Check water flow Check the evaporator condition of the filters look for obstructions in the chilled water circuit 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 A dirty 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
111. t Unit exposed to inductive Corrosions cracks Indications in the technical Unit exposed to internal or Strains cracks explosions Partial e complete destruction of Inspect the unit regularly Indications in the technical IOM 16A Estambul the circuit liquid gas metal parts Steg could be thrown out of the unit Unit damaged due to fatigue Strains cracks corrosion Leaks T a Indications in the technical IOM wear and tear pp y 9 supplied products supplied Indications in the technical IOM supplied Liquid gas metal parts could be thrown out of the unit Working on a part under Risk of explosion or part bursting pressure away from the machine Indications in the technical IOM supplied Brazing or un brazing parts Strains cracks pipe from the circuit bursting 64 Installation Operation Maintenance manual CHILLERS ANNEXES 0105E ECOLOGIC REFRIGERATION CIRCUIT REFRIGERANT DRAWING REFRIGERATION CIRCUIT COMPONENTS 1st amp 2nd scroll compressors 64 04b Pressure transducers HP amp BP Low and High pressure manometer 06a 665 Suction and discharge isolation valves Safety valve CE or UDT 3rd scroll compressor on size 370 STD LN HE amp SLN High pressure switch 2 2 VARIANTS Size 370 WA unit HE SLN CE or UDT 01 03 04 040 08 09 10 11 17 19 muy Std In he sin 370 STD LN HE SL
112. t 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 dehydration completely purge the unit Charge the unit until there is a constant flow of 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 A risk 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 Cil type R22 R22 R22 R22 R22 R407C R407C R407C R407C R407C 16 B
113. t the end of the 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 unit entrance 1 The components are located inside the units and must be installed by a 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 do
114. uit priority management Safety limit Freezing safety limit minimum with Glycol according to Safety limit Lennox setting EEV Superheat set point EEV Lennox set point EEV Lennox set point Proportional factor EEV Lennox set point Integral factor EEV Lennox set point Derivate factor HP SP High pressure set point for R134a unit HP Factor Reactivity set point for fan operation Configuration Unit model Configuration Type of unit Configuration Type of refrigerant R407C H134a R22 Configuration Electronic expansion valve Configuration All season control Configuration For units with reciprocating compressor extra capacity reduction Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Stages Single speed stage fans Modulation 1 fan with speed control others with single speed Low Speed 1 fan with 2 speed others with single speed XvINOO3 9341 nue OS NOILVH3dO XONNI 3 S010 SJX3NNV SH3TTIHO 5 CLIMATIC 50 Menu Tree ECOMAX range continued Screen Description Code Descriptio
115. 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 AIR COOLED CHILLERS amp SPLIT UNITS 0105 TROUBLESHOOTING REPAIRS mu ENNOX 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 H 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 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 tec
116. y 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 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 AT Operating limits for evaporator 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 E ECOM OPERATINGLIMITS all units muy LENNOX LCH VK 402V 422VE 442V 452VE 502V 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 3 3 3 3 3 Max difference water inlet outlet 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 S 3 3 3 3 3 Max difference water inlet outlet S 8 8 8 8 8 Min outside air temperature C 6 6 6 6 6 Min outside air te
117. y the presence of humidity in the system When the oil has changed colour or has been degraded it must be changed 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 32 Installation Operation Maintenance manual IOM AIR COOLED CHILLERS amp SPLIT UNITS 0105 E TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS PROBLEMS SYMPTOMS PROBABLE CAUSE A THE COMPRESSOR DOES NOT START Motor control circuits No power supply Check main power supply and established the compressor switch positions not run does not ru Compressor motor burnt out Low voltage reading on Voltage too low Contact power company he system does not start up RECOMMENDED ACTION Determine the cause Breaker tripped or fuses blown If the system is in running order close the disconnect Check condition of fuses No wate

INSTALLATION - OPERATING & MAINTENANCE MANUAL

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INSTALLATION - OPERATING &amp; MAINTENANCE MANUAL

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INSTALLATION - OPERATING & MAINTENANCE MANUAL