OPERATING MANUAL Enertronic Control System 2
Contents
1. cc fcc s ceto soie 32 tette etur tette tumet tui au MENU 33 BTE AANO oum oorr bl Um M UR A d 33 Diagriose fublctiO mis 35 5 nto Reo rn eter aa axo a Ei teure a 33 1 PREFACE The Enertronic Control System 2 provides the functionality required to protect control and operate your Lennox Ecologic or Seconscrew chiller It has the ability to operate those processes that take place in your chiller to the best advantage thus guaranteeing efficient operation throughout the life of the machine Operation of the Enertronic Control System 2 is based around a number of software and hardware modules These modules are combined to form a specific control system for the Lennox chillers The hardware for the control system comes in two versions namely Single circuit configuration Double circuit configuration These user instructions describe the operation and control of both configurations including the necessary hardware However the availability of the different functions and the presence of the different hardware modules are determined by the configuration of your Lennox chiller COPYRIGHT TO DETERMINE THE RELEVANT FUNCTIONALITY FOR YOUR APPLICATION THIS USER MANUAL MUST BE CONSULTED IN CONJUNCTION WITH THE USER INSTRUCTIONS SPECIFIC TO YOUR LENNOX CHILLER FOR ALL GUIDELINES PERTAINING TO SAFETY USE AND MAINTENANCE AND WARRANTY REFERENCE SHOULD ALSO BE MADE2. is not applicable to your Lennox chiller e The messages relating to the second refrigerant circuit are not important in the case of a single circuit chiller 8 EC 91 0005 REV C EN 30 Level 1 Level 2 F1 Measurements F1 Refrigerant F2 Settings Main menu Diagnose F4 Status F2 Secondary F1 Settings F2 Reset test F3 Access F1 Circuits F2 Eve s Table 18 Functions of display module 8 EC 91 0005 REV C EN Level 3 Level 4 F1 Circuit 1 F2 Circuit 2 F1 Setpoint water outlet control F2 Setpoint condenser control F3 Setpoint EVe control F4 External setpoint adjust F1 Reset mode F2 Test mode F1 Eve circuit 1 F2 Eve circuit 2 accessible with the correct access code Parameter Condensing pressure bar Condensing temperature Evaporating pressure bar Evaporating temperature Condensing pressure bar Condensing temperature Evaporating pressure bar Evaporating temperature Evaporator water outlettemp Setpoint water outlet control Ambient temperature External control signal V Adjust F2 down F3 up CS Adjust F2 down F3 up Adjust F2 down F3 up 2 increase decrease Only glycol applications F3 activate F3 activate minutes max 60 F1 F5 tor access Overall diagnose Diagnose circuit 1 Diagnose circuit 2 Sequence Percentage 1 2 Hours ran 1 2 St
3. 3 7 Inputs and outputs of double circuit version equipped with screw type compressors This applies amongst others to machine types WA 285D to WA 430D SC W 240D to SC W 410D SC S 240D to SC S 410D The inputs and outputs are located as outlined for the previous version But from a functional point of view there are differences because the machines are equipped with screw type compressors 3 7 1 Digital outputs of double circuit version equipped with screw type compressors Number a amp O Table 11 Numbering of digital outputs Function Control compressor 1 Control 75 capacity stage compressor 1 Control 100 capacity stage compressor 1 Control compressor 2 Control 75 capacity stage compressor 2 Control 100 capacity stage compressor 2 Control condenser fan group 1 circuit 1 Control condenser fan group 2 circuit 1 Control condenser fan group 3 circuit 1 high speed fan 1 Control economiser circuit 1 Control expansion valve 1 circuit 1 Control expansion valve 2 circuit 1 Control evaporator heating Control transmission pump evaporator circuit Control condenser fan group 1 circuit 2 Control condenser fan group 2 circuit 2 Control condenser fan group 3 circuit 2 high speed fan 1 Control economiser circuit 2 Control expansion valve 1 circuit 2 Control expansion valve 2 circuit 2 Failure indication Not used 8 EC 91 0005 REV C EN LED indicator Depending on present operating circumstances and machi
4. Delay in engaging for oil warming Anti cycling active circuit remains disengaged Reduction in cooling capacity unloading Compressor stop Compressor stop after 6 min Immediate compressor stop Compressor stop Compressor stop Compressor stop Compressor stop Compressor stop Table 16 Compressor safety features Limit values Maximum 6 hours 10 min if operating time gt 5 min 30 min if operating time lt 5 0 94 x maximum discharge pressure Pressure switch value P1 3 bar 0 2 bar Firmly set Firmly set Anti clockwise phase rotation Firmly set Machine dependent Failure No No No Yes Yes Yes Yes Yes Yes Yes Yes Reset required No No No Yes on pressure switch Yes general reset Yes general reset No automatic after cooling Yes general reset Yes general reset Yes general reset Yes on motor starters Interruption lt 30 min no wait time except poss anti cycling interruption gt 30 minutes wait time time interruption lasts Maximum 6 hours e g on first start up With use of glycol see Figure 8 previous page 8 EC 91 0005 REV C EN 22 4 3 Safety features for the condensers The condenser fans in your Lennox chiller are protected against overloading This is achieved by internal protection elements and overload relays In both cases a failure will result in disenga
5. 6 1 2 Diagnose function Tables 19 to 21 inclusive provide information regarding the possible messages that can be generated by the diagnose function 10 Circuit OK 11 Low pressure failure circuit 1 14 High pressure failure circuit 1 15 Oil level compressor 1 too low optional 16 Motor overload protection compressor 1 tripped Diagnose circuit 1 17 Thermistor phase sequential protection compressor 1 tripped 19 Temperature protection condenser fan s circuit 1 tripped 21 Anti cycling protection compressor 1 tripped 22 High pressure capacity reduction circuit 1 active 24 action EVe circuit 1 gt 12 fort gt 1 hour 25 action EVe circuit 1 20 fort 5 minutes 26 Suction gas temperature sensor circuit 1 defective Table 19 Diagnosis register of circuit 1 8 EC 91 0005 REV C EN 33 30 31 34 35 36 37 39 41 42 44 45 46 Diagnose circuit 2 Table 20 Diagnosis register of circuit 2 50 51 52 53 54 56 57 66 67 68 69 70 71 72 Overall diagnosis Table 21 General diagnosis register Sequence Circuit OK Low pressure failure circuit 2 High pressure failure circuit 2 Oil level compressor 2 too low optional Motor overload protection compressor 2 tripped Thermistor phase sequential protection compressor 2 tripped Temperature protection condenser fan s circuit 2 tripped Anti cycling protection compressor 2 tripped High pressure capacity reduction circuit 2 active action E
6. LED indicator 80 Starting command On 81 Contact for flow or pump switch On 82 Peak load limiting On 83 High pressure protection input circuit 1 On 84 Safety chain compressor 1 circuit 1 On 85 Safety chain compressor 2 circuit 1 On 86 Safety chain compressor 3 circuit 1 B 87 Safety chain condenser circuit 1 On 96 Failure contact pump unit optional On 97 Input to activate second setpoint optional B 98 Not used n a 99 High pressure protection input circuit 2 On 100 Safety chain compressor 1 circuit 1 On 101 Safety chain compressor 2 circuit 2 On 102 Safety chain compressor 3 circuit 2 iE 103 Safety chain condenser circuit 2 On Table 9 Numbering of digital inputs Depending on present operating circumstances and machine configuration 8 EC 91 0005 REV C EN 3 6 4 Analog inputs of double circuit version equipped with scroll compressors Number Function LED indicator 64 External setpoint adjustment 0 10VDC optional 65to67 Not used n a 68 Water inlet temperature sensor lon optional n a 69tto71 Not used n a 112 Low pressure transmitter circuit 1 n a 113 High pressure transmitter circuit 1 114 Low pressure transmitter circuit 2 115 High pressure transmitter circuit 2 116 Suction gas temperature sensor circuit 1 117 Suction gas temperature sensor circuit 2 118 Ambient temperature sensor 119 Waiter outlet temperature sensor Table 10 Numbering of analog inputs 8 EC 91 0005 REV C EN
7. single circuit version equipped with scroll 9 Analog inputs of single circuit version equipped with scroll compressors 9 INPUTS AND OUTPUTS OF SINGLE CIRCUIT VERSION EQUIPPED WITH A SCREW TYPE 10 Digital outputs of single circuit version equipped with a screw type 10 Digital inputs of single circuit version equipped with a screw type compressor 11 Analog inputs of single circuit version equipped with a screw type 11 INPUTS AND OUTPUTS OF DOUBLE CIRCUIT VERSION EQUIPPED WITH SCROLL 12 Digital outputs of double circuit version equipped with scroll 12 Analog outputs of double circuit version equipped with scroll 13 Digital inputs of double circuit version equipped with scroll compressors 13 Analog inputs of double circuit version equipped with scroll 14 INPUTS AND OUTPUTS OF DOUBLE CIRCUIT VERSION EQUIPPED WITH SCREW TYPE COMPRESSORS 15 Digital outputs of double circuit version equipped with s
8. to 55 inclusive The status of the respective input or output is indicated by LEDs except for analog inputs The following tables show the different inputs and outputs Where applicable the status of the respective LED indicator during normal operation is also shown 3 4 1 Digital outputs of single circuit version equipped with scroll compressors Number Function LED indicator 0 Control compressor 1 js 1 Control compressor 2 f 2 Control compressor 3 i 3 Not used n a 4 Not used n a 5 Not used n a 16 Control condenser fan 1 3 17 Control condenser fan 2 18 Control condenser fan 3 high speed fan 1 j 19 Control expansion valve 1 20 Control expansion valve 2 m 21 Control evaporator heating bs 22 Control transmission pump evaporator circuit i 23 Failure indication On Table 1 Numbering of digital outputs Depending on present operating circumstances and machine configuration 8 EC 91 0005 REV C EN 8 3 4 2 Digital inputs of single circuit version equipped with scroll compressors Number Function LED indicator 32 Starting command On 33 Contact for flow or pump switch On 34 Failure contact pump unit optional On 35 High pressure protection input On 36 Safety chain compressor 1 On 37 Safety chain compressor 2 38 Safety chain compressor 3 2 39 Safety chain condenser On Table 2 Numbering of digital inputs Dependent on machine configuration 3 4 3 Analog inputs of single circuit version equipped with scroll compressors Num
9. 078 2039 2000 1961 19228 18828 1843 t SORE e0 15 10 5 0 5 10 15 20 25 30 35 40 Figure 5 Sensor resistance temperature relationship 8 EC 91 0005 REV C EN 18 4 SA FETY FEATURES The Enertronic Control System 2 has extensive safety features for the different components used in your Lennox chiller The safety features can be divided into four main groups i e Safety features for the evaporator Safety features for the compressors Safety features for the condensers General safety features 4 1 Safety features for the evaporator The evaporator on your Lennox chiller is protected from freezing by the Enertronic Control System 2 This is primarily achieved by monitoring the flow or differential pressure switch in the hydraulic system An opened contact on this switch will lead after 5 seconds to disengaging of the compressors in your chiller Too low a water outlet temperature will result in the disengaging of the compressors and engaging of the heating tape If your Lennox chiller is designed with a hydraulic module or pump unit the electric heater unit in the integrated buffer tank is engaged at the same time as the heating tape If due to unforeseen circumstances the water outlet temperature drops still further the controller will switch the chiller off frost failure using an electronic locking device Too low an evaporation temperatu
10. 4 Nol oe 24 Analog setpoint adjustment padded dh pa de d e dried 25 Operation with two setpoints sss eene nnne nnne entente 25 1 19 date ed d dte 25 Pretf rence SWIICDS 26a 25 Peak load IMNO A 2 3 pen ietapr aeta initelibiiaibetafii istae i 25 CONTROL OF AIR COOLED CONDENSERS esee eene enne insit inrs inis inan etas itas inns ensi 26 Discrete 26 Pulse widlli COPnlrol ed ice d iu cadet e E Y RS CR e DERE 26 Control of condenser fans using frequency controllers esee 27 CONTROL OF WATER COOLED CONDENSER esee inns inns nennen 27 CONTROLLING THE ELECTRONIC EXPANSION VALVE eeeeeeee nennen enne 28 OPERA TCA os a peters reve e o E nave et re fa he PR a ne o rom f hte ee onte e em foh et eed 29 OVERVIEW OF OPERATING FUNCTIONS sees eene nnne nnne inns inns 30 Specific TUrICTOFIS eer ec mm c eem n norm cared mof ELT 32 Setpoint of water outlet control esses enne tnnt trennen trennen nnn 32 Setpoint of condenser control enne trennen nnne nnn 32 SOMONE OF EN G S
11. ED IF ACCESS IS GAINED USING THE ACCESS FUNCTION INCORRECT SETTINGS CAN LEAD TO FAULTS IN THE CHILLER 6 1 1 3 Setpoint of EVe s This is used to adjust the desired value for the control of the superheating or the control of the electronic expansion valves The value can lie between 4K and 15K The desired value is lowered or raised by pressing keys F2 and F3 respectively THE VALUE CAN ONLY BE MODIFIED IF ACCESS IS GAINED USING THE ACCESS FUNCTION INCORRECT SETTINGS CAN LEAD TO FAULTS OR DAMAGE TO THE CHILLER 8 EC 91 0005 REV C EN 32 6 1 1 4 Reset mode This menu allows the machine to be reset using function key F3 This reset may be necessary if the locking safety feature is tripped by the Enertronic Control System Chapter 4 REPEATED RESETTING OF THE INTERLOCKS AS A CONSEQUENCE OF INCORRECT SIZING OF THE HYDRAULIC SYSTEM THE CHILLER OR OTHER SETTINGS CAN RESULT IN DAMAGE TO THE CHILLER 6 1 1 5 Test mode The test mode provides qualified service personnel with access to a number of functions crankcase heater delay blockage with low ambient temperature anti cycling timers whereby a rapid diagnosis can be made of the operation of your Lennox chiller Test mode remains active for a maximum of one hour after which it must be reactivated OPERATION IS ONLY POSSIBLE ONCE ACCESS HAS BEEN GAINED USING THE ACCESS FUNCTION IMPROPER USE OF TEST MODE WILL LEAD TO FAILURE IN OR DAMAGE TO THE CHILLER
12. OPERATING MANUAL Enertronic Control System 2 The integrated control system for Lennox chillers in the Ecologic and Seconscrew ranges M meinen Manufacturer Lennox Benelux B V Postbus 1028 3860 BA NIJKERK Watergoorweg 87 3861 MA NIJKERK Netherlands Tel 31 0 33 2471800 Fax 4431 0 33 2459220 8 EC 91 0005 REV C EN 2 1 2 2 3 1 3 2 3 3 3 4 3 4 1 3 4 2 3 4 3 3 5 3 5 1 3 5 2 3 5 3 3 6 3 6 1 3 6 2 3 6 3 3 6 4 3 7 3 7 1 3 7 2 3 7 3 3 7 4 3 8 4 1 4 1 1 4 2 4 3 4 4 4 5 8 EC 91 0005 REV C EN CONTENTS PREEAGE red adu 4 VERSIONS aunseantsan nante eid apiid npn n RM HUN ERR 5 SINGLE CIRCUIT CONFIGURATION 5 DOUBLE CIRCUIT CONFIGURATION Mm 5 HARDWARE esse eta al ccs Ee odes tactic a E as ce r EEEa 6 HARDWARE OF SINGLE CIRCUIT VERSION isses teen tnter teret tnter tette nnne 6 HARDWARE OF DOUBLE CIRCUIT VERSION 7 FUNCTION LEDS e 7 INPUTS AND OUTPUTS OF SINGLE CIRCUIT VERSION EQUIPPED WITH SCROLL COMPRESSORS 8 Digital outputs of single circuit version equipped with scroll 0 5 8 Digital inputs of
13. S ANOTHER VALUE MAY APPLY FOR SUPERHEATING The superheating will be increased if as the result of a very high water temperature an impermissibly high loading of the compressors may result effect As already stated in the general safety features too great a correction of the feed forward value by the action will result in a failure indication 8 EC 91 0005 REV C EN 28 OPERATION Your Enertronic 2 chiller control system has a display unit containing 5 function keys Using this display and the intelligence integrated in the software your Lennox chiller can be operated simply and its operating status can be determined The display has a 4 line LCD screen Figure 7 AS soon as one of the function keys is pressed the LCD screen will light up If no key is pressed for 1 hour the lighting is dimmed Using the function keys certain selection screens or menus are selected The tasks performed by the various function keys depend on the menu selected Using an access code certain operating parameters in your Lennox chiller can be modified LENNOX Enertronic Control System Figure 10 Display module The following pages explain the various menus In Table 18 you will find a schematic overview of the various menus IT IS VERY IMPORTANT THAT OPERATING OR MAINTENANCE PERSONNEL ARE FAMILIAR WITH THE OPERA
14. TION OF THE DISPLAY SO THAT INFORMATION REGARDING THE OPERATION OF YOUR LENNOX CHILLER CAN BE RETRIEVED EFFICIENTLY 8 EC 91 0005 REV C EN 29 6 1 Overview of operating functions The operations that can be performed using the display module can be roughly divided into four groups Measurements Settings Diagnose Status In sequence these functions provide the following options Measurements This allows a choice to be made to read out the different values measured in your Lennox chiller Settings The functions in the group settings can be used to modify the desired values for different control circuits Reset and test modes are also part of this group Diagnose Using this function the current operating status of your Lennox chiller can be determined very effectively Status Status stores functions that provide information concerning the functioning of specific components in your Lennox chiller These groups can be selected with the keys F1 to F4 from the main menu The function keys can again be used to select a submenu within a group Some menus provide the option sometimes after keying in an access code of operating or modifying specific things within the Enertronic Control System The function key F5 always has the same function that is to return to the previously selected menu THE NEXT PAGE PROVIDES AN OVERVIEW OF THE VARIOUS MENUS AND THEIR FUNCTIONS Note e options menu F1
15. TO THE USER INSTRUCTIONS APPLYING TO YOUR SPECIFIC LENNOX CHILLER ALL THE TECHNICAL AND TECHNOLOGICAL INFORMATION CONTAINED IN THIS MANUAL INCLUDING ANY DRAWING AND TECHNICAL DESCRIPTIONS PROVIDED BY US REMAIN THE PROPERTY OF LENNOX BENELUX B V AND MUST NOT BE UTILISED EXCEPT IN THE OPERATION OF THIS PRODUCT REPRODUCED ISSUED TO OR MADE AVAILABLE TO THIRD PARTIES WITHOUT THE PRIOR AGREEMENT OF LENNOX BENELUX B V 8 EC 91 0005 REV C EN 4 2 VERSIONS The Enertronic Control System 2 is an independently operating control system which provides the same functionality for both the single circuit machine and the double circuit machine This functionality can be subdivided into three main groups Safety functions Control functions Operating functions In terms of hardware a distinction is made between machines equipped with scroll compressors and machines using screw type compressors The hardware is the same But the functionality of the control system is different because additional components have to be activated with machines using screw type compressors This manual refers where necessary to the machine type 2 1 Single circuit configuration The single circuit configuration is made up from one hardware configuration integrating two configurations which are different when it comes to using inputs and outputs This configuration is used amongst others for the following machine ranges Single circuit machines using scroll compr
16. Ve circuit 2 gt 12 for t gt 1 hour action EVe circuit 2 lt 20 for t lt 5 minutes Suction gas temperature sensor circuit 2 defective General preset values OK Delay for oil heating active Machine blocked due to too low ambient temperature Machine blocked due to too low water outlet temperature Frost protection tripped control Contact on flow switch not closed No start command present Water outlet temperature sensor defective Ambient temperature sensor defective Advance time transmission pump in evaporator circuit active Lag time transmission pump in evaporator circuit active Protection transmission pump pump unit tripped No start command from LON network present Peak load limiting active 1 circuit 2 starts after 1 2 circuit 2 starts after 2 Table 22 Starting sequence of cooling circuits 8 EC 91 0005 REV C EN 34 8 91 0005 REV C EN Subject to modification Manufacturer Lennox Benelux B V Postbus 1028 3860 BA NIJKERK Watergoorweg 87 3861 MA NIJKERK Netherlands Tel 31 0 33 2471800 Fax 4431 0 33 2459220 35
17. according to the machine version and the options you have chosen 3 3 Function LEDs The function LEDs provide information concerning the correct operation of the control system In normal operation the Supply 24VDC and Run LEDs will show a yellow light If the status of the function LEDs is different you should contact the service department at Lennox One exception to this is the status of the Battery LED When this LED shows red this indicates that the back up battery in the control system is flat Provided the machine is connected to the mains voltage this battery can be replaced during the periodic maintenance of your chiller If the battery should become flat while the machine is disconnected from the mains voltage only the temporarily stored information e g hour counters will be lost The software stored in non volatile eprom memory will always remain stored The functioning of the chiller cannot therefore be adversely affected by the battery running low The standard life of a battery is 2 to 5 years Note the function LEDs are not available in the single circuit version 8 EC 91 0005 REV C EN 3 4 Inputs and outputs of single circuit version equipped with scroll compressors This applies amongst others to machine types WA 40E to WA 110E WW 45E to WW 130E WS 45E to WS 130E The outputs numbered 0 to 23 are located on the top of the control The inputs are grouped on the bottom of the control numbered 32
18. arts 1 2 Feed forward action Integrating action Total action Superheat K Feed forward action Integrating action Total action Superheat K 31 6 1 1 Specific functions A number of specific functions require further explanation 6 1 1 1 Setpoint of water outlet control This can be used to modify the desired value of the water outlet temperature control Changes of up to 6K with respect to the standard setpoint are possible The standard setpoint usually 6 C is determined by the configuration of your Lennox chiller The setpoint may also be lowered to 5 0 C as long as your chiller is configured for glycol operation and the hydraulic system is filled with a water glycol mixture with a sufficiently high degree of protection against freezing Reducing or raising the desired value is achieved by pressing keys F2 or F3 N PARTICULAR CHANGING THE SETPOINT TO A VALUE BELOW THE FACTORY SETTING CAN TRIP THE SAFETY FEATURES OF YOUR LENNOX CHILLER IF THERE IS INSUFFICIENT WATER IN THE HYDRAULIC SYSTEM CERTAIN MACHINE CONFIGURATIONS WILL NOT PERMIT THE MINIMUM VALUE FOR THE SETPOINT TO BE SELECTED PLEASE CONSULT THE RELEVANT TECHNICAL SPECIFICATION 6 1 1 2 Setpoint of condenser control This can be used to modify the desired value for the condenser control system The value can lie between 25 C and 55 The desired value is lowered or raised by pressing keys F2 and respectively THE VALUE CAN ONLY BE MODIFI
19. ber Function LED indicator 48 Low pressure transmitter 49 High pressure transmitter 50 External setpoint adjustment 0 10VDC optional 51 Not used n a 52 Suction gas temperature sensor 53 Not used n a 54 Ambient temperature sensor 55 Waiter outlet temperature sensor Table 3 Numbering of analog inputs 8 EC 91 0005 REV C EN 3 5 Inputs and outputs of single circuit version equipped with a screw type compressor This applies amongst others to machine types SC W 160E to SC W 205E SC S 160E to SC S 205E The inputs and outputs are located as outlined for the previous version But from a functional point of view there are differences because the machines are equipped with screw type compressors 3 5 1 Digital outputs of single circuit version equipped with a screw type compressor Number a amp O N o Table 4 Numbering of digital outputs Function Control compressor Control 75 capacity stage compressor Control 100 capacity stage compressor Not used Failure indication Control transmission pump evaporator circuit Control condenser fan 1 Control condenser fan 2 Control condenser fan high speed fan 1 Control economiser Control expansion valve 1 Control expansion valve 2 Control evaporator heating Not used 8 EC 91 0005 REV C EN LED indicator n a Depending on present operating circumstances and machine configuration 10 3 5 2 Digital inputs of sin
20. crew type compressors 15 Analog outputs of double circuit version equipped with screw type compressors 16 Digital inputs of double circuit version equipped with screw type compressors 16 Analog inputs of double circuit version equipped with screw type 50 5 17 TRANSFER FUNCTION OF ANALOG SENSORS sseseesesesceeeseseeeeaeeecateesacsesecacsecacsesacaeeesaeeesaceeseeaeeesateesatensesates 18 SAEETY FEATURES one ht Oeil eene 19 SAFETY FEATURES FOR THE EVAPORATOR sssescsseseseseesesteceaceesacaeeceaesecacsecaceecacaeecaesesateesacaesecateesateesataeeeeaees 19 Transmission pump of evaporator sssssssssssessesee enne tnter ennt tnnt 20 SAFETY FEATURES FOR THE COMPRESSOR S esee sese ene insere 22 SAFETY FEATURES FOR THE CONDENSERS 2 cscessseececesceecacsecaeseseescsecacsesaeeesacsesecacsecaesesaeaeeecaceesaeesseaseeeates 23 GENERAL adi uc 23 GENERAL MACHINE cCGm 23 5 5 1 5 1 1 5 1 1 1 5 1 1 2 5 1 1 3 5 1 2 5 1 3 5 1 4 5 2 5 2 1 5 2 2 5 2 3 5 3 5 4 6 1 6 1 1 6 1 1 1 6 1 1 2 6 1 1 3 6 1 1 4 6 1 1 5 6 1 2 8 EC 91 0005 REV C EN CONTROLS iiiaae E 24 97 7 o 1499 1 9 PETIT 24 Water outlet temperature control sse nennen 2
21. denser capacity to the cooling capacity to be supplied under different outside air conditions a pair of controls are available discrete control on off pulse width control and control using frequency controllers The aim of these controls is to keep the condensation temperature as low as possible The desired condensation temperature 35 C is reduced even more to make as efficient as possible use of the chiller when operating under partial load See figure 9 Tc min Tc min 10K 100 Vollast Figure 9 Reduction in condensation temperature when operating under partial load 5 2 1 Discrete control This type of condenser control operates according to the conventional principle of engaging and disengaging condenser fans If the condensation temperature rises by 5K above the desired value a fan will be switched on If the condensation temperature is still above the specified value after 30 sec another fan will be switched on The time constant of 30 seconds will be reduced to 1 sec if the condensation temperature rises above 0 9 x the maximum value f after switching on one fan and the elapse of a fixed time 75 sec the condensation temperature has dropped to a value lower than the desired value the appropriate fan will be switched off The switch on value for this fan will be set to the desired value 10K 5 2 2 Pulse width control The principle o
22. essors WA 40E to WA 110E WW 45E to WW 130E WS 45E to WS 130E Single circuit machines using screw type compressors SC W 160E to SC W 205E SC S 160E to SC S 205E 2 2 Double circuit configuration The double circuit configuration is made up from one hardware configuration integrating two configurations which are different when it comes to using inputs and outputs This configuration is used amongst others for the following machine ranges Double circuit machines using scroll compressors WA 90D to WA 230D WW 105D to WW 255D WS 105D to WS 255D Double circuit machines using screw type compressors WA 285D to WA 430D SC W 240D to SC W 410D SC S 240D to SC S 410D FOR ALL CONFIGURATIONS ONLY THOSE FUNCTIONS RELEVANT TO YOUR APPLICATION ARE AVAILABLE INTEGRATING CERTAIN OPTIONS INTO A MACHINE MAY RESULT IN A SINGLE CIRCUIT MACHINE BEING EQUIPPED WITH HARDWARE WHICH IS COMMONLY USED FOR DOUBLE CIRCUIT MACHINES IN THAT CASE THE INPUTS AND OUTPUTS OF CIRCUIT 2 ARE NOT USED 8 EC 91 0005 REV C EN 5 3 HARDWARE The hardware for the Enertronic Control System 2 consists of a programmable logic controller PLC This PLC collects information from the chiller in the form of digital 1 or 0 and analog 0 10 volt and resistance signals The status of the digital inputs is indicated by LEDs Light Emitting Diodes Using these signals the software in the PLC will generate control tasks for the main chiller components Digital outp
23. ging of the respective refrigerant circuit and the generation of a failure indication When an internal motor protection trips it is reset automatically after it has cooled down If the fault is caused by an overload relay tripping this must be resolved by resetting the relevant relay 4 4 General safety features The table below shows the safety features which are not directly related to the evaporator compressor or condenser on your Lennox chiller but which do have a direct effect on the operation of the machine Cause Ambient temperature too low Faulty temperature sensor water outlet ambient or suction gas temperature Impermissibly small action of expansion device Impermissibly large action of expansion device Fault on transmission pump in evaporator circuit optional Table 17 General safety features Result Machine stop Machine stop Machine blocked Machine blocked Machine stop control of electronic expansion valve Chapter 5 Dependent on your chiller version 4 5 General machine reset Limit values 0 or 20 C No Measured value Yes lt 50T or gt 60 lt 20 for more than Yes 5 min gt 12 for morethan 1 Yes hour Determined by pump Yes type and protection Failure Reset required No No Yes general reset Yes general reset No If one of the safety features mentioned in this chapter trips and needs to be cancelled by a gene
24. gle circuit version equipped with a screw type compressor Number Function LED indicator 32 Starting command On 33 Contact for flow or pump switch On 34 Failure contact pump unit optional On 35 High pressure protection input On 36 Motor overload protection compressor 1 On 37 Thermistor phase sequential protection compressor On 38 Oil level protection compressor 1 optional On 39 Safety chain condenser circuit On Table 5 Numbering of digital inputs Dependent on machine configuration 3 5 3 Analog inputs of single circuit version equipped with a screw type compressor Number Function LED indicator 48 Low pressure transmitter 49 High pressure transmitter 50 External setpoint adjustment 0 10VDC optional 51 Not used n a 52 Suction gas temperature sensor 53 Not used n a 54 Ambient temperature sensor 55 Waiter outlet temperature sensor Table 6 Numbering of analog inputs 8 EC 91 0005 REV C EN 3 6 Inputs and outputs of double circuit version equipped with scroll compressors This applies amongst others to machine types WA 90D to WA 230D WW 105D to WW 255D WS 105D to WS 255D In this case as well the outputs numbered from 0 to 55 inclusive are on top of the control and the inputs numbered 64 to119 are on the bottom The LEDs work in the same way as in the single circuit version The tables below summarise the inputs and outputs used 3 6 1 Digital outputs of double circuit versio
25. higher the pump is switched on the moment the ambient temperature drops below 6 C The pump also starts if the water temperature drops below 3 5 C If a water glycol mixture with a glycol content of 34 or higher is used the pump is switched on at a water temperature below 7 5 C This is exactly the limit at which the compressors are disengaged and the evaporator heating is engaged see Figure 6 Once all conditions for releasing the chiller including external start command have been satisfied the transmission pump will be switched on first After a 2 minutes pump pre run time the chiller will be released A failure indication is generated if the contact of the flow switch is interrupted for longer than 5 seconds At that moment the cooling capacity is switched off If the cooling demand ceases to exist by eliminating the external start command the compressors will stop and the transmission pump will switch off after 10 minutes lag time THE GLYCOL PERCENTAGE SPECIFIED AT THE TIME OF ORDERING HAS BEEN TAKEN INTO ACCOUNT IN THE SOFTWARE 8 EC 91 0005 REV C EN 20 6 Figure 6 shows the relationship 4 between the glycol percentage and 2 the disengaging of all cooling 0 capacity as well as the engaging of the evaporator heating and the heater 2 unit in the buffer ta
26. ing a potential free contact you can choose to activate a second setpoint In comfort applications this function may for example be used if dehumidification is required In process applications this function may be used for ice buffer operation The value of the second setpoint must be specified when ordering your chiller 5 1 2 Economiser operation If your chiller is designed with screw type compressors a subcooling system will under certain conditions come into effect to ensure even more efficient operation of your chiller This system is termed economiser operation and provides more subcooling of the liquid refrigerant fed to the expansion device 5 1 3 Preference switch In the case of chillers with two refrigerant circuits based on the number of operating hours per circuit or a failure occurring the preference for the circuit that will be engaged first is switched 5 1 4 Peak load limiting An input is reserved on the control system for activating peak load limiting If a potential free contact associated with this input is closed for example during peak take off of your electricity supply then in the case of a two circuit chiller the compressors in the second refrigerant circuit are disengaged By doing so you can temporarily halve the electricity consumption and naturally the cooling capacity of your Lennox chiller under full load 8 EC 91 0005 REV C EN 25 5 2 Control of air cooled condensers To adapt the con
27. n equipped with scroll compressors Number a gt WO M o Table 7 Numbering of digital outputs Function Control compressor 1 circuit 1 Control compressor 2 circuit 1 Control compressor 3 circuit 1 Control compressor 1 circuit 2 Control compressor 2 circuit 2 Control compressor 3 circuit 2 Control condenser fan 1 circuit 1 Control condenser fan 2 circuit 1 Control condenser fan 3 circuit 1 high speed fan 1 Control expansion valve 1 circuit 1 Control expansion valve 2 circuit 1 Control evaporator heating Control transmission pump evaporator circuit Failure indication Control condenser fan 1 circuit 2 Control condenser fan 2 circuit 2 Control condenser fan 3 circuit 2 high speed fan 1 Control expansion valve 1 circuit 2 Control expansion valve 2 circuit 2 Not used Not used Not used 8 EC 91 0005 REV C EN LED indicator n a n a n a Depending on present operating circumstances and machine configuration 12 3 6 2 Analog outputs of double circuit version equipped with scroll compressors Number Function LED indicator 48 Water control valve circuit 1 0 10VDC optional 49 Water control valve circuit 2 0 10VDC optional 50 Fan speed control circuit 1 0 10VDC optional 51 Fan speed control circuit 2 0 10 optional Table 8 Numbering of analog outputs 3 6 3 Digital inputs of double circuit version equipped with scroll compressors Number Function
28. n which this control is based is the switching on and off of a fan over a short period cycle time 5 sec By varying the engaging and disengaging time the speed of this fan can be set to any desired value between standstill and full load By using this type of control on the first fan of a condenser the capacity of this condenser can be modulated Thus a condensation temperature may be maintained at exactly the desired value provided the environmental conditions permit so 8 EC 91 0005 REV C EN 26 IN AIR COOLED ECOLOGIC CHILLERS USING SCROLL COMPRESSORS THE FIRST FAN OF EACH CIRCUIT IS PULSE WIDTH CONTROLLED THE OTHER FANS BEING DISCRETELY CONTROLLED IN AIR COOLED ECOLOGIC CHILLERS USING SCREW TYPE COMPRESSORS THE FIRST TWO FANS OF EACH CIRCUIT ARE PULSE WIDTH CONTROLLED THE OTHER FANS BEING DISCRETELY CONTROLLED 5 2 3 Control of condenser fans using frequency controllers Machines that do not allow pulse width control for instance split air cooled machines can be controlled using frequency controllers The frequency controllers are activated from the Enertronic Control System Activating is also done using the condensation temperature The Enertronic Control System generates a PI action based on the difference between the measured and desired condensation temperatures This control action is converted into a 0 10VDC signal available at an analog output It is possible to activate one frequency controller per circuit 5 3 Cont
29. ne configuration 15 3 7 2 Analog outputs of double circuit version equipped with screw type compressors Number Function LED indicator 48 Water control valve circuit 1 0 10VDC optional 49 Water control valve circuit 2 0 10VDC optional 50 Fan speed control circuit 1 0 10VDC optional 51 Fan speed control circuit 2 0 10 optional Table 12 Numbering of analog outputs 3 7 3 Digital inputs of double circuit version equipped with screw type compressors Number Function LED indicator 80 Starting command On 81 Contact for flow or pump switch On 82 Peak load limiting On 83 High pressure protection input circuit 1 On 84 Motor overload protection compressor 1 On 85 Thermistor phase sequential protection compressor 1 On 86 Oil level protection compressor 1 optional On 87 Safety chain condenser circuit 1 On 96 Failure contact pump unit optional On 97 Input to activate second setpoint optional p 98 Not used n a 99 High pressure protection input circuit 2 On 100 Motor overload protection compressor 2 On 101 Thermistor phase sequential protection compressor 2 On 102 Oil level protection compressor 2 optional On 103 Safety chain condenser circuit 2 On Table 13 Numbering of digital inputs Depending on present operating circumstances and machine configuration 8 EC 91 0005 REV C EN 3 7 4 Analog inputs of double circuit version equipped with screw type compressors Number Function LED indicat
30. nk optional 4 6 8 10 0 5 10 15 20 25 30 3 40 45 glycol Figure 6 Disengaging in the event of low water outlet temperature Figure 7 shows dependent on the 5 percentage of glycol applied the limit 0 values for the water outlet temperature at which a frost failure will 5 occur 40 15 20 25 0 5 10 15 20 25 30 35 40 45 10 y yvvI Figure 7 Frost failure limit values 3 5 Figure 8 shows the relation between the Ba 3 values at which after a certain time delay a low pressure failure is detected and the glycol 25 percentage applied in the secondary circuit 2 1 5 1 0 5 0 0 5 10 15 20 25 30 35 40 45 glycol Figure 8 Low pressure detection values 21 8 EC 91 0005 REV C EN 4 2 Safety features for the compressor s The compressors in your Lennox chiller can be protected in different ways against external or undesired operating conditions The possible safety features and their characteristics are shown in the following table Cause Engaging or interruption of the mains voltage Disengaging lowest capacity stage of single cooling circuit High discharge pressure Too high discharge pressure Low suction pressure delayed Low suction pressure direct High motor temperature scroll compressors High motor temperature screw type compressors Faulty phase sequence in electrical supply screw type compressors Oil level too low screw type compressors split chiller High motor current Result
31. or 64 External setpoint adjustment 0 10VDC optional 65to67 Not used n a 68 Water inlet temperature sensor lon optional n a 69tto71 Not used n a 112 Low pressure transmitter circuit 1 n a 113 High pressure transmitter circuit 1 114 Low pressure transmitter circuit 2 115 High pressure transmitter circuit 2 116 Suction gas temperature sensor circuit 1 117 Suction gas temperature sensor circuit 2 118 Ambient temperature sensor 119 Waiter outlet temperature sensor Table 14 Numbering of analog inputs 8 EC 91 0005 REV C EN 3 8 Transfer function of analog sensors In some cases e g when troubleshooting the transfer function of the analog measurement transducer must be known This is as follows for the low and high pressure transmitters U V U V 10 10 9 9 t of CUu UJ p WM c N N p Bar Bar 0 3 6 9 12 15 18 21 24 27 30 gt 5 18 9 Figure 3 Transfer function of high pressure sensor Figure 4 Transfer function of low pressure sensor Note Pe Effective pressure or manometer pressure The temperature sensors water outlet ambient air suction gas are of the type PT 2000 The relationship between temperature and resistance is as follows R 2311 0272 2233 2195 2156 2117 2
32. ral machine reset you must use the display module A general machine reset can then be initiated via the reset menu F2 F2 F1 For an explanation see Chapter 0 Error Not a valid bookmark self reference 8 EC 91 0005 REV C EN 23 5 CONTROLS To operate your Lennox chiller as efficiently as possible the control functions for the main chiller components are integrated into the Enertronic Control System A distinction is made between Capacity control Condenser control Control of electronic expansion valve 5 1 Capacity control To bring the cooling capacity of your Lennox chiller in line with the loading in your application the cooling capacity supplied is adjusted by the engaging or disengaging of the compressors or capacity stages screw type compressors The engaging or disengaging of cooling capacity is performed on the basis of the water outlet temperature 5 1 1 Water outlet temperature control This control procedure enables the temperature of the water leaving the chiller to conform as accurately as possible to the required value setpoint Staged engaging of cooling capacity also modifies the water outlet temperature in steps This step response can vary depending on the number of compressors capacity stages per compressor and the layout of the hydraulic system The water outlet temperature controller uses an adaptive principle to calculate the ideal engaging and disengaging values for the compres
33. re in a refrigerant circuit which may also result in freezing is prevented by disengaging the respective refrigerant circuit when the suction pressure of the compressors is lower than the permitted minimum over a certain time period LP failure see safety features for the compressors Cause Result Limit values Failure Reset required Low water outlet All compressors off T1 lt 3 5 C No No temperature evaporator heating on heating on in buffer tank optional Risk of freezing Machine blocked T2 lt 2 5 C Yes Yes general reset Low ambient temperature Transmission pump 4 lt 5 0 C T4 lt 6 C No No evaporator on at 34 glycol Flow or pressure difference Machine stop after 5 sec Machine dependent Yes No switch off Too low evaporation Appropriate refrigerant circuit See safety features for Yes Yes general temperature off the compressors reset Table 15 Evaporator safety features f glycol is used a different value will apply see figures on p 21 8 EC 91 0005 REV C EN 19 4 1 1 Transmission pump of evaporator The transmission pump in the hydraulic circuit will be switched on at ambient temperatures below 5 C If a water glycol mixture is used the pump will be switched on at a lower ambient temperature according to the glycol content The switch on point used for a given glycol content can be found by reading the temperature from Figure 6 and adding 1 5 K to this value For instance if the glycol content is 34 or
34. rol of water cooled condenser To adapt the condenser capacity to the cooling capacity to be supplied under different ambient conditions water control valves can be used The water control valve is intended to control the capacity of the water cooled condenser Activating of the water control valves is also done using the condensation temperature The difference between the measured and desired condensation temperatures is adopted to calculate a PI action This action is converted into a 0 10VDC signal available at an analog output It is possible to activate one water control valve per circuit For the desired condensation temperature refer to Chapter 5 2 8 EC 91 0005 REV C EN 27 5 4 Controlling the electronic expansion valve The Enertronic Control System 2 provides the exact refrigerant dosage to the evaporator It achieves this by using process data provided by different measurement points in the chiller Two open shut solenoid valves connected in parallel are used as the control device These valves are operated with a certain time delay so that the evaporator is fed with a uniform flow of refrigerant The correct dosage is obtained by operating the valves using pulse width control The control action for the pulse width control is determined by a calculated feed forward value corrected using a P and action based on the superheating achieved The superheating to be achieved will be about 6K IN CERTAIN MACHINE CONFIGURATION
35. sor or capacity stage each time a compressor is engaged In other words the optimum bandwidth for each compressor is set each time one is engaged This bandwidth is restricted to a minimum of 0 5K and a maximum of 2 0K with respect to the setpoint To adapt the operation of your Lennox chiller perfectly to your application there are a number of options to modify the setpoint of the water outlet temperature control 5 1 1 1 Setpoint As mentioned earlier the setpoint is the desired value for the chilled medium leaving the chiller water or water glycol mix This value can be modified manually using the display module on the control For water applications a setting range of 6 C to 12 C applies In the case of water glycol mixtures gt 34 glycol the maximum range of 5 C to 12 C applies 8 EC 91 0005 REV C EN 24 5 1 1 2 Analog setpoint adjustment Analog setpoint adjustment provides the possibility of increasing or decreasing the operating range of your chiller continuously to a maximum of 10K This is achieved by converting a 0 10 VDC signal sent from an external control circuit into a setpoint setting corresponding to 0 10K The display module F2 F1 F4 is used to select whether the 0 10 VDC signal results in an increase or decrease in the setpoint A decrease is naturally only possible in the case of glycol applications 5 1 1 3 Operation with two setpoints Operating with two setpoints means that by clos
36. uts implemented as relay contacts and transistors control the switching equipment for the main chiller components in order to perform the specified control tasks The status of the digital outputs is also indicated by LEDs 3 1 Hardware of single circuit version Figure 1 shows the control system for the single circuit version Output LEDs 00000000 00000000 Serial interface Display r E4 FS 00000000 00000000 Input LEDs Figure 1 Single circuit control system NOTE Removing the cover without cutting off the power may provoke damage to the hardware 8 EC 91 0005 REV C EN 6 3 2 Hardware of double circuit version Figure 2 shows an overview of the control system for the double circuit version Output LEDs 00000000 00000000 00000000 00000000 PEDE Serial interface Display Lez F3 ee Les ae Pu 00000000 00000000 00000000 00000000 9118017 16115 14019122 19230210100 99 FEMM nncoscgena Functie LED s Input LEDs Figure 2 Double circuit control system NOTE Removing the cover without cutting off the power may provoke damage to the hardware The hardware of the control system may vary in terms of number and type of inputs and outputs
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