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INSTALLATION - OPERATING & MAINTENANCE MANUAL

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1. Main screen Code Description Code Description Code Description Code Unit 1 Alarm 1000 1 date time 2 date time 3 date time 2 Data 2000 1 General 2100 1 Temperature 2110 1 Outside 2111 C 2 Inlet 2112 e 3 Outlet 2113 4 Wat Cond 2114 2 Circuit 1 2120 1 SuperHeat 2121 2 Condensing 2122 3 Saturated 2123 4 T Suction 2124 5 P Condensing 2125 6 P Saturated 2126 3 Circuit 2 2130 1 SuperHeat 2131 Is 2 T Condensing 2132 3 Saturated 2133 4 T Suction 2134 5 Condensing 2135 6 Saturated 2136 4 Circuit 3 2140 1 SuperHeat 2141 2 Condensing 2142 3 Saturated 2143 4 T Suction 2144 5 P Condensing 2145 6 P Saturated 2146 5 Circuit 4 2150 1 SuperHeat 2151 2 T Condensing 2152 3 Saturated 2153 4 T Suction 2154 C 5 P Condensing 2155 b 6 P Saturated 2156 b 6 Other 2160 1 Sw On Off 2161 On Off 2 Sw Flow 2162 On Off 3 Sw Reset 2163 On Off 4 Sw Unoc 2164 On Off 5 Sw Dis C1 2165 On Off 6 Sw Dis C2 2166 On Off 7 Sw Dis C3 2167 On Off 8 Sw Dis C4 2168 On Off 50 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONT
2. ELECTRICAL POWER SUPPLY Control circuit Voltage kr ke s mal LURES KORKA rack Lage makk adle 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 LENNOX Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 33 TROUBLESHOOTING REPAIRS 8 5 8 5 1 LI MANUFACTURER S RECOMMENDED INSPECTIONS UID CHILLERS WITH SCROLL COMPRESSOR S 8 5 1 1 Number of recommended preventive maintenance visits LENNOX NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up A 2 Inspection visit Tube analysis 1 1 1 2 2 1 3 3 1 3 4 3 5 1 3 10 6 1 3 7 1 3 8 1 3 9 1 10 1 3 1 10 Every year 3 times a year Every 3 years This table is published for units operating under normal conditions with an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 34 Installation Operation Maintenance manual ECOLOGIC RANGE 0605 TROUBLESHOOTING REPAIRS LENNOX gt START UP
3. Leaving chilled water temperature C Outdoor air temperature MAX 5i alimente mit C us one into b ees codes C Power supply voltage V Ph Hz Refrigerantityper 1 0 Date and time measurements were taken Outdoor air temperature C Company responsible for measurements Nameoftechnicidnz onsite decirte ea er idee ree cision Aae ean Remarks Circuit 1 Circuit 2 Circuit 3 Circuit 4 Compr Compr Compr Compr Compr Compr Compr Compr 1 2 3 1 2 3 1 1 Number of hours of operation Compressors in service per circuit Evaporating pressure Bar Suction piping temperature C Condensing pressure Bar Discharge piping temperature C Oil pump temperature C Oil pressure Bar Oil level A Current on phase 1 per compressor Current on phase 2 per compressor A Current on phase 3 per compressor C Liquid line temperature Bar Evaporator pressure drop C Chilled water temperature C Leaving chilled water temperature Bar Condenser pressure drop C Condenser entering water Condenser leaving water temperature pressure switch cut out Bar
4. Connection to be made by user MAXIMUM LENGTH 50m Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 E 17 LENNOX 6 1 3 Connection diagrams CLIMATIC 50 OPERATION Y8 EB 38 TE HrU 12e r 59 alt 18 24 va 9 m om x x NON a d x X 88859 98 28 6 6 eo666 66666 5606 09098 2 9 a EE c 4 8896868868868 REY ug eg Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 18 OPERATION LENNOX 6 2 UNIT OPERATION 6 2 1 Functions of refrigeration circuit components 6 2 1 1 Thermostatic expansion valve Very important The thermostatic expansion valve fitted on each machine has been selected for a given operating range it must be replaced with a model with the same reference from the same manufacturer 6 2 1 2 Filter drier This is designed to remove all traces of humidity from within the refrigeration circuit since this can impair opera tion of the unit by acidification of the oil which causes slow disintegration of the varnish protecting the compressor motor windings 6 2 1 3 High and low pressure gauges option Enables instantaneous readout of suction and discharge pressures Sightglass humidity indicator optional on units fitted with scroll type or reciprocating com
5. Directive 89 336 EEC Relating to electromagnetic compatibility Personal Liability for the Manufacture Name Fabrice EXCOFFIER Function Customer Service Manager Date 11 01 2005 Signature LENNOX France Division climatisation de LGL France Si ge social LGL France Zl les Meuri res 69780 Mions France Soci t Anonyme au capital de 37 029 000 RCS LYON B 309 528 115 N IDENTIFICATION TVA FR 59 309 528 115 APE 292 F Installation Operation Maintenance manual CHILLERS ANNEXES 0605 E 65 LENNOX BELGIUM LUXEMBOURG CZECH REPUBLIC FRANCE GERMANY IRELAND NETHERLANDS POLAND PORTUGAL RUSSIA SLOVAKIA UKRAINE UNITED KINGDOM OTHER COUNTRIES ECOLOGIC IOM 0605 E www lennoxeurope com LENNOX BENELUX N V S A www lennoxbelgium com LENNOX JANKA a s www janka cz LENNOX FRANCE www lennoxfrance com LENNOX DEUTSCHLAND GmbH www lennoxdeutschland com LENNOX IRELAND www lennoxireland com LENNOX BENELUX www lennoxnederland com LENNOX POLSKA Sp 2 wwv lennoxpolska com LENNOX PORTUGAL Lda www lennoxportugal com LENNOX DISTRIBUTION MOSCOW www lennoxrussia com LENNOX SLOVENSKO s r o www lennoxdistribution com LENNOX REFAC S A www lennox refac com LENNOX DISTRIBUTION KIEV www lennoxrussia com LENNOX UK www lennoxuk com LENNOX DISTRIBUTION www lennoxdistribution com Due to Lennox s on
6. one compressor unloaded g 30 ae ad 29 W AT Start up with CLIMATIC 30 Thermostatic expansion valve C 35 37 36 36 33 33 and NO unloading Start up with CLIMATIC 50 Thermostatic expansion valve C 47 45 44 47 47 43 and ONE compressor unloaded Start up with CLIMATIC 50 Electronic expansion valve C 48 46 45 48 48 44 and ONE compressor unloaded 42 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC OPERATING LIMITS ECOLOGIC WA WA LENNOX EFFICIENCY HIGH 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature Maximum inlet water temperature Minimum difference water inlet outlet Maximum difference water inlet outlet Minimum outside air temperature Minimum outside air temperature with low ambient kit Maximum outside air temperature Normal operation with CLIMATICT 50 12 C 7 C water C 53 51 51 54 53 53 51 51 52 53 49 one compressor unloaded Start up with CLIMATICT 50 C 52 49 49 53 52 52 49 49 50 52 46 Electronic expansion valve and ONE compressor unloaded ECOLOGIC WA LOW NOISE SUPER WA 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature C 5 Maximum inlet water temperature C 20 Mi
7. If necessary ins tall a buffer tank Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formula hereafter Q gt Cooling capacity of the chiller in KW N gt Number of capacity stage of the chiller Dt Water temperature Delta T Vt 72 x Q n x dt itres 10 Installation Operation Maintenance manual IOM RANGE 0605 INSTALLATION TRANSPORT HANDLING LENNOX Example for a chiller with 400kW water conditions 12 C 7 C and 4 capacity stages the minimum volume is Vt 72 x 400 5 x 4 1440 I This formula will give the minimum water capacity of the installation that will ensure a temperature rise of the water loop of dt n C during anti short cycle of compressors This formula is only applicable for air conditioning installation and must not be used for process cooling where temperature stability is required 3 4 6 Flow switch Aflow switch must be installed on the evaporator water inlet or outlet so as to enable detection of water flow through the heat exchanger before the unitis started up This will protect the compressors against any eventual liquid slugging during the starting phase and prevent accidental ice formation in the evaporator if the flow of water is interrupted Flow switches are available on option
8. coupling manometer for groove lock coupling Add 02 18 Add 01 19 Add 04a 17a Add amp 01 19 40 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC HYDRAULIC DRAWING UNIT WITH FREE COOLING OPTION WA 150 STD LN LENNOX STD LN HE SLN ITEMS SUPPLIED LOOSE Groove lock coupling Unit isolation valve In Out manometers without 04a ira groove lock coupling option Paddle flow switch mounted on tube Water inlet filter ITEMS MOUNTED INSIDE THE UNIT Plate heat exchanger Temperature sensors Flow switch differential 9 Drain 5 Free cooling coil Isolating valves Three way valve OPTIONS Paddle flow switch Differential flow switch BASIC UNIT Water inlet filter Supplied loose Supplied mounted Unit isolation valve Add 03 Add 05 Add 22 Add 02 18 Kit for aroove lock Inlet outlet manometer 16 ds Inlet Outlet manometer kit for groove lock 15a 15b pung coupling Add 01 19 Add 04a 17a Add 04b 17b and 01 19 641 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC OPERATING LIMITS ECOLOGIC WA LENNOX STANDARD WA 150 200 230 270 300 370 Minimum outlet water temperature C Maximum inlet wat
9. 1 Config 2451 Liste No C Only H Pump 2 State 2452 Liste 2 Stopped StartHeat Started Start 0 5 Started1 I Defrost Wait Flow Wait CH Ant Sho Cy Schedule Switch Fault 1 3 Sw State 2453 On Off 4 Sw High P 2454 On Off 5 Sw Low P 2455 On Off 6 Relay 2456 On Off 7 H Pump 2457 On Off 8 Valve 2458 On Off 9 Run Time 2459 H eme cere SFE cm S 7 gt OCU OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX Main screen Code Description Code Description Code Description Code Unit 2 data 2000 4 Compressor 2400 2460 1 Config 2461 Liste No C Only H Pump 2 State 2462 Liste Stopped StartHeat Started Start 0 5 Started1 I Defrost Wait Flow Wait CH Ant Sho Cy Schedule Switch Fault 1 3 Sw State 2463 On Off 4 Sw High P 2464 On Off 5 Sw Low P 2465 On Off 6 Relay 2466 On Off 7 H Pump 2457 On Off 8 Valve 2458 On Off 9 Run Time 2459 H 5 EEV 2500 1 Circuit 1 2510 1 Config 2511 Liste No Yes 2 State 2512 mor aaa Started Wait Flow Wait CH Schedule Switch 3 Position 2513 2 Circuit 2 2520 1 Config 2521 Liste No Yes 2 State 2522 ca Started Wait Flow Wait CH Schedule Switch 3 Position 2523 3 Circuit 3 2530 1 Config 2531 Liste No Yes 2 State 2532 ont el Started Wait Flo
10. 2 Sp Wat 2 3332 C 17 40 50 set point see page 13 IOM Climatic 50 s Water SP Ambiant air temperature set FAR Out 3333 19 point see page 13 IOM Climatic 50 1 5 E Water SP Ambiant air temperature set POE 3334 19 0 90 point see page 13 IOM Climatic 50 5 Reactiv 3335 1 5 50 Capacity Factor Reactivity factor for heating mode Safety limit Chilled water outlet 2 Safety 3340 1 Wat Low 3341 aC 3 10 51 10 12 temperature limit minimum with Glycol according to 2 Wat high 3342 C 22 53 53 Safety limit Hot water outlet temperature limit Liste C1___ C 2 C12 C 3 C1 3 IC 23 Circ enable Circuit operation 4 Compressor 3400 1 Circuit 3410 1 Enable 3411 C123 C _4 1 Mars 15 Mars 15 management Circuit authorize to C1 4 C24 C12 operate _41C__34 C1 34 234 C1234 2 Rotat 3412 Liste Auto C 1 C 2 1 15 15 Comp priority Circuit priority IC 31C 4 management 2 5 Safety limit Freezing safety limit Pen Trost re c 5 minimum with Glycol according to 2 Time limit 3422 5 1 30 360 Safety limit Lennox setting ED 5 Temp SP Ambiant air temperature set FREE ee De 99 Ts 120 point see page 13 IOM Climatic 50 4 W Cd Mini 3424 C 5 25 33 Safety limit Condensing water outlet temperature limit 5 W Cd Maxi 3425 C 20 55 66 Safety limit Condensing water outlet temperature limit 657 Installation Operation Maintenance manual IOM ECOLO
11. The normally open contact of the flow switch should be connected to the terminals provided to that effect in the unit electrical box See the wiring diagram supplied with the unit The normally closed contact can be used as an indication of a lack of flow condition Warranty is void if a flow detection device is not fitted and connected to the LENNOX control panel 3 5 ELECTRICAL CONNECTIONS First of all make sure 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 A main isolator switch must be inserted between the end of the power supply cable and the unit to enable total iso lation of the latter when necessary Chillers are supplied as standard without a main isolator switch This is available as an option WARNING Wiring must conform to applicable regulations The type and location of fused isolators must also conform with regulations For the sake of safety install them where they can be seen and in easy reach of the unit Units must have full earthing continuity IMPORTANT Operation of a unit with the wrong power supply or with excessive phase imbalance constitutes abuse and is not covered by the
12. be 6 In Custom 3860 1 BE50 1 3861 0 0 5 customised input of the extension board BE50 Liste Not Used Sw Configuration Free input to be 2 BE50 2 3862 Setpoint Sw Cool 0 0 5 customised input of the extension board Sw Heat C1 Disable BE50 C2 Disable C3 Configuration Free input to be 3 BE50 3 3863 Disable C4 Disable 0 0 5 customised input of the extension board Sw Unoc Free BE50 Configuration Free input to be 4 BE50 4 3864 0 0 5 customised input of the extension board BE50 Configuration Free input to be 7 In Custom 3870 1 BE50 1 3871 0 0 2 customised input of the extension board BE50 Configuration Free input to be 2 BE50 2 3872 0 0 2 customised input of the extension board Liste Not Used S P 50 Offset Free Configuration Free input to be 3 BE50 3 3873 0 0 2 customised input of the extension board BE50 Configuration Free input to be 4 BE50 4 3874 0 0 2 customised input of the extension board BE50 61 Installation Operation Maintenance manual ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX ls Code Description Code Description Code Description Code Unit Min Factory Max Comments Allows a reset of ALL set point to standard factory settings when 9 Com 3900 1 Display 3910 1 Standard Sp 3911 Yes No Off available No possib
13. been made according to the recommendation described S Installa tion The unit refrigeration circuit sketch is given in the ANNEXES at the end of the IOM page 48 amp 49 or supplied with the unit 4 3 HYDRAULIC SYSTEM INSTALLATION CHECKS The unit hydraulic sketch is given in the ANNEXES at the end of the IOM See page 38 to 41 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 The components located inside the units and must be installed 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 installa
14. fouling by measuring the water pressure drop Excessive oil migration in the circuit measure evaporating pressure superheat and the temperature of the oil pump Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 27 TROUBLESHOOTING REPAIRS LENNOX 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION F THE COMPRESSOR CUTS OUT ON ANTIFREEZE PRESSURE SWITCH Antifreeze pressure switch Check that the pressure switch tripped is operating properly Low water flow in the evaporator Check the water pump Evaporator obstructed Determine the degree of fouling by measuring water pressure drop Evaporator frozen up Measure pressure drop in water circuit keep water circulating until evaporator has thawed completely Low refrigerant charge Check the refrigerant charge and add refrigerant if necessary G THE COMPRESSOR CUTS OUT ON ITS MOTOR PROTECTION THERMAL RELAY Thermal protection Tripped Check operation of thermal protection change it if necessary Motor windings are not being Measure superheat in the sufficiently cooled evaporator adjust it if necessary H COMPRESSOR CUTS OUT THROUGH ACTION OF THE MAIN POWER FUSE Power supply on two phases Check power supply voltage only Faulty motor windings Replace the compressor Compressor seized R
15. made available to third parties without the prior written agreement of Lennox 2 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 PREFACE LENNOX 1 PREFACE You must read and be familiar with this operating manual prior to commission the chiller Please closely follow the instructions We would like to stress the importance of training with respect to the correct handling of the chiller Please consult Lennox on the options available in this field It is important that this manual be stored in a permanent location in the vicinity of the chiller Text Important general instruction Danger of Injury or damage to the chiller This manual contains important instructions regarding the commissioning of the chiller It also includes important instructions to prevent personal injury and damage to the machine during operation Furthermore in order to promote fault free operation of the chiller maintenance information has been included Please do not hesitate to contact one of our employees should you require further information on specific chiller subjects Order related documentation will be forwarded under separate cover This documentation consists of CE declaration Operating manual for control system Installation Operating manual Wiring diagram Refrigerant flow diagram except for WA RA WAH LCH Unit detail are given on unit nameplate The data published in this manual is based o
16. module H1 par BUREAU VERITAS S A organisme notifi n 0062 concern e s par l approbation du syst me de qualit Number s of the EC design examination certificate s Issued under Ihe scope of module H1 by BUREAU VERITAS S A notified body nr 0062 concerned by the approval of he quality system Cette attestation est valable jusqu au 02 09 2005 This certificate is valid until Le maintien de l approbation est soumis la r alisation par le Bureau Veritas des audils essais et v rifications selon le contrat sign par le fabricant et le Bureau Veritas The approval is conditional upon the surveillance audits tests and verifications to be carried out by Bureau Veritas as per the provisions stated in the agreement signed by both the manufacturer and Bureau Veritas Cette attestation est pr sum e nulle et fe fabricant supportera seul les cons quences de son ulilisalion i les assurances donn es par le fabricant lors de la demande d intervention en mati re a d applicallon de son syst me qualit approuv b de conformit de son quipement son approbation CE de la canceplion et c d inspeclion et d essais des produits finis se r v lent inexactes et de mani re g n rale si le fabricant ne respecte pas l une ou l autre des obligalions mises sa charge par la directive n 97 23 CE du 29 mal 1997 telle que transpos e dans le s droit s nationatfaux applicabfe s This certificate shall be deemed to ba
17. nit weight Type compresseur Clinpresser type Pression d eprouve Test pressure Pression d BP taa I Pression Max service HP Max operating pressure HP Pression Max service BP Max operating pressure BP zo tre 15 te 251 400 380 6 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 INSTALLATION TRANSPORT HANDLING LENNOX 3 1 2 Storage When units are delivered on site they are not always required immediately and are sometimes put into storage In the event of medium to long term storage we recommend the following procedures Ensure that there is no water in the hydraulic systems Keep the heat exchanger covers in position Keep protective plastic film in position Ensure the electrical panels are closed Keep all items and options supplied in a dry and clean place for future assembly before using the equipment 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 igno red such as operating pressures electrical components locations roofs terraces and other structures located well above ground level Only highly qualified contractors and technicians with sound knowledge of this type of equipment are aut
18. pressure drop OGOOOO ELECTRICAL EQUIPMENT Check the main power supply matches the unit data plate Check that the unit is correctly earthed Checked order of power supply phases for scroll and screw compressor units Checked correct direction of rotation of fan motors and proper operation of the latter Direction of rotation of pump correct Control cabinet wired up Power 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 OGOOOOOOOO GENERAL O Cooling load available minimum 50 O Coordination between different professions for final commissioning CUSTOMER ORDER NUMBER LENNOX REFERENCE D SIGNATION iei ee tat Farr Sekken Boe DUR PA alae UA ae COMMENTS h nda behind etude de hace oie Shee bi d d bee Be gd te oh eae be fedre dets NAME ina n ed Ren SIGNATURE sua e va hek oe 436 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 ANNEXES INSTALLATION OPERATION MAINTENANCE MANUAL ANNEXES ECOLOGIC HYDRAULIC CIRCUIT DRAWINGS 38 ECOLOGIC OPERATING LIMITS 42 RISK ANALYSIS AND HAZARDOUS SITUATIO
19. valve GGG C93 9 Size 370 Thermostatic poses Electronic HP LP BASIC UNIT expansion expansion pressure STD LN valve low valve HE SLN valve ambi nt gauges Suction and 01 03 04a 04b08 0 Add 14 12 Add 05a Add 06a 9 10 11 17 19 Add 14 812 amp 15 amp 05b amp 06b 48 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC REFRIGERATION CIRCUIT REFRIGERANT DRAWING LENNOX 150 200D 230D 1st amp 2nd scroll compressors High pressure switch Pressure transducers HP amp BP Low and High pressure mano 052 056 meter Suction and discharge isolation valves Safety valve CE or UDT EFRIGERATION CIRCUIT COMPONENTS Air cooled condenser Evaporator Fan motor Manual isolating valve Filter drier Thermostatic expansion valve Evaporator Condenser heat ex C OGOOGO External temperature sensor Check valve Restrictor 4 way inverting valve Liquid receiver 8 9 9 9 9 08 Heating resistance option changer BASIC UNIT VARIANT OPTIONS BASIC UNIT CE or UDT HP LP pressure gauges 2 isolating valves 01 03 04a 04b 19 22 08 09 10 11 23 20 17 14 21 07 or 07b Add 06a 06b Add 05a 05b Installation Operation Maintenance manual CHILLERS ANNEXES 0605 49 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX 2
20. 1 LEN001 02 FRA BUREAU VERITAS S A agissant dans le cadre de sa notification num ro d organisme notifi 0062 atteste que le syst me de qualit appliqu par le fabricant pour la conception fa fabrication l inspection finale et les essais des quipements sous pression identifi s ci apr s a t examin selon les prescriptions du module H1 de l annexe de la directive Equipements sous pression N 97 23 CE et est conforme aux dispositions correspondantes de la directive BUREAU VERITAS S A acting within the scope of its notilication notified body number 0062 attests that the quality system operated by the manufacturer for design manufacture final inspection and testing of the pressure equipment identified hereunder has been examined against the provisions of annex Hi module H1 of the Pressure Equipment directive n 97 23 EC and found to satisfy the provisions of the directive which apply to it Fabricant nom Manufacturer narne LENNOX France Usine de MIONS Adresse Address 2 1 Les Meuri res BP 71 F 69780 MIONS Marque commerciale Trade mark LENNOX Description des quipements Ensemble sous pression Equipment description Identification des quipements concern s liste en annexe le cas ch ant Suivant liste en annexe Identification of equipment concerned list attached where necessary Num ro s d attestation s d examen CE de la conception mise s dans le cadre de l application du
21. Ax 150D VENT3 C1 VENT2 C1 3 VENT1 C1 M33 VENT1 C2 FR C1 2V FR C2 VENT2 C1 VENT1 C1 Cp 1 VENT2IC1 M32 M34 vent2c2 FR C1 VENT1 C1 FR C1 WAJRA 2700 WAJRA 3700 WA RA 3000 WAI RA 2000 WAJRA 2300 VENT2 C1 VENT2 C2 x 22 lt 3 9 28 VENT2 C1 VENT2 C2 VENT1 C2 VENT1 C1 FR C2 VENT1 C1 VENT1 C2 FRC FR C1 FR C2 VENT1 C1 FR C1 VENT1 C2 FR C2 2 BH z w VENT2 C1 VENT2 C2 VENTS C1 VENT3 C2 VENT3 C1 VENT3 C2 VENT3 C1 VENT3 C2 E 29 VENT4 C1 VENT4 C2 VENT4 C1 VENT4 C2 WAH 150D 32 VENT2 C1 WAH 2000 WAH 2300 Cp 1 1 VENT1 C1 2v 01 FRIC1 Cp 2 V VENT1 C1 VENTA FR C2 M34 vENT2 C2 ERE Cp 1 2 Cp 2 M33 VENT1 C2 VENTE VENT2 C2 FRIC2 422 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 MAINTENANCE LENNOX 7 MAINTENANCE The following maintenance instructions form a part of the operations required for this type of equipment However It is not possible to give fixed and precise rules for permanent maintenance procedures capable of keeping all units in perfect operating condition since too many factors depending on local conditions specific to the installation the way the machine is op
22. 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 could cause rapid evaporator freeze up When the contact opens due to a lack of flow the unit must stop immediately If the purchaser installs a flow switch himself electrical connections should be made to the two remote interlock terminals dry contact 20 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION LENNOX 6 2 3 Automatic sequences 6 2 3 1 Starting sequence Press the unit start switch the power light will come on The control circui
23. COLOGIC RANGE 0605 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 practices The warranty will be legally null and void if Service and maintenance have not been executed in accordance with the regulations repairs have not been carried out by Lennox personnel or have been implemented without prior written permission by Lennox Modifications have been made to the equipment without prior written permission by Lennox Settings and protections have been modified without prior written permission by Lennox Non original or other than the prescribed refrigerants or lubricants are used The equipment has not been installed and or connected in accordance with the installation instructions The equipment is being used improperly incorrectly negligently or not in accordance with its nature and or purpose 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 installa tion Lennox does not vouch for the completeness of this information and can therefore not accept liabil
24. 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 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 e ECOLOGIC RANGE 0605 435 CHECK LIST LENNOX gt This check list should be filled in by the contractor to make sure that unit installation takes pla
25. Company certifies under its responsibility that the equipment under pressure identified below is in conformity with the requirements of the directive that are applicable EQUIPMENT UNDER PRESSURE N 97 23 CE Description of Equipment Under Pressure and the Procedure of Evaluation to be in Conformity Type of Machine Serial Number Year of Manufacture Cat gorie de la DESP Procedure of Evatuation Module H1 Attestation N Certificat d examen CE de a conception Module H1D Attestation N Description of Components Under Pressure Type of Component Category of Risk COMPRESSEUR SZ 300 EVAPORATOR FILTER DRYER VS489 EXPENSION VALVE TRE 80 TUBE PRESSURE SWITCH P100 SAFETY VALVE 450PSI Name and Address of the Organisation Auditing the Quality Assurance System NF EN ISO 9001 AFAQ F 92224 Bagneux Cedex FRANCE 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 NF EN 60204 1 Safety of machinery Electrical equipment of machines References to Other Standards a Directive 98 37 EC Relating to machinery Directive 93 68 EEC Relating to electrical equipment designed for use within certain voltage limits
26. ENNOX ls Code Description Code Description Code Description Code Unit Min Factory Max Comments 2 Circuit 2 3520 1 SuperHeat 3521 5 7 5 7 15 EEV Superheat set point With Glycol 2 Anticipation 3522 0 Calc my LEEV Eennox paint EE opening at 1st stage start 3 P 3523 0 30 EEV Lennox set point Proportional factor 44 3524 0 EEV Lennox set point Integral factor 5 D 3525 0 EEV Lennox set point Derivate factor 3 Circuit 3 3530 1 SuperHeat 3531 5 7 Superneat set point VU Glycol 2 Anticipation 3532 0 EVI Eentiox set point IE EV opening at 1st stage start 3 P 3533 C 0 EEV Lennox set point Proportional factor 44 3534 0 EEV Lennox set point Integral factor 5 D 3535 0 EEV Lennox set point Derivate factor 4 Circuit 4 3540 1 3541 5 7 l EEV SUperhgat MAR Glycol 2 Anticipation 3542 0 EEV Lennox set polit EEY opening at 1st stage start 3 P 3543 C 0 EEV Lennox set point Proportional factor 44 3544 0 EEV Lennox set point Integral factor 5 D 3545 0 EEV Lennox set point Derivate factor 6 Ventilation 3600 1 Sp Cond 3614 b 11 SAI Mighipressure Ser 0 R134a unit 2 Reactiv 3612 1 HP Factor Reactivity set point for fan operation 459 Installation Operation Maintena
27. GIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX 2 Code Description Code Description Code Description Code Min Factory Max Comments Function Defrost Choice of defrost 1 cycling or 0 dynamic 3 Defrost 3430 2 Outside 3432 8 10 20 in c 3433 119 2 i 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 Smet 1 ae 360 of time If cycling defrost this is the time delay to start the defrost once the tempe rature conditions are met Function Defrost Running time of 5 Time Fc 3435 S 5 60 300 fans after defrost cycle in order to dry the outside coil 5 EEV 3500 1 Circuit 1 3510 t SuperHeat 3511 C 5 7 5 7 15 2 Superheat set point Wit 2 Anticipation 3512 0 Calc 50 EEV Lennox set point EEV opening at 1st stage start 3 P 3513 C 0 30 EEV Lennox set point Proportional factor 4 3514 S 0 30 999 EEV Lennox set point Integral factor 5 D 3515 0 1 999 EEV Lennox set point Derivate factor 458 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED L
28. H P pressure switch cut in Bar Low pressure switch cut in Bar Oil pressure switch cut out Bar Antifreeze pressure switch cut out Bar switcht Fan 2 Fan 3 Fan 4 432 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 TROUBLESHOOTING REPAIRS 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 concentration 1 use DRE EXE EE E REIS Flow switch operational d bit Chilled water pump interlock Filler On water circult eben ee hee ae eo ee ad CONDENSER WATER CIRCUIT Inlet Outlet pressure guages for pressure drop DkPa Condenser inlet temperature C Condenser outlet temperature C Regulation on condenser water inlet Condenser pump interlock Filt r ori water Circuit ooo PR ER Aa dates Sana eves a Unrestricted air flow on condenser coils 2
29. INSTALLATION OPERATING amp MAINTENANGE MANUAL PROVIDING gt GE LENNOX gt ECOLOGIC TABLE OF CONTENTS LENNOX INSTALLATION OPERATION MAINTENANCE MANUAL Ref ECOLOGIC IOM 0605 E The present manual applies to the ECOLOGIC range WA WAH T PREFACE ewe ne see re ERES E Dr sekst Ene ade 3 2 WARRANTY e eer es ee ee ew E RU 5 El SPA Eser 5 3 225000 rd eee 6 3 1 transport handling 6 3 24 the unit com Guta Seely dei eed M LE 7 3 3 lay out and installation requirements 8 3 4 water CONNECTIONS i e lemen tired quer bt ke re ae 10 3 5 electrical connections sara arm bends Bn eee 11 3 0 SOUNd 1EVEIS re vede rd Pac Berte hei ala PEE ea EDS vag 11 3 7 Tefrigerant charge a uidere mir el urt 11 3 8 re Sr Pee ser REA 12 4 PRELIMINARY 13 4 1 limilS Loew Midis MED dine Bibi El frr bas bis 13 4 2 refrigeration circuit checks and recommendations 13 4 3 hydrauli
30. INUED LENNOX Main screen Code Description Code Description Code Description Code Unit 2 Data 2000 1 General 2100 7 Out Custom 2170 1 Relay 1 2171 On Off 2 Relay 2 2172 On Off 3 Relay 3 2173 On Off 4 Relay 4 2174 On Off 8 In Custom 2180 1 Switch 1 2181 On Off 2 Switch 2 2182 On Off 3 Switch 3 2183 On Off 4 Switch 4 2184 On Off 9 In Custom 2190 1 Temp 1 2191 C 2 Temp 2 2192 C 3 Temp 3 2193 C 4 Temp 4 2194 C 2 Control 2200 1 Water 2210 1 Sp Cool 2211 C 2 Sp Heat 2212 C 3 Cap Cool 2213 4 Cap Heat 2214 5 Sw 2 Sp 2215 On Off 6 Offset 2216 C 2 Ventilation 2220 1 SetPoint 2221 b 2 Capa V1 2222 3 Capa V2 2223 4 Capa V3 2224 5 Capa V4 2225 3 Pump 1 Config 2311 Liste NO Single Double Liste Stopped Started1 Started2 2 State 2312 Schedule Fault 1 Fault 2 3 Sw Flow 2313 On Off 4 Sw State 2314 On Off 5 Relay 1 2315 On Off 6 Running T 1 2316 h 7 Relay 2 2317 On Off 8 Running T 2 2318 h 4 Compressor 2400 1 Comp 1 C1 2410 1 Config 2411 Liste No C Only H Pump Liste Stopped StartHeat Started Start 0 5 Started1 Defrost Wait Flow I Wait CH Ant Sho Cy Schedule 2 State 2412 Switch Fault 1 3 Sw State 2413 On Off 4 Sw High P 2414 On Off 5 Sw Low P 2415 On Off 6 Relay 2416 On Off 7 H Pump 2417 On Off 8 Valve 2418 On Off 9 Run T
31. LENNOX warranty If phase imbalance exceeds 2 for voltage 1 for current contact your local electricity company immediately before powering up the unit 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 neces sary to provide further treatment such as sound proofing or installation of screens around units installed externally The choice of the location for the installation can be of great importance reflection absorption transmission of vibrations The type of unit support is also very important inertia of the room and the structure of the walling interfere with the installation and its behaviour Before taking any other steps first determine whether the sound level is compatible or not with the environment what it is perfectly justifiable and that these measures envisaged will not cause unreasonable cost Determine what level of sound proofing is necessary on the equipment the installation silencer vibration isolators screens and on the building reinforcement of flooring false ceilings wall cover
32. N 69780 MIONS FRANCE BVQI certifie que Syst me de Management de la Qualit de I Entreprise susmentionn e a t valu et jug conforme aux exigences de la norme SIANDARD CONCEPTION FABRICATION ET CESSION INTERNE DE BIENS D QUIPEMENT DESTIN S AU CONDITIONNEMENT D AIR ET LA R FRIG RATION DESIGN MANUFACTURING AND INTERNAL TRANSFER OF EQUIPMENT GOODS DEDICATED TO AIR CONDITIONING AND REFRIGERATION Date de certification onyinale 22 avril 2005 Sous r serve du fonctionnement continu et satisfaisant du systeme qualit de l entreprise ce cernficat est valable jusqu au 31 mars 2008 Pour venfier la validit du certificat appelez le 04 78 66 82 60 lout clurcissement sur cette certification peut tre obtenu aupr s de l entreprise certifi e Numero de Certificat 172696 Date 22 avril 2005 Num ro d Affaire 1411599 BUREAU EN CHARGE BUREAU EMETTEUR BVQI France S A BVQI France Dir Contrats 60 avenue du G nera ce Gale tue des Vergers Silc 4 92046 Parsia Dofenso 59760 Limones Franco France Installation Operation Maintenance manual CHILLERS ANNEXES 0605 63 CERTIFICATES PED LENNOX 64 BUREAU VERITAS S A 2001 Bureau Veritas S A is a Notified Body under the number 0062 BUREAU VERITAS ATTESTATION D APPROBATION DE SYSTEME DE QUALITE module H1 CERTIFICATE OF QUALITY SYSTEM APPROVAL module H1 N CE PED H
33. NG TO 97 23 CE DIRECTIVE FICHE D ANALYSE DES SITUATIONS DANGEREUSES SUIVANT LA DIRECTIVE 97 23 CE LENNOX Event Effect Risk Actions to Eliminate the Risk Intormation to minimise the Occurrence of a risk 1A 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 IOM supplied with the unit Level the machine during commissioning In the case where Indications general mechanical Unusual stress in the frame the unit is installed on anti vibration B Unit not installed properly or i drawings in the technical guide 2A leading to possible and strains Leaks mountings all supporting points must leveled to the ground P and the IOM supplied with the vibrations and cracks be used and the block hardness must unit be selected according to the type of units being installed Unsuited hydraulic or Unusual bu pipe work Proper support and fitting of the pipe Indications in the technical IOM 3A leading to possible and strains Leaks refrigeration pipe work ai work on site supplied with the unit vibrations and cracks Outdoor temperature below Strains vibrations and cracks Partial or complete destruction Provide anti frost pr
34. NS ACCORDING TO 97 23 CE DIRECTIVE 46 ECOLOGIC REFRIGERATION CIRCUIT DRAWINGS 48 CLIMATIC 50 MENU TREES See specific CLIMATIC 50 user manual ECOLOGIC range wi ewes sheets week na eed ed AG 50 CERTIFICATES MONS TSO 90012200012 adr rate ae Dave eae tas ERE 63 PED beh era od PLE He vas pee eae 64 CE CONFORMITY 2 Iia E aoa o OP Rd CD PALA 65 LENNOX Ref CHILLERS IOM 0605 E 27 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITHOUT HYDRAULIC OR HYDRONIC MODULE LENNOX 150 STD LN 75 100 110 HE SLN 200 gt 370 STD LN HE SLN 90 130 150 HE SLN ITEMS SUPPLIED LOOSE Groove lock coupling Unit isolation valve Water inlet filter Paddle flow switch ITEMS MOUNTED INSIDE THE UNIT Temperature sensors 2 In Out without groove lock coupling option in Outmanometers mounted on groove lock coupling option Plate heat exchanger Flow switch Differential OPTIONS Flow switch paddle Flow switch differential Add 01 19 Add 04a 17a Add 04b 17b amp 01 19 BASIC UNIT Water inlet filter Supplied loose Supplied mounted Unit i
35. 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 filling of the system under pressure shall be carried out using connections provided for this purpose and suitable equipment To prevent the risk of explosion due to spraying of coolant and oil the relevant circuit shall be drained and at zero pressure before any disassembly or unbrazing of the refrigerating parts takes place There is a residual risk of pressure build up by degassing the oil or by heating the exchangers after the circuit has been drained Zero pressure shall be maintained by venting the drain connection to the atmosphere on the low pressure side The brazing shall be carried out by a qualified brazer The brazing shall comply with the standard NF EN1044 minimum 30 silver Replacing components In order to maintain CE marking compliance replacement of components shall be carried out using spare parts or using parts approved by Lennox Only the coolant shown on the manufacturer s nameplate shall be used to the exclusion of all other products mix of coolants hydrocarbons etc CAUTION In the event of fire refrigerating circuits can cause an explosion and spray coolant gas and oil 4 Installation Operation Maintenance manual IOM e E
36. 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 with indicator lights enabling visualisation of the state of operation or non operation of a function or given circuit There is also an indicator to show that the unit is powered up an emergency stoppage indicator for each compres sor an indicator to show stoppage of the compressor via the regulating system through the main control thermostat which is sensitive to chilled water temperature a run light per compressor and a general fan default stoppage indicator on air cooled units On units with
37. c system installation checks 13 4 4 installation of external hydraulic components supplied loose by lennox 13 4 5 check list before start up 4 13 5 lt UNIT START UP dl 15 5 1 checks to be made during start up 15 5 2 oil eharge vakse AAGE em Aer AEE EHE 16 5 3 retfrigerant charge uir ae Bae Ae e A bue As Says 16 coin cw due n n EEE Not tester en a ae 17 6 1 climatic COntrol alee dette EE er EE CLE RUE a 17 6 2 unit Operations uos pressen Eni delle BEES Mg 19 T ea eek je RONDE 23 TA weekly maintenance ua seas KS Terne REX WE eo era ee UE 23 7 2 annual maintenance pi purk priser piss Dens ace Pv ee ee ee se Elene ae nej 23 7 3 cleaning the condenser 24 7 4 compressorsi il drainage uoo rer pue EE eR erede 24 5 important 2 Lure e NEL Sed ED ape a ive i s Fen Fa i PG 24 8 TROUBLESHOOTING REPAIRS 25 8 1 list of the most common problems 25 8 2 contro devices mE ED MEER ig hg 31 8 3 operation and start up ch
38. ce according to ap propriate industry practices WARNING Disconnect the power supply before carrying out any inspections on the unit If the unit must be left powered up proceed with precaution to avoid risk of electrocution Note some units have a separate control circuit supply that is not isolated when the main power supply is OFF This must be isolated separately RECEPTION O Check absence of transport damage O Check for missing items O Availability of suitable lifting gear slings and spacers UNIT PLACEMENT O Shipping crate removed O Clearances checked O Vibration isolators mounted O Unit set in place O Unit levelled CHILLED WATER CIRCUIT All piping checked for leakage Thermometers installed Water pressure regulator installed Balancing valves installed Flow switch installed System rinsed cleand and filled before being connected to the unit Checked presence of filter on unit inlet and state of cleanliness of the filter Checked operation of the pump and evaporator pressure drop 0 000000 CONDENSER WATER CIRCUIT Checked order of power supply phases for scroll and screw compressor units 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 O Checked operation of the pump and condenser
39. conditions which reduce the heat exchange capacity of the coils will cause an increase in condensing pressure This will lead to a loss of capacity and an increase in compressor power input To prevent air flow to be reversed due to prevaling winds units cannot be completely shrouded with a higher uninterrupted wind shield If such a configuration cannot be avoided an air ejection duct must be installed at the same height as the surrounding shield Itis important that units must be leveled failure to install unit correctly will void warranty CLEARANGES DRAWINGS FOR MORE DETAILS PLEASE CONSULT OUR APPLICATION GUIDES OR THE DRAWINGS SUPPLIED WITH THE UNIT ECOLOGIC range gt 3 meters gt 2meters 4 gt 2 Not recommended Not allowed For any air cooled unit it is necessary to have a minimum distance between air coil and any obstacle of 1 5 meters VAN For any chiller a minimum distance of 1 meter is required for the good opening and servicing of the elec trical box Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 9 INSTALLATION TRANSPORT HANDLING LENNOX 3 4 WATER CONNECTIONS 3 4 1 Water connections Evaporator Condenser The water circulating pump will be preferably installed upstream so that the evaporator condenser will be subjected to positive pressure Entering and leaving water connections are indicated on the certified drawing sent with the un
40. d 12 18 Inlet Outlet 06 07 08 09 13a Unit isolation Pump Unit Kit for groove Inlet Outlet manometer kit or valve isolation valve lock coupling manometer for groove lock 13b 14 15a 15b 16 coupling Add 02 18 Add 02 12 18 Add 01 16 Add 04a 17a Add 30 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITH HYDRAULIC MODULE LENNOX STD LN HE SLN _ 99 ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT 14 15a 15b 16 13a or 13b Groove lock coupling Paddle flow switch Single pump Unit isolation valve 25L expansion vessel Double pump Water inlet filter Second 25L expansion vessel for Air purge WA gt 150D In Out manometers without Single 50L expansion vessel Temperature sensor return groove lock coupling option WA lt 150D In Out manometers mounted on Temperature sensor supply groove lock coupling option Plate heat exchanger OPTIONS Expansion vessel BASIC UNIT Flow switch Expansion vessel SUE for Expansion vessel Smale en paddle mounted Water inlet filter 25L WA 150 STD amp 50L for all other WA g pamp p 075 090 100 110 units HE amp SLN Add 05 Add 03 Add 10 Add 11b Add 10 amp 11a Inlet Outlet m Kit for groove lock Inlet Outlet manometer kit Unit isolation valve 4
41. d discharge temperatures 11 Check chilled liquid entering and leaving temperatures 12 Check outdoor air temperature 13 Check liquid refrigerant temperature at the condenser outlet Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 150 UNIT START UP LENNOX These verifications should be made as quickly as possible with a stable cooling load i e the cooling load of the installation should be the same as the capacity developed by the unit Measurements taken without heeding this condition will result in unusable and probably wrong values These verifications can only be made once the proper operation of all safety devices and unit controls has been established 5 2 OIL CHARGE Units have a complete operating charge of oil when they are shipped and there is no need to add any oil before start up or afterwards Note that unit shutdowns by the differential oil pressure switch are usually caused by other problems than a lack of oil in the refrigeration circuits Overcharging with oil can cause serious problems on an installation particularly for the compressors The only time any oil might need adding is when a compressor is replaced 5 3 REFRIGERANT CHARGE Self contained units have a complete refrigerant charge at the time they are shipped This charge may need to be topped up when the unit is installed or at other times during the service life of the unit Additional charge can be introduced t
42. e Zone Setting Starting time Hour 2 Schedule 3200 1 Time 3210 1 Start Uno 3211 h 0 24 24 for Unocupied zone set 6 3 to get 6h30mn modulo 10mn Zone Setting Starting time for Zone 2 Start z A 3212 h 0 0 24 A set 6 3 to get 6h30mn modulo 10mn Zone Setting Starting time for Zone 3 Start z B 3213 h 0 24 24 B set 6 3 to get 6h30mn modulo 10mn Zone Setting Starting time for Zone 4 Start z C 3214 h 0 24 24 C set 6 3 to get 6h30mn modulo 10mn 55 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX Main screen Code Description Code Description Code Description Code Unit Min Factory Max Comments 56 3 Control 3300 2 Anticipation 1 Change over 3220 3310 1 Foot 3221 C 10 10 20 Anticipation Function Bottom of the slope in C Limit of activation of the function This allows an anticipated startup in the morning depending on the outdoor temperature Only for the Zone A 2 Gradient 1 Mode 3222 3311 mn C Liste Cool Only Heat Only Auto Auto Stop 100 Anticipation Function Slope in Minutes of anticipation per degrees Change over Change over mode for heat pump units 0 chiller only 1 HP only 2 automatic with pump 3 automatic without pum
43. e and other substances in suspension inside the condenser tubes Use non corrosive solvent to remove scale deposits The water circuit in the condenser is manufactured in steel and copper water treatment specialist given the right information will be able to recommend the right solvent for removing scale The equipment to be used for external water circulation the quantity of solvent and the safety measures to be taken must be approved by the company supplying the cleaning products or by the company conducting these operations 7 4 COMPRESSORS OIL DRAINAGE Oil for refrigeration equipment is clear and transparent It keeps its colour over a long period of operation Given that a correctly designed and installed refrigeration system will operate without any problems there is no need to replace the compressor oil even after a very long period of operation Oil that has become dark in colour has been exposed to impurities in the refrigeration piping system or to excessive temperatures on the discharge side of the compressor and this inevitably impairs the quality of the oil Darkening of the colour of the oil or degradation of its qualities can also be caused by the presence of humidity in the system When the oil has changed colour or has been degraded it must be changed 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 wi
44. e 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 or 150D WAIRA 270D WAIRA 300D WA RA 2000 VENT1 C1 WAIRA 2300 VENT1 C2 8 VENT1 C1 a S psi FRIC2 VENT1 C1 VENT1 C2 except EIN except LN c1 c2 VENT C1 C2 except ER Except LN v 8 FR C1 except LN ca VENT2 C1 2 2 VENT2 C1 5 VENT2 C2 og use VENT3 C2 VENT1 C2 VENT3 C1 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 21 OPERATION MND WAIRA 3700 VENT1 C2 FR C2 except LN VENT1 C1 FRIC1 except LN B E VENT2 C1 VENT2 C2 9 VENT3 C1 VENT3 C2 WA RA 100E WAJRA 110E WA RA 75E VW WA RA 90D WAIRA 1300
45. eck sheet 32 8 4 regular checks to be made chiller unit environment 33 8 5 manufacturer s recommended inspections 34 CHECK LIST bres rase sk pee sette Nede DEPE dcr e des 36 ANNEXES Se SR VR Rip LEE EE eh TE 37 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 1 LENNOX 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 C Certifi ISO 9001 2000 par Product designed and manufactured under a quality management system certified to ISO 9001 9000 ET LENNOX have been providing environmental solutions since 1895 our range of air cooled chillers continues to meet the standards that have made LENNOX a household name Flexible design solutions to meet YOUR needs and uncompromising attention to detail Engineered to last simple to maintain and Quality that comes as standard Information on local contacts at www lennoxeurope com All the technical and technological information contained in this manual including any drawing and technical descriptions provided by us remain the property of Lennox and must not be utilised except in operation of this product reproduced issued to or
46. eclaration 2 1 2 Warning labels The chiller is marked with the following warning labels to alert to potential hazards on or near the potentially haz ardous part High temperatures Electrical Rotating Sharp voltage parts parts Check regularly that the warning labels are still in the correct positions on the machine and replace them if neces sary Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 5 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 36 The exterior has not been damaged in any way The lifting and handling equipment are suitable for the equipment and comply with the specifications of the handling instructions enclosed here in Accessories ordered for on site installation have been delivered and are in good working order If the unit is delivered with its operating charge of refrigerant that there has been no leakage use an electronic detector The equipment supplied corresponds to the order and matches the delivery note If the product is damaged exact details must be confirmed in writing by registered post to the shipping company within 48 hours of delivery working days A copy of the l
47. eplace the compressor I THE COMPRESSOR STARTS WITH DIFFICULTY Faulty windings Replace the compressor Mechanical problem Replace the compressor 28 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued PROBLEMS SYMPTOMS PROBABLE CAUSE LENNOX RECOMMENDED ACTION J THE COMPRESSOR IS NOISY If starting on a single winding on compressors fitted with part winding start or wye delta Check operation of the starter contacts the start up time delay and the condition of the windings Broken mechanical parts inside compressor Compressor knocking Replace the compressor Suction line is unusually cold a Liquid slugging b Expansion valve blocked in open position Broken suction valves a Check superheat and that the expansion valve bulb is correctly installed b Repair or replace Replace broken valves High discharge pressure The Pressure operated water valve water regulating valve or the pressure operated water valve taps or knocks or irregular fouled water pressure is to high Clean the valve Install and expansion tank upstream of the valve Compressor shuts down through action of the oil pressure safety switch Low oil charge Add oil K DISCHARGE PRESSURE TOO HIGH Water flow to low or wat
48. er temperature too high in the condenser Water is far too hot at condenser outlet Adjust the pressure operated water valve or the thermostat on the cooling tower Water is far too cold at the Condenser tubes fouled condenser outlet Clean the tubes Presence of air or incondensibles in the circuit or excessive refrigerant charge Condenser abnormally hot Purge incondensibles and or air and recover excess refrigerant Chilled water leaving temperature too high Excessive cooling load Reduce load reduce water flow if necessary L DISCHARGE PRESSURE IS TOO LOW Water is very cold at condenser outlet Condenser water flow too high or water temperature is too low Adjust the pressure operated water valve or the thermostat on the cooling tower Bubbles in sightglass Low refrigerant charge Repair the leak and add refrigerant Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 29 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION M SUCTION PRESSURE IS TOO HIGH The compressor runs continuously Too much cooling demand on the evaporator Check the system Suction line unusually cold Liquid refrigerant returns to compressor a Expansion valve opened to far a Adjust superheat a
49. er temperature C Minimum difference water inlet outlet C Maximum difference water inlet outlet C Minimum outside air temperature C Minimum outside air temperature with low ambient kit C 10 Maximum outside air temperature Normal operation with CLIMATIC 30 12 C water inlet 7 C water outlet C 43 44 44 44 43 43 Normal operation with CLIMATICTM 50 12 C 7 C water one compressor unloaded C 51 59 59 51 51 48 Start up with CLIMATICT 30 Thermostatic expansion valve and NO unloading C 37 39 39 38 36 37 Start up with CLIMATICT 50 Thermostatic expansion valve and ONE compressor unloaded Start up with CLIMATIC 50 Electronic expansion valve C 49 46 46 48 48 45 and ONE compressor unloaded ECOLOGIC WA WA 150 200 230 270 300 370 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 10 with low ambient kit Maximum outside air temperature Normal operation with CLIMATICTM 30 S 12 C water inlet 7 C water outlet M 4 X p i 2 Normal operation with CLIMATICTM 50 5 12 C 7 C water
50. erated the frequency of operation climatic conditions atmospheric pollution etc Only trai ned experienced personnel can establish strict maintenance procedures adapted to the conditions listed above Nonetheless we recommend a regular maintenance schedule 4 times a year for chillers operating all year long 2times 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 itis caused by a lack of maintenance or by operating conditions beyond those recommended in this manual Shown below and as an illustration only are some of the most common rules applied for maintenance 7 1 WEEKLY MAINTENANCE 1 Check the compressor oil level This should be half way up 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 minut
51. es 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 12 3 Check the oil pressure 4 The flow of liquid refrigerant through the sightglass should be steady and without bubbles Bubbles are a sign of a low charge a possible leak or of a restriction in the liquid line Contact a qualified technician Each sightglass is fitted with a humidity indicator The colour of the element changes according to the level of hu midity in the refrigerant but also according to temperature It should indicate dry refrigerant If it shows wet or CAUTION contact a qualified refrigeration technician CAUTION When starting up the unit run the compressor for at least 2 hours before taking a humidity reading The humidity detector is also sensitive to temperature and as a consequence the system must be at normal operating temperature to give a meaningful reading 5 Check operating pressures If they are higher or lower than those recorded when the machine was put into service see the chapter 8 6 Inspectthe entire system so as to detect any eventual abnormality noisy compressor loose casing panels leaky pipes or juddering contacts 7 Record temperatures pressures dates et times and any other observations in t
52. es with water cooled condensers the condenser water circuit must be ready to operate filled with water pressure tested bled filter cleaned after 2 hours of operation of the water pump Cooling tower in operating condition water supply and overflow checked fan in operating condition 5 Reset all manually resetting safety devices where necessary Open power circuits to all components compressors fans 6 Power up the unit with the main disconnect switch option Visually check the oil level in the compressor crank cases bullseyes This level may vary from one compressor to another but should never be higher than the first third of the way up the bullseyes CAUTION Power up the compressor crankcase heaters at least 24 hours before starting the unit This will enable the refrigerant in the crankcases to evaporate off 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 Q Q1xvP2 P1 where P2 pressure drop measured on site 1 pressure drop published by LENNOX for liquid flow of Q1 Q1 nominal flow Q real flow 8 On units with air cooled condensers check for correct operation of the fans and that the protective grilles are in good condition Make
53. etter must be addressed to LENNOX and the supplier or distributor for information purpo ses Failure to comply will invalidate any claim against the shipping company Please be reminded that LENNOX is not responsible for off loading and positioning 3 1 1 1 Unit Nameplate The rating plate provides a complete reference for the model and ensures that the unit corresponds to the model ordered It states the electrical power consumption of the unit on start up its rated power and its supply voltage The supply voltage must not deviate beyond 10 10 The start up power is the maximum value likely to be achieved for the specified operational voltage The customer must have a suitable electrical supply It is therefore importantto check whether the supply voltage stated on the unit s rating plate is compatible with that of the mains electrical supply The rating plate also states the year of manufacture as well as the type of refrigerant used and the required charge for each compressor circuit LENNOX Tel 04 72 23 20 20 69780 MIONS FRANCE Type Unit type WA 230DKLN N Serie Serial N R 125995 01 anne You Coarsoos Rofrigerant Fluide Nombre de circuits Circuits N R 2 Kg Cireuit Pression Max service HP Max operating pressure HP bar frigo nominale Ke Ee 400 3 80 vpn 230 1 50 Valeur alim primeipale nuxiliaire gg o o Temp Air ambiant Maxi Air ambiant temp Maxi Poids
54. gain until the source of the problem has been located 5 Check that there is sufficient cooling load on the day the start up is conducted at least 50 of the nominal load PROCEDURE TO FOLLOW WHEN STARTING THE UNIT 5 a Press the power ON OFF switch The compressor will only start if the 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 indica ting a correct refrigerant charge and without non condensable gas If the humidity indicator changes colour indicating the presence of humidity replace the filter drier cartridge if the latter is of the replaceable type Even better check the sub cooling after the condenser 5 c Check that when the cooling load has been balanced by the capacity of the unit the chilled liquid is at design temperature 6 Check the current values per phase on each compressor motor 7 Check the current values per phase on each fan motor 8 Check compressor discharge temperature 9 Check compressor oil pump temperatures semi hermetic reciprocating compressors 10 Check suction and discharge pressures and compressor suction an
55. going commitment to quality Specifications Ratings and Dimensions subject to change without notice and without incurring liability Improper installation adjustment alteration service or maintenance can cause property damage or personal injury Installation and service must be performed by a qualified installer and servicing agency
56. he flow switch Anti short cycle relay action Wait until the anti short cycle time delay has expired Faulty control thermostat Check for proper operation set points contacts Oil pressure switch tripped Check the oil pressure switch and determine the cause of the trip out Antifreeze thermostat or low pressure safety switch tripped Compressor thermal protection relay tripped High pressure safety switch tripped Check evaporating pressure the condition of the antifreeze thermostat and the low pressure safety switch Check for proper operation of the relay Check the condensing pressure and the condition of the high pressure safety switch Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 25 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION B THE COMPRESSOR DOES NOT START Low pressure safety switch trip out Check low pressure safety switch differential Normal operation with too frequent starts and stoppages due to action of the low pressure safety switch Bubbles in sightglass Or normal compressor operation but the low pressure safety switch trips out and resets frequently Low refrigerant charge Check the charge through the sightglass on the liquid line carry out a leak test the
57. he service log 8 Leak detection is recommended 7 2 ANNUAL MAINTENANCE On units with water cooled condensers it is important that the unit be serviced regularly by a qualified technican at least once every year or every 1000 hours of operation Failure to observe this rule can lead to cancellation of the warranty and will clear LENNOX of whatever responsibility A service visit by a qualified technician is also recommended after the first 500 hours of operation after the unit is first put into service 1 Inspect valves and piping Clean the filters if necessary clean the condenser tubes see cleaning the condenser 87 3 2 Clean the chilled water piping filters CAUTION The chilled water circuit may be pressurised Observe the usual precautions when depressurising the circuit before opening it Failure to observe these rules could lead to accidents and cause injury to service personnel 3 Clean any corroded surfaces and repaint them Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 23 MAINTENANCE LENNOX 4 Inspect the chilled water circuit for any signs of leakage Check operation of the water circulating pump and its ancillaries Check the percentage of antifreeze in the chilled water circuit top up as 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 procedu
58. horised 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 operations and when setting it on the ground IS PROPERLY ISOLATED AND LOCKED OUT NOTE SOME UNITS MAY HAVE SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPA RATE ISOLATION PLEASE CHECK THE WIRING DIAGRAM CAUTION BEFORE EACH SERVICE OPERATION SURE THAT THE UNIT POWER SUPPLY 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
59. hrough the Schrader valves on the suction line Every time fluid is added check the state of the charge with the sightglass provided to that effect on the liquid line and also by the amount of liquid subcooling at the con denser 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 shu tdown Remember to power up the crankcase heaters at least 24 hours before the unit is restarted 16 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 OPERATION LENNOX 6 OPERATION 6 1 CLIMATIC CONTROL cf See the specific CLIMATIC 50 manual cf See the specific Basic CLIMATIC controller manual 6 1 1 Menu Tree ECOLOGIC range See Annexes page 50 to 62 6 1 2 Connection diagrams CLIMATIC 30 Aremote controller is offered as an option To install this optional remote controller proceeded as follow Connect exactly as indicated in electrical diagram The wire should not exceed 50 m The three cables for connection from the keypad to the power board must be kept separate from other cables using an individual cable channel and use shielded cables with a cross section of 1 2 Electrical box at the unit Terminal block Remote controller optional ISX AK D Three lead shielded cable with a cross section of 1mm
60. igerant charge Check the refrigerant charge in the sightglass and top up if necessary Filtrer drier partly obstructed Check the drier and replace as required change the filter cartridge Expansion valve partly closed Check expansion valve bulb and capillary measure superheat Liquid line valve not open far enough Open the valve completely Noisy compressor or abnormally high suction pressure or low discharge pressure Leaky compressor valves Check valve gas tightness replace the valve plate if necessary Tighten compressor nuts and bolts E THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH Oil pressure switch tripped Check operation of the oil pressure safety switch Oil level in sightglass is too low Oil pressure too low Check the oil level in the sightglass on the crankcase check the cleanliness of the oil filter check the oil pump Visible oil leak Oil level too low Low oil charge Check that there is no leakage and add oil Leaky oil sump Repair and add oil Suction line unusually cold compressor noisy Liquid refrigerant present in the compressor crankcase Check appearance of the oil in the sightglass Measure temperature of the oil pump measure superheat at the expansion valve check that the valve bulb is tightly attached Poor heat exchange in the evaporator Check water flow Check
61. igidity and point load positions enable installation to minimise vibrations Vibration isolators may be used by contractors on installations requiring particularly low vibration levels Use of vibration isolators MUST be accompanied by installation of flexible connections in the unit water piping Vibration isolators must also be fixed to the unit BEFORE 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 48 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 INSTALLATION TRANSPORT HANDLING LENNOX t is essential that the units be installed with sufficient free space around them to enable proper circulation of air ejected by the condensers and to provide easy access to all unit components for servicing and maintenance If the air rejected by the condenser encounters any obstacles it will tend to be recycled by the fans This will cause an increase in the temperature of the air used to cool the condensers Obstruction of the air outlet will also impair air distribution across the entire heat exchanging surface of the condenser Both of these
62. ime 2419 h 51 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX Main screen Code Description Code Description Code Description Code Unit 2 Data 2000 4 Compressor 2400 2 Comp 2 C1 2420 1 Config 2421 Liste No C Only H Pump 2 State 2422 Liste Stopped StartHeat Started Start 0 5 Started1 Defrost 3 Sw State 2423 On Off 4 Sw High P 2424 On Off 5 Sw Low P 2425 On Off 6 Relay 2426 On Off 7 H Pump 2427 On Off 8 Valve 2428 On Off 9 Run Time 2429 h 4 e 2 2430 1 Config 2431 Liste No C Only H Pump 2 State 2432 Liste i Stopped StartHeat Started Start 0 5 Started1 I Defrost Wait Flow Wait CH Ant Sho Cy Schedule Switch Fault 1 3 Sw State 2433 On Off 4 Sw High P 2434 On Off 5 Sw Low P 2435 On Off 6 Relay 2436 On Off 7 H Pump 2437 On Off 8 Valve 2438 On Off 9 Run Time 2439 h 2 2 2440 1 Config 2441 Liste No C Only H Pump 2 State 2442 Liste Stopped StartHeat Started Start 0 5 Started1 I Defrost Wait Flow Wait CH Ant Sho Cy Schedule Switch Fault 1 3 Sw State 2443 On Off 4 Sw High 2444 On Off 5 Sw Low P 2445 On Off 6 Relay 2446 On Off 7 H Pump 2447 On Off 8 Valve 2448 On Off 9 Run Time 2449 H 22 sr 2450
63. ing TE Partial or complete destruction of m 3 7A Possibility of a unit being hit by Extreme heat explosion cracks the circuit liquid gas metal parts Provide an appropriate protection Indications in the technical IOM lightning against lightning supplied could be thrown out of the unit IOM Installation and Operation Manual 46 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE LENNOX N Event Effect Risk Actions to Eliminate the Risk ee Occurrence of a risk Modification of the mechanical 8A Unit exposed to extremely ang enemica properties Of certain Ke ud complete sad of Protect the units against these types of Indications in the technical IOM materials with a risk or corrosion the circuit liquid gas metal parts 2 corrosive materials products supplied rupture pipe bursting leaks and could be thrown out of the unit cracks Unit exposed to explosive i complete Protect the units against these types of Indications in the technical IOM 9A Risk of explosion or pipe bursting the circuit liquid gas metal parts materials products supplied could be thrown out of the unit Inappropriate Heat Transfer 5 Partial or complete destruction of Usual fluids are Water or Water with Indications in the technica
64. ings It may be necessary to contact an engineering office that specialises in sound abatement 3 7 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 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 411 INSTALLATION TRANSPORT HANDLING LENNOX outlet For unit using R22 the charging may be done in vapour phase in that case connection will be made to the suction valve Note Splits units are supplied with a refrigerant or nitrogen holding charge Before pulling down the vacuum for dehydra tion completely purge the unit Charge the unit until there is a constant flow 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 Arisk of damage to the compressor Excessive power consumption 3 8 OIL CHARGE All units are delivered with a complete oil charge In the case of split units it may be nece
65. is earthed properly Indications in the technical IOM interferences supplied Unit exposed to internal or Strains cracks explosions Panel ju complete destruction of Inspect the unit regularly Indications in the technical IOM 16A the circuit liquid gas metal parts external vibrations supplied could be thrown out of the unit Unit damaged due to fatigue Strains cracks corrosion Inspect the unit regularly Indications in the technical IOM 16A Leaks Apply local regulations wear and tear supplied IOM Installation and Operation Manual Installation Operation Maintenance manual CHILLERS ANNEXES 0605 E 47 ECOLOGIC REFRIGERATION CIRCUIT LENNOX REFRIGERANT DRAWING STD LN HE SLN STD LN HE SLN Airflow REFRIGERATION CIRCUIT COMPONENTS 1st amp 2nd scroll compressors 3rd scroll compressor on size 370 STD LN HE amp SLN High pressure switch Pressure transducers HP amp BP Low and High pressure mano e 059 meter Suction and discharge isolation valves Safety valve CE or UDT VARIANTS EXPANSION DEVICE OPTIONS Expansion valve bypass for low Air cooled condenser ambient operations Fan motor Electronic expansion valve Manual isolating valve Evaporator heat echanger Filter drier Suction temperature sensor Soleno d valve External temperature sensor amp 02 Sight glass Heating resistance option Thermostatic expansion
66. is mounted on anti vibration mountings these should be fitted to the unit before final positioning WA 150 HE 150 SLN 200 STD WA Pr 200 LN 150 STD 150 LN Bien 230 STD230 LN WAH 200 std 300 std Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 lt INSTALLATION TRANSPORT HANDLING LENNOX WA 200 HE 200 SLN WA 230 HE 270 HE 230 SLN 270 SLN 270 STD 300 HE 270 LN 300 SLN 370 HE w eue j 370 SLN 370 STD 370 LN WAH 150 STD 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 r
67. it 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 OF FILTER THE INLET OF PLATE EXCHANGER WILL WARRANTY VOID Hydraulic drawings in Annexes page 38 to 41 or supplied with the unit 3 4 2 Water analysis The water must be analysed the water circuit installed must include all items necessary for treatment of the water filters additives intermediate exchangers bleed valves vents isolating valves etc according to the results of the analysis We do not advise operation of the units with open loops which can cause problems with oxygenation nor operation with untreated ground water Use of untreated or improperly treated water can cause deposits of scale algae and sludge or cause corrosion and erosion It is advisable to call in a qualified water treatment specialist to determine what kind of treatment will be necessary The manufacturer cannot accept liability for damage caused by the use of untreated or impro
68. ity for any possible omissions In the air cooled chillers heat is being transported by a pressurised refrigerant with changes in pressure and tem perature Fans have been provided to discharge heat into the environment The protection of operating and main tenance personnel was central in the design of the air cooled chiller Safety features have been included to prevent excessive pressure in the system Sheet metal parts have been fitted to prevent inadvertent contact with hot pipes The fans are equipped with protective grids and the electrical control panel is completely touch proof This excludes some parts operating at a safe voltage 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 d
69. l IOM 10A Corrosion excessive heat i Fluid the circuit Leaks Glycol supplied Inappropriate refrigerant fluid in Corrosion excessive heat complete Only use the fluid specified on the Indications of the refrigerant fluid 11A pda the circuit liquid gas metal parts is the circuit combustion or explosion unit s nameplate on the unit nameplate could be thrown out of the unit Authorized oils Refer to the Indication on the compressor Inappropriate oil in the Partial or complete destruction of 12A Corrosion excessive heat a compressor nameplate or the nameplate or the manufacturer compressor the circuit Leaks documentation documentation Isolate the section of the circuit to be 13A Working on a part under Risk of explosion or part bursting Liquid gas metal parts could be 2 255 the retrigerant Indications in the technical IOM pressure away from the machine thrown out of the unit y DART supplied Always wear protection goggles and gloves Parts to be brazed using best Brazing or un brazing parts Strains cracks pipe Partial or complete destruction of enginsenng practices Use brazing Indications in the technical IOM 14A from the cir uit b rstin the circuit liquid gas metal parts materials approved by Lennox Ensure riad 9 could be thrown out of the unit the circuit is leak free before refilling with refrigerant 15A Unit exposed to inductive Corrosions cracks Ore Ensure the unit
70. le for configurations and clock as there is no factory settings for these Configuration Identification address 2 Link 3920 1 ID 3921 1 4 2 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 2 Number 3922 1 1 4 2 the master Liste Not Used Master Slave relationship refer to pe 8920 Backup Rol Backup 0 9 2 page 7 for details Liste Not Used M S Master Slave relationship refer to OMR ova Temp M S Aver 9 9 2 page 7 for details Liste Not Used M S Master Slave relationship refer to Outside 3973 Temp M S Aver 0 9 2 page 7 for details 3 BMS 3930 4 ID 3931 1 1 200 Configuration Identification number on the 485 Bus Liste Climatic Configuration Type of BMS 0 2 Type 3932 ModBus LonWorks 0 0 2 Mode Lennox Climatic 1 MODBUS 2 Web LONWORKS Liste 1200 2400 BMS communication speed between Baud 3299 4800 9600 19200 0 3 4 1200BDS and 19800 BMS Activation of the control by a computer or an automat Fang 9294 VIF 0 9 1000 mode BMS is activated if this value is different from zero This value is decreased every second 5 BMS Unoc 3935 On Off 2 BMS Cancel the override unoccupied mode 462 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 CERTIFICATES LENNOX Certification 349 9 Ai Antribu ca c LGL FRANCE Zone Industrielle Les Meuri res N
71. n the most recent information available It is supplied conditional to later modifications We reserve the right to modify the construction and or design of our chillers at any time without prior notification or obligation to adapt previous supplies accordingly Any work on the Chiller should be carried out by trained and licenced competent technician 1 The following risks are present 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 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 43 PED DECLARATION LENNOX gt All Units are compliant with the PED directive 97 23 CE The following note must be followed carefully IMPORTANT NOTICE All work on the unit must be carried out by a qualified and authorised employee Non compliance with the following instructions may result in injury or serious accidents Work on the unit The unit shall be isolated from the electrical supply by disconnection and locking using the main isolating switch Workers shall wear the appropriate personal protective equipment helmet gloves glasses etc
72. n top up the refrigerant charge Suction pressure too low Filter drier frozen up Filter drier obstructed Check the state of the drier and replace the filter Solenoid valve closed Check that the valve is operating properly Expansion valve closed Check bulb and capillaries operation of the valve Compressor suction valve Check the filter C THE COMPRESSOR SHORT CYCLES ON HIGH PRESSURE SAFETY SWITCH TRIP OUT High pressure safety switch trip out Check high pressure safety switch differential Low air water flow in condenser or dirty condenser coil poor heat exchange Check that pumps are operating correctly or the state of cleanliness of the coils check fan operation Incondensibles in the refrigeration circuit Bleed from circuit and top up the refrigerant charge Note it is not permitted to discharge refrigerant to atmosphere 26 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS continued LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION D THE COMPRESSOR RUNS IN LONG CYCLES OR RUNS CONTINOUSLY Faulty control thermostat Check operation Temperature too low in the conditioned space low Chilled water thermostat set too Adjust it Bubbles in sightglass Low refr
73. nce manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX ae Code Description Code Description Code Description Code Min Factory Max Comments 7 Option 3700 8 Config 3800 1 Unit 3810 1 Range 3811 Liste 0 8 3 Configuration Unit model 2 Size 3812 Liste 0 x 61 Configuration Type of unit 3 gaz 3813 RARE ne d 0 1 Configuration Type of refrigerant R134a 2 Compressor 3820 1 3821 a E 2 LAK 3822 Yes No Configuration All season control Configuration For units with 3 Stages 3823 Yes No reciprocating compressor extra capacity reduction 4 Starter 3824 Yes No E Configuration For units with compressor soft starter Configuration Fan configuration No No fans Liste No Stages Stages Single speed stage fans 3 Ventilation 3830 1 Circuit 1 3831 Modulation Low 0 0 3 Modulation 1 fan with speed control Speed others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Liste No Stages Stages Single speed stage fans 2 Circuit 2 3832 Modulation Low 0 0 3 Modulation 1 fan with speed control Speed others with single speed Low Speed 1 fan with 2 speed others with single speed Configuration Fan configuration No No fans Liste No Stage
74. nd check that the expansion valve bulb is correctly fitted in place b Expansion valve blocked in open position b Repair or replace N SUCTION PRESSURE IS TOO LOW Bubbles in sightglass Low refrigerant charge Repair the leak and add refrigerant Excessive pressure drop across the filter drier or the solenoid valve Filter drier obstructed Replace the cartridge No refrigerant passing through the expansion valve Expansion valve bulb has lost its charge Replace the bulb Loss of capacity Expansion valve obstructed Clean or replace Conditioned space too cold Compressor short cycling Superheat value too high Control thermostat contacts stuck in closed position Capacity modulation setting too low Excessive pressure drop in the evaporator Repair or replace Adjust Check the external equalizing line on the expansion valve Low pressure drop in the evaporator Low water flow Check water flow Check the condition of the filters look for obstructions in the chilled water circuit piping 30 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 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 co
75. ndensing pressure is usually caused by Adirty condenser Low water flow Low air flow The low pressure switch monitors the pressure at which the refrigerant evaporates in the evaporator tubes Low evaporating pressure is usually caused Low refrigerant charge Afaulty expansion valve An obstructed liquid line filter drier 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 Aworn 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 N Only trained and qualified personnel is authorised to service and maintain this equipment Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 431 TROUBLESHOOTING REPAIRS LENNOX 8 3 OPERATION AND START UP CHECK SHEET Machine identifications File number Year of manufacture NORMAL CONDITIONS OF USE
76. nimum difference water inlet outlet C Maximum difference water inlet outlet C Minimum outside air temperature C Minimum outside air temperature 10 with low ambient kit Maximum outside air temperature Normal operation with CLIMATICT 50 12 C 7 C water C 52 49 49 53 52 52 50 49 5 51 5 52 3 47 1 one compressor unloaded Start up with CLIMATICT 50 Thermostatic expansion valve C 50 46 46 51 50 49 47 46 48 49 43 and ONE compressor unloaded Start up with CLIMATICT 50 Electronic expansion valve C 51 47 48 52 51 50 48 47 49 50 44 and one compressor unloaded 43 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC OPERATING LIMITS LENNOX ECOLOGIC WAH COOLING MODE WAH 150 200 230 Minimum outlet water temperature C 5 Maximum inlet water temperature C 20 Minimum difference water inlet outlet C Maximum difference water inlet outlet C Minimum outside air temperature C Maximum outside air temperature Normal operation with CLIMATICT 50 12 C 7 C water C 51 50 49 one compressor unloaded Start up with CLIMATIC 50 Thermostatic expansion valve C 49 47 46 and ONE compressor unloaded ECOLOGIC WAH HEATING MODE WAH Minimum inlet water temperature Maximum outlet water temperature Minimum difference water inlet o
77. otection ei Water Indications in the technical IOM 4A of the circuit liquid gas could be treated with Glycol or trace heaters freezing pipe bursting supplied with the unit thrown out of the unit along the pipe work Recommended minimum and bibas the sd ai 4 Partial or complete destruction 22 outdoor 20 Indications of the Min Circuits exposed to an unusual properties of certain materials with to 50 C during operation 5A of the circuit liquid gas could be N outdoor temperature on the unit heat source a risk or rupture or pipe bursting 30 C to 65 C during storage thrown out of the unit leaks or cracks appearing Do not expose any part of the machine to a naked flame Increase of the refrigerant Maximum chilled water return Unusual increase in the n pressure in the heat exchanger temperature 45 C temperature of the Chilled 5 Partial complete destruction of 5 With a risk of exceeding the area aa Maximum hot return water Indications in the technical IOM water return to the evaporator the circuit liquid gas metal parts x working pressure leading to temperature 50 C supplied with the unit or the hot return water to the er could be thrown out of the unit ae possible strains vibrations cracks Install a temperature limitation device condenser and pipe or vessel burst
78. p operation 2 Winter 3312 C 10 19 50 Change over Change over winter setting 3 Summer 3313 C 10 22 50 Change over Change over summer setting 2 Water Cool 1 Sp Wat 1 3321 16 5 10 17 Water SP Outlet chilled water temperature set point see page 11 IOM Climatic 50 minimum with Glycol according to 2 Sp Wat 2 3322 C 5 10 17 Water SP Outlet chilled water temperature set point see page 11 IOM Climatic 50 minimum with Glycol according to 3 Sp Out 1 3323 C 10 22 50 Water SP Ambiant air temperature set point see page 13 IOM Climatic 50 4 Sp Out 2 3324 C 10 30 50 Water SP Ambiant air temperature set point see page 13 IOM Climatic 50 5 Reactiv 3325 BIC 50 Capacity Factor Reactivity factor for cooling mode Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX set Code Description Code Description Code Description Code Unit Min Factory Max Comments Water SP Outlet hot water temperature 3 Water Heat 3330 1 Sp Wat 1 3331 C 17 40 50 set point see page 13 IOM Climatic 50 Water SP Outlet hot water temperature
79. perly treated water salt water or brine 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 ice at the lowest outdoor air temperatures expected on an 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 imba lance between earthing points EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS 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
80. pressors Enables visual verification of the state of the liquid refrigerant monophase ou diphasic in the liquid line upstream of the thermostatic expansion valve Enables detection of humidity in the circuit 6 2 1 4 Crankcase heater Every compressor is fitted with a single phase crankcase heater that is activated when the compressor stops to ensure separation of the refrigerant and the compressor oil It is therefore powered up when the compressor is not running NB Scroll and reciprocating 6 C ambient type compressors are not fitted with a crankcase heater 6 2 1 5 High pressure switch This pressostat initiates unconditional stoppage of the unit if compressor discharge pressure exceeds the operating limits Reset is automatic Screw and reciprocating compressor with R407C high pressure switch equal 26 5 bars Scroll compressor with R407C high pressure switch equal 29 bars 6 2 1 6 Low pressure switch This pressure switch initiates unconditional stoppage of the unit if if evaporating pressure drops below the value P 1 6 C ambient temperature machines standard P 2 4 bars relative 2 optional 20 C ambient temperature machines P 0 8 bars relative 6 2 1 7 Fan control pressure switch and thermostat The function of these devices is to ensure a level of head pressure compatible with proper unit operation An increase in outdoor air temperature increases head pressure and this is maintained at it
81. re depending on the case These inspections should include the following operations Check the contacts of motor contactors and control devices Check the adjustment and operation of each control device Conduct an oil analysis to determine the acidity Record the results Chanage the oil if necessary WARNING Oil analyses should be carried out by a qualified technician Misinterpretation of the results could cause damage to the equipment Also analysis operations should be conducted according to the right procedures so as to avoid accidents and potential injury of service personnel Follow the recommendations given by LENNOX as concerns compressor oil see the appropriate table Conduct a refrigerant leak test Check motor winding isolation Other operations may be necessary depending on the age and the number of hours of operation of the installa tion 7 3 CLEANING THE CONDENSER 7 3 1 Air cooled condensers Clean the coils either with a vacuum cleaner cold water compressed air or with a soft brush non metallic On units installed in a corrosive atmosphere coil cleaning should be part of the regular maintenance program On this type of installation all dust gathered on the coils should be quickly removed by regular cleaning Caution do not use high pressure cleaners that could cause permanent damage to the aluminium coil fins 7 3 2 Multitube water cooled condensers Use cylindrical brush to remove sludg
82. rt 3 5 Started4 Start 4 5 Started5 Wait Flow Wait CH Fault 1 3 Sw State 2623 On Off 4 Relay 1 2624 On Off 5 Relay 2 2625 On Off 6 3 2626 On Off 7 Relay 4 2627 On Off 8 Relay 5 2628 On Off 9 Modulat 2629 Liste No 1 Yes 2 Yes 3 Yes 4 Yes 5 Yes 1 Modulat 2 Fan 2 Circuit 3 2630 1 Config 2631 2 Modulat 3 Modulat 4 Modulat 5 Modulat 1 LowSpeed 2 LowSpeed 3 LowSpeed 4 LowSpeed 5 LowSpeed Liste Stopped Start 0 5 Started1 Start 1 5 Started2 2 State 2632 Start 2 5 Started3 Start 3 5 Started4 Start 4 5 Started5 Wait Flow Wait CH Fault 1 3 Sw State 2633 On Off 4 Relay 1 2634 On Off 5 Relay 2 2635 On Off 6 Relay 3 2636 On Off 7 Relay 4 2637 On Off 8 Relay 5 2638 On Off 9 Modulat 2639 Liste No 1 Yes 2 Yes 3 Yes 4 Yes 5 Yes 1 Modulat 1 Fan Circuit 4 2640 1 Config 2641 2 Modulat 3 Modulat 4 Modulat 5 Modulat 1 LowSpeed 2 LowSpeed 3 LowSpeed 4 LowSpeed 5 LowSpeed Liste Stopped Start 0 5 Started1 Start 1 5 Started2 2 State 2642 Start 2 5 Started3 Start 3 5 Started4 Start 4 5 Started5 Wait Flow Wait CH Fault 1 3 Sw State 2643 On Off 4 Relay 1 2644 On Off 5 Relay 2 2645 On Off 6 Relay 3 2646 On Off 7 Relay 4 2647 On Off 8 Relay 5 2648 On Off 9 Modulat 2649 7 Option 2700 1 Free Cooling 2710 1 Config 2711 Liste No Yes 2 State 2712 Liste S
83. s Stages Single speed stage fans 3 Circuit 3 3833 Modulation Low 0 0 3 Modulation 1 fan with speed control Speed others with single speed Low Speed 1 fan with 2 speed others with single speed 60 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 E OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX Code Description Code Description Code Description Code Unit Min Factory Max Comments 4 Option 3840 1 3841 SP n 2 Configuration Pump configuration 2 Glycol 3842 0 50 Configuration Glycol persentage 3 Recovery 3843 Yes No e Configuration Heat recovery option Configuration Free output to be 5 Out Custom 3850 1 BE50 1 3851 0 0 6 customised First output of the extension Liste Not Used C 1 board 50 Alarm 2 Alarm Configuration Free output to be 2 BE50 2 3852 C 3 Alarm C 4 Alarm 0 0 6 customised Second output of the Fans Al Pump Al extension board BE50 Heat Mode 1 100 1 C 2 100 100 Configuration Free output to be 3 BE50 3 3853 C 4 10094 U 100 0 0 6 customised Third output of the U On Z A Z B Z C extension board BE50 Uno Bms Free Configuration Free output to be 4 BE50 4 3854 0 0 6 customised Fourth output of the extension board BE50 Configuration Free input to
84. s required value by fan operation 6 2 1 8 Antifreeze function This function only exists on units designed for brine or glycol water chilling for which the freezing temperature de pends on the concentration of the solution Whatever type of device is used see case 1 and 2 cut out by the antifreeze function causes immediate unit stop page CASE 1 Antifreeze thermostat This device monitor chilled liquid temperature at the evaporator outlet It triggers when the temperature goes below the minimum value 4 C for water CASE 2 Antifreeze pressure switch This monitors evaporating pressure of the refrigerant It triggers when the temperature goes below the preset mini mum value Note On units fitted with CLIMATIC control see the appropriate user manual for more specific details Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 419 OPERATION LENNOX 6 2 1 9 Differential oil pressure safety switch only on units with semi hermetic compressors a Reciprocating compressors This pressure switch initiates unconditional unit stoppage if differential oil pressure drops for more than two minutes below a pre established minimum safety value Differential oil pressure is the difference between the oil pump discharge pressure and the gas pressure inside the compressor crankcase suction pressure The differential oil pressure safety switch is factory set and is not modifi able on site
85. solation valve Add 03 Add 05 Add 22 Add 02 18 16 i Inlet Outlet manometer 15a 15b Kit for groove lock coupling Inlet Outlet manometer kit for groove lock coupling 38 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 E ECOLOGIC HYDRAULIC HYDRONIC DATA UNIT WITH HYDRONIC MODULE LENNOX STD LN HE SLN ITEMS SUPPLIED LOOSE 01 19 Groove lock coupling Unit isolation valve In Out manometers without 04a ira groove lock coupling option In Out manometers mounted on groove lock coupling option Water inlet filter ITEMS MOUNTED INSIDE THE UNIT Paddle flow switch Water tank 200L or 500L Safety valve Air purge Water drain 25L expansion vessel Second 25L expansion vessel for GG G9 9 Single 50L expansion vessel WA lt 150D Pump suction isolation valve Single pump Double pump Air purge Temperature sensor return Temperature sensor supply 3 2 9 9 WA gt 1500 Plate heat exchanger OPTIONS Flow switch Expansion Expansion BASIC UNIT 200 500L tank paddle Water inlet filter Expansion vessel 50L for vessel 50L for Pump isolation and single or double pump p ted vessel 25L 075 090 100 110 all other WA valve amp SLN units Add 05 Add 03 Add 10 Add 11b Add 10 11a Ad
86. ssary 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 Refrigerant R407C Screw CSH BSE170 R407C Scroll 52 Maneurop 160 SZ Copeland 3MA Mobil EAL Scroll ZR Copeland Arctic 22CC ICI Emkarate RL32CF R407C Reciprocating D8 Copeland Mobil EAL Arctic 22 R407C Reciprocating MS Maneurop 160 SZ 412 Installation Operation Maintenance manual IOM e ECOLOGIC RANGE 0605 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 42 to 45 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 46 amp 47 or supplied with the unit 4 2 REFRIGERATION CIRCUIT CHECKS AND RECOMMENDATIONS In case of split units check the installation has
87. sure that rotation is in the right direction 9 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 14 Installation Operation Maintenance manual IOM RANGE 0605 UNIT START UP LENNOX 5 UNIT START UP 5 1 CHECKS TO BE MADE DURING START UP 5 1 1 CHECKS TO BE MADE DURING START UP Before starting the unit fill in the check list sheet on page 36 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 a
88. t 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 pressure overshoot loss of oil pressure motor protection etc The relay in question initiates unconditional stoppage of the compressor on that circuit and the safety stoppage indicating light comes on Some defaults give rise to immediate stoppage of the entire unit Tripped flow switch Tripped antifreeze thermostat In cases other than that of manually reset safety devices starting up of the circuit or the machine takes place auto matically once the default has been cleared 6 2 3 4 Loss of power supply There ar
89. th 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 24 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 TROUBLESHOOTING REPAIRS 8 1 LIST OF THE MOST COMMON PROBLEMS LENNOX PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A THE COMPRESSOR DOES NOT START Motor control circuits established the compressor does not run No power supply Check main power supply and switch positions Compressor motor burnt out Replace Low voltage reading on voltmeter Voltage too low Contact power company The system does not start up Breaker tripped or fuses blown Determine the cause If the system is in running order close the disconnect Check condition of fuses No water flow in the evaporator Measure flow check 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 t
90. tion and according to their own specific requirements Place all water valves and refrigerant valves in their operating positions and start the water circulating pumps Ensure main power supply is isolated before any work is started Ensure unit is correctly earthed and that earth continuity is correctly done Check that anti vibration mountings are correcity installated and set 2 Check the cleanliness and the tightness of all electrical connections both the connections made at the factory and the connections made on site Also make sure that all thermostat bulbs are correctly inserted and tightened in the various wells if necessary add heat conducting paste to improve contact Make sure all sensors are correctly fitted and that all capillary tubes are fastened Installation Operation Maintenance manual IOM RANGE 0605 13 PRELIMINARY CHECKS LENNOX The technical data printed at the top of the wiring diagram should correspond with those indicated on the unit nameplate 3 Make sure that the power supplied to the unit corresponds to its operating voltage and that phase rotation corresponds to the direction of rotation of the compressors screw amp scroll 4 Make sure that the water circuits mentioned in 1 are completely filled with water or brine as the case may be with the air bled out of all high points including the evaporator ensuring they are perfectly clean and leaktight In the case of machin
91. topped Started Wait Flow Wait CH 2 Heat Recovery 2720 1 Config 2721 Liste No Yes 2 State 2722 Liste Stopped Started Wait Flow Wait CH 3 Inlet 2723 4 Outlet 2724 5 Sw State 2725 On Off 54 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX in Code Description Code Description Code Description Code Unit Min Factory Max Comments 3 Setting 3000 1 General 3100 1 Order 3110 1 On Off 3111 On Off Off Unit Listes Started ump operation mode set up see Pum Stopped P1 Only AMOR p 2 3112 0 0 6 operation description page 11 IOM P2 Only P1 N P2 R Climatic 50 P2 N P1 R Clock 3 Reset Al 3113 Yes No E Off E Reset Discharges the safety measures of the unit 2 2 Override Cancel override action 4 Resume 3114 Yes No Off set with the DC50 Liste Quickly 5 Test 3115 Defrost 24 24 7 7 0 0 3 Lennox set point 2 Clock 3120 1 Hour 3121 H 0 23 Clock Clock setting Hour 2 Minute 3122 m 0 59 Clock Clock setting minute 3 Day 3123 e 1 31 Clock Clock setting Day 4 Month 3124 1 12 Clock Clock setting Month 5 Year 3125 2 99 Clock Clock setting Year 6 Win Sum 3126 sic 2 vec 2 Clock automatic switch summer time winter tim
92. utlet Maximum difference water inlet outlet Minimum outside air temperature with water outlet 35 C Maximum outside air temperature 44 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 ECOLOGIC OPERATING LIMITS LENNOX STD LN HE SLN WA 075 090 100 110 130 150 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 m3 h 8 C AT Water Maximum flow rate m3 h 3 C 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 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 C AT Water Maximum flow rate m h 3 C 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 45 Installation Operation Maintenance manual CHILLERS ANNEXES 0605 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDI
93. void and the manufacturer shall alone bear any consequences pursuant to its use where the manufacturer fails fo comply with his undertakings as per he agreement in respect of a implementalion of the approved quality system b conformity of the equipment with the EC design approval conditions inspection and tests on the final product and generally where the manufacturer faits In particular to comply with any of his obligations under directive nr 97 23 EC of 29 may 1997 as transposed in the applicable lavi s Le Sign par Signed b sie ug 3 2 V 02 SEPTEMBRE 2002 P BERIOU p Y LE Code d enregistrement Registration code 2002 3948 Etabli Made at LYON DARDILLY La pr sente altestalion esi soumise aux Conditions G n rales de Service de Bureau Veritas jointes la d intervention sign e demandeur This certificate is subject to the terms of Bureau Veritas General Conditions of Service attached to the agreement signed by the applicant PRTPV112 42 Page 1 2 bttp www bureauventas com ped Installation Operation Maintenance manual CHILLERS ANNEXES 0605 CERTIFICATES DECLARATION OD CONFORMITY CE LENNOX ADV DECONF M001 1 Site industriel de Mions LENNOX 21 Les Meuri res BP 71 5 69780 Mions France France T l phone 33 0 4 72 23 20 20 Fax 33 0 4 72 23 04 56 DECLARATION OF CONFORMITY CE The Undersigned
94. w Wait CH Schedule Switch 3 Position 2533 4 Circuit 4 2540 1 Config 2541 Liste No Yes 2 State 2542 ee I Started Wait Flow Wait CH Schedule Switch 3 Position 2543 Liste No 1 Yes 2 Yes 3 Yes 4 Yes 5 Yes 1 Modulat 6 Ventilation 2600 1 Fan Circuit 1 2610 1 Config 2611 2 Modulat 3 Modulat 4 Modulat 5 Modulat 1 LowSpeed 2 LowSpeed 3 LowSpeed 4 LowSpeed 5 LowSpeed Liste Stopped Start 0 5 Started1 Start 1 5 Started2 Start 2 5 2 State 2612 Started3 Start 3 5 Started4 Start 4 5 Started5 Wait Flow Wait CH Fault 1 3 Sw State 2613 On Off 4 Relay 1 2614 On Off 5 Relay 2 2615 On Off 6 Relay 3 2616 On Off 7 Relay 4 2617 On Off 8 Relay 5 2618 On Off 9 Modulat 2619 453 Installation Operation Maintenance manual IOM ECOLOGIC RANGE 0605 OPERATION CLIMATIC 50 MENU TREE ECOLOGIC RANGE CONTINUED LENNOX Main screen Code Description Code Description Code Description Code Unit Liste No 1 Yes 2 Yes 3 Yes 4 Yes 5 Yes 1 Modulat 2 data 2000 6 Ventilation 1 Fan Circuit 2 2620 1 Config 2621 2 Modulat 3 Modulat 4 Modulat 5 Modulat 1 LowSpeed 2 LowSpeed 3 LowSpeed 4 LowSpeed 5 LowSpeed Liste Stopped Start 0 5 Started1 Start 1 5 Started2 2 State 2622 Start 2 5 Started3 Sta

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