Инструкции на Чиллеры Lennox серии HYDROLEAN с водяным охлаждением

Текст инструкции

1. Стр. 1 WATER COOLED CHILLERS AND SPLIT UNITS

   INSTALLATION OPERATION MAINTENACE MANUAL Ref: HYDROLEAN-IOM-0805-E The present manual applies to the following Chiller versions : Hydrolean Range: SWC-SWH-SWR Our company is a member of the Eurovent Certification Program, all LENNOX chillers are tested and rated in accordance with Eurovent…

2. Стр. 4 PREFACE

   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…

3. Стр. 5 PED DECLARATION

   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…

4. Стр. 6 WARRANTY

   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…

5. Стр. 7 3 – INSTALLATION

   3.1 - Transport - Handling 3.1.1 - Controls and delivery checks On receipt of anew 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 50): - The exterior has not been damaged in any way.…

6. Стр. 8 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.…

7. Стр. 9 WARNING: Hydrolean Size 120,135 and 165 are very narrow and high: there is

   a risk of the unit tipping over when being handled with a fork lift. 3.3 - LAY-OUT AND INSTALLATION REQUIREMENTS The following preparations are important for the installation of the chiller: - Water -cooled chillers such as Hydrolean or MCW are designed for indoor installation. Please consult Lennox…

8. Стр. 10 CLEARANCES DRAWINGS

   For more details, please consult our Application Guides or the drawings supplied with the unit. Hydrolean 020 to 040 Hydrolean 050 to 100 Hydrolean 120 to 165 For any chiller a minimum distance of 1 meter is required for the good opening and servicing of the electrical box. 3.4 - WATER CONNECTIONS…

9. Стр. 11 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…

10. Стр. 12

    A main isolator switch must be inserted between the end of the power supply cable and the unit to enable total isolation of the latter when necessary. Chillers are usually supplied with a main isolator switch. If not it is available as an option. WARNING Wiring must conform to applicable…

11. Стр. 13 Units with remote condenser

    Unit with remote condenser without capacity control H1: 15 m. maxi H2: 5 m. maxi H3: 0,3 m. maxi H4: 0,15 m. maxi Unit with remote condenser with capacity control 1 - Lower trap with single tube 2 - Clode coupled trap 3 - Lower trap with double tubes 4 - Higher trap with double tubes WARNING: The…

12. Стр. 14 Condensing Units

    Condensing unit without capacity control Condensing unit with capacity control Min. 0,25% gradient Min. 0,25% gradient H1: 15 m. maxi H2: 5 m. maxi H4: 0,15 m. maxi .14 1 - Lower trap with single tube 2 - Clode coupled trap 3 - Lower trap with double tubes 4 - Higher trap with double tubes…

13. Стр. 15 Minimum refrigeration capacity in kW for oil entrainments up Suction risers

    refrigerant R407C Tubing Nominal OD, mm Suction saturated gas temp temp °C °C 0 0,39 0,71 1,20 2,04 3,88 6,88 11,11 21,31 36,85 55,86 -5 10 0,37 0,68 1,14 1,94 3,68 6,53 10,54 20,20 34,94 52,95 10 0,47 0,86 1,45 2,47 4,69 8,33 13,44 25,77 44,58 67,56 5 20 0,44 0,81 1,36 2,31 4,39 7,79 12,58 24,13…

14. Стр. 16 3.7.5 - Refrigerant charge

    Chillers with R407C must be filled in the liquid phase. Never charge a machine operating on R407C in the vapour phase (vapour): the composition of the mixture could be modified. In liquid phase, connect either to a liquid isolating valve, or to the quick-connector on the liquid line at the valve…

15. Стр. 17 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 «APPENDIX» at the end of the IOM, These tables will give you all necessary information…

16. Стр. 18 The components are located inside the units or in a separate box and must be installed by a

    qualified engineer. Note: In case of plate heat exchangers it is mandatory that a filter is installed at exchanger unit entrance. These filters must remove all particles with a diameter greater than 1 mm. 4.4 - CHECK LIST BEFORE START-UP Before proceeding with start up, even for a test of short…

17. Стр. 19

    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 = Q1 x √(P2/P1) Where P2 = pressure drop measured on site P1…

18. Стр. 20 UNIT START UP

    5 – UNIT START-UP 5.1 - CHECKS TO BE MADE DURING START UP Before starting the unit, fill in the check list sheet 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…

19. Стр. 21 UNIT START UP

    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…

20. Стр. 22 6 – OPERATION

    6.1 – OPERATING LIMITS WARNING: It is very important ensure the units operate well inside these envelopes. 6.1.1 –HYDROLEAN COOLING AND HEAT PUMP VERSION SIZE 20-25-35-40-50-65-80-90 Cond Water Outlet (°C) 53°C 48°C 40°C Water + Glycol 20°C 15°C Pressure Regulated Water Valve SWC Only -10°C 3°C 5°C…

21. Стр. 23 6.1.3 –HYDROLEAN WITH REMOTE CONDENSER (ALL SIZES)

22. Стр. 24 6.2 - UNIT OPERATION: REFRIGERATION CIRCUIT

    6.2.1 –TANDEM SCROLL ASSEMBLIES With “NEW” tandem assemblies the oil balancing is achieved through the use of a large two phase line tube. It is IMPERATIVE that this tube is perfectly level during operation to ensure proper oil balancing between the two crankcases It is also IMPERATIVE for the…

23. Стр. 25 6.2.2 –COPELAND SCROLL DISCHARGE TEMPERATURE PROTECTION (STANDARD)

    If the oil in the compressor gets too hot it will start to deteriorate and loose its ability to lubricate, and will eventually cause a compressor failure. Lennox compressors are sometimes fitted with a specially designed sensor in the hottest part of the compression cycle, just above the discharge…

24. Стр. 26 6.2.7 –SIGHT GLASS (Standard on SWR Not available on Other Models)

    This feature when fitted enables visual check of the state of the liquid refrigerant (phase liquid gas or both) in the liquid line, upstream of the thermostatic expansion valve. It also enables to some extent the detection of humidity in the circuit. 6.2.8- CRANCKASE HEATER (Standard) Every…

25. Стр. 27 6.3 - UNIT OPERATION: ELECTRICAL AND CONTROL FEATURES

    cf. See the specific «Basic CLIMATIC controller» manual 6.3.1 – ANTIFREEZE PROTECTION (Standard): This feature is provided as standard by the climatic controller: and can be adjusted for brine or glycol/water chilling for which the freezing temperature depends on the concentration of the solution.…

26. Стр. 28 6.3.5 – CONTROL OF EXTERNAL SINGLE PUMP FOR EVAPORATOR (Option)

    The optional control and protection of external pump for evaporator can be selected on all Hydrolean units. It consists in the addition of a circuit breaker and contactor controlled by the climatic 30. The protection is located in the main electrical panel close to the compressor protections. The…

27. Стр. 29 6.3.7 – CONTROL AND PROTECTION OF EXTERNAL FANS (Option)

    The optional control and protection of external fans can be selected on all Hydrolean units. It consists in the addition of a circuit breaker and contactor per fan and controlled as standard by adjustable pressure switches. This protection can be located in the main electrical panel or in an…

28. Стр. 30 Incompatibilities between Options and Features on Hydrolean

    UNIT TYPE AND SIZE SW CONTROLLER MODEL Energy 211B AVAILABLE OPTIONS & FEATURES Dynamic Set Point or Remote Heat/Cool or Control on Hot Water Remote ON / OFF or Control on Hot Water SW Energy 211B Remote ON / OFF or Dynamic Set Point or Remote Heat/Cool or Control on Hot Water SW Energy 620 Remote…

29. Стр. 31 6.3.9 – HOT WATER CONTROL (OPTION)

    This option can only be selected on Hydrolean Cooling only units SWC and consist in a special configuration of the program and temperatures probes fitted to the condenser It is NOT recommended to use a Pressure Regulating Valve when the Control on Hot Water Option is selected 50-65-8090-100…

30. Стр. 32 6.3.11 – REMOTE ALARM (Standard)

    This feature can be installed on all Hydrolean units. WARNING: On units between 20 and 100kW this feature requires the installation of dry contacts: This implies a modification of the customer electrical installation (Max 12V 500mA on the controller). On other sizes fitted with energy 620 controller…

31. Стр. 33 6.4 – OTHER FEATURES AND OPTIONS

    6.4.1 –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.…

32. Стр. 34 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…

33. Стр. 35 7.2 ANNUAL MAINTENANCE

    On units with water cooled condensers, it is important that the unit be serviced regularly by a qualified technician, 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…

34. Стр. 36 7.3.3 Plate heat exchanger condensers

    Use a non corrosive solvent to remove scale deposits. 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 /…

35. Стр. 37 8 – TROUBLESHOOTING – REPAIRS

    8.1 LIST OF THE MOST COMMON PROBLEMS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A) THE COMPRESSOR DOES NOT START - Motor control circuits established, the compressor does not run - No power supply - Compressor motor burnt out - Breaker tripped or fuses blown - The system does not start…

36. Стр. 38 PROBABLE CAUSE

    RECOMMENDED ACTION B) THE COMPRESSOR DOES NOT START - Normal operation with too frequent starts and stoppages due to action of the low pressure safety switch. Bubbles in sight glass. Or, normal compressor operation, but the low pressure safety switch trips out and resets frequently - Suction…

37. Стр. 39 PROBABLE CAUSE

    RECOMMENDED ACTION 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 sight glass is too low - - Oil pressure too low - Check the oil level in the sight glass on the crankcase, check the…

38. Стр. 40 PROBABLE CAUSE

    RECOMMENDED ACTION 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 sufficiently cooled - Measure superheat in the evaporator, adjust it if necessary H)…

39. Стр. 41 PROBABLE CAUSE

    RECOMMENDED ACTION K) DISCHARGE PRESSURE TOO HIGH - Water is far too hot at condenser outlet - Water flow to low or water temperature too high in the condenser - Condenser tubes fouled - Adjust the pressure operated water valve or the thermostat on the cooling tower - Clean the tubes - Presence of…

40. Стр. 42 8.2 CONTROL DEVICES

    Operation By reacting to compressor discharge pressure, the high pressure switch monitors efficiency of the condenser. Poor efficiency, the result of an excessive condensing pressure, is usually caused by : - A dirty condenser - Low water flow - Low air flow The low pressure switch monitors the…

41. Стр. 43 8.3 REGULAR CHECKS TO BE MADE - CHILLER UNIT ENVIRONMENT

    CHILLED WATER CIRCUIT VALUE Inlet / Outlet pressure gauges for pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . kPa Evaporator inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C Evaporator outlet temperature . . . . . .…

42. Стр. 44 8.4 MANUFACTURER’S RECOMMENDED INSPECTIONS

    8.4.1 - LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR(S) 8.5.1.1 - Number of recommended preventive maintenance visit: NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit 30000 h inspection Tube analysis 1(1) +10 15 000 h…

43. Стр. 45 8.4.1.2 - Description of inspection duties - Liquid chiller with reciprocating compressor(s)

    START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system (if used) - Verification of operating parameters and unit performance - Transmission of the machine service…

44. Стр. 46 8.4.2 - LIQUID CHILLERS WITH SCROLL COMPRESSOR(S)

    8.4.2.1 - Number of recommended preventive maintenance visits : NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit Tube analysis 1(1) +10 Every year 3 times a year Every 3 years This table is published for units operating…

45. Стр. 47 8.4.2.2 - Description of inspection duties - Liquid chiller with scroll compressor(s)

    START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system (if used) - Verification of operating parameters and unit performance - Transmission of the machine service…

46. Стр. 48 8.4.3 - LIQUID CHILLERS WITH SCREW COMPRESSOR(S)

    8.4.3.1 - Number of recommended preventive maintenance visits : NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit Tube analysis 1(1) +10 Every year 3 times a year Every 3 years This table is published for units operating…

47. Стр. 49 8.4.3.2 - Description of inspection duties - Liquid chiller with screw compressor(s)

    START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system - Verification of operating parameters and unit performance - Transmission of the machine service log 500 H…

48. Стр. 50 CHECK LIST

    Machine identifications : Year of manufacture : NORMAL CONDITIONS OF USE Leaving chilled water temperature : °C Outdoor air temperature : Max : °C Power supply voltage : V/Ph/Hz Refrigerant type : Date and time measurements were taken : Outdoor air temperature : °C Company responsible for…

49. Стр. 51 CHECK LIST

    This check list should be filled in by the contractor to make sure that unit installation takes place according to appropriate industry practices. WARNING: Disconnect the power supply before carrying out any inspections on the unit. If the unit must be left powered up, proceed with precaution to…

50. Стр. 52 APPENDICIES

    .52 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

51. Стр. 53 APPENDIX 1

    GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN COOLING ONLY Standard Components Options 01.a/ 01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 09 Pressure regulated water valve 04 Thermostatic expansion valve 05 Filter drier 06 Low & high…

52. Стр. 54 APPENDIX 1

    GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN COOLING ONLY Standard Components Options 01.a/ 01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 09 Pressure regulated water valve 04 Thermostatic expansion valve 05 Filter drier 06 Low & high…

53. Стр. 55 GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN HEAT PUMP

    Standard Components Options 01.a/ 01.b/ Compressors 07a/ 07b/ 02 Evaporator 03 Condenser 04 Thermostatic expansion valve 05.a 05.b 06.a 06.b A .55 Low & high pressure gauges Filter drier & filter by-pass Low & high pressure switch 4 way reversing valve Installation - Operation - Maintenance manual…

54. Стр. 56 GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN HEAT PUMP

    Standard Components Options 01.a/ 01.b/ Compressors 07a/ 07b/ 02 Evaporator 03 Condenser 04 Thermostatic expansion valve 05.a 05.b 06.a 06.b A .56 Low & high pressure gauges Filter drier & filter by-pass Low & high pressure switch 4 way reversing valve Installation - Operation - Maintenance manual…

55. Стр. 57 GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN REMOTE CONDENSER*

    Standard Components Options 01.a/01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 04 Thermostatic expansion valve 05 Removable cartridge drier filter 06.a/06.b Low & high pressure switch 10 Manual shut-off valve 11 Sight glass 12 Liquid…

56. Стр. 58 GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN REMOTE CONDENSER*

    Standard Components Options 01.a/01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 04 Thermostatic expansion valve 05 Removable cartridge drier filter 06.a/06.b Low & high pressure switch 10 Manual shut-off valve 11 Sight glass 12 Liquid…

57. Стр. 59 HYDROLEAN 20-25-35-40

    Load Distribution (Kg - Operating weights) Clearances Piping - A BOX (20/25/35/40) SWC/SWH SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC MECHANICAL DATA .59 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E…

58. Стр. 60 HYDROLEAN 50 65 80 90 100

    Load Distribution (Kg - Operating weights) Piping - B BOX (50/65/80/90/100) SWC/SWH Clearances SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC MECHANICAL DATA .60 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS…

59. Стр. 61 HYDROLEAN 120 135 165

    Load Distribution (Kg - Operating weights) Piping - C BOX (120/135/165) SWC/SWH Clearances SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC 120 MECHANICAL DATA .61 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS…

60. Стр. 62 HYDROLEAN

61. Стр. 63 PRESSURE DROP OF HYDROLEAN PLATE HEAT EXCHANGERS WITH WATER AND

    ETHYLENE GLYCOL 30% FILTERS PRESSURE DROP .63 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

62. Стр. 64 PRESSURE DROP OF PRESSOATIC CONTROL WATER VALVE «FULLY OPEN"

    .64 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

63. Стр. 65 CERTIFICATES – ISO 9001 : 2000

    .65 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

64. Стр. 66 CERTIFICATES – PED

    .66 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

65. Стр. 67 CERTIFICATES – DECLARATION OF CE CONFORMITY

    .67 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0805-E

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