Инструкции на Чиллеры Lennox серии ECOLOGIC, MCC, NEOSYS бренда Lennox

Installation, operating

and maintenance AIR COOLED CHILLERS Providing indoor climate comfort CHILLER_AC-IOM-0708-E

TABLE OF CONTENTS

AIR COOLED CHILLERS AND SPLIT UNITS INSTALLATION OPERATION MAINTENANCE MANUAL Ref: CHILLERS_IOM-0708-E The present manual applies to the following CHILLER ranges: ECOLOGIC range: WA MCC range NEOSYS range NAC – NAH Special unit n° Our company is a member of the Eurovent Certification Programme, all…

INTRODUCTION

1 - INTRODUCTION 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…

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…

F Gas Regulation

EC Regulation No 842/2006 on fluorinated greenhouse gases Operators of refrigeration equipments must comply with the 6 main obligations defined in the F Gas Regulation OBLIGATION Applicability Recovery of F gases during plant servicing and maintenance and at the All stationary systems end of plant…

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…

       All installation parts must be maintained by the personnel in charge, in order to avoid material deterioration and injuries to people. Faults and leaks must be repaired immediately. The authorized technician must have the responsibility to repair the fault immediately. Each time…

INSTALLATION - TRANSPORT - HANDLING

3. INSTALLATION 3.1 - Transport - Handling 3.1.1 - Controls and delivery checks On receipt of 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…

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.…

таблицы и схемы — в просмотре

3.3 - LAY-OUT AND INSTALLATION REQUIREMENTS

The following preparations are important for the installation of the chiller: - Air-cooled chillers with helicoids fans such as Ecologic or NEOSYS are designed for outdoor installation. Please consult Lennox prior to implementing other types of installation. - Locate the chiller where it is least…

ECOLOGIC range

> 3 meters 2 meters 2 meters 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. For any chiller a minimum distance of 1 meter is required for the good opening and servicing of the electrical box. 3.4…

The use of a water filter in the water circuit upstream of the heat exchanger is mandatory. This filter must remove all particles with a diameter greater than 1 mm, and must be positioned within 1 meter of the inlet of the exchanger. It may be supplied as an option by the manufacturer. This filter…

3.4.4 - Electrolytic corrosion

We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an imbalance between earthing points. AN EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT WARRANTY 3.4.5 - Minimum water content The minimum volume of the…

T

3.4.6 – Neosys range with hydraulic module - maximum water content The maximum water content of the installation is determined by the capacity of the expansion vessel. On units fitted with a standard Hydraulic Module it is possible to determine the maximum water content of the installation. NEOSYS…

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…

3.7 - CONNECTION OF SPLIT UNITS

Connections between the unit and the condenser or the evaporator must be made by a qualified refrigeration engineer and require several important precautions. In particular, the shape and dimensions of the gas lines must be carefully designed to ensure proper oil return in all cases and prevent…

UNITS WITH REMOTE CONDENSER

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

CONDENSING UNITS

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

Minimum refrigeration capacity in kW for oil entrainments up Suction risers

Refrigerant: R407C Table C Saturated temperature (°C) Tubing nominal OD, mm Suction gas temperature (°C) -5 0,39 0,71 1,20 2,04 3,88 6,88 11,11 21,31 36,85 55,86 115,24 199,30 0,37 0,68 1,14 1,94 3,68 6,53 10,54 20,20 34,94 52,95 109,25 189,14 0,47 0,86 1,45 2,47 4,69 8,33 13,44 25,77 44,58 67,56…

Ensure conduct liquid line and gas line pressure tests are in conformity with applicable legislation. Before starting up a unit on a receiver, the piping and the condenser must be dehydrated. Dehydration should be carried out using a double stage vacuum pump, capable of drawing 600Pa absolute…

3.7.7 - Air cooled condensers

An air cooled condenser connected to a unit must have the same number of circuits as the unit. Selection of the condenser must be made carefully to enable transfer of the heat capacity of the unit even at the highest temperatures expected on an installation. It is mandatory to control the head…

PRELIMINARY CHECKS

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, These tables will give you all…

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…

9) On units with ducted fan, check the air flow and duct pressure drop

On delivery, the drive belts are new and correctly tensioned. After the first 50 operating hours check and adjust the tension. 80% of the total elongation of belts is generally produced during the first 15 hours of operation. Before adjusting the tension, make sure that the pulleys are correctly…

10) Before making any electrical connections, check that insulation resistance between power supply connection terminals is in keeping with applicable regulations. Check the insulation of all electrical motors using a DC 500V megohmeter, following the manufacturer’s instructions. CAUTION: Do not…

UNIT START-UP

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 §8.3 of this manual and follow the instructions below to be sure that the unit is correctly installed and ready to operate. 1) Thermometers and…

10) Check suction and discharge pressures and compressor suction and discharge temperatures

11) Check chilled liquid entering and leaving temperatures. 12) Check outdoor air temperature. 13) Check liquid refrigerant temperature at the condenser outlet. These verifications should be made as quickly as possible with a stable cooling load, i.e. the cooling load of the installation should be…

OPERATION

6 - OPERATION 6.1 - CLIMATIC CONTROL cf. See the specific CLIMATIC 50 manual cf. See the specific «Basic CLIMATIC controller» manual 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…

6.2.1.7 - Fan control pressure switch and thermostat

The function of these devices is to ensure a level of head pressure compatible with proper unit operation. An increase in outdoor air temperature increases head pressure, and this is maintained at its required value by fan operation. 6.2.1.8 - Antifreeze function: This function only exists on units…

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…

6.2.3.6 - Fan motor control

Special units with screw compressors - Fans electrical box labelling

size 442 / 452 size 502 / 552 size 702 / 752 size 602 / 652 size 803 / 853 size 952 / 1003 / 1053 / 1153 Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS - 0708-E • 33 •

MAINTENANCE

7. MAINTENANCE Warning : During the life-time of the system, inspection and tests must be carried out in accordance with national regulations. The information on operating inspections given in annex C of standard EN378-2 can be used if no similar criteria exist in the national regulations. The…

7.2 ANNUAL MAINTENANCE

It is important that units are 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 service visit by a qualified technician is…

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…

TROUBLESHOOTING – REPAIRS

8.1 LIST OF THE MOST COMMON PROBLEMS PROBLEMS – SYMPTOMS A) PROBABLE CAUSE RECOMMENDED ACTION THE COMPRESSOR DOES NOT START - Motor control circuits established, the compressor does not run - Low voltage reading on voltmeter - No power supply - Check main power supply and switch positions…

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 sightglass. - Low pressure safety switch trip out - Check low pressure safety switch differential - Low refrigerant charge - Check…

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 - Chilled water thermostat set too low - Adjust it - Bubbles in sightglass - Low refrigerant charge - Check the refrigerant charge…

PROBABLE CAUSE

RECOMMENDED ACTION F) THE COMPRESSOR CUTS OUT ON ANTIFREEZE PRESSURE SWITCH - Antifreeze pressure switch tripped - Check that the pressure switch is operating properly - Low water flow in the evaporator - Check the water pump - Evaporator obstructed - Determine the degree of fouling by measuring…

PROBABLE CAUSE

RECOMMENDED ACTION - 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 - Replace the compressor a) Liquid slugging…

PROBABLE CAUSE

RECOMMENDED ACTION M) SUCTION PRESSURE IS TOO HIGH - The compressor runs - Check the system continuously - Too much cooling demand on the evaporator - Suction line unusually cold. a) Expansion valve opened to far a) Adjust superheat and check that the expansion valve bulb is correctly fitted in…

8.2 CONTROL DEVICES

Operation By reacting to compressor discharge pressure, the high pressure sensor monitors efficiency of the condenser. Poor efficiency, the result of an excessive condensing pressure, is usually caused by : - A dirty condenser - Low water flow (in case of water cooled unit) - Low air flow (in case…

8.3 MANUFACTURER’S RECOMMENDED INSPECTIONS

8.3.1 - LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR(S) 8.3.1.1 - Number of recommended preventive maintenance visits : 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…

8.3.1.2 - Description of inspection duties - Liquid chiller with reciprocating compressor(s)

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

8.3.2 - LIQUID CHILLERS WITH SCROLL COMPRESSOR(S)

8.3.2.1 - 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…

8.3.2.2 - 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 leaktightness - Configuration of the microprocessor based management system (if used) - Verification of operating parameters and unit performance - Transmission of the machine service…

8.3.3 - LIQUID CHILLERS WITH SCREW COMPRESSOR(S)

8.3.3.1 - Number of recommended preventive maintenance visits : NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit 30000 h inspection Tube analysis 1(1) 1 1 Every 30000 hours Every 3 years 3 +10 Every year 3 times a year This…

8.3.3.2 - 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 leaktightness - Configuration of the microprocessor based management system - Verification of operating parameters and unit performance - Transmission of the machine service log 500 H /…

NEOSYS - Hydraulic data

       1- All Victaulic Connections 2- Inlet Filter (Supplied Loose) 3- Automatic Air Vent 4- Expansion Vessel, relief Valve & manometer 5- Single or Dual Pump, High or Low Pressure 6- New Electronic Stainless Steel Flow Switch 7- High Performance Stainless steel Evaporator 8- Pressure…

NEOSYS - Hydraulic data

Lennox Neosys Filter Pressure Drop Pressure drop (kPa) 10 1 0,1 DN100 NAC 200 --> 340 DN125 NAC 380-->480 0,01 1 Water flow rate (m3/h) 10 100 Neosys Evaporator Pressure Drop Pressure drop (kPa) 100 NAC 200-230 NAC 270-300 NAC 340 NAC 380 NAC 420-480 Flow Rate (m3/h) Installation - Operation…

UNIT WITHOUT HYDRAULIC OR HYDRONIC MODULE

WA 270  370 STD – LN – HE – SLN / WA 90 – 130 - 150 HE – SLN ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT 01 19 Groove lock coupling 15a 02 18 Unit isolation valve 16 Plate heat exchanger Water inlet filter In/Out manometers without groove lock coupling option in/Out manometers mounted on…

UNIT WITH HYDRONIC MODULE

ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT 01 19 Groove lock coupling 05 Paddle flow switch 11b 02 18 Unit isolation valve 06 Water tank 200L or 500L 12 Water inlet filter In/Out manometers without groove lock coupling option In/Out manometers mounted on groove lock coupling option 07 Safety…

UNIT WITH HYDRAULIC MODULE

WA STD – LN - HE – SLN ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT 01 02 Groove lock coupling Unit isolation valve 05 10 Water inlet filter 11a 04a 17a 04b 17b In/Out manometers without groove lock coupling option In/Out manometers mounted on groove lock coupling option 11b Paddle flow switch…

UNIT WITH FREE COOLING OPTION

WA 150 STD – LN WA 150 HE – SLN and 200/230/270/300/370 STD/LN/HE/SLN ITEMS SUPPLIED LOOSE ITEMS MOUNTED INSIDE THE UNIT 01 19 Groove lock coupling 16 Plate heat exchanger A Free cooling coil 02 18 Unit isolation valve 15a Temperature sensor B Isolating valves 15b Temperature sensor C Three way…

NEOSYS - OPERATING LIMITS

NAC Min. outlet water temperature °C 5 Max. inlet water temperature °C 20 Min. difference water inlet/outlet °C 3 Max. difference water inlet/outlet °C 8 Min. outdoor air temperature °C 6 Min. outdoor air temperature with Low Ambiant kit °C -10 Maximum outside air temperature : • Normal operation…

NAH HEATING MODE

Min.Cond outlet water °C 24 Max. Cond outlet water °C 50 Min. difference water inlet/outlet °C 3 Max. difference water inlet/outlet °C 8 300 Outside air Limits : Min. outside air temperature with water outlet 37°C Max. outside air temperature -12 °C 30 Cond Water Outlet (°C) Operating Enveloppe…

ECOLOGIC - OPERATING LIMITS

WA STANDARD WA Minimum outlet water temperature °C 5 Maximum inlet water temperature °C 20 Minimum difference water inlet/outlet °C 3 Maximum difference water inlet/outlet °C 8 Minimum outside air temperature °C 6 Minimum outside air temperature with low ambient kit °C -10 Maximum outside air…

Screw chiller - operating limits

ALL UNITS Size Max. outside air temperature (2) °C Size Max. outside air temperature (2) °C Size Max. outside air temperature (2) °C Size 402V 422VE 442V 452VE 502V 50,5 552VE 602V 652VE 702V 752VE 50,5 50,5 50,5 50,5 50,5 803V 853VE 953V 1003VE 1053V 50,5 50,5 50,5 50,5 49 1153VE 1254V 1354VE 1404V…

RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97/23/CE DIRECTIVE

Actions to Eliminate the Risk Information to minimise the Occurrence of a risk Appearance of cracks, distortions, Leaks, liquid or gas projections, possibility of rupture Metal parts projections. Only handling the units using the chassis and lifting rings if available. Handling procedure shown in…

Actions to Eliminate the Risk

Information to minimise the Occurrence of a risk Unit exposed to extremely corrosive materials. Modification of the mechanical and chemical properties of certain Partial or complete destruction of materials with a risk or corrosion the circuit, liquid/gas/metal parts rupture, pipe bursting, leaks…

NEOSYS - REFRIGERATION CIRCUITS

>NAC 300 NAC Refrigeration Circuit 15 02 S All NAC units C1 & C2 Text AIRFLOW 07 06 S P T 01 HP P 03 04a S 14 13 04b 04a 1st & 2nd Scroll Compressors 05 Pressure relief Valve 11 Thermostatic Expansion Valve Third Scroll Compressor on size above 300kW 06 Air Cooled Condenser 12 Electronic Expansion…

NEOSYS - REFRIGERATION CIRCUITS

NAH Refrigeration Circuit 4b All NAH units C1 & C2 P S 03 4a 13 HP P T Text S AIRFLOW Cooling Heat Pump 1st & 2nd Scroll Compressors 06 Air Cooled Heat Exchanger 11 Plate Heat Exchanger 03 High Pressure Sw itch 07 Fan Motor 12 Non Return valve Pressure transducers HP & BP 08 Manual Isolating Valve…

ECOLOGIC - REFRIGERATION CIRCUIT

REFRIGERANT DRAWING WA STD REFRIGERATION CIRCUIT COMPONENTS 01 1st & 2nd scroll compressors 08 Air cooled condenser 15 Expansion valve bypass for low ambient operation 02 3rd scroll compressor on size 370 STD/LN/HE & SLN 09 Fan motor 16 Electronic expansion valve 03 High pressure switch 10 Manual…

RA - REFRIGERATION CIRCUIT

REFRIGERANT DRAWING RA STD REFRIGERATION CIRCUIT COMPONENTS 01 1st & 2nd scroll compressors 07a 07b Safety valve CE or UDT 12 Solenoïd valve 02 3rd scroll compressor on size 370 STD/LN/HE & SLN 08 Air cooled condenser 13 Sight glass 03 High pressure switch 09 Fan motor 18 Suction temperature sensor…

CERTIFICATES

Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS - 0708-E • 67 •

таблицы и схемы — в просмотре

START-UP AND MAINTENANCE LOGBOOK

INSTALLATION CHECK-UP This check list should be filled in before the start-up with the contractor to make sure that unit installation takes place according to appropriate industry practices. WARNING : Refer to Safety recommendation §2.1 prior to any work on the unit. DATE: TECHNICIAN: FIELD NAME…

• UNIT INSTALLATION

YES NO YES NO CLEARANCE AROUND UNIT IN CONFORMITY CORRECT CONDENSORS VENTILATION UNIIT LEVELLED VIBRATION ISOLATION MOUNTED AND PROPERLY DIMENSIONED VIBRATION ISOLATORS ON PIPING CONNECTION CORRECT EARTHING OF THE UNIT EARTH CONTINUITY ON PIPING • HYDRAULIC NETWORK GLYCOL PROTECTION IN CONFORMITY…

START-UP CHECK SHEET

Remarks: ………………………………………………………………………………………………

Reserves: TECHNICIAN Name Signature: CUSTOMER Name Signature: Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS - 0708-E • 73 •