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

Installation, operating

and maintenance AIR COOLED CHILLERS Providing indoor climate comfort CHILLER_AC-IOM-1106-E

TABLE OF CONTENTS

AIR COOLED CHILLERS AND SPLIT UNITS INSTALLATION OPERATION MAINTENANCE MANUAL Ref : CHILLERS_IOM-1106-E The present manual applies to the following CHILLER ranges : ECOLOGIC range : WA - WAH - RA MCC range Special unit n° Our company is a member of the Eurovent Certification Programme, all LENNOX…

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…

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 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…

3.2 - LIFTING THE UNIT

3.2.1 - Safety instructions Installation, start up and adjustment of this equipment can be dangerous if certain system specific factors are ignored, such as operating pressures, electrical components, locations (roofs, terraces and other structures located well above ground level). Only highly…

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 are designed for outdoor installation. Please consult Lennox prior to implementing other types of installation. - Locate the chiller where it is least affected by…

CLEARANCES DRAWINGS

For more details, please consult our Application Guides or the drawings supplied with the unit. ECOLOGIC range Unit with screw compressor OVERHEAD OBSTRUCTIONS ARE NOT PERMITTED > 3 meters 2 meters 2 meters Not recommended Not allowed For any air cooled unit, it is necessary to have a minimum…

If the external water pipes are in an area, where the ambient temperature is likely to fall below 0°C, insulate the piping and add an electric heater. As an option, the internal unit piping is protected. Ensure full earthling continuity For unit with shell and tube heat exchangers, a drainage plug…

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 To enable drainage of the circuit, make sure that drain cocks are installed at all the low points of the circuit. To drain the…

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) Liquid velocity under 2 m/s (to avoid liquid slugging)

4) For liquid risers, make sure that liquid subcooling is sufficient to counteract the loss of static pressure and prevent gas flashing. 3.7.2 - Discharge lines and suction lines Calculate these to obtain a gas velocity in vertical sections that enables compressor oil migration and steady return to…

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, page 55 to 62. These tables will…

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…

Check that according to the diagram below (figure 14), the following ratio remains the same

A(mm) 20 P(mm) The belts should always be replaced when : - the disk is set to maximum, - the belt rubber is worn or the wire is visible. Replacement belts must have the same rated size as the ones they are replacing. If a transmission system has several belts, they must all be from the same…

AT 18-18 FAN CURVE

Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 23 •

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…

6.2.2.4 - 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 compressor, an indicator to show…

In cases other than that of manually reset safety devices, starting up of the circuit or the machine takes place automatically once the default has been cleared. 6.2.3.4 - Loss of power supply : There are no problems restarting the machine after a loss of power supply of short duration (up to about…

HE - SLN WA/RA 270D / 300D HE - SLN WAH 150 D STD WA/RA 100E / 110E HE - SLN WA/RA 370D HE - SLN Special units with screw compressors - Fans electrical box labelling size 442 / 452 size 502 / 552 size 702 / 752 Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS…

size 952 / 1003 / 1053 / 1153

Size 1254 / 1354 / 1404 / 1504 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…

7.1 WEEKLY MAINTENANCE

1) Check the compressor oil level. This should be visible through the sightglass with the machine running at full load. Let the compressor operate for 3 to 4 heures before adding any oil. Check the oil level every 30 minutes. If the level does not reach the level indicated above, contact a qualified…

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…

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 continuously - Suction line unusually cold. Liquid refrigerant returns to compressor - Too much cooling demand on the evaporator - Check the system a) Expansion valve opened to far a) Adjust superheat and check that the…

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 /…

UNIT WITHOUT HYDRAULIC OR HYDRONIC MODULE

WA 150 STD – LN / WA 75 – 100 – 110 HE – SLN WA 270 Æ 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…

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…

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…

WA HIGH EFFCIENCY

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 temperature : •…

ECOLOGIC WAH - COOLING MODE

WAH 150 200 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 6 230 Maximum outside air temperature : • Normal operation with CLIMATIC™ 50 12°C/7°C water…

WA STANDARD

WA 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 Minimum flow rate 3 m /h 8°C ∆T Maximum flow rate 3 m /h 3°C ∆T Water Water Operating limits for evaporator Safety Low…

Screw chiller - operating limits

ALL UNITS - STANDARD Size 402V 422VE 442V 452VE 502V Operating limits 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. outside air temperature °C 6 Min. outside air temperature (1) °C -15 Max.…

ALL UNITS – HIGH AMBIENT

Size 442V 452VE 502V 552VE 602V 652VE Operating limits 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. outside air temperature °C 6 Min. outside air temperature (1) °C -15 Max. outside air…

ALL UNITS – LOW NOISE

Size 402V 422VE 442V 452VE 502V Operating limits 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. outside air temperature °C 6 Min. outside air temperature (1) °C -15 Max. outside air…

ALL UNITS – STANDARD / LOW NOISE / HIGH AMBIENT

Size 442V 452VE 502V 552VE 602V 652VE 153,53 153,5 Operating limits for Evaporator Water Test pressure Bar 10 Refrigerant Test pressure Bar 26,5 Water Max. operating pressure Bar 6 Refrigerant Max. operating pressure Bar 26,5 Water Min. flow m3/h 8°C ∆ T Water Max. flow m3/h 89,3 89,3 153,5 153,5…

702V

752VE 803V 853VE 953V 1003VE 153,5 180 180 1354VE 1404V 1504VE 250 250 Operating limits for Evaporator Water Test pressure Bar 10 Refrigerant Test pressure Bar 26,5 Water Max. operating pressure Bar 6 Refrigerant Max. operating pressure Bar 26,5 Water Min. flow m3/h 8°C ∆ T Water Max. flow m3/h…

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

N° Event Effect Risk Actions to Eliminate the Risk Information to minimise the Occurrence of a risk 1A Violent Chocks, Static or Dynamic Loads applied Appearance of cracks, distortions, possibility of rupture Leaks, liquid or gas projections, Metal parts projections. Only handling the units using…

Event

Effect Risk 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 materials with a risk or corrosion rupture, pipe bursting, leaks and cracks. Partial or complete…

ECOLOGIC - REFRIGERATION CIRCUIT

REFRIGERANT DRAWING WA STD – LN - HE – SLN 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…

ECOLOGIC - REFRIGERATION CIRCUIT

REFRIGERANT DRAWING WAH 150 / 200D / 230D REFRIGERATION CIRCUIT COMPONENTS 01 1st & 2nd scroll compressors 08 Air cooled condenser/Evaporator 19 External temperature sensor 02 High pressure switch 09 Fan motor 20 Check valve 04a 04b Pressure transducers HP & BP 10 Manual isolating valve 21…

RA - REFRIGERATION CIRCUIT

REFRIGERANT DRAWING RA STD – LN - HE – SLN 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…

CERTIFICATES

Installation - Operation - Maintenance manual (IOM) • AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 66 •

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 - 0105-E • 72 •