Инструкция на Чиллеры Lennox серии MCW... бренда Lennox

WATER COOLED CHILLERS AND SPLIT UNITS

INSTALLATION OPERATION MAINTENANCE MANUAL Ref: WC CHILLER-IOM-0108-E The present manual applies to the following Chiller versions: MCW Range: MCW-MCSB Our company is a member of the Eurovent Certification Program, all LENNOX chillers are tested and rated in accordance with Eurovent certification…

PREFACE

1 – PREFACE You must read and be familiar with this operating manual prior to commission the chiller. Please follow the instructions closely. 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…

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 nil and void if: - Service and maintenance have not been executed in…

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.…

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.…

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 prior to implementing other types of installation. - The ground beneath the unit must be flat, level and of…

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 unit or shown in the…

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…

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…

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 - Close coupled trap 3 - Lower trap with double tubes 4 - Higher trap with double tubes WARNING: The…

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 - Close coupled trap 3 - Lower trap with double tubes 4 - Higher trap with double tubes…

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…

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…

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…

Elec connection to main

electrical panel STANDARD FEATURES 02 A 04 EVAPORATOR 01 B 05 COMPONENTS SUPPLIED LOOSE 01 A 03 A CONDENSER 01 05 B 01 .18 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

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…

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…

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…

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…

6 – OPERATION

6.1 – OPERATING LIMITS WARNING: It is very important ensure the units operate well inside these envelopes. 6.1.1 –MCW all sizes Cond Water Outlet (°C) 53°C 48°C 40°C Water + Glycol 20°C 15°C -10°C .23 3°C 5°C 12°C 18°C Evap Water Outlet (°C) Installation - Operation - Maintenance manual (IOM) •…

6.1.2 –MCSB WITH REMOTE CONDENSER (ALL SIZES)

Indication on Pipe sizing for MCSB type units .24 Discharge Lines Liquid Lines per circuit Mini Dia. Min / Max Inches Speed per circuit Mini Dia. Speed Inches m/s 1" 5/8 10 / 15 m/s 1"1/8 0,5 / 1,5 m/s 1" 5/8 10 / 15 m/s 1"1/8 0,5 / 1,5 m/s 1" 5/8 10 / 15 m/s 1"3/8 0,5 / 1,5 m/s 2" 1/8 10 / 15 m/s…

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…

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…

6.3 - UNIT OPERATION: ELECTRICAL AND CONTROL FEATURES

cf. See the specific «CLIMATIC 50 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. The…

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.…

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…

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…

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 /…

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…

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…

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…

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)…

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…

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…

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 . . . . . .…

8.4 MANUFACTURER’S RECOMMENDED INSPECTIONS

8.4.1 - LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR(S) 8.4.1.1 - 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…

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…

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…

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…

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…

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…

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…

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…

APPENDIX 1

GENERAL REFRIGERATION CIRCUIT DIAGRAM: MCW APPENDICES 082 112-132-162-222-262-322 .47 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

APPENDIX 1

GENERAL REFRIGERATION CIRCUIT DIAGRAM: MCW 422 Standard Components Options M1/ M2/ M3 Compressors 14 Evaporator 28 Valves 9 Condenser P RT Low & high pressure sensors 12 Thermostatic expansion valve 10 Filter drier HP SP High pressure switch .48 P Low & high pressure gauges Installation - Operation…

APPENDIX 2

GENERAL REFRIGERATION CIRCUIT DRIAGRAM: MCSB 222-262-322 .49 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

APPENDIX 2

GENERAL REFRIGERATION CIRCUIT DRIAGRAM: MCSB 422 Standard Components Options M1/ M2/ M3 Compressors 14 Evaporator 28 Valves 7 Check valve P RT Low & high pressure sensors 12 Thermostatic expansion valve 30 Sight glass 10 Filter drier YV Electrical valve HP SP High pressure switch .50 P Low & high…

MCW 82 SK

MCW 82 SK .51 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

MCW 112-132-162 SK

.52 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

MCW 222-262-322 SK

.53 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

MCW 422 SK

.54 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

MCSB 222-262-322 SK

.55 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

MCSB 422 SK

.56 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

APPENDIX 3: EVAPORATOR and CONDENSER PRESSURE DROP

Pressure drop heat exchangers 100 size 82 size 112 Pressure drop kPa size 222-262 size 132 size 162 size 422 size .57 Water flow m3/h 100 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

CERTIFICATES – ISO 9001 : 2000

.58 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

CERTIFICATES – PED

.59 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

CERTIFICATES – DECLARATION OF CE CONFORMITY

.60 Installation - Operation - Maintenance manual (IOM) • Water Cooled CHILLERS & SPLIT UNITS - 0108-E

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