Lennox EMEA NEOSYS User manual

INSTALLATION, OPERATING AND
MAINTENANCE
CHILLER-IOM-2004-E
AIR COOLED CHILLERS (NEOSYS)
WATER COOLED CHILLERS (HYDROLEAN&MWC)
NEOSYS- HYDROLEAN- MWC
20-1000kW

SOMMAIRE
AIR COOLED, WATER COOLED CHILLERS AND
SPLIT UNITS
INSTALLATION
OPERATION
MAINTENANCE MANUAL
Ref : CHILLER-IOM-2004-E
The present manual applies to the following chiller versions:
NEOSYS range: NAC-NAH
HYDROLEAN range: SWC-SWH-SWR
MWC range: MWC-MRC
INSPECTIONS AND REQUALIFICATION ACCORDING PRESSURE EQUIPMENT DIRECTIVE MUST
FOLLOW THE LOCAL REGULATIONS WHERE THE UNIT IS INSTALLED.
Commissioning, monitoring, periodic verification and requalification obligations may be made mandatory in
some countries. Please refer to it when installing the equipment.
Our company is a member of the Eurovent Certification Program, all LENNOX chillers are tested
and rated in accordance with Eurovent certification program
Our products comply with the European standards
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 used (except in operation of this product), reproduced, issued to or made
available to third parties without the prior written agreement of LENNOX.

INTRODUCTION
CHILLER-IOM-2004-E
INTRODUCTION ...................................................................................................................................................................1
1. GENERAL DESCRIPTION.................................................................................................................................................. 2
2. SAFETY CODES &REGULATIONS.....................................................................................................................................2
3. MACHINE DESIGNATION ................................................................................................................................................ 2
4. SAFETY DEFINITION ........................................................................................................................................................3
5. SAFETY PRESSURE SWITCH (NEOSYS AND MWC RANGES) .................................................................................................3
6. EMC DIRECTIVE COMPLIANCE........................................................................................................................................4
7. LIFETIME OF THE EQUIPMENT........................................................................................................................................ 4
8. DISPOSAL OF THE EQUIPMENT.......................................................................................................................................4
F-GAS REGULATION .............................................................................................................................................................5
WARRANTY .........................................................................................................................................................................5
SAFETY.................................................................................................................................................................................6
1. LABELS............................................................................................................................................................................7
INSTALLATION .....................................................................................................................................................................9
1. TRANSPORT –HANDLING...............................................................................................................................................9
2. LIFTING THE UNIT ......................................................................................................................................................... 10
3. LAY-OUT AND INSTALLATION REQUIREMENTS ............................................................................................................ 11
4. WATER CONNECTIONS.................................................................................................................................................13
5. ELECTRICAL CONNECTIONS ..........................................................................................................................................20
6. SOUND LEVELS ............................................................................................................................................................. 20
7. CONNECTION OF SPLIT UNITS ......................................................................................................................................20
PRELIMINARY CHECKS .......................................................................................................................................................26
1. LIMITS...........................................................................................................................................................................26
2. REFRIGERATION CIRCUIT CHECKS AND RECOMMENDATIONS.....................................................................................26
3. HYDRAULIC SYSTEM INSTALLATION CHECKS (NEOSYS) ................................................................................................26
4. INSTALLATION OF EXTERNAL HYDRAULIC COMPONENTS (FOR HYDROLEAN AND MWC)............................................ 26
5. HYDRAULIC CONNECTIONS AND OPTIONS (FOR HYDROLEAN AND MWC) .................................................................. 28
6. CHECK LIST BEFORE START-UP......................................................................................................................................29
7. MASTER-SLAVE CONFIGURATION (2 UNITS OR MORE) ................................................................................................ 30
8. COMMISIONING...........................................................................................................................................................30
OPERATION .......................................................................................................................................................................31
1. OPERATING LIMITS....................................................................................................................................................... 31
2. CLIMATIC CONTROL ..................................................................................................................................................... 34
3. UNIT OPERATION: REFRIGERATION CIRCUIT................................................................................................................35
4. UNIT OPERATION: ELECTRICAL AND CONTROL FEATURES ........................................................................................ 37
5. OTHER FEATURES AND OPTIONS................................................................................................................................. 41
MAINTENANCE ..................................................................................................................................................................42
1. MAINTENANCE PLAN ................................................................................................................................................... 42
2. CLEANING THE CONDENSER........................................................................................................................................45
3. COMPRESSORS /OIL DRAINAGE..................................................................................................................................45
4. CORRECTIVE MAINTENANCE........................................................................................................................................46
5. IMPORTANT ................................................................................................................................................................. 46
TROUBLESHOOTING –REPAIRS..........................................................................................................................................47
1. LIST OF THE MOST COMMON PROBLEMS ....................................................................................................................47
2. CONTROL DEVICES .......................................................................................................................................................51
3. REGULAR CHECKS TO BE MADE -CHILLER UNIT ENVIRONMENT..................................................................................52
4. MANUFACTURER’S RECOMMENDED INSPECTIONS ...................................................................................................53
CHECK LIST.........................................................................................................................................................................54
APPENDIX..........................................................................................................................................................................56

INTRODUCTION
CHILLER-IOM-2004-E
1. GENERAL REFRIGERATION CIRCUIT DIAGRAM: NEOSYS COOLING ONLY .....................................................................57
2. GENERAL REFRIGERATION CIRCUIT DIAGRAM: NEOSYS COOLING ONLY -WITH TOTAL HEAT RECOVERY OPTION......58
3. GENERAL REFRIGERATION CIRCUIT DIAGRAM: NEOSYS HEAT PUMP........................................................................... 59
4. GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN COOLING ONLY.............................................................. 60
5. GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN HEAT PUMP ................................................................... 62
6. GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN REMOTE CONDENSER....................................................64
7. GENERAL REFRIGERATION CIRCUIT DIAGRAM: MWC ..................................................................................................66
8. GENERAL REFRIGERATION CIRCUIT DIAGRAM: MRC.................................................................................................... 67
9. GENERAL MECHANICAL DRAWING–NAC/NAH ............................................................................................................ 68
10. GENERAL MECHANICAL DRAWING HYDROLEAN..........................................................................................................77
11. GENERAL MECHANICAL DRAWING MWC.....................................................................................................................80
12. PRESSURE DROPS- NEOSYS..........................................................................................................................................85
13. PRESSURE DROPS -HYDROLEAN.................................................................................................................................. 87
14. PRESSURE DROPS- MWC .............................................................................................................................................89
Original version is the English one.
Other versions are translations.

INTRODUCTION
CHILLER-IOM-2004-E 1
INTRODUCTION
You must read and be familiar with this operating manual prior to commission the unit. Please closely follow the instructions.
We would like to stress the importance of training with respect to the correct handling of the unit.
Please consult LENNOX on the options available in this field.
It is important that this manual is stored in a permanent location in the vicinity of the unit.
•EU declaration.
•Operating manual for control system.
•Installation Operating manual
•Wiring diagram
•Refrigerant flow diagram
•Unit detail are given on unit nameplate.
The data published in this manual is based on 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 licensed competent technician. The following risks are
present on 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.
The unit must be installed in accordance with local safety codes and regulations and can only be used in well ventilated area.
Inspections and requalification according pressure equipment directive must follow the local regulations where the unit is
installed.
!
!
IMPORTANT GENERAL INSTRUCTION

INTRODUCTION
CHILLER-IOM-2004-E 2
1. GENERAL DESCRIPTION
The CHILLER range of units is a chilled water production unit that also exists in heat pump version.
2. SAFETY CODES & REGULATIONS
The unit is designed for outdoor installation only. The unit must be installed in accordance with local safety codes and regulations and can
only be used in well ventilated area.
Please read carefully the manufacturer’s instructions before starting this unit.
Inspections and requalification according pressure equipment directive must follow the local regulations where the unit is installed.
3. MACHINE DESIGNATION
NA
NEOSYS
SW
HYDROLEAN
MW
MEDIUM WATER
COOLED
MR
MWC Remote
condenser
M
400V/3/50
C
Cooling only unit
H
Heat pump unit
R
Remote condenser
1-6
Revision number
M
R410A
N
No heat
Size of the unit
S
1 circuit
D
2 circuits
T
3 circuits
F
4 circuits
N A C 2 0 0 D N M 6 M
M W C 2 0 0

INTRODUCTION
CHILLER-IOM-2004-E 3
4. SAFETY DEFINITION
The chillers meet the following safety definitions, and is provided with CE markings if applicable (for further information see EU
declaration).
5. SAFETY PRESSURE SWITCH (NEOSYS and MWC ranges)
This equipment is protected with safety pressure switch calibrated at 42 bar g. Do not overcome this operating pressure
IMPORTANT NOTICE
All work on the unit must be carried out by a qualified and authorized employee.
Non-compliance with the following instructions may result in injury or serious accidents.
Work on the unit:
The risk analyses of our machines are carried out taking into account operation in a standard environment with unpolluted air. For any
specific application (kitchen, industry ...) please contact your local sales representative.
•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.).
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
authorization.
•EN-378-2016
•2006/42/EC “Machine Directive”
(Directive 2014/35/EU relating to low voltagestaken into account
in the machine directive according to Annex 1 §1.5.1)
•EN-60204-1
•2014/30/EU “EMC Directive”
•2014/68/EU Pressure Equipment Directive
•EU 517/2014 F-Gas
•2009/125/EC Ecodesign
oCooling only unit: EU 2016/2281 - 2015/1095
oHeat pump unit: EU 813/2013 –2016/2281 –2015/1095
•2011/65/EU RoHS Directive
•2012/19/EU WEEE
•EC 1005/2009

INTRODUCTION
CHILLER-IOM-2004-E 4
6. EMC DIRECTIVE COMPLIANCE
WARNING:
This equipment is an “A class» according EMC Directive. In an industrial environment, this device can create radio electrical noise. In this
case, the owner can be asked to take appropriated actions.
Neosys units comply with the following environmental standards:
•EN 61000-6-4 : Emissions for industrial environments
•EN 61000-6-2 : Immunity for industrial environments
Neosys units comply with the following most stringent environmental standards if EMC filter class B option or MS machine (without inverter):
•EN 61000-6-3: Emissions for residential, commercial and light industrial environments.
•EN 61000-6-2: Immunity for industrial environments
This applies to all machine installed with nominal amps below <75A:
•The short-circuit rate Rsce=33 is defined in the EN61000-3-12 standard relative to the harmonics readings on the supply network.
The appliances compliant with the harmonic current limits equivalent to Rsce=33 can be connected in whatever connection point of
the main supply system.
•The maximal allowable impedance of the main supply system Zmax=0.051Ω is defined by EN 61000-3-11 standard relative to the
voltage variation, fluctuation and flicker readings. The connection to the supply is a conditional connection submitted to the
preliminary agreement of the power supply local provider.
The differences between the different machines are related to the power of the compressors and the equipment associated with them. For
conducted and radiated emission, as well as for immunity, these differences are not such as to modify the results obtained.
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 suitableequipment.
•Toprevent 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 pressureside.
•The brazing shall becarriedoutby a qualified brazer.Thebrazing shall comply with the standard 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.
CAUTION:
In the event of fire, refrigerating circuits can cause an explosion and spray coolant gas and oil.
7. LIFETIME OF THE EQUIPMENT
The refrigerating system is designed for a lifetime of at least 10 years if the safety and maintenance instructions are strictly respected.
The lifetime of the equipment may be renewed if the periodic requalification certificate is validated by the expert (authorized body or DREAL
in France (Directions Régionales de l'Environnement, de l'Aménagement et du Logement)
8. DISPOSAL OF THE EQUIPMENT
Equipment shut-down and recuperation of oil and coolant must be carried out by qualified personnel conform to the recommendations of
standard NF EN 378.
All elements in the refrigeration system such as refrigerant, oil, coolant, filters, dryers and insulating materials must be recuperated, re-
used and/or disposed of in a correct manner (see NF EN 378 part 4). No materials may be discarded into the environment.

F-GAS REGULATION
CHILLER-IOM-2004-E 5
F-GAS REGULATION
PLEASE READ THE SAFETY DATA SHEET OF THE REFRIGERANT BEFORE ANY INTERVENTION OR INSTALLATION OF THE
MACHINE.
Operators of refrigeration equipment’s must comply with the obligations defined in:
•Regulation on Fluorinated greenhouse gases (F Gas)
•Regulation on substances that deplete the ozone layer
Non compliance with these requirements is an offence and liable of financial penalties.
Moreover, in case of problem it is mandatory to prove to the insurance company that the equipment complies with the F gas
Regulation.
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 is intended for appropriate use.
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.
•A flow protection device is not fitted.
•The unit maintenance booklet is not complete or not available.
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.
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 used (except in operation of this product), reproduced, issued to or made available to third
parts without the prior written agreement of Lennox.
The technical information and specifications contained in this manual are for reference only. The manufacturer reserves the right to modify
these without warning and without obligation to modify equipment already sold

SAFETY
CHILLER-IOM-2004-E 6
SAFETY
The safety information contained in this manual is provided as a guide for the safe handling of this installation. LENNOX does
not vouch for the completeness of this information and can therefore not accept liability for any possible omissions.
In the chillers, heat is being transported by a pressurized refrigerant, with changes in pressure and temperature. For air cooled chillers,
fans have been provided to discharge heat into the environment. The protection of operating and maintenance personnel was central in
the design of the 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. For air cooled chillers, 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 (< 24 Volt). The service panels can only be
opened using tools.
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 units 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 chillers. Operations on the cooling circuit or electrical equipment should be carried out by authorized personnel.
It is essential to follow non exhaustive recommendations hereunder:
•Never work on a unit that is still energized.
•Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorized engineer. These
procedures must be carried out with the unit shut-down.
•Never work on any of the electrical components, until the general power supply to the unit has been cut. During any maintenance
operations on the unit, lock the power supply circuit in the open position ahead of the machine. If the work is interrupted, check
the lock before resuming the work.
•WARNING: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuit disconnect switch
is open. Refer to the wiring diagram for further details.
•For some units, a separate 220V power supply may exist, check the electrical wiring for more information.
•In case of maintenance operations on fans (grills replacement …) ensure that the power is shut off to avoid automatic restart.
•Before the opening of the refrigerant circuit, check the pressure with manometers or pressure sensors.
•Never leave a unit stopped with valves closed on the liquid line, refrigerant could be trapped and the pressure would rise.
•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 repairs have been carried out to the unit, the operation of the safety devices must be re-checked.
•Follow guidance and recommendations given in safety and machine standards such as EN378, ISO5149, etc.
•Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and
other common substances.
•Never exceed the specified maximum operating pressures. Verify the allowable maximum high- and low-side test pressures by
checking the instructions in this manual and the pressures given on the unit name plate.
•Do not use air for leak testing. Use only nidron or dry nitrogen.
•Do not unweld or flame cut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and vapour) has
been removed from chiller. Traces of vapour should be displaced with dry air nitrogen. Refrigerant in contact with an open flame
produces toxic gases.
oDo not siphon refrigerant
oAvoid spilling liquid refrigerant on skin or splashing it into the eyes. Use safety goggles. Wash any spills from the skin
with soap and water. If liquid refrigerant enters the eyes, immediately and abundantly flush the eyes with water and
consult a doctor.

SAFETY
CHILLER-IOM-2004-E 7
1. LABELS
The chiller may be marked with the following warning labels to alert to potential hazards (on or near the potentially hazardous part).
High temperatures
Electrical Voltage
Rotating parts
Sharp parts
A2L: slightly flammable
Wear of PPE (Personal
protective equipment)
Warning
Inflammable dusty filters
Don’t walk
Don’t strap
Warning main switch
supplied from bottom
EUROVENT certification
Gravity center
Protection by water filter
mandatory
Protection by strainer filter
mandatory
Transport of non-
flammable liquefied gas
Transport of flammable
liquefied gas
OK to send document
Information to read
Electrical connections can loosen during transport.
Please check them before start-up.
CMIM marking (Morocco)
CE marking
CA marking (UK)
Regularly check that the warning labels are still in the correct positions on the machine and replace them if necessary

SAFETY
CHILLER-IOM-2004-E 8
All units are compliant with the Pressure Equipment Directive (PED).
Warning:
1. Attention: The high-pressure safety switches are essential elements which guarantee the system
remains within the admissible operating limits. Before switching on the installation, always ensure
all electrical connections are correct on these elements which are used to isolate the electrical power
supply to the compressor(s) they protect. Carry out a test to ensure the electrical power supply is
effectively isolated when the pressure switch attains its set value.
2. In case of installation in a seismic zone or in a zone which may be effected by violent natural
occurrences such as storms, tornados, floods, tidal waves, etc…, the installer and/or operator will
refer to valid standards and regulations in order to ensure the devices required are available as our
units are not designed to operate under such conditions without prior precautions.
3. The equipment is not designed to resist fire. The installation site will therefore have to respect valid
standards with regard to protection against fire (emergency instructions, map…).
4. In case of exposure to corrosive external atmospheres or products, the installer and/or operator shall
take the necessary precautions to avoid damage to the equipment and will make sure the equipment
provided has the necessary and sufficient anti-corrosion protection.
5. To respect a sufficient number of supports for the piping according to their size and weight under
operating conditions and to design the piping to avoid a water hammer phenomenon
6. For technical reasons, it is not possible to carry out hydrostatic tests on all our units so leak tests are
carried out as a compensatory measure. (The entire circuit is checked using leak detectors). For
machines charged with refrigerant, at the end of the test, an HP test is carried out in the factory to
make sure the pressure switch is working properly.
7. Before any work is carried out on the refrigeration circuit, the dry air or nitrogen pressure our units
are supplied with must be released (For units not charged with refrigerant in the factory.)
8. The emissions of refrigerant via the safety relief valves must be channeled to the exterior of the
machine room. The outlet relief valve will have to be sized in compliance with EN13136.
9. Installation and maintenance of these machines must be carried out by personnel qualified to work
on refrigeration equipment.
10. All interventions must be carried out in conformity with valid safety regulations (e. g.: EN 378), as
well as the recommendations indicated on the labels and handbooks provided with the machine. All
actions shall be taken to avoid access of unauthorized persons.
11. It is essential that any pipework or other components of the refrigeration circuit hazardous to people
because of their surface temperature are insulated or identified.
12. Ensure that the installation zone (room or area) of the machine has restricted access and ensure
the good condition of the covering.
!

INSTALLATION
CHILLER-IOM-2004-E 9
INSTALLATION
1. TRANSPORT –HANDLING
All unloading operations must be carried out with suitable equipment (crane, forklift truck, etc.). Optional removable handling rings are
available for certain products.
When using a forklift truck, you must respect the positions and the direction of handling indicated on the products. The equipment must be
handled with care to avoid damage to the bodywork, pipework, condenser, etc.
1.1. Controls and delivery checks
After the unit has been received, when it is ready to be installed or reinstalled, and before it is started up, it must be inspected for damage.
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.
•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 letter must be addressed to LENNOX and the supplier or distributor for information purposes. Failure to
comply will invalidate any claim against the shipping company.
Please be reminded that LENNOX is not responsible for off-loading and positioning.
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 +5/-5 %.
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 important to 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:
•year of manufacture
•weight of the unit
•type of refrigerant used + GWP*
(*Global warming potential)
•required charge for each circuit
•operating Pressure min/max
•operating Temperature min/max
CE marking: 5 possible cases
- CE
- CE0038
This product is used for Air Conditioning. Contains fluorinated greenhouse gases
covered by the Kyoto protocol. Hermetically sealed.

INSTALLATION
CHILLER-IOM-2004-E 10
1.2. Storage
Whenunitsaredeliveredonsitetheyarenotalwaysrequiredimmediatelyandaresometimesputintostorage.Intheeventofmedium 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 inposition.
•Ensure the electrical panels areclosed.
•Keep all items and options supplied in a dry and clean place for future assembly before using the equipment.
It is strongly recommended to store units is a dry, sheltered place (in particular for units that will be installed indoor).
Storage temperature must be respected according to the information given on the rating plate.
2. LIFTING THE UNIT
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 qualified contractors and technicians with sound knowledge of this type of equipment, are authorized 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.
CAUTION: BEFORE EACH SERVICE OPERATION MAKE SURE THAT THE UNIT POWER SUPPLY IS PROPERLY
ISOLATED AND LOCKED OUT.
NOTE: SOME UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPARATE ISOLATION.
PLEASE CHECK THE WIRING DIAGRAM.
2.2. Handling
Handling operations must be carried out by qualified personnel. Comply strictly with the lifting instructions as well as with any other
applicable safety procedures. Wear protective glasses and work gloves. Unit handling operations must be carried out carefully to avoid
jolting the frame, the panels, the electrical box, 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!).
Rubber anti-vibrations mountings (AVM) & factory accessories are to be found in the control panel or in an extra box for
shipping. If the unit is mounted on anti-vibration mountings, these should be fitted to the unit before final positioning.
CAUTION: IN CASE OF REINSTALLATION OF THE UNIT, MAKE SURE THAT THE UNIT POWER SUPPLY IS PROPERLY
ISOLATED AND LOCKED OUT.
NEOSYS HYDROLEAN & MWC

INSTALLATION
CHILLER-IOM-2004-E 11
NOTE: SOME UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPARATE ISOLATION.
PLEASE CHECK THE WIRING DIAGRAM.
WARNING: HYDROLEAN Size 100, 120,135 and 160 are very narrow and high: there is a risk of the
unit tipping over when being handled with a fork lift.
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 NEOSYS are designed for outdoor installation. Please consult LENNOX prior to
implementing other types of installation.
•Water cooled chillers such as HYDROLEAN or MWC are designed for indoor installation. Please consult LENNOX prior to
implementing other types of installation.
•For outdoor air cooled chiller, position the chiller where it is less affected by wind (install windbreaks where wind speeds > 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 rigidity and point load positions enable installation to minimize 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 secured to the unit BEFORE being attached 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 secured 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 insulators seat flatly on the supporting surface.
•It is essential that the units be installed with sufficient free space around them to provide easy access to all unit components for
servicing and maintenance. For air cooled chiller only: 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 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.
•For air cooled chiller only: to prevent air flow to be reversed due to prevailing winds, units cannot be completely shrouded with a
higher, uninterrupted wind shield. If such a configuration cannot be avoided, an air ejection duct could be installed at the same
height as the surrounding shield after LENNOX representative written approval.
It is important that units must be levelled. Failure to install unit correctly will void warranty.
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INSTALLATION
CHILLER-IOM-2004-E 12
CLEARANCES DRAWINGS
For more details, please consult our Application Guides or the drawings supplied with the unit.
For any chiller, a minimum distance of 1 meter is required for the good opening and servicing of the electrical box. In case of a compressor
replacement, 1m is also reasonable to remove it.
NEOSYS
> 3 meters 2 meters 2 meters
Not recommended Not allowed
HYDROLEAN 025 ► 035 HYDROLEAN 050 ► 080 HYDROLEAN 100 ► 160

INSTALLATION
CHILLER-IOM-2004-E 13
MWC
4. WATER CONNECTIONS
4.1. Water connections - Evaporator / Condenser / Desuperheater / Total heat recovery
Before the system start-up check that the water circuits are connected to the right heat exchangers (e.g. no reversal between evaporator
and condenser or between water in and outlets). 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 sales brochure.
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.
LACK OF FILTER AT THE INLET OF A PLATE HEAT EXCHANGER WILL MAKE WARRANTY VOID.
Hydraulic drawings in Appendices, or supplied with the unit
It is important to follow non exhaustive recommendations hereunder:
•The water pipes must not transmit any radial or axial force to the heat exchangers nor any vibration. (Use flexible connections to
reduce the transmission of vibrations.)
•Manual or automatic air bleeders must be installed at all high points in the circuit(s).
•Drain connections must be installed at all low points to allow the whole circuit to be drained.
•An expansion device must be installed to maintain pressure in the circuit(s) as well as a safety device
•Comply with the water inlet and outlet connections shown on the unit.
•Install thermometers in both the entering and leaving water connections.
•Install stop valves, close to the entering and leaving water connections.
•After testing for leaks, insulate all pipe work, to reduce thermal leaks and to prevent condensation.
•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
•Connection pipes must under no circumstances generate strain on the piping system of our units. To do this, appropriate means
of support and fastening must be used.
•No support should be made on the body of the machine.
CHARGING AND REMOVING HEAT EXCHANGE FLUIDS SHOULD BE DONE BY QUALIFIED TECHNICIANS WITH
DEVICES THAT MUST BE INCLUDED ON THE WATER CIRCUIT BY THE INSTALLER. NEVER USE THE UNIT
HEAT EXCHANGERS TO ADD HEAT EXCHANGE FLUID.
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INSTALLATION
CHILLER-IOM-2004-E 14
4.2. Water analysis
The water must be analyzed; the water circuit installed must include all items necessary for treatment of the water: filters, additives,
intermediate exchangers, bleed valves, vents, isolating valves etc... depending on the results of the water analysis.
We do not advise operation of the units with open loops which can cause problems with oxygenation, or 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 improperly treated water, salt water or glycolated water.
Here are our non-exhaustive recommendations given as an indication:
•No NH4+ ammonium ions in the water, they are very detrimental for copper. <10mg/l
•Cl- Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture. < 10 mg/l.
•SO42- sulfate ions can cause perforating corrosion.< 30 mg/l.
•No fluoride ions (<0.1 mg/l).
•No Fe2+ and Fe3+ ions with dissolved oxygen. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l. Over those values, it means
a corrosion of steel which may generate a corrosion of copper parts under deposits of Fe –this is mainly the case with shell and
tube heat exchangers.
•Dissolved silicon: silicon is an acid element of water and can also lead to corrosion risks. Content < 1mg/l.
•Water hardness: TH >2.8 K. Values between 10 and 25 can be recommended. This will facilitate scale deposit that can limit
corrosion of copper. TH values that are too high can cause piping blockage over time.
•TAC< 100.
•Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to deoxygenate the
water by mixing it with inert gas as it is to over-oxygenate it by mixing it with pure oxygen. The disturbance of the oxygenation
conditions encourages destabilization of copper hydroxides and enlargement of particles.
•Specific resistance –electric conductivity: the higher the specific resistance, the slower the corrosion tendency. Values above 3000
Ohm/cm are desirable. A neutral environment favours maximum specific resistance values. For electric conductivity values in the
order of 200-6000 S/cm can be recommended.
•pH: pH neutral at 20°C (7 < pH < 8)
If the water circuit must be emptied for longer than one month, the complete circuit must be placed under nitrogen charge to avoid any risk
of corrosion by differential aeration.
4.3. Antifreeze protection
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.
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 A HEAT EXCHANGER DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX WARRANTY
4.4. Electrolyticcorrosion
We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an
imbalance between earthing points.
AN EXCHANGER THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE
UNIT WARRANTY
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INSTALLATION
CHILLER-IOM-2004-E 15
4.5. - Minimum watercapacity
The minimum volume of the chilled water circuit must be calculated with the formula here under.If necessary, install
a buffertank.Properoperationofregulatingandsafetydevicescanonlybeensuredifthevolumeofwaterissufficient.
The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formula
hereafter:
Vt → Minimum water content of the installation (in liters)
Q → Chiller cooling capacity (in kW)
N → Minimum power stage
Dt → Maximum temperature drift allowed (in K)
Tmin → Minimum operating time (in seconds)
Wd → Liquid density (in kg/m3)
Cp → Calorific capacity of the liquid (in kJ/(kg.K))
This formula is onlyapplicable for air-conditioning installation and must not be used for process cooling wheretemperature
stability isrequired.
Example for Dt=-6K, Tmin=360s, liquid = non-glycolated water (Wd= 1000kg/m3 and Cp=4.18 kJ/kg.°C) (==> Tminx1000/WdxCp=86)
Note: the volume of the condenser water loop has no impact on the chiller operation. In heat pump operation (with hot water set point
control option), the minimum volume of the condenser water loop must be calculated based on the heating capacity using the same
formula.
NAH
Unit size
Number of stages
Minimum Water
volume (l)
200
4
478
230
4
549
270
4
645
300
4
1075
340
5
975
380
5
908
420
6
1003
480
6
1147
MWC/MRC
Unit size
Number of stages
Minimum Water
volume (l)
180
4
645
230
5
659
280
6
669
330
5
946
380
4
1362
450
6
1075
510
6
1218
570
6
1362
650
6
1553
720
6
1720
NAC
Unit size
Number of stages
Minimum Water
volume (l)
200
6
478
230
6
549
270
6
645
300
4
1075
340
6
975
380
5
1089
420
6
1003
480
6
1147
540
6
1290
600
6
1433
640
6
1529
680
10
975
760
10
1089
840
12
1003
960
12
1147
1080
12
1290
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