Lennox AIRCOOLAIR KNCK 24E Instruction manual

AIRCOOLAIR
KNCK / KNHK
English/03-2005
INSTALLATION
OPERATION &
MAINTENANCE MANUAL

1
2.- INSTALLATION PAGE
WARNING: Read this manual bef re installati n, reparati n maintenance w rks.
PAGE
PAGE
10
10
11
11
12-16
17-21
22
23
24
25
26
2.1.- INSTALLATION GUIDELINES
2.2.- UNIT INSTALLATION
2.3.- UNIT LOCATION
2.4.- INSTALLATION CLEARANCES
2.5.- REFRIGERANT CONNECTIONS
2.6.- ELECTRICAL CONNECTIONS
DATA PAGE FOR UNIT COMMISSIONING
PAGE
4
5
5
6
7
8-9
PAGE 3
PAGE 2
TABLE OF CONTENTS
1.- GENERAL CHARACTERISTICS
1.1.- PHYSICAL DATA
1.2.- ELECTRICAL DATA
1.3.- TECHNICAL DATA
1.4.- OPERATING LIMITS
1.5.- UNIT DIMENSIONS
1.6.- AVAILABLE OPTIONS
4.- MAINTENANCE
4.1.- PREVENTIVE MAINTENANCE
4.2.- CORRECTIVE MAINTENANCE
4.3.- FAILURE DIAGNOSIS
3.- COMMISSIONING AND OPERATION
3.1.- PRELIMINARY CHECKS
3.2.- STEPS TO FOLLOW FOR COMMISSIONING THE UNIT
POINTS TO KEEP IN MIND
Lenn x have been pr viding envir nmental s luti ns since 1895, ur range f AIRCOOLAIR c ntinues t meet the standards
that have made LENNOX a h useh ld name. Flexible design s luti ns t meet YOUR needs and unc mpr mising attenti n
t detail. Engineered t last, simple t maintain and Quality that c mes as standard.
Inf rmati n n l cal c ntacts at www.lenn xeur pe.c m.
All the technical and techn l gical inf rmati n c ntained in this manual, including any drawing and technical descripti ns
pr vided by us, remain the pr perty f Lenn x and must n t be utilised (except in the perati n f this pr duct), repr duced,
issued t r made available t third parties with ut the pri r written agreement f Lenn x.

2
Risk f injury with
r tating bjects
L w
temperatures
High
temperatures
Risk f injury with
m ving bjects
Electrical
v ltage
Abrasive
surfaces
Standard Guidelines to Lennox equipment
All technical data c ntained in these perating instructi ns including the diagrams and technical descripti n remains
the pr perty f Lenn x and may n t be used (except f r the purp se f familiarizing the user with the equipment),
repr duced, ph t c pied, transferred r transmitted t third parties with ut pri r written auth rizati n fr m Lenn x.
The data published in the perating instructi ns is based n the latest inf rmati n available. We reserve the right
t make m dificati ns with ut n tice.
We reserve the right t m dify ur pr ducts with ut n tice with ut bligati n t m dify previ usly supplied g ds.
These perating instructi ns c ntain useful and imp rtant inf rmati n f r the sm th perati n and maintenance
f y ur equipment.
The instructi ns als include guidelines n h w t av id accidents and seri us damage bef re c mmissi ning the
equipment and during its perati n and h w t ensure sm th and fault-free perati n. Read the perating
instructi ns carefully bef re starting the equipment, familiarize y urself with the equipment and handling f the
installati n and carefully f ll w the instructi ns. It is very imp rtant t be pr perly trained in handling the equipment.
These perating instructi ns must be kept in a safe place near the equipment.
Like m st equipment, the unit requires regular maintenance. This secti n c ncerns the maintenance pers nnel
and management.
If y u have any queries r w uld like t receive further inf rmati n n any aspect relating t y ur equipment, d
n t hesitate t c ntact us.
POINTS TO KEEP IN MIND
DANGER AND WARNING SIGNS
Make sure t pen the p wer ff switch bef re t install, repair r make maintenance w rks in the unit, in rder t
prevent seri us electrical injuries.
T install the unit, keep in mind l cal and nati nal legislati n.
ELECTRICAL CONNECTIONS

3
High pressure:
L w pressure:
circuit 1
circuit
circuit 1
circuit
Air intake temperature t the utd r c il:
Air utput temperature t the utd r c il:
High pressure:
L w pressure:
circuit 1
circuit
circuit 1
circuit
Air intake temperature t the utd r c il:
Air utput temperature t the utd r c il:
Opti ns installed:
C mments:
ELECTRIC POWER CONSUMPTION (Amps)
ºC
1
ºC
ºC
1
ºC
1
ºC
ºC
Fan utd r secti n 1 Fan utd r secti n 1
Fan utd r secti n 2 Fan utd r secti n 2
ºC
1
ºC
C mpress r 1 C mpress r 2 C mpress r 1 C mpress r 2
DATA PAGE FOR UNIT COMMISSIONING
UNIT: SERIAL Nr.:
INSTALLATION ADDRESS:
INSTALLER: INSTALLER TEL.:
CHECKS:
SUPPLY VOLTAGE:
DATA INPUT:
DATE OF COMMISSIONING:
INSTALLER ADDRESS:
RATED VOLTAGE OF THE UNIT:
YES NO
GENERAL POWER SUPPLY CONNECTION
CONTROL PANEL CONNECTION
COOLING CYCLE HEATING CYCLE
COMPRESSOR OIL LEVEL INDICATOR
UNIT ON SHOCK ABSORBERS
DRAINAGE WITH TRAP
CONTROL PANEL IDENTIFICATION CODE

4
Kg
Kg
Kg
Kg
COMPRESSOR Nr. / Type
NET WEIGHT
C ling nly units KNCK
Heat pump units KNHK
UNIT MODEL
REFRIGERANT CHARGE
AIR FLOW
m
3
/h
COMPRESSOR Nr. / Type
NET WEIGHT
C ling nly units KNCK
Heat pump units KNHK
UNIT MODEL
REFRIGERANT CHARGE
AIR FLOW
m
3
/h
1 / Scr ll
4E
225
1 / Scr ll
3 E
250
1 / Scr ll
38E
270
1 / Scr ll
43E
300
2 / Scr ll
485
2 / Scr ll
490
2 / Scr ll
530
2 / Scr ll
590
48D/D 64D/D 86D/D
NITROGEN (*)
NITROGEN (*)
230 255 275 305
495 500 545 605
76D/D
6300 11500 11000 10500
19000 23000 22000 21000
KN C K
Type f unit
utd r
AIRCOOLAIR
24 ------
------: Standard unit versi n.
VFC: V ltage free c ntact
unit versi n.
E
E: ne circuit
D: tw circuits
D2: Units multi-split
KNCK: C ling nly unit R-407C
KNHK: Heat pump unit R-407C
Applicati n
C: C ling nly
H: Heat pump
Type f Refrigerant
K: R-407C
Appr ximately c ling
capacity in kW
(*) The units are supplied with nitr gen gas; this must be rem ved and charge the unit with refrigerant R-407C
depending n unit m del.
(see page 16 t calculate m del refrigerant charge f r KNCK / KNHK units t w rk with ind r units LECK / LEHK.)
As an pti n, kit R-407C refrigerant fact ry precharge is available.
1.- GENERAL CHARACTERISTICS
1.1.- PHYSICAL DATA

5
(1) The ab ve data sh ws n ise levels without is lati n f r c mpress r (standard unit)
( ) The ab ve data sh ws n ise levels with is lati n f r c mpress r ( pti nal)
(3) The ab ve data sh ws n ise levels with Kit "l w n ise" ( pti nal)
V/f (50 Hz)
Maximum abs rbed p wer
T tal p wer
V ltage
kW
kW
Maximum current
T tal current
Start up current
kW
UNIT MODELS
A
A
A
A
Fan
C mpress r
Fan
C mpress r
KNCK 4E
KNHK 4E
KNCK 3 E
KNHK 3 E
KNCK 38E
KNHK 38E
KNCK 43E
KNHK 43E
230V-400V+N/ 3Ph
24,30/14
25,90/15,60
167,60/100,60
1,60
0,28
8,62
8,90
3,50
0,90
12,90
13,80
36,50/21
40/24,50
227,50/130,50
3,50
0,85
15,55
16,40
46,10/25,60
49,60/29,10
282,50/161,50
0,83
19,07
19,90
53,30/30
56,80/33,50
333,50/192,50
3,50
KNCK-KNHK
48D/48D
KNCK-KNHK
64D/64D
KNCK-KNHK
76D/76D
KNCK-KNHK
86D/86D
48,60/28
54,60/34
196,30/119
6
1,50
17,24
18,74
7
1,80
25,80
27,60
73/42
80/49
267,50/155
7
1,70
31,10
32,80
92,20/51,20
99,20/58,20
332,10/190,60
1,66
38,14
39,80
106,60/60
113,60/67
390/226
7
- Gl bal s und p wer level measured in c mpliance with ISO standard 3744 and under Eur vent certificati n pr gram.
- S und pressure in dB(A) calculated at 10 m, in a free field n a reflecting surface, is given as a guide nly and
with a directibility f +/- 3 dBA.
- Only the s und p wer spectrum and the gl bal s und p wer value are used in determining pressure
characteristics n site.
- The ab ve data sh ws n ise levels f standard unit and unit with c mpress r is lati n when unit's fan is w rking
n c ling r heating m de at maximum speed.
- The ab ve data sh ws n ise levels f unit with Kit "l w n ise" when c ling nly units, r heat pump units
( n c ling m de) are w rking with utd r temperatures f 35ºC, because n heating m de the Kit "l w n ise"
is disabled.
(1)
( ) 70,9 73,2 71,3 70,3 66,9 55,7 76,6 48,6
67,6
KNCK/
KNHK
(3)
(3)
(3)
(3)
(3)
(3)
(3)
(3)
(1)
( ) 75,3 78,2 77,9 76,9 71,0 64,3 82,7 54,7
83,3
(1)
( )
(1)
( )
8000 Hz4000 Hz000 Hz1000 Hz500 Hz50 Hz1 5 Hz
Sound
Power
Lw dB(A)
Spectrum per octave band (dBA) Sound
pressure at 10m
Lp dB(A)
4
64
76
86
71,1 74,9 73,2 72,5 69,6 57,0 78,6 50,6 67,6
69,9 71,9 68,8 67,6 65,3 53,6 74,6 46,6 61,8
70,0 72,7 71,2 74,5 71,4 62,4 79,0 51,0 74,8
66,6 72,4 68,4 68,4 64,3 53,9 74,6 46,6 71,6
67,0 69,7 68,2 71,5 68,4 59,4 76,0 48,0 71,8
67,7 72,1 69,7 70,7 64,8 57,2 75,8 47,8 73,7
63,0 70,4 67,4 68,6 65,0 55,0 74,0 46,0 62,0
75,4 79,7 78,9 78,4 73,2 65,3 84,0 56,0 83,3
69,6 75,4 71,4 71,4 67,3 56,9 77,6 49,6 74,6
75,6 79,1 78,8 80,6 77,2 70,3 85,5 57,5 83,3
75,4 77,8 77,9 78,4 74,2 67,8 83,6 55,6 83,3
76,5 80,1 79,3 80,2 74,4 68,0 85,1 57,1 83,3
75,9 78,4 78,1 78,1 71,9 66,1 83,4 55,4 83,3
70,7 75,1 72,7 73,7 67,8 60,2 78,8 50,8 76,7
(1)
( ) 72,3 75,2 74,9 73,9 68,0 61,3 79,7 51,7
80,3
3 72,4 76,7 75,9 75,4 70,2 62,3 81,0 53,0
80,3
(1)
( ) 72,4 74,8 74,9 75,4 71,2 64,8 80,6 52,6
80,3
38 72,6 76,1 75,8 77,6 74,2 67,3 82,5 54,5
80,3
(1)
( )
43 73,5 77,1 76,3 77,2 71,4 65,0 82,1 54,1
80,3
72,9 75,4 75,1 75,1 68,9 63,1 80,4 52,4 80,3
(1)
( )
48 67,9 74,1 72,5 73,8 69,5 57,0 78,7 50,7
71,9
67,9 72,3 69,9 69,8 66,1 56,0 75,7 47,7 71,9
1.2.- ELECTRICAL DATA R-407C
1.- GENERAL CHARACTERISTICS
1.3.- TECHNICAL DATA
SOUND PRESSURE / SOUND POWER LEVELS FOR OUTDOOR UNIT

6
COOLING MODE
HEATING MODE
DEPENDING ON MODEL
(TABLE 1)
INDOOR
TEMPERATURE
MAXIMUM TEMPERATURES MINIMUM TEMPERATURES
32º C DB / 23ºC WB 21º C DB / 15ºC WB
OUTDOOR
TEMPERATURE
INDOOR
TEMPERATURE 27º C DB 15ºC DB
OUTDOOR
TEMPERATURE
DEPENDING ON MODEL
(TABLE 2) -10º C DB / -11ºC WB
COOLING CYCLE
OPERATION
HEATING CYCLE
OPERATION
DEPENDING ON
MODEL (TABLE 1)
INDOOR
TEMPERATURE
MAXIMUM TEMPERATURES MINIMUM TEMPERATURES
32ºC DB / 23ºC WB
COOLING CYCLE
OPERATION
21ºC DB / 15ºC WB
OUTDOOR
TEMPERATURE
+19ºC STANDARD UNIT
+15ºC WITH MINIMUM INDOOR
TEMPERATURES 24ºC DB/ 18ºC WB
0ºC WITH OPTIONAL ON/OFF CPC
-10ºC (*)
+19º C STANDARD UNIT
+15ºC WITH MINIMUM INDOOR
TEMPERATURES 24ºC DB/ 18ºC WB
0º C WITH OPTIONAL ON/OFF CPC
-10ºC (*)
1.4.- OPERATING LIMITS
(To install with LECK - LEHK units)
OPERATING LIMITS FOR (COOLING ONLY) UNITS
OPERATING LIMITS FOR (HEATING PUMP) UNITS
DB.- Dry Bulb Temperature
WB.- Wet Bulb Temperature
(*) With kit h t gas by pass r pr p rti nal CPC ( pti ns).
(*) With kit h t gas by pass r pr p rti nal CPC ( pti ns).
TABLE - MAXIMUM OUTDOOR OPERATING TEMPERATURES (ºC) ON HEATING CYCLE WORKING AT MAXIMUM
INDOOR TEMPERATURES ( 7ºC DB)
TABLE 1 - MAXIMUM OUTDOOR OPERATING TEMPERATURES (ºC) ON COOLING CYCLE WORKING AT MAXIMUM
INDOOR TEMPERATURES (3 ºC DB / 3ºC WB)
MODELS
Maximum temperatures
4E
45
3 E
44
38E
44
43E
43
48D/D
45
64D/D
44
76D/D
44
86D/D
43
MODELS
Maximum temperatures
4E
17
3 E
16
38E
17
43E
13
48D/D
17
64D/D
16
76D/D
17
86D/D
16
1.- GENERAL CHARACTERISTICS
AMBIENT TEMPERATURE WITH AIR DUCTS IN OUTDOOR UNIT
Available static
pressure Pa
30
4E
Available pressure up to 50 Pa
Descripti n
Maximum ambient temperature ºC
3 E
38E 43E 48D/D
44 43 42 44
64D/D
76D/D
43
86D/D
42
50 Maximum ambient temperature ºC 43 42 41 43 42 41
Available static
pressure Pa
30
Available pressure up to 50 Pa
Descripti n
Minimum ambient temperature ºC
4E to 86D
48D to 86D
-9
50 Minimum ambient temperature ºC -8

7
1.5.- UNIT DIMENSIONS
1.- GENERAL CHARACTERISTICS
1.195
660
1.375
P wer supply
cable entry
Main switch
( pti n)
Electrical b x
Access t gas
and liquid lines
MODELS
KNCK/KNHK 3 E-38E-43E
980
1.195
1.375
P wer supply
cable entry
Main switch
( pti n)
Electrical b x
Access t gas
and liquid lines
MODELS KNCK/KNHK
48D-64D-76D-86D
48D -64D -76D -86D
1195
1.375
1.960
P wer supply
cable entry
Main switch
( pti n)
Electrical b x
P wer supply
cable entry
Access t gas
and liquid lines
MODELS
KNCK/KNHK 4E

8
MAIN SWITCH
The main switch is l cated n the access panel t the electrical b x f the utd r unit.
The main switch is equipped with a clutch gadget, which all ws pening the panel f the electrical b x, when it is
n OFF p siti n.
Verify that the main switch is large en ugh t handle the current f r the unit if electric heaters are installed.
PHASE SEQUENCER
The phase sequencer is l cated in the electrical b x in the utd r secti n, thus assuring that the unit will n t
begin perati n while the phase c nnecti n f the c mpress r is n t c rrect. Sh uld this ccur, then just switch
tw phase c nnecti ns.
ON/OFF CONDENSATION PRESSURE CONTROL
The c ndensati n pressure c ntr l c nsists f ne r tw pressure switches, which starts and st ps the utd r
fan, regulating the c ndensati n temperature; thus the unit will be able t perate in the c ling cycle when the
utd r temperature is bel w 19ºC (until 0ºC).
It includes crankcase heater f r c ling nly units. The purp se f the heater is t keep the il in the c mpress r
at the c rrect temperature while the c mpress r is st pped, s that it can be pr perly lubricated when starts again.
When the unit is perating at l w utd r temperatures (bel w 19ºC), it is advisable t fit a crankcase heater.
PROPORTIONAL CONDENSING PRESSURE CONTROL
It is an element which regulates utd r fan speed, in rder t c ntr l c ndensati n temperature. Thus, the unit
will be able t perate in the c ling cycles when the utd r temperature is bel w 19ºC (until -10ºC). This kit
includes crankcase heater f r c ling nly units.
COMPRESSOR STARTING CURRENT CONSTRAINED (SOFT STARTER) 400V-III
It is an electr nic element, which reduces the peak c mpress r starting current up t 40% (see pages f electrical
data with ut s ft starter).
HOT GAS BYPASS VALVE
The purp se f the BYPASS valve is t let the unit perate at l w utd r temperatures (until -10°C), t be used
in c ling nly and heat pump units in c ling cycle.
It regulates the capacity f the c mpress r by injecting h t gas fr m the c mpress r discharge side t the c il.
REMOTE AMBIENT SENSOR AND REMOTE DUCT SENSOR
These sens rs may be used in c njuncti n with rem te c ntr ller r all wing the c ntr ller t be m unted in a
r m away fr m the c nditi ned space.
REMOTE DUCT SENSOR:
The sens r will be l cated in the return-air duct, detecting the air temperature f the air being air-c nditi ned.
REMOTE AMBIENT SENSOR:
The sens r will be placed in the area t be air-c nditi ned.
1.6.- AVAILABLE OPTIONS
1.- GENERAL CHARACTERISTICS
MODELS
4E-3 E-38E-43E
48D/D -64D/D -76D/D -86D/D
WEIGHTS (*)
3
6
(*) Add t the unit's weight.

9
CONTROL USING A PROGRAMMABLE CONTROLLER
With the pr grammable c ntr ller pti n, the desired temperature can be pr grammed in the area 24 h urs a day,
7 days a week.
CONDENSER COIL GUARD
The c ndenser c il pr tecti n grill prevents light damage t the c il when shipping and when installed.
It cann t pr tect against very heavy impacts.
PRECOATED COIL
Special pr tecti n f the aluminum c ndenser c il fins, t pr tect it fr m aggressive external envir nmental
c nditi ns.
RUBBER DAMPERS
T install under the unit t av id transmissi n f vibrati ns t the fl r where unit is installed, while unit is
perating.
COMPRESSOR ACOUSTIC JACKET
Each c mpress r is fitted with a c mpress r ac ustic jacket this pr vides attenuati n f the c mpress r n ise
that radiates fr m the unit when in perati n.
KIT LOW NOISE
With this kit, each c mpress r is fitted with a c mpress r ac ustic jacket and als includes pr p rti nal pressure
c ntr l, which thr ugh a special regulati n decreases the fan speed and pr vides attenuati n f s und level.
Regulati n used n c ling m de with utd r temperatures bel w 35ºC. See page 5 f r N ise level perf rmances.
R-407C REFRIGERANT FACTORY PRECHARGED
This pti n includes service valves and R-407C refrigerant charged in utd r unit (f r 0 meters f c nnecti n
lines).
SERVICE VALVES
The unit is fitted with gas and liquid service valves, in rder t make easier installati n and maintenance perati ns.
Liquid service valve
Gas service valve
1.6.- AVAILABLE OPTIONS
1.- GENERAL CHARACTERISTICS