Lennox CLIMATIC 50 User manual

CLIMATIC™ 50
USER MANUAL
CHILLERS
English
January 2005

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TABLE OF CONTENTS
Page
INTRODUCTION........................................................................................................... 2
WIRING CONNECTIONS AND COMMUNICATION
Warning.................................................................................................................................3
CLIMATIC™ 50 Controller ....................................................................................................3
Climatic™ 50 controller – option DC50 remote connection...................................................4
Communication BMS ............................................................................................................5
Communication Master/Slave ...............................................................................................7
STANDARD CONTROL FEATURES
Scheduling ............................................................................................................................8
Anticipation – Heat pump mode only ....................................................................................9
Change over – Reversible units ...........................................................................................10
Evaporator pumps control ....................................................................................................11
Thermostat – Set point calculation .......................................................................................13
Thermostat – Control principle .............................................................................................14
Compressors control............................................................................................................15
High pressure unloading ......................................................................................................16
Defrost – Heat pump ............................................................................................................17
Driving the electronic expansion valve.................................................................................19
Condensing fans control ......................................................................................................21
Remote water temperature set point ....................................................................................24
Free-cooling .........................................................................................................................24
Energy recovery...................................................................................................................25
FAULT CODES
GENERAL FAULTS
Chilled water temperature, out of range .................................................................27
Insufficient water flow rate......................................................................................28
Communication with the extension board .............................................................29
REFRIGERATION CIRCUITS FAULTS
Low pressure cut out..............................................................................................30
Evaporator freezing protection ...............................................................................31
Faults probes and sensors.....................................................................................32
COMPRESSOR FAULTS
Compressor electrical protection............................................................................33
High pressure too high ...........................................................................................34
MISCELLAENOUS FAULTS
Insufficient flow rate provided by the pump ............................................................35
Fans circuit breakers open.....................................................................................36
Pump circuit breaker open .....................................................................................37
CLIMATIC™50 Inpout/ Output MAPPING ................................................................. 38
CONTROL INTERFACE AND DISPLAYS .................................................................. 39
DC 50 CONFORT DISPLAY........................................................................................ 40
DS 50 SERVICE DISPLAY .......................................................................................... 50
DS 50 MENU TREE ECOLOGIC RANGE ................................................................... 56
DS 50 MENU TREE ECOMAX RANGE ...................................................................... 65
FAULTS CODES ......................................................................................................... 74
BMS Points ................................................................................................................. 76
ModBus..................................................................................................................76
LonWorks...............................................................................................................79

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INTRODUCTION
CLIMATICTM50
The new generation of microprocessor based control, CLIMATICTM 50 may be fitted to the Lennox chiller
range. It inherits 15 years of technology and field operating experience from its predecessors the
CLIMATICTM1 and CLIMATICTM 2.
LENNOX has found the latest hardware technology available on the market place and developed a software
specifically designed for water chiller applications, maximising the LENNOX units efficiency and
performance.

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WIRING CONNECTIONS AND COMMUNICATIONS
IMPORTANT WARNING
Any wiring modification on the CLIMATIC 50 must be done by Lennox technician or employees having
valid electrical qualification and authorisation.
For any modification of wiring on the 24V supply or on 4-20mA sensor, check the polarity prior to
apply the power. Wrong polarity may cause serious damage and destroy the Plan network. Lennox
will not accept liability for damage caused by wrong power connection or any wiring modification
done by people without valid training and qualifications.
CONNECTION DIAGRAM
CLIMATIC™ 50 CONTROLLER

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WIRING CONNECTIONS AND COMMUNICATIONS
CONNECTION DIAGRAM
CLIMATIC 50 CONTROLLER - OPTION DC50 REMOTE CONNECTION

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WIRING CONNECTIONS AND COMMUNICATIONS
COMMUNICATION
BMS
Function
This is used to link a Climatic to a BMS network for remote control of the unit.
Description
The Climatic 50 can communicate according to various protocole:
1. Climatic protocol for connection with KP06 (see specific KP06 manual) or other Lennox
communication products (3932 = 0)
2. MODBUS Protocol (3932 = 1)
3. LONWORKS system (3932 = 2)
MODBUS and LONWORKS address table are given at the end of this manual.
The identification number of each unit can be set (3931) and the communication speed is adjustable
between 1200Bds and 19200Bds (3933).
MODBUS protocol
For this option the BM50 must be equipped with the board, PCO1004850
This card is used to interface BM50 to an RS485 network.
The card guarantees the optical isolation of the controller from the RS485 serial network.

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On the Climatic, set point 3932 = ModBus
Transmission Mode = RTU
Baud Rate = set point 3933 (1200 / 2400 / 4800 / 9600 / 19200)
Word Length = 8
Parity = NONE
Stop Bits = 2
Device Id = set point 3931 (1 to 200)
LONWORKS protocol
For this option the BM50 must be equipped with the board, PCO10000F0
This card is used to interface BM50 to a LonWorks® network, by FTT-10A 78 kbs (TP/FT-10).
On the Climatic, set point 3932 = LonWorks
Baud Rate = set point 3933 (4800)
Device Id = set point 3931 (1 to 200)
Application
Normally the Climatic work on its calendar zones of operation (Zone A, B, C, Unoccupied).
Warning: The points in writing received from the BMS are taken into account by Climatic only if mode BMS
is activated ("Watchdog", address 3934)
The BMS mode is activated if the watchdog is different from zero (DS50 address 3934, Modbus analogical
item1, Lonworks address I_Sp_BMS_Dog).
Every second, the Climatic 50 decreases the value of this address by 1. If this address reaches zero, then
the Climatic 50 works as a stand alone unit in order to check continuously the communication with BMS.
Normally, the BMS has to send a value to this address regularly (example 255 every 4 mn).

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WIRING CONNECTIONS AND COMMUNICATIONS
COMMUNICATION
MASTER/SLAVE
Function
Link several units in order to allow a “Master/Slave” relationship in between each units
Description
Two modes are available and can be set up using following set points:
3922 Ænumber of units linked (maximum 4)
3923 ÆOperation mode (see hereunder)
•Back-up mode
One unit is the back-up unit and will operate if any of the other units has a failure.
•Rolling Back-up mode
Same as above, except the "back-up" unit will be different each Tuesday.

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SCHEDULING
Function
Controlling operation of the unit according to the time and day
Description
CLIMATICTM 50 can handle 4 time zones over the 7 days of the week:
•Zone unoccupied
•Zone A
•Zone B
•Zone C
Starting time (hours and minutes) of each of these zones for each days of the week, can be set using
menus 3211 to 3218, (press PROG key to change day).
3211 ÆStarting hour Unoccupied Zone
3212 ÆStarting minute Unoccupied Zone
3213 ÆStarting hour Zone A
3214 ÆStarting minute Zone A
3215 ÆStarting hour Zone B
3216 ÆStarting minute Zone B
3217 ÆStarting hour Zone C
3218 ÆStarting minute Zone D
8h00 12h00 14h00 20h00
Monday Unoccupied ZA ZB ZC Unoccupied
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
For each time zone the following set points can be adjusted:
1. Pump control type. Set point 3112, (refer to the “pump control” pages for more details).
2. Change Over rules for heat pump units. Set point 3311 must be set for each time zone (press PROG
key to change time zones).
3. Heating and cooling temperature set points. Set point 3321 to 3324 for cooling and 3331 to 3334 for
heating (refer to the control set point pages for more details)
4. Compressor operation. Set point 3411 (refer to the compressor operation pages for more detailed
information)
5. Forced Low Speed Ventilation Operation (Low noise)
Note: “Monday” is the first day of the week for the scheduling on CLIMATICTM 50
As a factory setting, only Zone A is activated 24hours a day, 7 days a week

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ANTICIPATION – Heat pump mode only
Function
This allows an anticipated start-up in the morning depending on the outdoor temperature.
Description
This function only works for zone A, and allow the machine to move from unoccupied zone to zone A earlier if
the outdoor temperature is under a certain value.
This will allow the unit to anticipate a cool day.
This can be adjusted with set point 3321 and 3322.
3221 Æbottom of the slope (°C), Anticipation starting point .
3222 ÆSlope in Minutes of anticipation per degrees
Example:
WA chiller with Zone A
starting at 8.00 am
3221 set at 3°C
3222 set at 10mn/°C
If outside temperature is
0°C, the zone A will start
at 7.30 am
Outside air
temp
Zone A starting
time
0°C 3°C
7.30 am
8.00 am

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CHANGE OVER – REVERSIBLE UNITS
Function
For Reversible units only. This allows the reversible units to change automatically from winter to summer
operation.
Description
This function will change the unit from production of hot water to production of chilled water automatically and
can be set up with following set points:
3311 ÆChange over mode according to following values
0 Æcooling only
1 Æheating only
2 ÆAutomatic change over - pumps are running in dead zone
3 ÆAutomatic change over – pumps are stopped in dead zone
3312 ÆChange over winter setting
The set point 3312 is the outside air temperature under which the unit will operate as a heat pump.
3313 ÆChange over summer setting
The set point 3313 is the outside air temperature over which the unit will operate as a chiller.
Outside air tem
p
12°C 23°C
Heat pump operation
Chiller operation
Dead zone

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EVAPORATOR PUMP(S) CONTROL
Function
Ensure the presence of a flow rate of heat transfer fluid in the evaporator heat exchanger.
Description
Seven types of control rules can be set. They are defined using the menu 3112.
•If 3112 = Started .........................CLIMATICTM 50 does not control the pumps
•If 3112 = Stopped, ......................Pumps are stopped.
•If 3112 = P1 Only .........................CLIMATICTM 50 Control only runs pump n°1.
•If 3112 = P2 Only ........................CLIMATICTM 50 Control only runs pump n°2.
•If 3112 P1N P2S ..........................CLIMATICTM 50 Control handles both pumps with
N°1 as standard and N° 2 as backup.
•If 3112 = P2N P1S ......................CLIMATICTM 50 Control handles both pumps with
N°2 as standard and N° 1 as backup.
•If 3112 – Clock .............................CLIMATIC™ 50 control handles both pumps equalizing running
times and switching from one pump to the other every Tuesday at
18h00.
Pump operation can be set by changing the variable 3112 on the DS50 Service Display
Pump N°1 is running if all of the following conditions are met :
ÖAt least one ON/OFF of circuit “n” is ON
ÖUnit remote ON/OFF is ON *
ÖNOT in the unoccupied zone*
ÖSet point 3112 is not set to “External” or “Stopped”
ÖPump has been stopped for 1 minute or is already running.
ÖThere is no electrical fault on the pump
ÖThere is to « flow rate » fault
* These conditions are ignored if the outdoor temperature is below set point 3341 + 1°C, in order to prevent
the water from freezing.
A pump can be controlled by the CLIMATICTM50 even if electrically the network pump is not handled by the
refrigeration unit.
In the case where the customer is handling the control of his own pump, the following procedure must be
followed :
Start the pump at least 1 minute before validating the remote ON/OFF switch operation.
Switch off the pump 2 minutes at least after the remote ON/OFF switch has gone to 0.

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In the case of double pumps
The pump N°k is running if all of the following conditions are met:
ÖThe conditions detailed above for the single pump must be met for the pump k
ÖIn the case of forced operation, pump N°k is running (set point 3112 is set to “P1 Only” for pump N°1 and
“P2 Only” for Pump N°2)
ÖWhen running « Standard/Backup » Operation, pump N°k has priority (Set point 3112 set to “P1NP2S” for
Pump N°1 and “P2NP1S” for pump N°2).
ÖIn the case of “equalized run time” operation the running time of pump N°k is the smallest
In case of a fault on a pump when the set point 3112 is set to « P1NP2S », « P2NP1S » or « Clock », the
second pump, if available, will automatically start.
NOTE:CLIMATICTM 50 control only stops the pumps 2 minutes at least after the request to switch the
whole unit OFF has been given, in order to prevent any risks of freezing the evaporator heat
exchanger.

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THERMOSTAT – Set point calculation
Function
Set the chilled or hot water circuit temperature, depending on the outdoor conditions in order to optimise the
energy consumption.
Description
Calculation of the chilled water set point :
Calculation of the chilled water set point:
²
THERMOSTAT - Control principle
Outdoor
Temperature
3321
10°C
3322
7°C
Values are given for indications only.
Gradient can be positive or negative.
Values are given for indications only.
Gradient can be positive or negative.
3323
22°C
3324
30°C
Calculated
Set Point
Calculated
Set Point
3331
40°C
3332
30°C
3334
0°C
3333
19°C
Outdoor
Temperature

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Water Outlet Temperature
Change Rate
+ 2°C
Function
Adjust and hold the fluid outlet temperature as close as possible to the set point, by controlling the number of
compressor stages depending on the thermal load on the system.
Description
CLIMATICTM50 control constantly calculates the required capacity to reach the temperature set point.
This variable is called “CAPACITY FACTOR” (CF) and its value can vary from 0 to 100%.
It is directly linked to the number of control stages of the unit.
i.e.: For ecologic WA 230D K STD with 6 control stages, the CF will start and stop a stage at the following
values:0-17-33-50-67-83-100
It then evolves following the principles detailed in the diagram below (This applies to a chiller):
In any Cases, for a chiller, if the Low Water temperature limit is reached, Compressors are stopped.
In order to anticipate, the reference point is recalculated each time the difference between water temperature
and set point reach a minimum or a maximum.
The rate of change of the Capacity Factor (CF) is determined by another parameter called “REACTIVTY”
and which value is in:
% of CF / °C (Diff vs Set point) /min
REACTIVITY for Cooling Mode can be adjusted in menu 3325
REACTIVITY for Heating Mode can be adjusted in menu 3335
0°K
+ 2°K
- 1°K
- 2°K
FAST SLOW SLOW FAST
Zone
CF FROZEN
CF INCREASES
(Start more
Capacity Stages)
CF FROZEN
CF DECREASES
(Removes
Capacity Stages)
A
A
+ 1°K
Difference
between
Water outlet
Temperature
and SET POINT

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COMPRESSOR CONTROL
Function
Compressor stages are started and stopped in a pre-determined order which minimized the effect of the
« anti- short cycle protection and equalized running time.
Description
)Compressor Starting and Stopping Sequences
This Sequence is determined by the calculated compressor running time. This control also includes the
automatic and instantaneous back up of a compressor by another one if it becomes unavailable.
)Starting and Stopping Compressors
Compressor XXX starts if all the following conditions are met :
Ö The water circulation pump has been running for at least 1 minute.
Ö Remote ON/OFF switch for the complete unit is ON
Ö The ON/OFF control for the considered circuit is ON
Ö The unit, the compressor and the circuit do not have any “Majors Alarm” ON
Ö The control requires the start-up of a compressor.
Ö XXX is the compressor with the lowest run time amongst the stopped compressor. To see the run times
for each compressor refer to menu: 2419, 2429….2469
Ö Compressor XXX was not started for at least 6 minutes. The state of each compressor can be checked in
the following menu: 2412, 2422, 2432…, 2462

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HIGH PRESSURE UNLOADING
Function
Reduce the capacity of a refrigeration circuit before the HP cut out is reached
Description
High Pressure Unloading consists in reducing the variable capacity on a screw compressor, or to stop one
compressor on units fitted with tandems or trios.
)Activation of High Pressure Unloading
If High Pressure is over 22 bars and carries on increasing as all the fans are running full speed, one
compressor is stopped, or one stage of capacity reduction is activated on the affected circuit.
High Pressure Unloading is controlled as an additional virtual ventilation stage while the HP is over 22 bars.
See explanation in the fan control section.

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DEFROST – Heat Pump
Function
Avoid the ice on the Evaporator while the reversible unit works in winter operation
Description
To avoid the icing of the external air exchanger in winter operation, it is necessary to reverse the refrigerant
cycle on a regular basis to de-ice by heating the exchanger.
The defrost is activated when the air temperature is under a set point (3432) and the LP is lower than a set point
(3433)
While defrost is demanded, the defrost cycle is as following:
1. Stop compressor and fans
2. wait 5s
3. reverse 4 way valve
4. wait 5s
5. start compressor
6. When HP reach 22b or compressor are running for more than 4 minutes, stop compressor
7. wait 5s
8. reverse 4way valve
9. start fans at full speed in order to dry the exchanger for a period that can be adjusted with
set point 3435.
10. end of defrost
Two different type of Defrost demand are possible:
•Dynamic defrost (set point 3431 = 0)
•Cycling defrost (set point 3431 = 1)

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Dynamic defrost
This allows the unit to start the defrost cycle only when required. This is achieved through the measurement of the temperature
difference between the coil and the outdoor. The defrost will be initiated shortly after the Climatic50 has located the largest
gradient in the curve.
Cycling defrost
The unit will start a defrost cycle with a regular time period (set point 3434)
Defrost parameters summary:
3431 ÆDefrost mode: 0: dynamic – 1: cycling
3432 ÆOutside air temperature under which the defrost cycle is activated
3433 ÆLP temperature under which the defrost cycle is activated.
3434 ÆFor the dynamic defrost the unit will run this minimum amount of time. For cycling defrost, this is the time
delay to start the defrost once the temperature conditions are met
3435 ÆFan running time after the defrost cycle in order to dry the exchanger.
Temperature difference
between coil and
outdoor Coil
clean
Coil freezing Coil
frozen
Defrost cycle start
Highest gradient
Time