Lennox CLIMATIC 60 User manual

CLIMATIC™ 60
9 - 1000 kW
ECOLEAN™
NEOSYS™
User manual
CL60 AC-CHILLER-IOM-1011-E
Air cooled chiller

• 1 •
CLIMATIC™ 60
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CL60-AC CHILLER-IOM-1011-E
CONTROL MANUAL Ref : CL60-AC CHILLER-IOM-1011-E
TABLE OF CONTENTS
AIR COOLED CHILLER
INTRODUCTION
CLIMATIC™ 60 controller
Compatibility
Warning
OVERVIEW
Compressor
Condenser fan
Fan SMART ACOUSTIC SYSTEM™
Water evaporator
Changeover heating/cooling mode
Coil defrost
Free cooling
Electronic expansion valve
Electrical heater
Power factor corrector
Pump evaporator management
Pump evaporator flow control
Pump condenser management
Pump condenser flow control
Free input/output
ON/OFF control
Real time lock
Scheduling zone
Scheduling mode
Schedule anticipation start-up
COMMUNICATION
Master / slave
DS60 display
DC60 advanced display or DS60 display
DC60 list
BMS
Alarms
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 utilised (except in operation of this product), reproduced, issued to or made available to third
parties without the prior written agreement of Lennox.

• 2 • CL60-AC CHILLER-IOM-1011-E
INTRODUCTION
OVERVIEW
CLIMATIC™ 60 CONTROLLER
The new generation of microprocessor based control, CLIMATIC™ 60 may be fitted to the LENNOX chiller or heat pump range. It inherits
20 years of technology and field operating experience from its predecessors the CLIMATIC™ 1, CLIMATIC™ 2 and CLIMATIC™ 50.
LENNOX has found the latest hardware technology available on the market place and developed software specifically designed for
chiller and heat pump applications, maximising the LENNOX unit’s efficiency and performance.
COMPATIBILITY
This documentation is compatible with the chiller and heat pump range's programs from software version CH060 STD - Vers. 01.0 -
Rev 00.1:
• ECOLEAN™,
• NEOSYS™.
•
•
•
WARNING
Any parameter modification should be carried out by trained and licensed competent technician. Before start-up or restart of a unit
controlled by the CLIMATIC™ 60, it is mandatory to check adequacy between CLIMATIC™ 60 and the unit with its options. In case
of wrong parameters, the inputs / outputs connections could be incorrect and may create some operation problems for the units and
ultimately breakdowns. LENNOX cannot be held responsible for any claims on the units due to a wrong parameters sequence or a
parameters modification carried out by non competent technicians. In this case, the warranty will be legally null and void.
pLan bus Fieldbus bus
BMS bus

• 3 •
1
1
1
1
1
1
1
1
2
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3
3
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2
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3
12h/24h
6h
9h 3h
12h/24h
18h
21h 15h
1, ., .
., 2, .
1, 2, .
., ., 3
1, ., 3
., 2, 3
1, 2, 3
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
COMPRESSOR
Function
The CLIMATIC™ 60 manages the compressor(s) according to the outlet temperature demand and engages the number of compressor
calculated to reach the water set point.
Description
The CLIMATIC™ 60 offers possibilities to disable some compressor(s) on the circuit. Note this opportunity can also be done by dry
contact (Refer to the “Free input/output” paragraph).
The compressors allowed to run can be pre-specified according to the scheduling and can take different values for each schedule
mode (A, B, C, D, and BMS).
Setting
(3421)
Compressor on circuit
(case od 2 circuits)
NO
Moreover, the circuit priority can be specified (for units with 2 circuits)
“Auto”:
The CLIMATIC™ 60 decides the priority of the circuit which starts first. Note that the priority is swapped when all the compressors are
stopped in order to optimise the operating hours of the two circuits.
C Mode
C1: 1,2,3
C2: 1,2,3 A Mode
C1: 1,.,.
C2: 1,.,.
C Mode
C1: 1,2,3
C2: 1,2,3
B Mode
C1: 1,2,.
C2: 1,2,.
B Mode
C1: 1,2,.
C2: 1,2,.
D Mode
C1: .,.,3
C2: .,.,3
D Mode
C1: .,.,3
C2: .,.,3

• 4 •
(3331):
(3332):
(3335):
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
The compressor is subject to various operating time in order to prevent from damage operating.
• The minimum ON time of the compressor is fixed to 1 minute,
• The minimum OFF time of the compressor is fixed to 1 minute,
• The minimum between 2 starts of the same compressor is fixed to 5 minutes.
Compressor demand
Compressor demand
Compressor demand
Compressor output
Compressor output
Compressor output
Settings
The different settings to configure the compressors are available in the menu:
“Priority C1”:
The priority is fixed to circuit 1, which means circuit 1 starts first and stops the last.
“Priority C2”:
The priority is fixed to circuit 2, which means circuit 2 starts first and stops the last.
Enable of the compressor(s) on circuit 1
Enable of the compressor(s) on circuit 2
Priority of the circuit rotation.

• 5 •CL60-AC CHILLER-IOM-1011-E
COMPONENTS
CONDENSER FAN
Function
The CLIMATIC™ 60 is used to maintain the high pressure as stable as possible in order to increase the performance of the unit.
Description
The CLIMATIC™ 60 has 2 different fan managements according to the type of unit:
ECOLEAN™ (without fan speed inverter)
The CLIMATIC™ 60 manages 2 speeds on the fan (low and high speed).
NEOSYS™ standard unit (standard version without fan speed inverter)
The condensing temperature is reached according to the set point selected in the menu (3546). The fans are managed individually
except for the fans which are common for the two circuits.
In order to optimise the reactivity of the system at the startup of the circuit, an anticipation of the fan(s) is forced during the first 30s
according to the outside air temperature.
Example: Case of unit with 4 condenser fans.
Outside air temperature (°C
Stopped
Stopped
HP pressure (Bar)
Low speed
Low speed
High speed
High speed
Cooling mode
Heating mode
Outside air temperature (°C)
Compressor pressure demand (%)
Fan anticipation (%)
Fan stages

• 6 •
(3546):
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
Time
Temperature HP (°C)
Fan capacity (%)
Condensing set point
Settings
The different settings to adjust the condensing control are available in the menu:
NEOSYS™ (with fan speed inverter)
A fan inverter controlled by a PID algorithm is used to adjust the fans speed variation. Fan's startup anticipation is forced as for the
NEOSYS™ standard unit.
In order to optimise the performance of the unit, the condensing temperature is set according to outside air temperature and tries to
maintain a delta of 12°C (only for unit with electrionic expansion valve).
Note: this functionality can be disabled if the selected setting (3546) is different from the factory value. In this case the condensing
set point is the new selected value.
Outside air temperature (°C)
Set point = ext T° 12.0°C
Condensing set point (°C)
Condensing set point temperature.

• 7 •CL60-AC CHILLER-IOM-1011-E
COMPONENTS
FAN SMART ACOUSTIC SYSTEM™
Function
The CLIMATIC™ 60 controls the fan speed limited by the Smart Acoustic System™ which allows progressive adaptation of the unit
to the building load while respecting the noise level constraints and the operating limits.
Description
The maximum sound level and the fan strategies can be adjusted according to the schedule mode in order to benefit from the different
modes “High performance”, “Quiet” and “Quiet++” operation as well as in heating or cooling mode.
The acoustic mode offers 2 possibilities to manage the condenser fan:
Quiet”
In this mode, the fan capacity is limited according to the desired sound level. For fan using low / high speed, the high speed is locked. In
case of condensing temperature too high, the CLIMATIC™ 60 unlocks the limit or the high speed to prevent from unloading compressor.
Outside air temperature (°C
Outside air temperature (°C
Stopped
Stopped
HP pressure (Bar)
Low speed
Low speed
High speed
High speed
Cooling mode
Heating mode
Fan speed (%)
Maximum = (3545)
Maximum = (3545)
Fan capacity (%)
Maximum = 100%
Maximum = 100%
Temperature HP (°C)
(3546) Condensing set point
(3442) Unloading set point
Cooling mode
Heating mode

• 8 •
12h/24h
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9h 3h
12h/24h
18h
21h 15h
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
“Quiet++”
This mode is similar to the “Quiet” mode except that the fan speed limit or the high speed is never unlocked. In case of condensing
temperature too high, the CLIMATIC™ 60 will unload a compressor to prevent from high pressure security.
The Smart Acoustic System™ can be adjusted according to the scheduling and can take different values for each schedule mode (A,
B, C, D, and BMS).
Outside air temperature (°C
Stopped
Stopped
HP pressure (Bar)
Low speed
Low speed
High speed
High speed
Cooling mode
Heating mode
Fan speed (%)
Maximum = (3545)
Maximum = (3545)
Fan capacity (%)
Maximum = 100%
Maximum = 100%
Temperature HP (°C)
Compressor unloading
(3546) Condensing set point
(3442) Unloading set point
Cooling mode
Heating mode
C Mode
Quiet
A Mode
Quiet+
C Mode
Not Set
B Mode
Not Set
B Mode
Quiet
D Mode
Quiet+
D Mode
Quiet

• 9 •
12h/24h
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9h 3h
12h/24h
18h
21h 15h
(3544):
(3545):
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
C Mode
86dBA
A Mode
84dBA
C Mode
89dBA
B Mode
89dBA
B Mode
86dBA
D Mode
84dBA
D Mode
Quiet
Settings
The different settings to adjust the acoustic mode are available in the menu:
Acoustic mode
Maximum sound level noise (except for fan with low / high speed)

• 10 •
12h/24h
6h
9h 3h
12h/24h
18h
21h 15h
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
WATER EVAPORATOR
Function
The CLIMATIC™ 60 controls the chilled or heat temperature according to the specifed set point. The desired set point can be set by
different solutions.
Description
The CLIMATIC™ 60 offers various possibilities to specify the water evaporator set point.
Dynamic value
The CLIMATIC™ 60 determines the appropriate water set point according to the outside temperature in order to optimise the energy
consumption. This method requires to pre-define 2 different water set points corresponding to 2 outside temperatures.
Fix value
In this case the outside temperature has no effect on the water set point and the two set points must be set at the same value.
The cooling and heating set points can be pre-specified according to the scheduling and can take different mode for each schedule
mode (Night, Day, Day A, Day B, and BMS)
Outside air
temperature (°C)
Outside air
temperature (°C)
Outside air
temperature (°C)
Outside air
temperature (°C)
Cooling set point (°C)
Cooling set point (°C)
Heating set point (°C)
Heating set point (°C)
Mode
Day A
07.0°C Night
Mode
13.0°C
Mode
Day A
07.0°C
Mode
Day B
07.0°C
Mode
Day
07.0°C
Night
Mode
13.0°C
Mode
Day A
09.0°C

• 11 •CL60-AC CHILLER-IOM-1011-E
External current 4/20mA signal
In this case the actual set point is calculated according to the analog input current. The set points specify the corresponding set point
for 4mA and for 20mA.
Current input signal
4/20 mA
Current input signal
4/20 mA
Cooling set point (°C) Heating set point (°C)
COMPONENTS
Second external set point
In this case the actual set point is specifed by one of the two set points. The final set point depends on the status of the digital dry
contact allocated to this function.
External current 4/20 mA offset
In this case the set point is set by one of the previous solution and can be adjusted with an offset of +/- 1.0°C.
Digital input contact
Current inpu signal
4/20 mA
Outside air
temperature (°C)
Current inpu signal
4/20 mA
Cooling set point (°C)
Open Open
Closed Closed
Cooling set point (°C)
Actual set point Actual set point
Heating set point (°C)
Heating set point (°C)

• 12 • CL60-AC CHILLER-IOM-1011-E
COMPONENTS
DC60 terminal
The water set point is adjustable directly by the DC60. If the read set point is different from the one calculated by the BM60, the
new set point is set by the DC60 during the actual zone. Each time the zone is changing, the DC60 set point is overwriten by the
CLIMATICTM60 set point.
BMS value
The CLIMATIC™ 60 receives the water set point from the BMS. Refers to the “BMS” paragraph for more details.
Settings
The different settings to adjust the water evaporator set points are available in the menu:
Cooling mode
• (2236) or (3236): minimum outside air temperature corresponding to the water evaporator set point (3238) (used only for dynamic
set point),
• (2237) or (3237): maximum outside air temperature corresponding to the water evaporator set point (3239) (used only for dynamic
set point),
• (2238) or (3238):
* Dynamic set point: desired water evaporator temperature set point corresponding to outside air temperature (2236) or (3236),
* Fix set point: desired water evaporator temperature set point.
* External current 4/20 mA signal: water evaporator temperature set point corresponding to a current signal of 4 mA.
* Second external set point: first water evaporator temperature set point corresponding to an opened dry contact.
• (2239) or (3239):
* Dynamic set point: desired water evaporator temperature set point corresponding to outside air temperature (2237) or (3237),
* Fix set point: desired water evaporator temperature set point.
* External current 4/20 mA signal: water evaporator temperature set point corresponding to a current signal of 20 mA.
* Second external set point: second water evaporator temperature set point corresponding to a closed dry contact.
Heating mode
• (2246) or(3246): minimum outside air temperature corresponding to the water evaporator set point (3248) (used only for dynamic
set point),
• (2247) or (3247): maximum outside air temperature corresponding to the water evaporator set point (3249) (used only for dynamic
set point),
• (2248) or (3248):
* Dynamic set point: desired water evaporator temperature set point corresponding to outside air temperature (2246) or (3246),
* Fix set point: desired water evaporator temperature set point.
* External current 4/20mA signal: water evaporator temperature set point corresponding to a current signal of 4 mA.
* First external set point: first water evaporator temperature set point corresponding to an opened dry contact.
• (2249) or (3249):
* Dynamic set point: desired water evaporator temperature set point corresponding to outside air temperature (2247) or (3247),
* Fix set point: desired water evaporator temperature set point.
* External current 4/20mA signal: water evaporator temperature set point corresponding to a current signal of 20 mA.
* Second external set point: second water evaporator temperature set point corresponding to a closed dry contact.

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00 0 0
1 8.54 30.8 7.0 + 30.8*5.0/100
2 10.80 61.6 7.0 + 2*30.8*5.0/100
3 11.04 80.8 7.0 + (19.2+2*30.8)*5.0/100
4 12.00 100.0 7.0 + 2*(19.2+30.8)*5.0/100
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
Control
The CLIMATIC™ 60 adjusts and holds the fluid outlet temperature as close as possible to the set point, by controlling the number of
compressor stages depending on the thermal load of the system. The controller 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. Thus for a unit with 4 stages of regulation, the CF will start and stop a stage with the following
values: ~0-25-50-75-100%. It then evolves following the principles detailed in the diagram.
In order to anticipate, the reference point is recalculated each time the difference between air temperature and set point reaches a
minimum or a maximum.
Moreover the inlet temperature is used to limit the capacity factor to prevent from too slow reactivity of outlet capacity factor of the unit.
Example:
• Unit EAC 2104: cooling capacity: 210KW with:
* C1.Cp1 = 19.2%,
* C1.Cp2 = 30.8%,
* C2.Cp1 = 19.2%,
* C2.Cp2 = 30.8%.
• Maximum delta T° (inlet - outlet) at full load: setting (3261) = 5.0°C.
• Outlet water evaporator temperature set point: setting (3238) = (3239) = 7.0°C.
Difference between the outlet
water temperature and the
set point
Water temperature
can change
CF FROZEN
CF FROZEN
FAST SLOW SLOW FAST
CF INCREASES
(starts more capacity stages)
CF DECREASES
(removes capacity stages)
Stage Minimum inlet
temp. (°C)
Maximum
capacity factor
(%) Expression Compressor
ON circuit 1 Compressor ON circuit 2

• 14 •
12h/24h
6h
9h 3h
12h/24h
18h
21h 15h
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
CHANGEOVER HEATING/COOLING MODE
Function
The CLIMATIC™ 60 controls the changeover mode (for reversible units only) to specify the appropriate demand on heat or chilled
water production.
Description
The changeover can also be pre-specified according to the scheduling and can take different mode for each schedule mode (A, B,
C, D, and BMS).
The changeover mode can be set by different solutions:
Automatically:
The CLIMATIC™ 60 determines the appropriate production of water according to the outside temperature and moves automatically
the unit from cooling to heating mode and heating to cooling mode.
If the outside temperature is below the setting value (2225) or (3225), the unit will operate as a heat pump.
If the outside temperature is over the setting value (2226) or (3226), the unit will operate as a chiller.
Manually:
The changeover mode is forced for each schedule mode. The various modes available are “Cool” mode, “Heat” mode or "Dead zone".
In this case the outside temperature has not effect on the changeover mode.
Remotely:
The changeover mode is set according to a remote dry contact connect on a free custom digital input. In this case the unit swaps in
cooling or heating mode according to the status of the digital input. Please refer to the paragraph “Free Input / Output” for more details.
C Mode
Auto
A Mode
Dead zone
C Mode
Cool
B Mode
Cool
B Mode
Heat
D Mode
Heat
D Mode
Auto
Changeover mode
Heating mode
Dead zone
Cooling mode
Outdoor temperature (°C)

• 15 •CL60-AC CHILLER-IOM-1011-E
Terminal DC60:
The changeover mode (cool / heat) can be modified by the terminal DC60 by pressing the “mode” button.
When the “Auto” mode is selected, the icon “Cool” or “Heat” is displayed to signal the actual operating mode. Due to communication
delay, after pressing the “mode” button it is advised to wait few seconds, the time to refresh of the icon on the display.
COMPONENTS
Heat Cool Auto Dead zone
Settings
The different settings to adjust the changeover mode are available in the menu:
• (2224) or (3224): changeover mode (Cool, Heat, Auto, Dead zone) for each schedule mode (Night, Day, Day A, Day B, and BMS).
• (2225) or (3225): minimum outside temperature to swap to heating mode. (only if (2224) or (3224)=“Auto”).
• (2226) or (3226): maximum outside temperature to swap to cooling mode. (only if (2224) or (3224)=“Auto”).

• 16 • CL60-AC CHILLER-IOM-1011-E
COMPONENTS
COIL DEFROST
Function
The CLIMATIC™ 60 manages defrost procedure to avoid ice on the evaporator coil in heating pump mode (winter season).
Description
To avoid the icing of the external air exchanger during winter operating, it’s necessary to reverse the refrigerant cycle. There are 2
defrost mode:
• cyclic mode,
• dynamic mode (not available in the software CH060 vers.01-rev.0.1).
The defrost procedure is activated if the following conditions are met during 1 minute:
• the outside air temperature is (3562),
• one of the compressor(s) on the circuit has been running for a time (3564) since the last defrost,
• the saturation temperature is (3563).
The defrost procedure is characterized by the following steps:
1. stop the compressors on the concerned circuit,
2. wait for 30 s to equalise the pressure in the circuit,
3. start all compressors on the circuit (if the outlet T° is not too low),
4. reverse the reversing valve when P>2 bars,
5. start all condenser fans when the HP 55.0°C in order to dry the coil,
6. stop all condenser fans when the HP 40.0°C,
7. repeat the steps 4. to 5. 3 times,
8. stop the compressors on the concerning circuit,
9. wait for 1 min to equalise the pressure in the circuit,
10. end of procedure; restart the unit in heating mode.
11. reverse the reversing valve when P>2bar.
Note
• In case of alarm on the circuit during the defrost procedure, the defrosting is cancelled.
• If the HP pressure doesn’t reach 55°C after 6 min, during the step 6, the defrost procedure is cancelled.
• During the step 4 the compressor(s) could not start in order to not decrease too much the water temperature of the system.
Settings
The different settings to adjust the defrosting procedure are available in the menu:
• (3561): defrost mode (cyclic, dynamic),
• (3562): minimum of outside air temperature to enable defrost procedure,
• (3563): critical saturation temperature to enable defrost procedure
• (3564): minimum of interval time to enable defrost procedure.
Outlet water temperature (°C)
Compressor in defrost

• 17 •
(3164):
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
FREE COOLING
Function
The freecooling option ensures to reduce the electrical consumption using the outside air temperature to produce cool water.
Description
The freecooling uses water coil with helicoids fans controled by the CLIMATIC™ 60. The freecooling has a higher priority face to the
compressors. Once the freecooling capacity is over 95% for 2 min, the compressors can be engaged if necessary in order to reach
the cooling set point. If the freecooling capacity decreases below 90%, the capacity factor of the compressor(s) capacity is locked to
give the priority to the freecooling.
The freecooling is enabled if the following conditions are met:
• the unit is ready (On/Off, water flow, none alarm, etc..),
• the freecooling fan driver is operating (none alarm)
• outside temperature < (Inlet temperature – 3°C).
Settings
The setting to configure the freecooling option is available in the menu:
Configuration of the freecooling option.

• 18 •
(2224):
CL60-AC CHILLER-IOM-1011-E
COMPONENTS
ELECTRONIC EXPANSION VALVE
Function
The electronic expansion valve (EEV) option offers higher efficient control of the superheating temperature.
Description
The electronic expansion valve is driven by an external board (Electronic Valve Driver - EVD) which includes a PID algorithm to control
the superheating. The EVD is linked to the CLIMATIC™ 60 to send data like capacity, step, pressure, temperature.
Settings
The setting to adjust superheat temperature option is available in the menu:
Note: the modification of the superheating set point is taken in account at the next startup of the circuit.
Superheat set point.