Lennox ECOLOGIC Series Instruction manual

INSTALLATION -
OPERATING &
MAINTENANCE MANUAL
AIRCOOLED
CHILLERS
English/01-2005
Библиотека СОК 

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 1 •
AIR COOLED CHILLERS AND SPLIT UNITS
INSTALLATION
OPERATION
MAINTENANCE MANUAL
TABLE OF CONTENTS
Ref : CHILLERS_IOM-0105-E
ProductdesignedandmanufacturedunderaqualitymanagementsystemcertifiedtoAFAQISO9001
by AFAQ,
Our products comply with the European standards,
OurcompanyisamemberoftheEuroventCertificationProgramme,allLENNOXchillersaretested
and rated in accordance with Eurovent certification program,
LENNOX have been providing environmental solutions since 1895, our range of air cooledchillerscontinues to meet the standards
that have made LENNOX a household name. Flexible design solutions to meet YOUR needs and uncompromising attention to
detail. Engineered to last, simple to maintain and Quality that comes as standard. Information on local contacts at
www.lennoxeurope.com.
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.
The present manual applies to the following CHILLERs versions :
ECOLOGIC range : WA - WAH - RA
ECOMAX range : LCH - LCB
MCC range
MCB range

• 2 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 3 •
TABLE OF CONTENTS
1 - PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PED Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 - WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 - INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 - Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 - Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 - Lay-out and installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 - Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 - Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 - Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 - Connections of split units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 - Ducted units installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 - PRELIMINARYCHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 - Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 - Refrigeration circuit checks and recommendations . . . . . . . . . . . . . . . . . . . . 18
4.3 - Hydraulic system installation ckecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 - Installation of external hydraulic components (supplied loose by LENNOX) . 18
4.5 - Check list before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 - UNIT START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 - Checks to be made during start-up
5.2 - Oil charge
5.3 - Refrigerant charge
6 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 - CLIMATIC™ control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 - Unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 - Weekly maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 - Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3 - Cleaning the condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4 - Compressor oil drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.5 - Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 TROUBLESHOOTING - REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 List of the most common problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.3 Operation and start-up check sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.4 Regular checks to be made - Chiller unit environment. . . . . . . . . . . . . . . . . . . 41
8.5 Manufacturer’s recommended inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ANNEXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

• 4 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
PREFACE
1 - PREFACE
You must read and be familiar with this operating manual prior to commission the chiller.
Please closely follow the instructions.
Wewouldliketostresstheimportanceoftrainingwithrespecttothecorrecthandlingofthechiller.Please
consult Lennox on the options available in this field.
It is important that this manual be stored in a permanent location in the vicinity of the chiller.
Text Important general instruction
Danger of Injury or damage to the chiller
This manual contains important instructions regarding the commissioning of the chiller. It also includes important
instructions to prevent personal injury and damage to the machine during operation. Furthermore, in order to
promote fault-free operation of the chiller, maintenance information has been included.
Please do not hesitate to contact one of our employees should you require further information on specific chiller
subjects.
Order related documentation will be forwarded under separate cover.
This documentation consists of :
- CE declaration.
- Operating manual for control system.
- Installation Operating manual
- Wiring diagram.
- Refrigerant flow diagram (except for WA-RA-WAH-LCH)
- 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
latermodifications.We reserve therighttomodify the construction and/ordesignofour chillers, atanytime,without
prior notification or obligation to adapt previous supplies accordingly.
Any work on the Chiller should be carried out by trained and licenced 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.
It is expected that all works on equipment be carried out in accordance with all local standards and norms.
It is expected that all worls are carried out with good working practices.

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 5 •
PED DECLARATION
All Units are compliant with the PED directive 97-23-CE.
The following note must be followed carefully
IMPORTANT NOTICE
All work on the unit must be carried out by a qualified and authorised employee.
Non-compliance with the following instructions may result in injury or serious accidents.
Work on the unit :
. 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 authorisation.
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 suitable equipment.
. To prevent 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 pressure side.
. The brazing shall be carried out by a qualified brazer. The brazing shall comply with the standard NF
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, to the exclusion of all other
products (mix of coolants, hydrocarbons, etc.).
CAUTION :
In the event of fire, refrigerating circuits can cause an explosion and spray coolant gas and oil.

• 6 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
WARRANTY
2 - WARRANTY
The warranty of the chillers is subject to the warranty definitions as agreed upon in the order.
It is expected that the design and installation of the unit utilises good working practices.
The warranty will be legally 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.
-Theequipmentis beingusedimproperly,incorrectly, negligentlyornotin accordancewithitsnatureand/
or purpose.
-A flow protection device is not fitted.
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.
2.1 - 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 air cooled chillers, heat is being transported by a pressurised refrigerant, with changes in pressure and
temperature. Fans have been provided to discharge heat into the environment. The protection of operating and
maintenance personnel was central in the design of the air cooled 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. The fans are equipped with protective grids and the electrical control panel is completely touch-proof.
Thisexcludessomepartsoperatingatasafevoltage(<50Volt).Theservicepanelscanonlybeopenedusingtools.
Notwithstanding that the air cooled chillers 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 air cooled chillers. Operations on the
cooling circuit or electrical equipment should be carried out by authorised personnel.
2.1.1 - Safety Definition
The air cooled chillers meet the following safety definitions:
- Pr-EN-378-1.
- EU Directive 89/392/EG ("Machine Directive").
- EN-60204-1.
- "EMC Directive".
- Pressure Equipment Directive 97/23/CE.
And is provided with CE markings.(on the condition that the necessary options are present) (for further information
see II-A declaration).
2.1.2 - Warning labels
The chiller is marked with the following warning labels to alert to potential hazards (on or near the potentially
hazardous part).
Check regularly that the warning labels are still in the correct positions on the machine and replace them if
necessary.
High temperatures Electrical
voltage Rotating
parts Sharp parts

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 7 •
INSTALLATION - TRANSPORT - HANDLING
3. INSTALLATION
3.1 - Transport - Handling
3.1.1 - Controls and delivery checks
On receipt of a new equipment please check the following points. It is the customer’s responsibility to ensure that
the products are in good working order (fill the check list page 48):
- 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).
Acopy of the lettermust be addressedto LENNOX andthesupplier or distributorfor 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.
3.1.1.1 : 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 +10/-10 %.
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 the year of
manufacture as well as the type of refrigerant used and the required charge for each compressor circuit.
3.1.2 - Storage

• 8 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
When units are delivered on site they are not always required immediately and are sometimes put into storage. In
the event of medium to long-term storage, we recommend the following procedures :
- Ensure that there is no water in the hydraulic systems.
- Keep the heat exchanger covers in position.
- Keep protective plastic film in position.
- Ensure the electrical panels are closed.
- Keep all items and options supplied in a dry and clean place for future assembly before using the equipment.
Itisstronglyrecommendedtostoreunitsisadry,shelteredplace(inparticularforunitsthatwillbeinstalled
indoors).
3.2 - LIFTING THE UNIT
3.2.1 - Safety instructions
Installation, start up and adjustment of this equipment can be dangerous if certain system specific factors are
ignored,suchasoperatingpressures,electricalcomponents,locations(roofs,terracesandotherstructureslocated
well above ground level).
Only highly qualified contractors and technicians with sound knowledge of this type of equipment, are authorised
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
-Handleheavy orbulkyequipment carefullyduringliftingand movingoperations,andwhen settingiton theground.
CAUTION: BEFORE EACHSERVICE OPERATION MAKESURE THAT THEUNITPOWER 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.
3.2.2 - Handling
Handling operations must be carried out by qualified personnel. Comply strictly with lifting instruction pasted on the
unit. Unit handling operations must be carried out carefully to avoid jolting the frame, the panels, the electrical box,
the condenser coil fins, etc....
NOTE :
Theheat exchangers ofthe condenserscould beprotectedfrom damageduring transportbyplastic 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!).
NOTE :
Rubber anti-vibrations mountings (AVM) & factory accessories are to be found in the control panel for
shipping. If the unit is mounted on anti-vibration mountings, these should be fitted to the unit before final
positioning.
INSTALLATION - TRANSPORT - HANDLING

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 9 •
INSTALLATION - TRANSPORT - HANDLING
3.3 - LAY-OUT AND INSTALLATION REQUIREMENTS
The following preparations are important for the installation of the chiller :
- Air-cooledchillerssuch asEcologicorEcomax aredesigned foroutdoorinstallation. PleaseconsultLennoxprior
to implementing other types of installation.
- Locate the chiller where it is least 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.
Inlocationsexposedtofrost,thesupportingsurface,iftheunitisinstalledontheground,mustbebuiltonconcrete
stakesextendingdownwardsbeyondthenormaldepthoffrost.Itisalwaysadvisabletobuildasupportingsurface
detached from the general building structure to avoid transmission of vibrations.
- On normal applications, unit rigidity and point load positions enable installation to minimise 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 fixed to the unit BEFORE being fixed 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 fixed 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 isolators seat flatly on the supporting surface.
- It is essential that the units be installed with sufficient free space around them to enable proper circulation of air
ejected by the condensers and to provide easy access to all unit components for servicing and maintenance. 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.
- To prevent air flow to be reversed due to prevaling winds, units cannot be completely shrouded with a higher,
uninterrupted wind shield. If such a configuration cannot be avoided, an air ejection duct must be installed at the
same height as the surrounding shield.
It is important that units must be leveled failure to install unit correctly will void warranty.

• 10 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
INSTALLATION - TRANSPORT - HANDLING
3.4 - WATER CONNECTIONS
3.4.1 - Water connections - Evaporator/Condenser
Thewatercirculatingpumpwill be preferably installed upstream so that the evaporator/condenserwillbesubjected
topositive pressure.Enteringand leavingwaterconnections areindicatedonthecertified drawingsentwith theunit
or shown in the sales brochure.
For shell and tube heat exchangers, a drainage plug is located at the base of the evaporator. A drainage pipe may
be connected to this to enable drainage of evaporator water for service operations or for seasonal shut down.
Theuse of awaterfilterin the watercircuitupstreamof the heatexchangerismandatory. Thesefiltersmustremove
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 Annexes page 50 to 54, or supplied with the unit.
3.4.2 - Water analysis
Thewatermustbeanalysed;thewatercircuitinstalledmustincludeallitemsnecessaryfortreatmentofthewater:filters,
additives, intermediate exchangers, bleed valves, vents, isolating valves etc... according to the results of the analysis.
We do not advise operation of the units with open loops which can cause problems with oxygenation, nor
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 brine.
CLEARANCES DRAWINGS
For more details, please consult our Application Guides or the drawings supplied with the unit.
1 m
1,5 m
1 m
1,5 m
ECOLOGIC range
1,5 m
1,5 m
1 m
1 m
ECOMAX range
OVERHEAD OBSTRUCTIONS ARE NOT PERMITTED
> 3 meters > 2 meters
Not allowed
Not recommended
For any air cooled unit, it is necessary to have a minimum distance between air coil and any obstacle of 1,5
meters.
Foranychilleraminimumdistanceof1meterisrequiredforthegoodopeningandservicingoftheelectrical
box.
> 2 meters

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 11 •
INSTALLATION - TRANSPORT - HANDLING
3.4.3 - Antifreeze protection
3.4.3.1 : Use glycol/water solution
ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZING
The glycol/water solution must be sufficiently concentrated to ensure proper protection and prevent formation of
iceatthelowest outdoorair temperaturesexpectedonaninstallation.Takeprecautionswhenusingnonpassivated
MEG antifreeze solutions (Mono Ethylene Glycol or MPG Mono Propylene Glycol). Corrosion can occur with these
antifreeze solutions with oxygen.
3.4.3.2 : 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 AN EVAPORATOR DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX
WARRANTY.
3.4.4 - Electrolytic corrosion
We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an
imbalance between earthing points.
ANEVAPORATOR THAT ISPUNCTURED BY ELECTROLYTICCORROSION ISNOTCOVERED BYTHE UNIT
WARRANTY
3.4.5 - Minimum water capacity
Theminimum volumeofthechilledwater circuitmustbe calculatedwiththeformulahere under.Ifnecessary,install
a buffer tank. Proper operation of regulating and safety devices can only be ensured if the volume of water is
sufficient.
The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formula
hereafter:
Q !Cooling capacity of the chiller in kW
N !Number of capacity stage of the chiller
Dt !Water temperature Delta T.
Vt = 72 x Q/(n x dt) litres
Example, for a chiller with 400kW, water conditions 12°C/7°C and 4 capacity stages, the minimum volume is :
Vt = 72 x 400/(5 x 4) = 1440 l.
This formula will give the minimum water capacity of the installation that will ensure a temperature rise of the water
loop of (dt/n)°C during anti short cycle of compressors.
This formula is only applicable for air-conditioning installation and must not be used for process cooling
where temperature stability is required.
3.4.6 - Flow switch
Aflowswitchmustbeinstalledontheevaporatorwaterinletoroutlet,soastoenabledetectionofwaterflowthrough
the heat exchanger before the unit is started up. This will protect the compressors against any eventual liquid
slugging during the starting phase and prevent accidental ice formation in the evaporator, if the flow of water is
interrupted.
Flow switches are available on option.
The normally open contact of the flow switch should be connected to the terminals provided to that effect in the unit
electrical box. (See the wiring diagram supplied with the unit).
The normally closed contact can be used as an indication of a lack of flow condition.
Warranty is void if a flow detection device is not fitted and connected to the LENNOX control panel.
3.5 - ELECTRICAL CONNECTIONS
First of all, make sure that power supplies from the building to the place where the unit is installed are properly
established and that wire gauges are in keeping with the start up and running currents.
Check tightness of all electrical connections.
You MUST make absolutely certain that the power supplies applied to the power and control circuits are those for
which the electrical panel was manufactured.

• 12 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
A main isolator switch must be inserted between the end of the power supply cable and the unit to enable total
isolation of the latter when necessary. Chillers are supplied as standard without a main isolator switch. This is
available as an option.
WARNING
Wiring must conformto applicable regulations.The type andlocation offusedisolators mustalso conform
with regulations. For the sake of safety, install them where they can be seen and in easy reach of the unit.
Units must have full earthing continuity.
IMPORTANT
Operation of a unit with the wrong power supply or with excessive phase imbalance constitutes abuse and
is not covered by the LENNOX warranty. If phase imbalance exceeds 2 % for voltage and 1 % for current,
contact your local electricity company immediately before powering up the unit.
3.6 - SOUND LEVELS
Liquid chillers are a significant source of noise in refrigeration and air conditioning systems.
Accountis takenoftechnical constraints,bothin designandmanufacturing,soundlevels cannotbeimproved much
further than specified.
Sound levels must therefore be accepted for what they are, and the area surrounding the chillers should be treated
as necessary. The quality of installation can either improve or decrease initial sound characteristics: it may be
necessary to provide further treatment such as sound-proofing or installation of screens around units installed
externally. The choice of the location for the installation can be of great importance : reflection, absorption,
transmission of vibrations.
The type of unit support is also very important : inertia of the room and the structure of the walling, interfere with
the installation and its behaviour.
Before taking any other steps, first determine whether the sound level is compatible or not with the environment,
what it is perfectly justifiable and that these measures envisaged will not cause unreasonable cost.
Determinewhatlevel of soundproofingisnecessary on theequipment,theinstallation (silencer, vibrationisolators,
screens) and on the building (reinforcement of flooring, false ceilings, wall coverings).
It may be necessary to contact an engineering office that specialises in sound abatement.
3.7 - CONNECTION OF SPLIT UNITS
Connections between the unit and the condenser must be made by a qualified refrigeration engineer and require
several important precautions.
In particular, the shape and dimensions of the hot gas lines must be carefully designed to ensure proper oil return
in all cases and prevent liquid from returning into the cylinder heads when the compressor is stopped.
On units fitted with capacity reducers, the piping sizes must be calculated so that gas velocity is sufficiently high
when the unit is operating on capacity reduction.
Non application of these precautions will cancel the compressor warranty.
We recommend to follow ASHRAE recommendations.
3.7.1 - Liquid line sizing
Determine the size of liquid lines using :
1) Operating conditions at full load.
2) Maximum pressure drop of 100 kPa
3) Liquid velocity under 2 m/s (to avoid liquid slugging).
4) For liquid risers, make sure that liquid subcooling is sufficient to counteract the loss of static pressure and
prevent gas flashing.
3.7.2 - Discharge lines and suction lines
Calculatetheseto obtain a gas velocityin verticalsectionsthat enables compressor oil migrationandsteadyreturn
to the compressor (tables C and D - page 15).
Determine the dimensions of vertical lines using the following tables.
Horizontal lines may be bigger in order to compensate pressure drop in vertical lines.
The total pressure drop in the piping has to be lower or equal to 1°C at saturation pressure on the suction side.
INSTALLATION - TRANSPORT - HANDLING

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 13 •
H
2
H3
H
1
1
2
UNITS WITH REMOTE CONDENSER
Unit with remote condenser
without capacity control Unit with remote condenser
with capacity control
H3
H
1
3
4
H
2
2
2
H4
3
4
H4
H1 : 15 m. maxi
H2 : 5 m. maxi
H3 : 0,3 m. maxi
H4 : 0,15 m. maxi
1 - Lower trap with single tube
2 - Clode coupled trap
3 - Lower trap with double tubes
4 - Higher trap with double tubes
If receiver option : PED declaration class 3
If no receiver option : PED declaration class 1
AA
WARNING : The liquid level between the condenser and the check valve A must compensate the check valve
pressure drop
INSTALLATION - TRANSPORT - HANDLING

• 14 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
H
2
2
H1
CONDENSING UNITS
Condensing unit
without capacity control Condensing unit
with capacity control
H1
3
4
H2
2
2
H4
3
4
H4
H1 : 15 m. maxi
H2 : 5 m. maxi
H4 : 0,15 m. maxi
1 - Lower trap with single tube
2 - Clode coupled trap
3 - Lower trap with double tubes
4 - Higher trap with double tubes
Min 0,25% gradient
Min 0,25% gradient
If receiver option : PED declaration class 3
If no receiver option : PED declaration class 1
INSTALLATION - TRANSPORT - HANDLING

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 15 •
Minimum refrigeration capacity in kW for oil entrainments up Suction risers
Refrigerant : R407C
Table C Tubing nominal OD, mm
Saturated Suction gas
temperature (°C) temperature (°C) 12 15 18 22 28 35 42 54 67 79 105 130
-5 0 0,39 0,71 1,20 2,04 3,88 6,88 11,11 21,31 36,85 55,86 115,24 199,30
10 0,37 0,68 1,14 1,94 3,68 6,53 10,54 20,20 34,94 52,95 109,25 189,14
5100,47 0,86 1,45 2,47 4,69 8,33 13,44 25,77 44,58 67,56 139,39 241,30
20 0,44 0,81 1,36 2,31 4,39 7,79 12,58 24,13 41,73 63,25 130,49 225,90
Minimum refrigeration capacity in kW for oil entrainments up HOT-Gas risers
Refrigerant : R407C
Table D Tubing nominal OD, mm
Saturated Discharge
discharge gas
temperature (°C) temperature (°C) 12 15 18 22 28 35 42 54 67 79 105 130
30 70 0,60 1,09 1,84 3,13 5,95 10,55 17,03 32,65 56,47 85,59 176,59 305,70
80 0,58 1,06 1,79 3,04 5,78 10,25 16,55 31,74 54,90 83,21 171,67 297,19
90 0,57 1,04 1,74 2,96 5,64 10,00 16,14 30,95 53,53 81,13 167,39 289,77
40 80 0,62 1,13 1,90 3,24 6,16 10,93 17,65 33,85 58,55 88,73 183,07 316,92
90 0,60 1,10 1,85 3,16 6,00 10,65 17,19 32,96 47,01 86,40 178,26 308,60
100 0,58 1,07 1,80 3,07 5,83 10,34 16,70 32,02 55,38 83,94 173,17 299,79
50 90 0,63 1,16 1,94 3,31 6,29 11,16 18,02 34,55 59,77 90,58 186,88 323,52
100 0,61 1,12 1,88 3,21 6,10 10,82 17,47 33,50 57,95 87,83 181,21 313,70
110 0,60 1,09 1,83 3,13 5,94 10,54 17,02 32,63 56,44 85,53 176,47 305,49
3.7.3 - Mechanical isolation of refrigerant lines
Isolate refrigerant lines from the building to prevent the vibrations normally generated by the lines to the building
structure.Avoid bypassingthe isolationsystemontheunit byfixingrefrigerantlinesorelectricalconduits tootightly.
Any vibrations will be transmitted to the building by rigid piping.
Lack of vibration isolation on refrigerant pipework will lead to early failure of copper pipe and loss of gas.
3.7.4 - Pressure test
To avoid formation of copper oxide during brazing operations, blow a little dry nitrogen through the pipes.
Piping must be made with tubing that is perfectly clean, plugged during storage and between connections
operations.
During these operations, observe the following precautions:
1) Do not work in a confined atmosphere, refrigerant fluid can cause asphyxiation. Make sure there is sufficient
ventilation.
2) Donotuseoxygenoracetyleneinsteadofrefrigerantfluidandnitrogenforleaktesting:thiscouldcauseaviolent
explosion.
3) Always use a regulator valve, isolating valves and a pressure gauge to control test pressure in the system.
Excessivepressurecancause lines to burst damage totheunitand/orcausean explosion with severe personal
injury.
Ensure conduct liquid line and gas line pressure tests are in conformity with applicable legislation. Before starting
up a unit on a receiver, the piping and the condenser must be dehydrated. Dehydration should be carried out using
a double stage vacuum pump, capable of drawing 600Pa absolute pressure vacuum.
Best results are obtained with a vacuum down to 100 Pa. To get down to this level at normal temperatures, i.e.
INSTALLATION - TRANSPORT - HANDLING

• 16 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
15 °C, it is often necessary to leave the pump running for 10 to 20 hours. The duration of pump operation is not a
factor of efficiency. The pressure level must be checked before the unit is put into service.
3.7.5 - Refrigerant charge
Chillers with R407C must be filled in the liquid phase. Never charge a machine operating on R407C in the vapour
phase (vapour): the composition of the mixture could be modified.
Inliquidphase,connecteithertoaliquidisolatingvalve,ortothequick-connectorontheliquidlineatthevalveoutlet.
For unit using R22, the charging may be done in vapour phase in that case, connection will be made to the suction
valve.
Note:
Splits units are supplied with a refrigerant or nitrogen holding charge. Before pulling down the vacuum for
dehydration, completely purge the unit.
Charge the unit until there is a constant flow of bubble-free liquid in the sight-glass indicating that there is sufficient
charge and controlled that sub cooling is correct according to the system design value.
In all cases, do not top up the charge until the unit reaches a stable state of operation.
It is pointless to overcharge a system, this can adversely affect operation.
Overcharging causes :
- Excessive discharge pressure,
- A risk of damage to the compressor,
- Excessive power consumption.
3.7.6 - Oil charge
All units are delivered with a complete oil charge. In the case of split units, it may be necessary, due to the length
of piping installed, to add a certain amount of oil compatible with the type of compressor and refrigerant used.
Please refer to the following oil table.
Note : This table is valid for self-contained chillers only (or chillers mounted on receivers) on which the
leaving water temperature is not lower than -5°C. For other cases, consult the documentation shipped with
the machine.
Oil recommendation for Lennox chillers
Refrigerant Compressor type Brand Oil type
R22 Screw CSH… Bitzer B320SH
R22 Scroll SM… Maneurop Maneurop 160 P
R22 Scroll ZR… Copeland Suniso 3 GS
R22 Reciprocating D8… Copeland Suniso 160P
R22 Reciprocating MT… Maneurop Maneurop 160 P
R407C Screw CSH… Bitzer BSE170
R407C Scroll SZ… Maneurop Maneurop 160 SZ
R407C Scroll ZR… Copeland Copeland 3MA, Mobil EAL
Arctic 22CC, ICI Emkarate
RL32CF
R407C Reciprocating D8… Copeland Mobil EALArctic 22
R407C Reciprocating MS… Maneurop Maneurop 160 SZ
INSTALLATION - TRANSPORT - HANDLING

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E • 17 •
INSTALLATION - TRANSPORT - HANDLING
3.7.7 - Air cooled condensers
An air cooled condenser connected to a unit must have the same number of circuits as the unit. Selection of the
condenser must be made carefully to enable transfer of the heat capacity of the unit even at the highest
temperatures expected on an installation.
It is mandatory to control the head pressure in order to enable the unit to operate properly whatever the season:
Avariety ofdifferentsystems maybeused, butthemostsimpleandefficientofthesemodulatesfanoperationusing
a pressure or temperature control.
For condensers fitted with a small number of fans (1 or 2), it may be necessary to vary the fans speed.
Head pressure control systems that operate by flooding the condenser with liquid refrigerant should be avoided
since they entail very large refrigerant charges and can cause serious problems if they are not correctly controlled.
3.8 - DUCTED UNITS INSTALLATION
Notes :
- Be carefull of air cycling between inlet and outlet.
- For air outlet it is recommended to duct each fan separately.
Air outlet
Air inlet
Air outlet duct
Unit
Air inlet duct
Auxiliary drip tray (heat pump unit)

• 18 • Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 0105-E
4 - PRELIMINARY CHECKS
Check that all drain and purge plugs are in place and well tightened prior to fill the installation with water.
4.1 - LIMITS
Priortoany operation, please checkstheoperationlimits of the unitgiveninthe«ANNEXES» at theendoftheIOM,
page 55 to 62.
These tables will give you all necessary information concerning the operating envelop of the unit.
Please consult the «Risk analysis and hazardous situations according to 97/123 directive» given in the
«ANNEXES» at the end of the IOM, pages 63& 64, or supplied with the unit.
4.2 - REFRIGERATION CIRCUIT CHECKS AND RECOMMENDATIONS
In case of split units, check the installation has been made according to the recommendation described §
Installation.
The unit refrigeration circuit sketch is given in the «ANNEXES» at the end of the IOM, page 65 to 69 or supplied
with the unit.
4.3 - HYDRAULIC SYSTEM INSTALLATION CHECKS
The unit hydraulic sketch is given in the «ANNEXES» at the end of the IOM - See page 50 to 54.
4.4 - INSTALLATION OF EXTERNAL HYDRAULIC COMPONENTS (supplied loose by Lennox).
Some hydraulic components may be supplied loose by Lennox:
- Filters
- Expansion vessels
- Valves
- Manometers
-…
The components are located inside the units and must be installed by a qualified engineer.
Note : In case of plate heat exchangers it is mandatory that a filter is installed at exchanger unit entrance.
These filters must remove all particles with a diameter greater than 1 mm.
4.5 - CHECK LIST BEFORE START-UP
Before proceeding with start up, even for a test of short duration, check the following points, after having
made sure that all the valves on the refrigeration circuit are fully open (discharge valves and liquid valves).
Starting up a compressor with the discharge valve closed will either trip the HP safety switch, or blow the
cylinder head gasket or the internal pressure safety disc.
1) The liquid pump(s) and other apparatus interlocked with the unit (coils, air handling units, dry coolers, cooling
towers, terminals such as fan coil units, etc.) are in working order as required by the installation and according
to their own specific requirements.
Place all water valves and refrigerant valves in their operating positions and start the water circulating
pumps.
Ensure main power supply is isolated before any work is started. Ensure unit is correctly earthed and
that earth continuity is correctly done.
Check that anti-vibration mountings are correclty installated and set.
2) Check the cleanliness and the tightness of all electrical connections, both the connections made at the
factory and the connections made on site. Also make sure that all thermostat bulbs are correctly inserted and
PRELIMINARY CHECKS