Lennox WA Series User manual

Providing indoor climate comfort
CHILLER_AC-IOM-1106-E
Installation, operating
and maintenance
AIR COOLED CHILLERS
Библиотека СОК 

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 1 •
TABLE OF CONTENTS
AIR COOLED CHILLERS AND SPLIT UNITS
INSTALLATION
OPERATION
MAINTENANCE MANUAL
Ref : CHILLERS_IOM-1106-E
The present manual applies to the following CHILLER ranges :
ECOLOGIC range : WA - WAH - RA
MCC range
Special unit n°
Our company is a member of the Eurovent Certification Programme, all LENNOX chillers are tested
and rated in accordance with Eurovent certification program,
Our products comply with the European standards,
Product designed and manufactured under a quality management system certified to AFAQ ISO 9001
by AFAQ,
LENNOX have been providing environmental solutions since 1895, our range of air cooled chillers continues 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

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 2 •
available to third parties without the prior written agreement of Lennox.
TABLE OF CONTENTS
1 - INTRODUCTION............................................................................................................3
PED Declaration.........................................................................................................4
2 - WARRANTY................................................................................................................5
2.1 – Safety recommendations....................................................................................5
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 .......................................................................................13
3.6 - Sound levels......................................................................................................13
3.7 - Connections of split units ..................................................................................13
3.8 - Ducted units installation ....................................................................................19
4 - PRELIMINARY CHECKS .........................................................................................20
4.1 - Limits .................................................................................................................20
4.2 - Refrigeration circuit checks and recommendations ..........................................20
4.3 - Hydraulic system installation ckecks.................................................................20
4.4 - Installation of external hydraulic components (supplied loose by LENNOX)....20
4.5 - Check list before start-up ..................................................................................20
5 - UNIT START-UP.......................................................................................................24
5.1 - Checks to be made during start-up...................................................................24
5.2 - Oil charge ..........................................................................................................25
5.3 - Refrigerant charge ............................................................................................25
6 - OPERATION .............................................................................................................26
6.1 - CLIMATIC™ control ..........................................................................................26
6.2 - Unit operation....................................................................................................26
7. MAINTENANCE ........................................................................................................31
7.1 - Weekly maintenance.........................................................................................32
7.2 - Annual maintenance .........................................................................................32
7.3 - Cleaning the condenser ....................................................................................33
7.4 - Compressor oil drainage ...................................................................................33
7.5 - Important ...........................................................................................................33
8 TROUBLESHOOTING - REPAIRS...........................................................................34
8.1 List of the most common problems .....................................................................34
8.2 Control devices....................................................................................................40
8.3 Manufacturer’s recommended inspections .........................................................41
ANNEXES .........................................................................................................................47

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INTRODUCTION
1 - INTRODUCTION
You must read and be familiar with this operating manual prior to commission the chiller.
Please closely follow the instructions.
We would like to stress the importance of training with respect to the correct handling of the chiller.
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 later
modifications. We reserve the right to modify the construction and/or design of our chillers, at any time, without prior
notification or obligation to adapt previous supplies accordingly.
Any work on the Chiller should be carried out by trained and 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.

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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.

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 5 •
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.
- The equipment is being used improperly, incorrectly, negligently or not in accordance with its nature
and/or purpose.
- A flow protection device is not fitted.
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 RECOMMENDATIONS
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.
This excludes some parts operating at a safe voltage (< 24 Volt). The service panels can only be opened using tools.
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.
Make sure to get every safety precautions such as: individual protections (gloves, glasses, protective
clothes, safety shoes…), appropriates tooling, appropriate fire extinguishers for the system and the
refrigerant type within easy reach…
Make also sure that technicians are well trained to work on these units, and get necessary qualifications
(electrical, frigorific, local rules...). Any particular operation such as welding, soldering, or electrical works
must be done by properly qualified technicians.
It is essential to follow non exhaustive recommendations hereunder:
Never work on a unit that is still energized.
Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and
authorised engineer. These procedures must be carried out with the unit shut-down.
Never work on any of the electrical components, until the general power supply to the unit has been cut.
During any maintenance operations on the unit, lock the power supply circuit in the open position ahead
of the machine. If the work is interrupted, check the lock before resuming the work.
WARNING: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuit
disconnect switch is open. Refer to the wiring diagram for further details.
For some units, a separate 220V power supply may exist, check the electrical wiring for more informations
In case of maintenance operations on fans (grills replacement …) ensure that the power is shut off to
avoid automatic restart.
Before the opening of the refrigerant circuit, check the pressure with manometers or pressure sensors.
Never leave a unit stopped with valves closed on the liquid line, refrigerant could be trapped and the
pressure would rise.

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All installation parts must be maintained by the personnel in charge, in order to avoid material
deterioration and injuries to people. Faults and leaks must be repaired immediately. The authorized
technician must have the responsibility to repair the fault immediately. Each time repairs have been
carried out to the unit, the operation of the safety devices must be re-checked.
Follow guidances and recommenadations given in safety and machine standards such as EN378, ISO5149,
etc
Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently
with oil, grease, and other common substances.
Never exceed the specified maximum operating pressures. Verify the allowable maximum high- and low-
side test pressures by checking the instructions in this manual and the pressures given on the unit name
plate.
Do not use air for leak testing. Use only refrigerant or dry nitrogen.
Do not unweld or flamecut the refrigerant lines or any refrigerant circuit component until all refrigerant
(liquid and vapour) has been removed from chiller. Traces of vapour should be displaced with dry air
nitrogen. Refrigerant in contact with an open flame produces toxic gases.
Do not siphon refrigerant
Avoid spilling liquid refrigerant on skin or splashing it into the eyes. Use safety goggles. Wash any spills
from the skin with soap and water. If liquid refrigerant enters the eyes, immediately and abundantly flush
the eyes with water and consult a doctor.
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).
High temperatures
Electrical voltage Rotating parts Sharp parts
Check regularly that the warning labels are still in the correct positions on the machine and replace them if
necessary.

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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 36):
- The exterior has not been damaged in any way.
- The lifting and handling equipment are suitable for the equipment and comply with the specifications of the
handling instructions enclosed here-in.
- Accessories ordered for on site installation have been delivered and are in good working order.
- If the unit is delivered with its operating charge of refrigerant, that there has been no leakage (use an electronic
detector).
- The equipment supplied corresponds to the order and matches the delivery note.
If the product is damaged, exact details must be confirmed in writing by registered post to the shipping company
within 48 hours of delivery (working days).
A copy of the letter must be addressed to LENNOX and the supplier or distributor for information purposes.
Failure to comply will invalidate any claim against the shipping company.
Please be reminded that LENNOX is not responsible for off-loading and positioning.
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
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.
It is strongly recommended to store units is a dry, sheltered place (in particular for units that will be installed
indoors).

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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, such as operating pressures, electrical components, locations (roofs, terraces and other structures located
well above ground level).
Only highly qualified contractors and technicians with sound knowledge of this type of equipment, are 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
- Handle heavy or bulky equipment carefully during lifting and moving operations, and when setting it on the ground.
CAUTION : BEFORE EACH SERVICE OPERATION MAKE SURE THAT THE UNIT POWER
SUPPLY IS PROPERLY ISOLATED AND LOCKED OUT.
NOTE : SOME UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT
REQUIRES SEPARATE ISOLATION. PLEASE CHECK THE WIRING DIAGRAM.
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 :
The heat exchangers of the condensers could be protected from damage during transport by plastic plates.
The machine is also wrapped in packing foil. It is recommended to leave this protection in place during any
transport and lifting operations, and not to remove the plastic plates until commissioning (take care that the
protecting foil wrapping is not blown away!).
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.

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3.3 - LAY-OUT AND INSTALLATION REQUIREMENTS
The following preparations are important for the installation of the chiller :
- Air-cooled chillers with helicoids fans such as Ecologic are designed for outdoor installation. Please consult Lennox
prior 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.
In locations exposed to frost, the supporting surface, if the unit is installed on the ground, must be built on concrete
stakes extending downwards beyond the normal depth of frost. It is always advisable to build a supporting surface
detached from the general building structure to avoid transmission of vibrations.
- On normal applications, unit rigidity and point load positions enable installation to 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.

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 10 •
CLEARANCES DRAWINGS
For more details, please consult our Application Guides or the drawings supplied with the unit.
ECOLOGIC range Unit with screw compressor
OVERHEAD OBSTRUCTIONS ARE NOT PERMITTED
> 3 meters
Not recommended Not allowed
For any air cooled unit, it is necessary to have a minimum distance between air coil and any obstacle of 1,5
meters.
For any chiller a minimum distance of 1 meter is required for the good opening and servicing of the electrical
box.
3.4 - WATER CONNECTIONS
3.4.1 - Water connections - Evaporator/Condenser
The water circulating pump will be preferably installed upstream so that the evaporator/condenser will be subjected to
positive pressure. Entering and leaving water connections are indicated on the certified drawing sent with the unit or
shown in the sales brochure.
The water pipes connected to the unit must not transmit any radial or axial force to the heat exchangers nor any
vibration.
It is important to follow non exhaustive recommendations hereunder:
Comply with the water inlet and outlet connections shown on the unit.
Install manual or automatic air purge valves at all high points in the circuit.
Install a safety valve as well as an expansion tank to maintain the circuit pressure. This option may be
included inside the unit.
Install thermometers in both the entering and leaving water connections.
Install drain connections at all low points to allow the whole circuit to be drained.
Install stop valves, close to the entering and leaving water connections.
Use flexible connections to reduce the transmission of vibrations.
After testing for leaks, Insulate all pipe work, to reduce thermal leaks and to prevent condensation.
2 meters 2 meters

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If the external water pipes are in an area, where the ambient temperature is likely to fall below 0°C, insulate
the piping and add an electric heater. As an option, the internal unit piping is protected.
Ensure full earthling continuity
For unit with 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.
The use of a water filter in the water circuit upstream of the heat exchanger is mandatory. This filter must remove all
particles with a diameter greater than 1 mm, and must be positioned within 1 meter of the inlet of the exchanger. It
may be supplied as an option by the manufacturer. This filter will prevent the plate heat exchanger from clogging.
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.
CHARGING AND REMOVING HEAT EXCHANGE FLUIDS SHOULD BE DONE BY QUALIFIED TECHNICIANS WITH
DEVICES THAT MUST BE INCLUDED ON THE WATER CIRCUIT BY THE INSTALLER. NEVER USE THE UNIT
HEAT EXCHANGERS TO ADD HEAT EXCHANGE FLUID.
3.4.2 - Water analysis
The water must be analysed; the water circuit installed must include all items necessary for treatment of the water:
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.
Here are our non exhaustive recommendations given as an indication:
No NH4+ ammonium ions in the water, they are very detrimental for copper. <10mg/l
Cl- Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture. < 10 mg/l.
SO42- sulphate ions can cause perforating corrosion.< 30 mg/l.
No fluoride ions (<0.1 mg/l).
No Fe2+ and Fe3+ ions with dissolved oxygen. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l. Over
those values, it means a corrosion of steel which may generate a corrosion of copper parts under deposite of
Fe – this is mainly the case with shell and tube heat exchangers.
Dissolved silicon: silicon is an acid element of water and can also lead to corrosion risks. Content < 1mg/l.
Water hardness: TH >2.8 K. Values between 10 and 25 can be recommended. This will facilitate scale deposit
that can limit corrosion of copper. TH values that are too high can cause piping blockage over time.
TAC< 100.
Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to
deoxygenate the water by mixing it with inert gas as it is to over-oxygenate it by mixing it with pure oxygen. The
disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of
particles.
Specific resistance – electric conductivity: the higher the specific resistance, the slower the corrosion tendency.
Values above 3000 Ohm/cm are desirable. A neutral environment favours maximum specific resistance values.
For electric conductivity values in the order of 200-6000 S/cm can be recommended.
pH: pH neutral at 20°C (7 < pH < 8)
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 ice at
the lowest outdoor air temperatures expected on an installation. Take precautions when using non passivated MEG

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 12 •
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
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.
AN EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT
WARRANTY
3.4.5 - Minimum water capacity
The minimum volume of the chilled water circuit must be calculated with the formula here under. If necessary, 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 ÆCooling capacity of the chiller in kW
N ÆNumber of Compressor
X ÆNumber depending of the type of compressor (Scroll 12, screw 8, Recip 10)
Vt = 172 x Q/(n x X) litres
Example, for a screw chiller with 2 compressors 400kW, water conditions, the minimum volume is :
Vt = 172 x 400/(2 x 8) = 4300 l.
This formula will give the minimum water capacity of the installation that will ensure a temperature rise of the water
loop of 5°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
A flow switch must be installed on the evaporator water inlet or outlet, so as to enable detection of water flow through
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.

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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.
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 conform to applicable regulations. The type and location of fused isolators must also 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.
Account is taken of technical constraints, both in design and manufacturing, sound levels cannot be improved 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.
Determine what level of sound proofing is necessary on the equipment, the installation (silencer, vibration isolators,
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 or the evaporator must be made by a qualified refrigeration
engineer and require several important precautions.
In particular, the shape and dimensions of the 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

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 14 •
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
Calculate these to obtain a gas velocity in vertical sections that enables compressor oil migration and steady return
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 - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 15 •
UNITS WITH REMOTE CONDENSER
Unit with remote condenser
without capacity control
Unit with remote condenser
with capacity control
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
WARNING : The liquid level between the condenser and the check valve A must compensate the check valve
pressure drop
If receiver option : PED declaration class 3
If no receiver option : PED declaration class 1

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 16 •
CONDENSING UNITS
Condensing unit
without capacity control
Condensing unit
with capacity control
Min 0,25%
gradient
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
If receiver option : PED declaration class 3
If no receiver option : PED declaration class 1
Min 0,25% gradient
Min 0,25% gradient

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 17 •
Minimum refrigeration capacity in kW for oil entrainments up Suction risers
Refrigerant : R407C
Table C Tubing nominal OD, mm
Saturated
temperature
(°C)
Suction gas
temperature
(°C)
12 15 18 22 28 35 42 54 67 79 105 130
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
-5 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
10 0,47 0,86 1,45 2,47 4,69 8,33 13,44 25,77 44,58 67,56 139,39 241,30
5 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
temperature
(°C)
Suction gas
temperature
(°C)
12 15 18 22 28 35 42 54 67 79 105 130
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
30
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
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
40
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
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
50
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 bypassing the isolation system on the unit by fixing refrigerant lines or electrical conduits too tightly.
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) Do not use oxygen or acetylene instead of refrigerant fluid and nitrogen for leak testing : this could cause a
violent explosion.
3) Always use a regulator valve, isolating valves and a pressure gauge to control test pressure in the system.
Excessive pressure can cause lines to burst damage to the unit and/or cause an explosion with severe
personal injury.

Installation - Operation - Maintenance manual (IOM) •AIR COOLED CHILLERS & SPLIT UNITS - 1106-E • 18 •
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.
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.
In liquid phase, connect either to a liquid isolating valve, or to the quick-connector on the liquid line at the valve outlet.
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 EAL Arctic 22
R407C Reciprocating MS… Maneurop Maneurop 160 SZ