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Lennox SYSTEMA EOLO LXC 50 Manual
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Lennox SYSTEMA EOLO LXC 50 Manual

Lennox SYSTEMA EOLO LXC 50 Manual

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Heat exchanger gas units – service training
Federico Cortelazzo
Dariusz Przygocki
Barbara Kowalczyk
1
3
March 2022
st
rd
Smart Energy Company
www.systemapolska.pl

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Summary of Contents for Lennox SYSTEMA EOLO LXC 50

  • Page 1 Heat exchanger gas units – service training Federico Cortelazzo Dariusz Przygocki Barbara Kowalczyk March 2022 Smart Energy Company www.systemapolska.pl...
  • Page 2 Training agenda 1 March 2022 1. Basic information about HEGU + vocabulary 2. Signals on motherboard & wiring diagram 3. Control panel operating (tutorial) 4. Improvements & retrofit 5. GHEU’s operating cycles 6. Commissioning- (Pre-commissioning + Start-up + Hi/Lo power flow procedure) 7.
  • Page 3 Training agenda 1 March 2022 Devision into 2 groups Boussad ERIC Team leaders: Darek Federico Trainner: Topics: Preparation for commissioning Start-up Hi/ Lo procedurę Control panel operating / Ignition test / Alarms Replacement of electrodes, valve Burner disassembing & assembling Smart Energy Company www.systemapolska.pl...
  • Page 4 Heat exchanger gas units portfolio (G-20/ G-25) Model EOLO LXC 50 EOLO LXD 70 EOLO LXE 90 EOLO LXE+ 110 EOLO LXF 130 EOLO LXG 170 EOLO LXH 230 Cat. No. (S) 70LENX1000 70LENX1001 70LENX1002 70LENX1003 70LENX1004 70LENX1005 70LENX1006 LGL France E BALTIC C BOX E BALTIC D BOX E BALTIC E BOX...
  • Page 5 Heat exchanger gas units portfolio (G-31) Model EOLO LXC 50 EOLO LXD 70 EOLO LXE 90 Cat. No. (S) 70LENX0120 70LENX0121 70LENX0122 LGL France Goods E BALTIC C BOX E BALTIC D BOX E BALTIC E BOX Cat. No. (Longvic) 61298512 61299199 61299200...
  • Page 6 Name plate 1. Type of unit EOLO LXC 50 (E Baltic C box) 2. Serial no. L21B11084 CE sign & Certificate name 4. Type of gas 5. Nominal heat input & output 6. Country destination: France 7. Language: Frensh or Spanish or English or Smart Energy Company www.systemapolska.pl...
  • Page 7 Heat exchanger gas unit (E Baltic D box ) 1. Plate heat exchanger 2. Mounting plate 3. Control box 4. Burner unit 5, 6. Sensor temp. cover + 7, 8, 9,10 Temp. sensors 11. Insulation gasket 12. Pneumatic elbow 13. Elbow 14.
  • Page 8 Heat exchanger gas unit (E baltic D box 1. Plate heat exchanger (place, where gas is burned, surface phe heats air flow) 2. Mounting plate (place, where whole components are fix together) 3. Control box (set of controllers with opportunity to connect with Climatic, Control panel, connection with necessary components) 4.
  • Page 9 Burner units – model E Baltic C, D, E box Smart Energy Company www.systemapolska.pl...
  • Page 10 Burner units – model E Baltic F, G, H box Smart Energy Company www.systemapolska.pl...
  • Page 11 Burner unit – model E Baltic D box 1. Burner flange 2,3 Insulation plate 4. Burner head 5. Electrodes – set 7. Gas blower 8. Gas-air mixer 9. Gas valve 10. Flexible gas pipe 12. Hi voltage transformer 15. Gas blower control cable 18.
  • Page 12 Burner unit – model E Baltic D box 1. Burner flange 2,3 Insulation 4. Burner head (proper streading of gas & air mixture) 5. Electrodes – set ( ignition) 7. Gas blower (supply gas and air mixture) 8. Gas-air mixer (mix gas &...
  • Page 13 Burner unit – E baltic H box 1. Burner flange 2,3 Insulation 4. Burner head 5. Electrodes – set 6. Gas blower 7. Gas-air mixer 9. Gas valve 11 & 19 Gas pressure switch 13. Flexible gas pipe 15. Hi voltage transformer Smart Energy Company www.systemapolska.pl...
  • Page 14 Control box – the same for the all modules 4. Matherboard (main electronic board ) 5. Burner controller GENIUS M82/ Brahma ( management burner & control operating) 6. Air pressure switch 7. Safety thermostat (Klikson, overheating) 12. Communication plate ( communicate components with motherboard and Climatic) Smart Energy Company www.systemapolska.pl...
  • Page 15 Control box – common for each modules 32. Motherboard 34 – 36 Red lamp, Green lamp, Orange lamp 37.Air flow pressure swich* (not use by Lennox) 38. 4 pin adapter (valid for all units from serial no: L21G11320) 41 . Reset buton 43.

  • Page 16: Technical Documentation

    Technical documentation 1. Instruction Operation Manual (English, French, Spanish, Polish) 2. Spare parts list 3. Leaflet 4. PPT presentation 5. Commissioning diagram & tutorial 6. Hi/Lo procedure diagram & tutorial IOM in English, French, Spanish, Polish Smart Energy Company www.systemapolska.pl...
  • Page 17 Volume of buffer tank ( between burner & regulation valve or reducer) Model EOLO LXC EOLO LXD EOLO LXE EOLO LXE+ EOLO LXF EOLO LXG EOLO LXH Capacity in kW Volume in 0,02 0,031 0,039 0,048 0,056 0,065 0,095 PLS ADD THE WHOLE PIPES OF GAS Smart Energy Company www.systemapolska.pl...
  • Page 18 HEGU – improvements & retrofit 4 pin connection for 4 pobes of heat exchanger from serial no: L21G11320 Smart Energy Company www.systemapolska.pl...
  • Page 19 HEGU – Improvements & retrofit Electrodes from double to single – 2 pcs. For C, D, E, E+ From serial no: L21G11320 Smart Energy Company www.systemapolska.pl...
  • Page 20 HEGU – improvements & retrofit New burner Controller (Genious 821-TW30 is replecement by Brahma 500015521-32505) from serial no. L22B11503 Smart Energy Company www.systemapolska.pl...
  • Page 21 HEGU – improvements & retrofit Place of programming buton & reset buton form serial no. L22B11505 Smart Energy Company www.systemapolska.pl...
  • Page 22 HEGU – Retrofit 1. New burner controller Brahma instead of Genius 2. New type of electrodes 2 x single instead of one double ( use repair kits) 3. New shape of electrodes Smart Energy Company www.systemapolska.pl...
  • Page 23 Heat exchanger gas unit – SIGNAL Main Control board SCP674V130B1 The same communication board for each models Signals on the dispaly Smart Energy Company www.systemapolska.pl...
  • Page 24 Heat exchanger gas unit – Phases Reset burner No command No command Level of burner [%] to heat to operation Post ventilation mode Smart Energy Company www.systemapolska.pl...
  • Page 25 Heat exchanger gas unit – Mainboard operation Test mode Testing fase Combustion chamber Waiting time pre-ventillation Smart Energy Company www.systemapolska.pl...
  • Page 26 Heat exchanger gas unit – Main board operation Pasword service mode Max. & min. Time of to enter burner operation setting operation Y2/YC/Yt according to at Yc level Yc / Yt parameters Smart Energy Company www.systemapolska.pl...
  • Page 27 Heat exchanger gas unit – Main board operation burner burner not used BOOST max. burner min. in Lennox power starting power devices power Smart Energy Company www.systemapolska.pl...
  • Page 28 Motherboaed checking & settings PA - parameter introducting changes 33 – code for manual mode Modifiable parameters: Y2 – Burner modulation power in % fom 0 …99, default Burner operation parameter – MOI point 4.6, page 30, 31 Smart Energy Company www.systemapolska.pl...
  • Page 29 Motherboaed checking & settings rL – min burner fan speed value ro – offest of rL during standard operation rH – max. burner fan speed value Y2 – boost level Y9 – gas blower type HH- release firmware Non modifiable burner parameters ( read only) !!! Smart Energy Company www.systemapolska.pl...
  • Page 30 Parameter Y2 - changes 1. Press button until PA appears 2. After realeasing button, the value 00 appears 3. Press button again to enter code 33 ( manual operations) 4. Wait 3 s without doing nothing 5. You are in service mode during 4 minutes 6.
  • Page 31 Heat exchanger gas unit – Main board operation...
  • Page 32 Heat exchanger gas unit –Main board operation Model C Nominal heat input – 50 kW Min. heat input 10 kW Signs 00 – 10 kW 99 – 50 kW Example on E Baltic C box Smart Energy Company www.systemapolska.pl...
  • Page 33 Heat exchanger gas unit –Main board operation "00" "99" [kW] [kW] EOLO LXC 50 C-BOX EOLO LXD 70 D-BOX EOLO LXE 90 E-BOX EOLO LXE+ 110 E+ BOX EOLO LXF 130 F-BOX EOLO LXG 170 G-BOX EOLO LXH 230 H-BOX Smart Energy Company www.systemapolska.pl...
  • Page 34 Control panel operating 1. External control panel for Receiving information Resseting alarms Managing & Control HEGU 2. The name of alarms are not the same as alarms on Motherboard’ s display Smart Energy Company www.systemapolska.pl...

  • Page 35: Control Box -Wiring Diagram

    Control box –wiring diagram Wiring diagram – page 23 MOI (English) Matherboard – SCP674V130B1 Communication plate SCP674V202MB Smart Energy Company www.systemapolska.pl...
  • Page 36 Control box –Main board J8F – Gas blower control - E7 / E5 / E6 error J6B – Kr resistance kit relay power supply J7B a – min. gas pressure switch (option) J7B b – Air pressure switch J7C c - Safety thermostat connection J7C d –...
  • Page 37 Control box –Main board J8F – Gas blower modulating line / Hall sensor J1A – General power supply 230V J1B, J1B2 – Earth connection J9B – RESET connector J8B - Ignitor connection J8D - Gas valve connection J8C – Contacts in bridge – not used J8A –...
  • Page 38 Control box –communication plate J9 – connection to J11 – Modbus connection ext. display iFS – programming interface J2 – heat exchanger P3 – Inlet air temp. probe temp. sensor P4 – Airflow temp. probe J5 manual burner CN1, CN2 – connector to main start booard J1 –...
  • Page 39 Control box –wiring diagram J7B – Min. gas pressure switch / air pressure switch J7C – Max. gas pressure switch / safty thermostat J8F –gas blower control J9A2 – signal lamps J8A – gas blower J8C – Not used J8D – gas valve J8B - Ignitor Smart Energy Company www.systemapolska.pl...
  • Page 40 Control box –wiring diagram J1A - General power supply J9B – Machine reset J1B, J1B2 – protective conductor ETR – Kr resistance kit relay power supply – option (low temp outside) Smart Energy Company www.systemapolska.pl...
  • Page 41 Control box –wiring diagram Pp – use for programming main board P1 – heat exchanger temp. sensor GO – Manual burner operating control P4.1 to P4.4 - Outlet air temp. sensor Smart Energy Company www.systemapolska.pl...
  • Page 42 Gas heat exchanger unit - operating cycles Gas unit EOLO LX can be started by ModBus communication or manualy – close connector J5 contacts 1-2. Gas heater will start to work only when the main fans are running. Otherwise, the module will display an E3 error. In correct conditions gas unit will perform a startup cycle..
  • Page 43 Gas heat exchanger unit - operating cycles After testing fase burner goes to pre-purging fase. (30 sec.) Orange lamp ON The next step - open gas valve and apply high voltage to the electrodes. Green lamp ON Spark starts...
  • Page 44 Gas heat exchanger unit - operating cycles After successful ignition burner continues After a successful ignition burner continues boost phase for 3 minutes, i.e. work with starting power. then, after approx. 3 minutes, the burner switches to normal operation and displays the percentage power level between 0-99...
  • Page 45 Gas heat exchanger unit - operating cycles if the burner did not start, it makes two more attempts to start. After third unsuccessful attempt, the burner locks. Red lamp ON Error E4 on the display...
  • Page 46 Pre commissioning action Make sure the gas in the mains corresponds to that for which EOLO LX is regulated – Gas pressure & type comply with the data on name plate Check, with the pressure intake "IN" on the gas valve, that pressure entering the valve corresponds to that required for the type of gas being used.
  • Page 47 Pre commissioning action 1. Check the filter (3) 2. Open shut-off main gas valve (1) 3. Pre-purge gas pipe from air 4. Check tightness by tester 5. Turn on the main electrical power swich 1- shut-off valve, 2. checking point 3. filter, 4manometer, 5. gas regulator, 6. manometer, 13.
  • Page 48 Heat exchanger gas unit – Commissioning View of heat exchanger gas unit – E Baltic C box Smart Energy Company www.systemapolska.pl...
  • Page 49 Commissioning procedure – start-up Smart Energy Company www.systemapolska.pl...
  • Page 50 Gas valve adjustment= Hi / Lo procedure Preparation: 1. Check type of module 2. Find the table in IOM, page 61 3. Prepare combustion analyser 4. Use HEX 4 or Torx 25 for making adjustment Make pressure adjustment just after starting the burner Smart Energy Company www.systemapolska.pl...
  • Page 51 HEGU – procedure to put in Lo/Hi power Necessary tools for regulation Hex 4 or T25 / T40 Smart Energy Company www.systemapolska.pl...
  • Page 52 Procedure Lo/Hi power flow 1. The procedure is set to has gas valve 2. Use off set regulator (or gas air mixer for E, E+, F) for Lo power flow 3. Use internal valve screw 4. Gas valve is set to manual mode for 6 minutes 5.
  • Page 53 HEGU – procedure to put in Lo/Hi power Parameter manual mode 5..10 Time parameter (minutes) Setting capacity – max. Setting capaicty – min. The main codes necessary for using during procedure Smart Energy Company www.systemapolska.pl...
  • Page 54 Procedure to put in Lo/Hi power Gas air 1. Model C & D – mixer VK4205VE5002 2. Model E, E+ & F – VK 4415V1002B 3. Model G & H - VR415VE50924 Model C & D Model E, E+ &F Model G &H Smart Energy Company www.systemapolska.pl...
  • Page 55 HEGU – procedure to put in Lo/Hi power CO ppm Parameters on combustion analyser CO < 100 ppm - 7,8 - 8,9 % NOx ppm NOx < 30 ppm Ts ° C Ts – fume temp. ɳ % ɳ – efficiency λ...
  • Page 56 HEGU – procedure to put in Hi/Lo power Smart Energy Company www.systemapolska.pl...
  • Page 57 HEGU – procedure to put in Lo/Hi power The procedure should be carried out after the burner has just started Smart Energy Company www.systemapolska.pl...
  • Page 58 Supply pressure in countries Smart Energy Company Tabele 5.1, page 44 www.systemapolska.pl...
  • Page 59 Any changes in HEGU 1. Always make Hi/Lo procedure after replacement spare parts, change fuel 2. Check if is necessary to replace venturi. It is valid for Poland 3. Make calibration, if the gas valve is out of control Replacement venturi , if it is necessary (mainly Poland) Smart Energy Company www.systemapolska.pl...
  • Page 60 Heat exchanger gas unit parameters – IOM page 60 Models C box D box E box E+ box F box Parameters Unit G 20 Exhoust gas T °C G 25 Exhoust gas T °C Exhoust T °C 10,3 10,4 10,3 10,3 10,2 10,4...

  • Page 61: Gas Valve Calibration

    Gas valve calibration Based on E Baltic C box – IOM – page 62 Smart Energy Company www.systemapolska.pl...
  • Page 62 Fuel changes – valve calibration 1. Full open by turning right to the end 2. Set by turning 3.75 turns to the left 3. Target CO – 8.7% 1. Full open by turning right to the end 2. Set by turning 4 turns to the left 3.
  • Page 63 Heat exchanger gas unit – Maintenance T40 + T15 T40 + T25 T40 + T25 Model C, D model E, E+, F model G, H Replacement gas valve (tutorial) Smart Energy Company www.systemapolska.pl...
  • Page 64 Motherboaed checking & settings rL – min burner fan speed value ro – offest of rL during standard operation rH – max. burner fan speed value Y2 – boost level Y9 – gas blower type HH- release firmware Non modifiable burner parameters ( read only) !!! Smart Energy Company www.systemapolska.pl...
  • Page 65 Parameter Y2 - changes 1. Press button until PA appears 2. After realeasing button, the value 00 appears 3. Press button again to enter code 33 ( manual operations) 4. Wait 3 s without doing nothing 5. You are in service mode during 4 minutes 6.
  • Page 66 Heat exchanger gas unit – Maintenance Replacement electrodes – standard procedure (tutorial) Smart Energy Company www.systemapolska.pl...
  • Page 67 Burner – electrode change in module C, D, E, E+ From serial no: L21G11320 Smart Energy Company www.systemapolska.pl...
  • Page 68 Heat exchanger gas unit – Maintenance 3 repair kits burner with index no. 70LXPAL0023-0025 (C, D, E) Smart Energy Company www.systemapolska.pl...
  • Page 69 Heat exchanger gas unit – Maintenance Remove burner unit from heat exchanger gas unit Smart Energy Company www.systemapolska.pl...
  • Page 70 Heat exchanger gas unit – Maintenance Remove the insulation gasket & Unscrew 4 nuts Smart Energy Company www.systemapolska.pl...
  • Page 71 Heat exchanger gas unit – Maintenance Remove burner plate & install the repair kits burner Smart Energy Company www.systemapolska.pl...
  • Page 72 Heat exchanger gas unit – Maintenance Screw 4 nuts & Install the insulation gasket Smart Energy Company www.systemapolska.pl...
  • Page 73 Heat exchanger gas unit – Maintenance Install the burner unit with new electrode set to heat exchanger gas unit Smart Energy Company www.systemapolska.pl...
  • Page 74 Heat exchanger gas unit – Troubleshooting Smart Energy Company www.systemapolska.pl...
  • Page 75 Heat exchanger gas unit – Troubleshooting Display of Control Panel Reason Solution Notes Motherboard Lack of air flow Check fan air flow & fan Air switch ratation speed Overheating of he Reset burner probe Burner is blocked 1. Valve regulation, Valve, electrodes 2.
  • Page 76 Heat exchanger gas unit – ALARM Alarm Main electronic board is disconnected with communication board Solution Check that the communication board is fitted correctly Alarm & solutions Smart Energy Company www.systemapolska.pl...
  • Page 77 Heat exchanger gas unit – ALARM Alarm General / contact J7B is opened (min. gas pressure switch Pg / Air pressure switch) Solution Check the required gas pressure, check circuit of J7B contact Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 78 Heat exchanger gas unit – ALARM Alarm (Happend or in progres) Contact J7C is open. Max. gas pressure switch is open or overheat thermostat is opened (Klikson) Solution Check gas pressure Pushs reset on overheat thermostat (Klikson) Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 79 Heat exchanger gas unit – ALARM Alarm Burner is lockouted. The red light is on. Solution Pushs reset buttom during 3 s Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 80 Heat exchanger gas unit – ALARM E4 Reason Solution Power supply reversed Connect correctly & respect the phase and neutral polarity between phase and neutral Lack of gas in the burner Check the gas suply line Wrong type of gas 1.
  • Page 81 Heat exchanger gas unit – ALARM E4 Reason Solution Ignition electrode(s) are 1. Electrodes are installed incorrectly, improve it ( see drawing incorrectly positioned or in MOI page 57 damaged or out of working 2. Replace them with original spare parts. Note! Use the same type of elctrodes for box F, G, H and for C, D, E, E+ with serial no higher than L21G11320.
  • Page 82 Heat exchanger gas unit – ALARM E4 Reason Solution Poor grounding Check the grounding Burner controller faulty Check burner controller corect operation and / or replace it Gas valve does not work 1. Check the way of operation the gas supply on the valve, replace with the orginal one, if it is necessary 2.
  • Page 83 Heat exchanger gas unit – ALARM E4 Reason Solution Power supply reversed Connect correctly & respect the phase and neutral polarity between phase and neutral Lack of gas in the burner Check the gas suply line Wrong type of gas 1.
  • Page 84 Heat exchanger gas unit – ALARM Alarm To low min. speed of gas blower, than burner switchs off Solution Check connection of gas blower control Check parameter Y9 on the mainboard Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 85 Heat exchanger gas unit – ALARM E5 Reason Solution Wrong connection of controling Check wire, plug & conectors (J8F) gas blower Gas blower control cable dameged Gas blower defectives Replace with original spare part if necessary Motherboard defective Wrong parameters Y9 on Check and/or set Y9 parameter: motherboard Box D, E, E+, F, G Y9 = 1...
  • Page 86 Heat exchanger gas unit – ALARM Alarm Error of high speed of gas blower, than burner switchs off Solution Check connection of gas blower control Check parameter Y9 on the mainboard Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 87 Heat exchanger gas unit – ALARM E6 Reason Solution Wrong connection of controling Check wire, plug & conectors (J8F) gas blower Gas blower control cable dameged Gas blower defectives Replace with original spare part if necessary Motherboard defective Wrong parameters Y9 on Check and/or set Y9 parameter: motherboard Box D, E, E+, F, G Y9 = 1...
  • Page 88 Heat exchanger gas unit – ALARM Alarm Start-up test failed, burner locks out Solution Remove & restore power to the board Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 89 Heat exchanger gas unit – ALARM Alarm To high temperature of heat exchanger surface - probe P1 ( PT1000) Solution Wait for decreasing temperature using fans in operating. Change sensor (damage) Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 90 Heat exchanger gas unit – ALARM Alarm Red & green lamps is lighting at the same time Internal error Solution Closes RT contact Alarms & solutions Smart Energy Company www.systemapolska.pl...
  • Page 91 Heat exchanger gas unit – ALARM Alarm Serious alarm, damaged database Solution Contacts the service center Checks the value: rL, rH & Y9 After introducing the new parameters provided by producer, turns off the power supply of the board at least 10 s. Alarms &...
  • Page 92 Heat exchanger gas unit – ALARM Alarm Memory fault - EEPROM Solution Switch off power supply for 10s. Restore software of main board and communication board Alarms & solutions Smart Energy Company www.systemapolska.pl...

  • Page 93: Maintenance Interval

    Heat exchanger gas unit – maintenance plan MAINTENANCE INTERVAL Maintenance Every year Check / clean gas filter Check the gas pressure supply at the gas valve. Check flue exhaust + air intake grill Check the Venturi pipe / clean it if necessary Check exchanger / clean it if necessary.
  • Page 94 Gas heat exchanger unit – maintenance plan 1. Check / clean gas filter Perform a visual inspection and clean the gas filter cartridge which is located outside the device behind the main gas valve 2. Check the gas pressure supply at the gas valve. Measure the gas pressure with a pressure gauge.
  • Page 95 Gas heat exchanger unit – maintenance plan 4. Check the Venturi pipe / clean it if necessary Remove any dirt at the mouth of the Venturi pipe with a brush. Be careful to not let it fall inside the piece. 5.
  • Page 96 Gas heat exchanger unit – maintenance plan 7. Check and clean condensate drain. Remove any dirt from the pipe. Check if condensate flow out freely form the exchanger. 8. Check operation of flame and ionisation controling. When the burner is working, close the gas valve and verify that the burner is stopped.
  • Page 97 THANK YOU FOR ATTENTION Smart Energy Company www.systemapolska.pl...

  • Page 98: Control Box -Wiring Diagram

    Control box –wiring diagram J1A - General power supply J9B – Machine reset J1B, J1B2 – protective conductor ETR – Kr resistance kit relay power supply Smart Energy Company www.systemapolska.pl...
  • Page 99 Control box –wiring diagram Pp – use for programming main board P1 – heat exchanger temp. sensor GO – Manual burner operating control P4.1 to P4.4 - Outlet air temp. sensor Smart Energy Company www.systemapolska.pl...

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