Lennox NEOSYS Installation, Operating And Maintenance Manual

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Installation,

operating

and maintenance

Air cooled chillers

Water cooled chillers

20 > 1000 kW

HYDROLEAN

(NEOSYS)

(HYDROLEAN & MWC)

NEOSYS

MWC

CHILLER-IOM-1309-E

lennoxemeia.com

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Summary of Contents for Lennox NEOSYS

Page 1 Installation, operating and maintenance NEOSYS HYDROLEAN Air cooled chillers (NEOSYS) Water cooled chillers (HYDROLEAN & MWC) 20 > 1000 kW CHILLER-IOM-1309-E lennoxemeia.com...
Page 3 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.
Page 4: Table Of Contents
Connection of split units PRELIMINARY CHECKS Limits Refrigeration circuit checks and recommendations Hydraulic system installation checks (NEOSYS) Installation of external hydraulic components (for HYDROLEAN and MWC) Hydraulic connections and options (for HYDROLEAN and MWC) Check list before start-up Master-slave conﬁ guration (2 units or more)
Page 5 Manufacturer’s recommended inspections CHECK LIST APPENDICIES Risk analysis and hazardous situations according to 97/23/CE directive General refrigeration circuit diagram: NEOSYS (cooling only) General refrigeration circuit diagram: NEOSYS (heat pump) General refrigeration circuit diagram: HYDROLEAN (cooling only) General refrigeration circuit diagram:...
Page 6: Introduction
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 ﬁ eld. It is important that this manual is stored in a permanent location in the vicinity of the chiller.
Page 7: Ped Declaration
• The European Restriction of the Use of Certain Hazardous Substances (RoHS) SAFETY RELIEF (NEOSYS, MCW and MRC ranges) This equipment is protected with safety pressure relief calibrated at 42,7 bar g and safety pressure switch calibrated at 42 bar g.
Page 8: F Gas Regulation
F GAS REGULATION EC Regulation No 842/2006 on ﬂ uorinated greenhouse gases Operators of refrigeration equipments must comply with the 6 main obligations deﬁ ned in the F Gas Regulation OBLIGATION APPLICABILITY Recovery of F gases during plant servicing and maintenance and at the end of plant life. All stationary systems Use adequately trained staff to carry out installation, servicing and maintenance and leakage All stationary systems...
Page 9: Warranty
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.
Page 10 WARRANTY 1.1 - Safety deﬁ nition The water cooled chillers meet the following safety deﬁ nitions: • Pr-EN-378-1. • 2006/42/CE (“Machine Directive”). • EN-60204-1. • 2004/108/CE “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). 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).
Page 11: Installation
If the product is damaged, exact details must be conﬁ rmed 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.
Page 12: Lifting The Unit
CAUTION: IN CASE OF REINSTALLATION OF THE UNIT, 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. NEOSYS HYDROLEAN & MWC • 10 • CHILLER-IOM-1309-E...
Page 13: Lay-Out And Installation Requirements
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 NEOSYS are designed for outdoor installation. Please consult LENNOX prior to implementing other types of installation.
Page 14 For more details, please consult our Application Guides or the drawings supplied with the unit. For any chiller, a minimum distance of 1 meter is required for the good opening and servicing of the electrical box. In case of a compressor replacement, 1m is also reasonable to remove it. NEOSYS 2 meters 2 meters >...
Page 15: Water Connections
INSTALLATION 4 - WATER CONNECTIONS 4.1 - Water connections - Evaporator/Condenser/Desuperheater Before the system start-up check that the water circuits are connected to the right heat exchangers (e.g. no reversal between evaporator and condenser or between water in and outlets). The water circulating pump will be preferably installed upstream so that the evaporator/ condenser will be subjected to positive pressure.
Page 16 Note: air bleeders are not designed to admit air. FREEZING OF A HEAT EXCHANGER DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX WARRANTY. • 14 •...
Page 17 INSTALLATION 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 EXCHANGER THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT WARRANTY 4.5 - Minimum water capacity The minimum volume of the chilled water circuit must be calculated with the formula here under.
Page 18 Example: 20% glycol instead of water -->: water ﬂ ow x 1,05; Pressure drop x 1,1; Cooling capacity x 0,98 4.6 - NEOSYS range with hydraulic module - maximum water content The maximum water content of the installation is determined by the capacity of the expansion vessel.
Page 19 The normally closed contact can be used as an indication of a lack of ﬂ ow condition. Warranty is void if a ﬂ ow detection device is not ﬁ tted and connected to the LENNOX control panel.
Page 20: Electrical Connections
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.
Page 21 INSTALLATION Units with remote condenser Unit with remote condenser without capacity control Unit with remote condenser with capacity control H1: 15 m. maxi 1 - Lower trap with single tube H2: 5 m. maxi 2 - Clode coupled trap H3: 0,3 m. maxi 3 - Lower trap with double tubes H4: 0,15 m.
Page 22 INSTALLATION Condensing units Condensing unit without capacity control min 0,25% Condensing unit with capacity control Min 0,25% gradient Min 0,25% gradient H1: 15 m. maxi 1 - Lower trap with single tube H2: 5 m. maxi 2 - Clode coupled trap H4: 0,15 m.
Page 23 INSTALLATION 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 sub cooling is sufﬁ cient to counteract the loss of static pressure and prevent gas ﬂ ashing. For MRC and HYDROLEAN units: If the refrigerant in the liquid line ﬂ...
Page 24 INSTALLATION Correction tables for MRC and HYDROLEAN units: Condensing temperature °C Discharge gas velocity correction factors 1,37 1,25 1,15 1,07 1,01 0,96 0,93 0,92 Suction 1,41 1,30 1,20 1,11 1,05 1,00 0,97 0,96 temperature °C 1,47 1,34 1,24 1,16 1,09 1,04 1,01 1,00...
Page 25 Please refer to the following oil tables. Overcharging with oil can cause serious problems on an installation, particularly for the compressors. Oil Recommendation for LENNOX chillers Refrigerant...
Page 26: Preliminary Checks
PRELIMINARY CHECKS IMPORTANT • Start up and commissioning must be conducted by LENNOX authorised engineer. • Never shut off power to the crankcase heaters except for long service operations or seasonal shutdown Check that all drain and purge plugs are in place and well tightened prior to ﬁ ll the installation with water.
Page 27: Hydraulic Connections And Options (For Hydrolean And Mwc)
PRELIMINARY CHECKS 5 - HYDRAULIC CONNECTIONS AND OPTIONS (FOR HYDROLEAN AND MWC) Standard connections are Victaulic type for MWC and external threaded for Hydrolean, ﬂ ange connections (MWC only) and ﬁ lters are options Condenser Evaporator Plug Diameter Water inlet Flange option Filter option Water outlet...
Page 28: Master-Slave Configuration (2 Units Or More)
Q = Q1 x √(P2/P1) Where P2 = pressure drop measured on site P1 = pressure drop published by LENNOX for a liquid ﬂ ow of Q1 Q1 = nominal ﬂ ow Q = real ﬂ ow Adjust the evaporator circuit and condenser circuit water ﬂ ows (via regulating valves, pump speed position..) to come close to the designed conditions (LENNOX software).
Page 29: Unit Start Up
UNIT START UP 1 - CHECKS TO BE MADE DURING START UP Before starting the unit, ﬁ ll in the check list sheet of this manual and follow the instructions below to be sure that the unit is correctly installed and ready to operate. 1.
Page 30: Water Flow Checks
UNIT START UP 7. Check the current values per phase on each compressor motor. 8. Check the current values per phase on each fan motor (If available) 9. Check compressor discharge temperature. 10. Check suction and discharge pressures and compressor suction and discharge temperatures. 11.
Page 31 UNIT START UP 1. Low pressure switch: this pressure switch initiates unconditional shut down of the unit if evaporating pressure drops below the Low pressure set point value. On HYDROLEAN the low pressure switch is auto reset. The controller will lock the fault preventing a new start up after three faults. •...
Page 32: Operation
OPERATION 1 - OPERATING LIMITS WARNING: It is very important ensure the units operate well inside these envelopes. 1.1 - NEOSYS 200 > 420 - 600 > 840 - 1080 Min. outlet water temperature °C Min. outlet water temperature with brine operation option Max.
Page 33 OPERATION NAH HEATING MODE Min. condenser outlet temperature °C Max. condenser outlet water °C Min. difference water intlet/outlet °C Max. difference water inlet/outlet °C Min. outside air temperature with water outlet 37°C °C Max. outside air temperature °C Cond water outlet (°C) 50°C 45°C 40°C...
Page 34 OPERATION 1.4 HYDROLEAN WITH REMOTE CONDENSER 1.5 - HYDROLEAN WITH REMOTE CONDENSER (SIZES 025-035-050-070-080-100-120) (SIZES 135-160) Indication on Pipe sizing for SWR type units Discharge Line Liquid Line Circuit 1 Circuit 2 Circuit 1 Circuit 2 Mini Dia. Min / Max speed Mini Dia. Min / Max speed Mini Dia. Min / Max speed Mini Dia. Min / Max speed Inches Inches Inches...
Page 35: Climatic Control
OPERATION MRC version All sizes Operating limits (Water Delta T on evap: 5K) Min. evap. outlet water temperature °C Max evap. outlet water temperature °C Min. difference water inlet/outlet °C Max. difference water inlet/outlet °C Min. condensing temperature °C Max. condensing temperature Operation at full capacity °C 2 - CLIMATIC CONTROL...
Page 36 If the oil in the compressor gets too hot it will start to deteriorate and loose its ability to lubricate, and will eventually cause a compressor failure. LENNOX compressors are sometimes ﬁ tted with a specially designed sensor in the hottest part of the compression cycle, just above the discharge port of the scroll sets.
Page 37: Unit Operation: Electrical And Control Features
OPERATION 3.6 - Pressure regulated water valve (option for water cooled units only) This device is available as an option for low capacity water cooled condensing units (HYDROLEAN or MCW). The PRESSURE REGULATED WATER VALVE should be installed on the condensing water system. It enables water ﬂ ow through the heat exchanger to be adjusted so as to maintain condensing pressure at an appropriate value.
Page 38 OPERATION 4.4 - Flow switch for the chilled liquid (option) This control device initiates unconditional unit stoppage as soon as the ﬂ ow of chilled liquid (water, brine, etc...) ensured by the pump becomes insufﬁ cient, since this could cause rapid evaporator freeze up. When the contact opens due to a lack of ﬂ ow the unit must stop immediately.
Page 39 OPERATION Size of the protections provided for both evaporator and condenser single pumps 25 35 50 70 80 100 120 PMP1 (Max kW with 400V and Cosφ = 0,6) Protection Range Provided (A) 1,6-->2,5 2,5-->4 2,5-->4 4-->6,3 6,0-->10 PMP2 (Max kW with 400V and Cosφ = 0,6) Protection Range Provided (A) 1,6-->2,5 2,5-->4...
Page 40 OPERATION Wiring for external fan protection Wiring for control of external fan Incompatibilities between options and features on HYDROLEAN UNIT TYPE AND SIZE SW 25 35 SW 50 70 80 SW 100 120 135 160 CONTROLLER MODEL Climatic 40 Remote ON / OFF Dynamic Set Point or Remote Heat/Cool or Remote ON / OFF or...
Page 41: Other Features And Options
OPERATION 4.10 - Hot water control (option) This option can only be selected on HYDROLEAN Cooling only units SWC and consist in a special conﬁ guration of the program and temperatures probes ﬁ tted to the condenser. It is NOT recommended to use a pressure regulating valve when the control on hot water option is selected. 4.11 - Remote heat cool (standard if no incompatibilities refer to previous page for details) This option can only be selected on HYDROLEAN Heat Pump version SWH and consist in a special conﬁ...
Page 42: Maintenance
C of standard EN378-2 can be used if no similar criteria exist in the national regulations. We recommend regular and thorough servicing of the LENNOX unit. The following maintenance instructions form a part of the operations required for this type of equipment.
Page 43: Annual Maintenance
On units with water cooled condensers, it is important that the unit be serviced regularly by a qualiﬁ ed technician, at least once every year or every 1000 hours of operation. Failure to observe this rule can lead to cancellation of the warranty and will clear LENNOX of whatever responsibility.
Page 44: Cleaning The Condenser
Darkening of the colour of the oil or degradation of its qualities can also be caused by the presence of humidity in the system. When the oil has changed colour or has been degraded, it must be changed. On request, LENNOX can carry out an oil analysis.
Page 45: Corrective Maintenance
MAINTENANCE 6 - CORRECTIVE MAINTENANCE MAKE SURE THAT THE UNIT IS COMPLETELY DISCONNECTED FROM THE POWER SUPPLY BEFORE CARRYING OUT ANY TYPE OF WORK ON THE UNIT. If some component in the cooling circuit must be replaced, follow these recommendations: •...
Page 46: Troubleshooting - Repairs
TROUBLESHOOTING – REPAIRS 1 - LIST OF THE MOST COMMON PROBLEMS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A. THE COMPRESSOR DOES NOT START • Motor control circuits established, the • No power supply • Check main power supply and switch compressor does not run positions •...
Page 47 • Liquid line valve not open far enough • Open the valve completely • Noisy compressor, or abnormally high • Leaky internal compressor valves/seals • Contact LENNOX, compressor may have suction pressure or low discharge • Low oil level to be changed.
Page 48 TROUBLESHOOTING – REPAIRS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION D. THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH • Oil pressure switch tripped • Check operation of the oil pressure safety switch • Oil level in sight glass is too low - •...
Page 49 TROUBLESHOOTING – REPAIRS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION F. THE COMPRESSOR CUTS OUT ON ITS MOTOR PROTECTION THERMAL RELAY • Thermal protection tripped • Check operation of thermal protection, change it if necessary • Motor windings are not being sufﬁ ciently •...
Page 50 TROUBLESHOOTING – REPAIRS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION J. DISCHARGE PRESSURE TOO HIGH • Water is far too hot at condenser outlet • Water ﬂ ow to low or water temperature • Adjust the pressure operated water valve too high in the condenser or the thermostat on the cooling tower •...
Page 51: Control Devices
TROUBLESHOOTING – REPAIRS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION • Conditioned space too cold • Control thermostat contacts stuck in • Repair or replace closed position • Compressor short-cycling • Capacity modulation setting too low • Adjust • Superheat value too high •...
Page 52: Regular Checks To Be Made - Chiller Unit Environment
TROUBLESHOOTING – REPAIRS 3 - REGULAR CHECKS TO BE MADE - CHILLER UNIT ENVIRONMENT CHILLED WATER CIRCUIT VALUE Inlet / Outlet pressure gauges for pressure drop ..........................kPa Evaporator inlet temperature ................................°C Evaporator outlet temperature ................................°C Glycol concentration ..................................
Page 53: Manufacturer's Recommended Inspections
TROUBLESHOOTING – REPAIRS 4 - MANUFACTURER’S RECOMMENDED INSPECTIONS 4.1 - LIQUID CHILLERS WITH SCROLL COMPRESSOR(S) 4.1.1 - Number of recommended preventive maintenance visits: NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Major technical Year Start up 500/1000h visit Inspection visit Tube analysis inspection Every year 3 times a year...
Page 54 TROUBLESHOOTING – REPAIRS 4.1.2 - Description of inspection duties - Liquid chiller with scroll compressor(s) START UP • Check unit installation • Check water ﬂ ow and water circuit ancillaries • Check safety devices • Check leak tightness • Conﬁ guration of the microprocessor based management system (if used) •...
Page 55: Check List
CHECK LIST Machine identiﬁ cations: Affair number: Year of manufacture: NORMAL CONDITIONS OF USE Leaving chilled water temperature: °C Outdoor air temperature: Max: Min: °C °C Power supply voltage: V/Ph/Hz Refrigerant type: Date and time measurements were taken: Outdoor air temperature: °C Company responsible for measurements: Name of technician:...
Page 56 • All unions tightened with a torque wrench GENERAL • Cooling load available, minimum 50 % • Coordination between different professions for ﬁ nal commissioning CUSTOMER ORDER NUMBER ............LENNOX REFERENCE: ............DESIGNATION ....................................... COMMENTS: ................................................................................NAME: ........................ SIGNATURE: ............
Page 57: Appendicies
APPENDICIES APPENDICIES CHILLER-IOM-1309-E • 55 •...
Page 58: Risk Analysis And Hazardous Situations According To 97/23/Ce Directive
APPENDIX 1 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97/23/CE DIRECTIVE Information to minimise N° Event Effect Risk Actions to Eliminate the Risk the occurrence of a risk V i o l e n t C h o c k s , A p p e a r a n c e Leaks, liquid or gas Only handling the units using...
Page 59 Use IOM supplied circuit, liquid/gas/ brazing materials approved by metal parts could be LENNOX. Ensure the circuit is thrown out of the unit leak free before reﬁ lling with refrigerant. 15A U n i t e x p o s e d...
Page 60: General Refrigeration Circuit Diagram: Neosys Cooling Only
APPENDIX 2 GENERAL REFRIGERATION CIRCUIT DIAGRAM: NEOSYS COOLING ONLY 1st & 2nd scroll compressors Pressure relief valve Thermostatic expansion valve Third scroll compressor on size Air cooled condenser Electronic expansion valve above 300 kW High pressure switch Fan motor Evaporator heat exchanger 04a / Pressure transducers HP &...
Page 61: General Refrigeration Circuit Diagram: Neosys (Heat Pump)
APPENDIX 3 GENERAL REFRIGERATION CIRCUIT DIAGRAM: NEOSYS HEAT PUMP NAH Refrigeration Circuit All NAH units C1 & C2 AIRFLOW Cooling Heat Pump 1st & 2nd scroll compressors Air cooled heat exchanger Plate heat exchanger High pressure switch Fan motor Non return valve 04a / Pressure transducers HP &...
Page 62: General Refrigeration Circuit Diagram: Hydrolean Cooling Only
APPENDIX 4 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN COOLING ONLY 025 - 035 050 - 070 - 080 Standard Components Options 01.a/ 07a/ 01.b/ Compressors Low & high pressure gauges 07b/ 01.c Evaporator Pressure regulated water valve Condenser Thermostatic expansion valve Filter drier 06a/ Low &...
Page 63 APPENDIX 4 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN COOLING ONLY 100 - 120 - 135 - 160 400mm High Pressure operated water valve for dual circuit units (option) Standard Components Options 01.a/ 07a/ 01.b/ Compressors Low & high pressure gauges 07b/ 01.c Evaporator Pressure regulated water valve...
Page 64: General Refrigeration Circuit Diagram: Hydrolean Heat Pump
APPENDIX 5 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN HEAT PUMP 025 - 035 050 - 070 - 080 Standard Components Options 01.a/ 07a/ Compressors Low & high pressure gauges 01.b/ 07b/ Evaporator Condenser Thermostatic expansion valve Filter drier & ﬁ lter by-pass 06.a Low &...
Page 65 APPENDIX 5 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN HEAT PUMP 100 - 120 - 135 - 160 400mm Standard Components Options 01.a/ 07a/ Compressors Low & high pressure gauges 01.b/ 07b/ Evaporator Condenser Thermostatic expansion valve Filter drier & ﬁ lter by-pass 06.a Low &...
Page 66: General Refrigeration Circuit Diagram: Hydrolean Remote Condenser
APPENDIX 6 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN REMOTE CONDENSER 025 - 035 050 - 070 - 080 Standard Components 01.a/ Liquid solenoid valve 01.b/ Compressors 01.c Evaporator Condenser Options Thermostatic expansion valve 07a/ Removable cartridge drier ﬁ lter Low & high pressure gauges 07b/ 06.a Low &...
Page 67 APPENDIX 6 GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN REMOTE CONDENSER 100 - 120 - 135 - 160 Standard Components 01.a/ Liquid solenoid valve 01.b/ Compressors 01.c Evaporator Condenser Options Thermostatic expansion valve Removable cartridge drier ﬁ lter 07a/ Low & high pressure gauges 07b/ 06.a Low &...
Page 68: General Refrigeration Circuit Diagram: Mcw
APPENDIX 7 GENERAL REFRIGERATION CIRCUIT DIAGRAM: Circuit 1 & 2: 2 or 3 compressors per circuit Main components Compressors High pressure relief valve Water cooled evaporator High pressure safety switch Water cooled condenser High and low pressure transducers Expansion valves High pressure safety switch Cartridge drier ﬁ...
Page 69: General Refrigeration Circuit Diagram: Mrc
APPENDIX 8 GENERAL REFRIGERATION CIRCUIT DIAGRAM: Circuit 1 & 2: 2 or 3 compressors per circuit Main components Compressors High pressure relief valve Water cooled evaporator High pressure safety switch Manual shut off valves High and low pressure transducers Expansion valves High pressure safety switch Cartridge drier ﬁ...
Page 70: General Mechanical Drawing
G3/D3 G1/D1 G2/D2 G3/D3 NAH 200 NAC 200 NAH 230 NAC 230 NAC 270 Lennox recommend load distribution as detailed above. CLEARANCES ANTI-VIBRATION MOUNTS (OPTION) Overhead obstructions are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m. 2 m.
Page 71 LOAD DITRIBUTION G1/D1 G2/D2 G3/D3 G4/D4 (Kg - Operating weights with dual pump hydraulic module) NAH 270 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m.
Page 72 G1/D1 G2/D2 G3/D3 G4/D4 (Kg - Operating weights with dual pump hydraulic module) NAC 300 NAH 300 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m.
Page 73 G3/D3 G4/D4 G1/D1 G2/D2 G3/D3 G4/D4 NAC 340 NAH 340 NAC 380 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m. 2 m. 1,5 m.
Page 74 G4/D4 G1/D1 G2/D2 G3/D3 G4/D4 NAC 420 NAH 380 NAC 480 NAH 420 Lennox recommend load distribution as detailed above, NAH 480 ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m. 1,5 m.
Page 75 LOAD DITRIBUTION G1/D1 G2/D2 G3/D3 G4/D4 (Kg - Operating weights with dual pump hydraulic module) NAC 540 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m.
Page 76 LOAD DITRIBUTION G1/D1 G2/D2 G3/D3 G4/D4 G5/D5 (Kg - Operating weights with dual pump hydraulic module) NAC 600 NAC 640 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstruction are not permitted Ø 200 Ø M18 Ø...
Page 77 Note: In case of single main power connection (option), main power supply and disconnect switch are located at the right side of the unit. LOAD DITRIBUTION (Kg - Operating weights with dual pump hydraulic module) NAC 680 NAC 760 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstructions are not permitted Ø 200 Ø M18 Ø...
Page 78 LOAD DITRIBUTION (Kg - Operating weights with dual pump hydraulic module) NAC 840 NAC 960 NAC 1080 Lennox recommend load distribution as detailed above, ANTI-VIBRATION MOUNTS (OPTION) CLEARANCES Overhead obstructions are not permitted Ø 200 Ø M18 Ø 14,5 1,5 m.
Page 79: Hydrolean 025 / 035
APPENDIX 9 GENERAL MECHANICAL DRAWING HYDROLEAN 025 / 035 823 ±15 509 ±15 135 ±5 502 ±15 802 ±15 76 ±5 D2/D1 G2/G1 D1/G1 D2/G2 G1/G2 D1/D2 460 ±5 750 ±5 20 ±5 20 ±5 25 ±5 25 ±5 45 ±5 LOAD DISTRIBUTION CLEARANCES (kg - Operating weights)
Page 80 APPENDIX 9 GENERAL MECHANICAL DRAWING HYDROLEAN 050/070/080 DIMENSIONAL DATA 652 ±15 1498 ±15 132 ±15 1472 ±15 367 ±15 646 ±15 D2/D1 G2/G1 D1/G1 D2/G2 G1/G2 D1/D2 20 ±15 598 ±15 20 ±15 76 ±15 1180 ±15 76 ±15 LOAD DISTRIBUTION CLEARANCES (kg - Operating weights) 0,5 m...
Page 81 APPENDIX 9 GENERAL MECHANICAL DRAWING HYDROLEAN 100/120/135/160 DIMENSIONAL DATA 134 ±15 652 ±15 1522 ±15 70 ±15 49 ±15 646 ±15 1472 ±15 D2/D1 G2/G1 D1/G1 D2/G2 G1/G2 D1/D2 20 ±15 598 ±15 20 ±15 76 ±15 1180 ±15 76 ±15 176 ±15 290 ±15 LOAD DISTRIBUTION...
Page 82: Mwc 180
Water outlet Out1 4" 4" Condenser Water inlet 4" Water outlet Out2 4" Liquid line 7/8" Discharge line 1" 1/8 LOAD DITRIBUTION (Kg - Operating weights) MWC 180 MRC 180 Lennox recommend load distribution as detailed above • 80 • CHILLER-IOM-1309-E...
Page 83 2 x 1"1/8 2 x 1" 1/8 7/8" 1" 3/8 Discharge line 2 x 1"3/8 2 x 1"3/8 2 x 1" 3/8 1" 1/8 LOAD DITRIBUTION (Kg - Operating weights) Lennox recommend load distribution as detailed above CHILLER-IOM-1309-E • 81 •...
Page 84 APPENDIX 9 MWC 450  570 1000 Mini 1438±5 231±5 Out2 Out1 G1/G2 D1/D2 D1/G1 D2/G2 150±5 1600±5 1008±5 Fixing detail view 1900±5 1200±5 2200±5 Fixing detail view 4 x n 20 In/Out = Ø 5" Victaulic Out1 Out2 450  570 450 ...
Page 85 APPENDIX 9 MWC 650  720 719±5 719±5 231±5 1000 Mini Out2 Out1 G1/G2 D1/D2 D1/G1 D2/G2 150±5 1600±5 1008±5 Fixing detail view 1900±5 1200±5 2200 ± 15 Fixing detail view 4 x n 20 Out1 Out2 Out2 In/Out = Ø 5" Victaulic MRC 650 MRC 720 650 ...
Page 86: Hydraulic Data
APPENDIX 10 HYDRAULIC DATA All victaulic connections Inlet ﬁ lter (supplied loose) Automatic air vent Expansion vessel, relief valve & manometer Single or dual pump, high or low pressure New electronic stainless steel ﬂ ow switch High performance stainless steel evaporator Pressure adjustment valve Pressure taps and drain valve Confi guration for fl anged connections...
Page 87: Pressure Drops
APPENDIX 10 NEOSYS PRESSURE DROPS EVAPORATORS CURVE Curve Curve 1080 Flow rate (m Flow rate (m FILTER CURVE Curve 1080 Flow rate (m Pressure drops are given for information only. A tolerance of +/- 20 kPa must be considered when selecting water pumps.
Page 88 APPENDIX 11 HYDROLEAN PRESSURE DROPS HYDROLEAN Evaporator/Condenser curve PRESSURE DROP OF HYDROLEAN A2 B1 B2 C1 C2 PLATE HEAT EXCHANGERS WITH CLEAR WATER Water ﬂ ow m PRESSURE DROP OF HYDROLEAN A1 A2 B1 B2 C1 C2 PLATE HEAT EXCHANGERS WITH WATER AND ETHYLENE GLYCOL 30% Water ﬂ...
Page 89 APPENDIX 11 HYDROLEAN PRESSURE DROPS FILTERS Water ﬁ lter diameter W = 1'' 1/2 X = 2'' Y = 2'' 1/2 Z = 3'' Water ﬂ ow rate (m HYDROLEAN Filter curve "FULLY OPEN" PRESSOSTATIC CONTROL WATER VALVE WVFX25 WVS32 WVS40 Water ﬂ...
Page 90 APPENDIX 11 PRESSURE DROPS EVAPORATORS CURVE 90 100 Water ﬂ ow rate (m CONDENSER CURVE 80 90 100 FILTER CURVE Water ﬂ ow rate (m Curves DN 100 Evaporator Condenser Filter DN 125 DN100 DN100 DN100 DN100 DN100 DN125 DN125 DN125 DN125 DN125...
Page 91: Start-Up And Maintenance Logbook
APPENDIX 12 START-UP AND MAINTENANCE LOGBOOK INSTALLATION CHECK-UP This check list should be ﬁ lled in before the start-up with the contractor to make sure that unit installation takes place according to appropriate industry practices. Refer to safety recommendation prior to any work on the unit. DATE: TECHNICIAN: FIELD NAME:...
Page 92: Unit Installation
APPENDIX 12 UNIT INSTALLATION Clearance around unit in conformity Correct condensors ventilation Uniit levelled Vibration isolation mounted and properly dimensioned Vibration isolators on piping connection Correct earthing of the unit Earth continuity on piping HYDRAULIC NETWORK Glycol protection in conformity Primary loop Secondary loop Water tank...
Page 93: Start-Up Check Sheet
APPENDIX 13 START-UP CHECK SHEET Unit type: Technician name: Construction year: Start-up date: THERMAL DATA Evaporator I / O temp. / °C / °C / °C / °C Condenser I / O temp / °C / °C / °C / °C Ambient air temp / °C / °C...
Page 94 APPENDIX 13 Remarks: ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Reserves: ........................................
Page 95: Maintenance Logbook
APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 1 (500H / 1000H) Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level...
Page 96 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 3 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 97 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 5 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 98 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 7 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 99 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 9 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 100 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 11 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 101 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 13 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 102 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 15 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 103 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 17 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 104 APPENDIX 14 MAINTENANCE LOGBOOK MAINTENANCE visit n° 19 Date Y / N Value Comments Unit general control (corrosion, damages…) Exchanger cleaning Leak test done Oil acidity test carried Replacement of ﬁ lter drier cartridge Water ﬁ lters cleans Evaporator pressure drop Water condenser pressure drop Glycol concentration level Unit operating parameters checked and in conformity...
Page 105: Refrigerant Transactions Logbook: Ec Regulation N° 842/2006
APPENDIX 15 REFRIGERANT TRANSACTIONS LOGBOOK: EC REGULATION N° 842/2006 GENERAL INFORMATION Site name Serial number Site address Site operator Cooling load Refrigerant type Refrigerant quantity (kg) Unit manufacturer Year of installation REFRIGERANT ADDITIONS Date Engineer Quantity (kg) Reason for addition REFRIGERANT REMOVAL Date Engineer...
Page 106 APPENDIX 15 LEAK TESTS (Part 2) Date Engineer Test result Follow up action required FOLLOW UP ACTIONS Date Engineer Related to test dated Action taken TESTING of AUTOMATIC LEAK DETECTION SYSTEM (If ﬁ tted) Date Engineer Test result Comments Remarks: .................................................................................
Page 108 PORTUGAL  +33 4 72 23 20 00  +351 229 066 050 Due to Lennox’s ongoing commitment to quality, the speciﬁ cations, ratings and dimensions are subject to change without notice and without incurring liability. Improper installation, adjustment, alteration, service or maintenance can cause property damage or personal injury.

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Lennox NEOSYS Installation, Operating And Maintenance Manual

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