Lennox MCC Series Installation, Operating And Maintenance Download Page 83

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Installation - Operation - Maintenance manual (IOM)

•

AIR COOLED CHILLERS & SPLIT UNITS - 0105-E

• 81 •

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 filter drier cartridge

Water filters cleans

Evaporator pressure drop

Kpa

Water condenser pressure drop

Kpa

Glycol concentration level

Unit operating parameters checked and in conformity

Fans currents level checked and in conformity

Compressors data

CP1 CP2 CP3

CP4

CP5

CP6

Operating hours

Current at 100% load

Comments et remarks:

TECHNICIAN

CLIENT

Name

Signature: Signature:

MAINTENANCE visit n° 18

Date

Y / N

Value

Comments

Unit general control (corrosion, damages…)

Exchanger cleaning

Leak test done

Oil acidity test carried

Replacement of filter drier cartridge

Water filters cleans

Evaporator pressure drop

Kpa

Water condenser pressure drop

Kpa

Glycol concentration level

Unit operating parameters checked and in conformity

Fans currents level checked and in conformity

Compressors data

CP1 CP2 CP3

CP4

CP5

CP6

Operating hours

Current at 100% load

Comments et remarks:

TECHNICIAN

CLIENT

Name

Signature: Signature:

Summary of Contents for MCC Series

Page 1: ...Providing indoor climate comfort CHILLER_AC IOM 1106 E Installation operating and maintenance AIR COOLED CHILLERS...

Page 2: ......

Page 3: ...esigned 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 t...

Page 4: ...RY 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 LENNO...

Page 5: ...re 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...

Page 6: ...tem 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 shal...

Page 7: ...nt 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 Vol...

Page 8: ...amecut 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 Refri...

Page 9: ...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 ordere...

Page 10: ...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 C...

Page 11: ...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 s...

Page 12: ...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 exch...

Page 13: ...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 in...

Page 14: ...ulated using the formula hereafter Q Cooling capacity of the chiller in kW N Number of Compressor X Number depending of the type of compressor Scroll 12 screw 8 Recip 10 Vt 172 x Q n x X litres Exampl...

Page 15: ...lers 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...

Page 16: ...hing 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...

Page 17: ...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 T...

Page 18: ...ntrol 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 wi...

Page 19: ...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 4...

Page 20: ...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 va...

Page 21: ...ferent systems may be used but the most simple and efficient of these modulates fan operation using a pressure or temperature control For condensers fitted with a small number of fans 1 or 2 it may be...

Page 22: ...lic sketch is given in the ANNEXES at the end of the IOM See page 50 to 54 4 4 INSTALLATION OF EXTERNAL HYDRAULIC COMPONENTS supplied loose by Lennox Some hydraulic components may be supplied loose by...

Page 23: ...dition water supply and overflow checked fan in operating condition 5 Reset all manually resetting safety devices where necessary Open power circuits to all components compressors fans 6 Power up the...

Page 24: ...To rectify this it may be necessary to modify the pulley and belt setting To this effect the motors are fitted with variable pulleys 9b AIRFLOW BALANCING Measure the absorbed amps If the absorbed amp...

Page 25: ...Installation Operation Maintenance manual IOM AIR COOLED CHILLERS SPLIT UNITS 1106 E 23 AT 18 18 FAN CURVE...

Page 26: ...the day the start up is conducted at least 50 of the nominal load PROCEDURE TO FOLLOW WHEN STARTING THE UNIT 5 a Press the power ON OFF switch The compressor will only start if the evaporating pressur...

Page 27: ...t unit shutdowns by the differential oil pressure switch are usually caused by other problems than a lack of oil in the refrigeration circuits Overcharging with oil can cause serious problems on an in...

Page 28: ...type or reciprocating compressors Enables visual verification of the state of the liquid refrigerant monophase ou diphasic in the liquid line upstream of the thermostatic expansion valve Enables detec...

Page 29: ...switch only on units with semi hermetic compressors a Reciprocating compressors This pressure switch initiates unconditional unit stoppage if differential oil pressure drops for more than two minutes...

Page 30: ...the flow of chilled liquid water brine etc ensured by the pump becomes insufficient since this could cause rapid evaporator freeze up When the contact opens due to a lack of flow the unit must stop im...

Page 31: ...ed for as long as it takes to bring sump oil back up to temperature then restart the unit 6 2 3 5 Pressostatic water valve This device is available as an option for low capacity water cooled condensin...

Page 32: ...LLERS SPLIT UNITS 1106 E 30 WA RA 200D 230D HE SLN WA RA 270D 300D HE SLN WA RA 370D HE SLN WAH 150 D STD WA RA 100E 110E HE SLN Special units with screw compressors Fans electrical box labelling size...

Page 33: ...enced personnel can establish strict maintenance procedures adapted to the conditions listed above Nonetheless we recommend a regular maintenance schedule 4 times a year for chillers operating all yea...

Page 34: ...to detect any eventual abnormality noisy compressor loose casing panels leaky pipes or juddering contacts 7 Record temperatures pressures dates et times and any other observations in the service log...

Page 35: ...able to recommend the right solvent for removing scale The equipment to be used for external water circulation the quantity of solvent and the safety measures to be taken must be approved by the compa...

Page 36: ...ck the water pump and water circuitry and filters Find the cause of the trip out Flow switch contacts open Check circulation of liquid in the evaporator and the condition of the flow switch Anti short...

Page 37: ...hen top up the refrigerant charge Filter drier obstructed Check the state of the drier and replace the filter Solenoid valve closed Check that the valve is operating properly Expansion valve closed Ch...

Page 38: ...ompressor valves Check valve gas tightness replace the valve plate if necessary Tighten compressor nuts and bolts E THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH Oil pressure switch tripped Ch...

Page 39: ...keep water circulating until evaporator has thawed completely Low refrigerant charge Check the refrigerant charge and add refrigerant if necessary G THE COMPRESSOR CUTS OUT ON ITS MOTOR PROTECTION THE...

Page 40: ...pressure is to high or irregular Clean the valve Install and expansion tank upstream of the valve Compressor shuts down through action of the oil pressure safety switch Low oil charge Add oil K DISCHA...

Page 41: ...ghtglass Low refrigerant charge Repair the leak and add refrigerant Excessive pressure drop across the filter drier or the solenoid valve Filter drier obstructed Replace the cartridge No refrigerant p...

Page 42: ...line filter drier A damaged compressor cylinder bank unloader The control thermostat monitors chilled water temperature at the evaporator inlet The most common causes of subnormal temperatures in this...

Page 43: ...up 500 1000H visit Major technical inspection Inspection visit 15 000 h inspection 30000 h inspection Tube analysis 1 1 1 2 2 1 3 3 1 3 4 3 1 5 1 3 1 1 6 1 3 7 3 1 8 1 3 9 1 3 10 3 1 1 10 Every year 3...

Page 44: ...JOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges if necessary Check up on the microprocessor based management system if used Adjustmen...

Page 45: ...TS Year Start up 500 1000H visit Major technical inspection Inspection visit Tube analysis 1 1 1 2 2 1 3 3 1 3 4 3 5 1 3 1 1 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 1 10 Every year 3 times a year Every 3 years...

Page 46: ...depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements...

Page 47: ...00 1000H visit Major technical inspection Inspection visit 30000 h inspection Tube analysis 1 1 1 2 2 1 3 3 1 3 4 3 5 1 3 1 1 6 1 3 7 3 1 1 8 1 3 9 1 3 10 3 10 Every year 3 times a year Every 30000 ho...

Page 48: ...use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessa...

Page 49: ...DRAWINGS ECOLOGIC range 48 OPERATING LIMITS ECOLOGIC range 52 Screw compressor chiller 56 RISK ANALYSIS AND HAZARDOUS SITUATIONS ACCORDING TO 97 23 CE DIRECTIVE 61 REFRIGERATION CIRCUIT DRAWINGS ECOL...

Page 50: ...isolation valve 16 Plate heat exchanger 03 Water inlet filter 22 Flow switch Differential 04a 17a In Out manometers without groove lock coupling option 04b 17b in Out manometers mounted on groove loc...

Page 51: ...on groove lock coupling option 09 Water drain 14 Air purge 10 25L expansion vessel 15a Temperature sensor return 11a Second 25L expansion vessel for WA 150D 15b Temperature sensor supply 16 Plate hea...

Page 52: ...ove lock coupling option 11b Single 50L expansion vessel WA 150D 15a Temperature sensor return 04b 17b In Out manometers mounted on groove lock coupling option 15b Temperature sensor supply 16 Plate h...

Page 53: ...n valve 15a Temperature sensor B Isolating valves 03 Water inlet filter 15b Temperature sensor C Three way valve 04a 17a In Out manometers without groove lock coupling option 22 Flow switch differenti...

Page 54: ...n valve and ONE compressor unloaded C 49 46 46 48 48 45 Start up with CLIMATIC 50 Electronic expansion valve and ONE compressor unloaded C 49 47 47 49 49 46 WA LOW NOISE WA 150 200 230 270 300 370 Min...

Page 55: ...c expansion valve and ONE compressor unloaded C 52 49 49 53 52 52 49 49 50 52 46 WA SUPER LOW NOISE WA 075 090 100 110 130 150 200 230 270 300 370 Minimum outlet water temperature C 5 Maximum inlet wa...

Page 56: ...ure C 6 Maximum outside air temperature Normal operation with CLIMATIC 50 12 C 7 C water one compressor unloaded C 51 50 49 Start up with CLIMATIC 50 Thermostatic expansion valve and ONE compressor un...

Page 57: ...r Safety Low pressure cut out bar 0 7 Safety Interlocking of low pressure bar 2 2 Safety High pressure cut out bar 29 Safety High pressure reset bar 20 WA 200 230 270 300 370 Operating limits for evap...

Page 58: ...Max difference water inlet outlet C 8 Min outside air temperature C 6 Min outside air temperature 1 C 15 Max outside air temperature 2 C 48 5 48 5 48 5 49 49 Size 803V 853VE 953V 1003VE 1053V Operatin...

Page 59: ...52VE 803V 853VE 953V 1003VE Operating limits Min outlet water temperature C 5 Max inlet water temperature C 20 Min difference water inlet outlet C 3 Max difference water inlet outlet C 8 Min outside a...

Page 60: ...nce water inlet outlet C 8 Min outside air temperature C 6 Min outside air temperature 1 C 15 Max outside air temperature 2 C 50 5 50 5 50 5 50 5 50 5 Size 803V 853VE 953V 1003VE 1053V Operating limit...

Page 61: ...essure Bar 10 Refrigerant Test pressure Bar 26 5 Water Max operating pressure Bar 6 Refrigerant Max operating pressure Bar 26 5 Water Min flow m3 h 8 C T Water Max flow m3 h 89 3 89 3 153 5 153 5 153...

Page 62: ...low pressure Bar 0 7 Safety Interlocking of low pressure Bar 2 2 Safety Cut of high pressure Bar 26 5 Safety Interlocking of high pressure Bar 20 Size 1053V 1153VE 1254V 1354VE 1404V 1504VE Operating...

Page 63: ...ction of the circuit liquid gas could be thrown out of the unit Provide anti frost protection ei Water treated with Glycol or trace heaters along the pipe work Indications in the technical IOM supplie...

Page 64: ...specified on the unit s nameplate Indications of the refrigerant fluid on the unit nameplate 12A Inappropriate oil in the compressor Corrosion excessive heat Partial or complete destruction of the ci...

Page 65: ...sure transducers HP BP 11 Filter drier 18 Suction temperature sensor 05a 05b Low and High pressure manometer 12 Solenoid valve 19 External temperature sensor 06a 06b Suction and discharge isolation va...

Page 66: ...04b Pressure transducers HP BP 10 Manual isolating valve 21 Restrictor 05a 05b Low and High pressure manometer 11 Filter drier 22 4 way inverting valve 06a 06b Suction and discharge isolation valves 1...

Page 67: ...nser 13 Sight glass 03 High pressure switch 09 Fan motor 18 Suction temperature sensor 04a 04b Pressure transducers HP BP 10 Manual isolating valve 19 External temperature sensor 05a 05b Low and High...

Page 68: ...Installation Operation Maintenance manual IOM AIR COOLED CHILLERS SPLIT UNITS 0105 E 66 CERTIFICATES...

Page 69: ...Installation Operation Maintenance manual IOM AIR COOLED CHILLERS SPLIT UNITS 0105 E 67...

Page 70: ...Installation Operation Maintenance manual IOM AIR COOLED CHILLERS SPLIT UNITS 0105 E 68...

Page 71: ...around unit Clearance conform to regulation Dangerous working conditions CONFIRMATION OF INSTALLER DATA GIVEN PRIOR TO COMMISSIONING YES NO Compressors crankcase heater ON 24 hours before start up Con...

Page 72: ...NFORMITY PRIMARY LOOP SECONDARY LOOP WATER TANK WATER PUMP AT THE EVAPORATOR ENTRY WATER FLOW SWITCH AT THE EVAPORATOR OUTLET PRESSOSTATIC FLOW SWITCH WATER PUMP AT THE CONDENSER ENTRY CONTROL OF THE...

Page 73: ...mp C C C C Oil level Refrigerant type charge Kg Kg Kg Kg LP safety cut b b b b HP safety cut b b b b ELECTRICAL DATA CIRCUIT 1 CIRCUIT 2 Power supply V C1 C2 C3 C1 C2 C3 CIRCUIT 3 CIRCUIT 4 L1 A L2 A...

Page 74: ...Installation Operation Maintenance manual IOM AIR COOLED CHILLERS SPLIT UNITS 0105 E 72 Remarks Reserves TECHNICIAN CUSTOMER Name Name Signature Signature...

Page 75: ...in conformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 2 Date Y N Value Com...

Page 76: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 4 Date Y N Value Comments...

Page 77: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 6 Date Y N Value Comments...

Page 78: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 8 Date Y N Value Comments...

Page 79: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 10 Date Y N Value Comments...

Page 80: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 12 Date Y N Value Comments...

Page 81: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 14 Date Y N Value Comments...

Page 82: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 16 Date Y N Value Comments...

Page 83: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 18 Date Y N Value Comments...

Page 84: ...nformity Compressors data CP1 CP2 CP3 CP4 CP5 CP6 Operating hours Current at 100 load Comments et remarks TECHNICIAN CLIENT Name Name Signature Signature MAINTENANCE visit n 20 Date Y N Value Comments...

Page 85: ......

Page 86: ...IOM 0106 E BELGIUM LUXEMBOURG CZECH REPUBLIC FRANCE GERMANY NETHERLANDS POLAND PORTUGAL RUSSIA SLOVAKIA SPAIN UKRAINE UNITED KINGDOM AND IRELAND OTHER COUNTRIES Due to Lennox s ongoing commitment to...

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