Lennox AAH051, AAH041, AQUA4 AAH Series, AAH071, AAH081 Application Manual

APPLICATION
GUIDE

Polyvalent air cooled heat pump

AQUA

4

AAH

50  330 kW

AQUA4-AGU-1405-E

lennoxemeia.com

1 Table of Contents

1 TABLE OF CONTENTS ........................................................................................................ 1

2 MODEL NUMBER DESCRIPTION ......................................................................................... 2

3 KEY CUSTOMER BENEFITS ................................................................................................ 3

3.1 THE AQUA4 P ................................................................................................................ 3

3.2 THE AQUA4 M ................................................................................................................ 3

3.3 BENEFITS ...................................................................................................................... 3

4 FEATURES AND BENEFITS ................................................................................................ 4

4.1 STANDARD EQUIPMENT ..................................................................................................... 4

4.2 INNOVATIONS PRODUCT: SOLVING THE DEF ROSTING PROBLEM.................................................. 5

4.3 STRUCTURE ................................................................................................................... 5

4.4 REFRIGERANT CIRCUIT...................................................................................................... 5

4.5 COMPRESSORS ............................................................................................................... 5

4.6 BRAZED PLATE HEAT EXCHANGERS ..................................................................................... 5

4.7 CONTROL BOX ................................................................................................................ 5

4.8 CONTROL AND COMMUNICATION ......................................................................................... 6

5 OPTIONS AND ACCE SSORIES ............................................................................................ 7

6 APPLICATION ................................................................................................................... 10

7 OPERATING COMBINATION DEPENDING ON THE THERMAL LOAD: ................................. 14

8 OPERATING LIMITS .......................................................................................................... 16

9 TECHNICAL DATA - PERFORMANCES .............................................................................. 17

10 OVERVIEW DIAGRAMS ..................................................................................................... 42

11 INSTALLATION ................................................................................................................. 45

11.1 FOR FURTHER INFORMATION SEE THE USER AND MAINTENANCE MANUAL. .................................. 45

11.2 PRE LIMINARY PROCEDURES ............................................................................................. 45

11.3 WATER CONNECTIONS .................................................................................................... 46

11.4 EL ECTRICAL CONNECTIONS ............................................................................................. 48

11.5 EL ECTRIC CONNECTIONS OF THE CIRCULATION PUMP ............................................................ 48

11.6 USE OF GLYCOL SOLUTIONS ............................................................................................ 48

11.7 OPERATING AND STORAGE LIMITS ..................................................................................... 48

La déclaration de conformité accompagne chaque unité

AQUA4–AGU-1405-E - 1 -

Déclaration de conformité

1 = 2 compressors / 2 circuits
4 = 4 compressors / 2 circuits

M= 2 pipes
P= 4 pipes

S= standard noise level
L= Low noise level

2 MODEL NUMBER DESCRIPTION

The AQUA4 units are identi fied by the followi ng codes: Example AAH081MS

A AQUA

A Air Cooled

H Heat Pump

08 Nominal Cooling c apacity x10 [kW] (ex.: 08 = 80 kW)

1
M
S

4

AQUA4–AGU-1405-E - 2 -

Cooling

Heating

Circuit 1

Circuit 2

Cooling + Heating

Circuit 1

Circuit 2

Cooling

Circuit 1

Heating

Hot water

Cooling + Hot
water (DHW)

Heating + Hot
water (DHW)

Circuit 1

Circuit 2

Circuit 2

Circuit 2

Circuit 1

Circuit 1

3 KEY CUSTOMER BENEFITS

Nominal cooling capacity @ 12/7°C and 35°C air ambient: 50 to 330kW
Nominal heating capacity @ 40/45°C and 7°C air ambient: 50 to 340kW

3.1 The AQUA4 P: unique concept for thermal comfort with less energy consumption.

The polyvalent heat pump AQUA4 P units are designed to meet the requirements of simultaneous and independent cooling and
heating for air c onditioning in the m ost efficient way. The AQUA
building and are more commonly called 4 pi pe system.

4

P units provide a hot water circuit and a cold water circuit to the entire

3.2 The AQUA4 M: hot water all the year at a lower cost.

The polyvalent heat pump AQUA4 M units are designed to m eet the requirement s of cooling and / or heati ng in the most effic ient way.
The units have the abil ity to provide hot water simultaneously or independently of cooling and heating needs. The AQUA
generally call ed 2 pipe units because two hydraulic pipes are connected to the t erminal building, the other two hydraul ic pipes are
generally dedicated to hot sanitary water.

production (DHW)

4

M units are

3.3 Benefits :

Conserving and optimizing energy consumption

- High energy ratio at part load and full load (EER/COP/ESEER)

- Simultaneous or independent demands for heating and cooling

- Constantly balanced heating and cooling needs to obtain ma ximum Total Efficiency Ratio : TER*

- 100% heat recovery at any conditions

- Advanced programmable pCO1 with a local control inter face PGD1

Secure operatin g m ap as standard

- Winter cooling operation down to -15°C ambient.

- Heating operation down to -10°C ambient wi th 45°C outlet wate r temperature

- Heat recovery or production of hot water temperature fr om 25°C to 55°C

- High ambient operating up to 45°C

Quieter unit

- -8 dB(A) noise level reduction vs traditional heat pump in standard

- Jump to -12dB(A) noise level reduction with low noise version

- Innovative hybri d structure of fan blades

- Unique sound proof cabinet enclosing all components to r educe radiated sound levels

Defrost without impacting comfor t

- Hydrophilic tr eatment on coil

- Dynamic control on defrost

- Circuits defrost completely independently

- Integrated water tank up to 765 litres

(*) TER : Total Efficiency Rat io is the total energy ef ficiency of the unit s when there is a produc tion of chilled water and hot water
simultaneously. Cold water and hot wat er are valuated to the total power consumpt ion of the unit: TER = (cooling capacity + recovered
heating capacity) / total power consum ption. Energy ratio TER of polyvalent heat pumps are si gnificantly higher than the standard EER
and COP demonstr ating considerable energy savings during inter-season per iods (version P) or dom estic hot water production (M
version).

AQUA4–AGU-1405-E - 3 -

4 FEATURES AND BENEFITS

4.1 Standard equipment

• R410A refrigerant

• Two ref rigerant circuits

• ISO 9001 certification.

• Compli ant with CE norms (P ED directive 97'23)

• Galvanized steel base fr am e powder coated RAL70 31

• Galvanized steel cabinet powder coated panels RAL9002

• Main di sconnect switc h w ith lock

• Ventilated electrical control panel

• High efficiency scr oll compressors mounted in a closed technical box

• High efficiency braze plate heat exchangers insulated

• Thermostatic expansion valves

• Axial fans with innovative hybrid structure of blades

• Speed var iation on ventilation, modulatio n phase cut out

• Copper tubes and aluminum f ins coils with hydrophilic coating

• Grouved water connections (Victaulic type)

• Paddl e w ater flow switch

• Low nois e version: Low speed on fan with sound insulation of the entire technical box.

• Advanced control programm able pCO1 with local interface

• Other s components :

• Note : the low noise versions have a fully soundproofed technica l casing and include l ow fan speed

o PGD1 unit display
o Scheduling
o Defrost system independent of each c ircuit
o Water set-point offset based on outdoor air temperature.
o Operating time equalisation of the compressors and pumps
o Master/slave or cascade control .

o Filter driers m olecular sieve
o Liquid moisture i ndicator
o Tanks and liquid separators with mar king complies wit h EE C D irective 97/23 PED
o High and low press ure switch
o Solenoid valves
o Schrader valves

AQUA4–AGU-1405-E - 4 -

4.2 Innovations Product: solving the defrosting problems

Thanks to two indepe ndent thermodynamic circuits, the AQUA4 unit is essential on the market as an exclusive solution t hat can
continue to produce hot water for heating or sanitary uses while simultaneously performing a defrosting cycle.

During winter, especially in the -3°C - +3°C range, the high rel ative air humidity condenses water around the coil fins. Since the coil is at
a lower temperature than the air, any water that touches it solidifies and blocks the exchange of heat nec essary for the system to
correctly operat e. The defrost cycle is a temporary reversal of the thermodynamic cycle operat ing the appliance in cooling mode and is
used to melt ice present between the fins. This phase is of course problematic but AQUA
following innovat ions:

 Hydrophilic coils are installed. These reduce the size of the wate r drops along with ice blockage between fins. Due to the

lower surface tension, water tends to slide away due to gravity, thus preventing the formation of frost at low temperatures.

 Software management minim ises defrosting cycle time, allowing cycle operation onl y w hen necessary. Fans operate at

maximum power only wh en the ice is no longer attached to the fins. It can then be pushed out from the coil.

 The two thermal circuits in AQUA

machine operating, with basically no t hermal discomfort for the user.

4

M and AQUA4 P are completely independent. Whil e one defrosts, the other keeps the

4

system can mitigate this problem thr ough the

4.3 Structure

All AQUA4 series units have a load bearing base and paneling in galvanized sheet metal paint ed with polyester pow ders and
polymerized in the oven at 180°C. The unit is attractivel y designed and when all door s are closed all the components are inac cessible.
This, along with t he extensive use of s oundproofing material inside the compartment and around the compressors (available for the
low-noise versi on), reduces sound to e xceptionally low level s. The water/cool er connections are on the back (when looki ng at the
electric panel) reducing the space required for installation. The unit is fully accessible as all the panels can be removed (except the one
with the water connections). Routine maintenance however only requires access from the front.

4.4 Refrigerant circuit.

The cooling circuit is manufactured i n our factory, with top brand component s by operatives trained, according t o D irective 97/23, on al l
the brazing operati ons.

4.5 Compressors

Only top-quality Scroll compressor s are used on AQUA4 units. Scroll compressors are the bes t solution in terms of reliability and
efficiency. T hey also provide the lowest amount of sound emissions. Process optimisation, along with a carefull y selected intrinsic
volumetric com pression ratio (RVI), clearly improves the isentropic compression performance and reduces energ y losses. The use of a
scroll compressor allows low visc osity oils to be used. Thi s, in comparison t o higher viscosity oils, reduces ther mal resistance at the
evaporator. It also increases the evap oration temperature by over 1.5°C (EER increases by more than 5.5%) compared to other
solutions.
Compressor motors are protected against overheating, overloads and high delivery gas tempera tures. They are mounted on anti­vibration rubber , complete with oil charge and inserted in a soundproof compartment with sound-absorbing material . They are also
equipped with an automatic crankcase heater that, when the compressor st ops, prevents the oil from being diluted by the r efrigerant.

4.6 Brazed plate heat exchangers

Only brazed plate heat exchangers ar e used, made of austenit ic stainless steel AISI 316, with AISI 316L connections. These feature a
reduced carbon content that favours brazing operations. The brazed plate heat exchanger represents state-of-the-art technology in
terms of thermal exchange efficiency and allows a strong reduction of the refrigerant load compared to standard solutions. The high
degree of turbulence generated by internal plate corrugat ion, along with plat e smoothness, m akes it difficult for dirt to accumulate or for
limescale to build up on the condenser circuit. These heat exchangers also make it possible to use R410A fl uid which, thanks to the
high-level of its thermal conductivity in its liquid phase and to its azeotropic behaviour, enhances thermal exchange during evaporation.
The performances are improved over other methane-deriv ative fluids of t he H FC group.

- NOTE: due to thermal ins ulation the data plat e (in compliance wi th PED CE 97/23) is not legible. However, the serial number of the
heat exchanger and the declaration of conformity are both recorded during production and are an i ntegral part of the company
archive.

4.7 Control box

The electric panel is built and wired in accordance with standard EN 60204-1. The electric panel is accessed from the front of the
machine. Before it can be accessed, t he unit must be disconnec ted from the power suppl y using the mains di sconnect switch, which
also functions as a door-lock. All the remote controls are implemented with low voltage 24 V signals, powered by an isolation
transformer inside the electric panel. All the control boards have an air circulation system wi th auxiliary fans. The position of the main
switch makes wir ing operations in the work site easier. This avoids several difficult operations as well as having to twist the power
cords. All the ut ilities are protec ted against surges and short circuits. The circuit breaker set-up can be configure d for any load

AQUA4–AGU-1405-E - 5 -

(optional). Ther m al protection, however, is carried out by thermistor chains. These are set in the windings of each elec tric motor and are
controlled by onboard electronics. All units are equipped as standard with a phase sequence relay w hich inhibits compressor operation
if the phase sequence is not carried out: only one direction of rotation is possible for scroll compr essors, as well as for the screw and
Rotary compressors. The unit is s uitable for outdoor i nstallation.

4.8 Control and communication

The AQUA4 series units come complete with Advanced Carel, pCO series microprocessor control, in addition to the f unctions descri bed
below, it is possible to customise the software to meet all system requests. T hese include cascade management of the units with
‘’step-control’’ or ‘’cascade’’ logic. The microprocessor on board the unit controls the various operating parameters with an electric
panel keypad:

• Compressor connecti on/disconnection to maintain the set -point of the chiller inlet water T

• Alarm management

• Alarm signals

• Dis play of operating parameters

• Evapor ator anti-freeze pr otection

• Contr ol of maximum number of compressor starts

• RS232, RS485 serial output control (optional)

• Inc orrect phase sequence ( not viewed on display, prevents the compressor from st arting)

Concerning interface communication, Modbus ®, BacNE T ® (RS485 or TCP / IP) or LonWorks ® (optional) interface communication
cards are provided for connection to BM S systems as an option.

o High / low pressure
o Anti-freeze
o Flow switch
o Pump alarm

AQUA4–AGU-1405-E - 6 -

Options

Features and Benef its

Power supply

5 Options and Accessories

Supply 400V / 3 ph / 50Hz with 230V transform er and fuses Supply without neutr al with a 230V transformer and fuses.

Supply 400V / 3 ph + Neutr al / 50Hz with circuit breakers

Supply 400V / 3 ph / 50Hz with 230V transform er and circuit
breakers

Hydraulic module of both water circuits
Hydraulic module with low-pressure single pump

Hydraulic module with high-pressure single pump

Hydraulic module with low-pressure twin pumps (parall el
operating)

Hydraulic module with high-pressure twin pumps (parallel
operating)

Hydraulic module with low-pressure twin pumps (normal/backup
switching)

Hydraulic module with high-pressure twin pumps (normal/backup
switching)

Supply with neutral, the fuses have been replaced by
thermomagnetic circuit breakers.

Supply without neutral but with a 230V transformer and
thermomagnetic circuit breakers.

Single pump providing low static pressure with expansion vessel
and safety valve

Single pump providing high static pressure with expansion vessel
and safety valve

Dual pumps providing low static pres sure with expansion ves sel
and safety valve. The two pumps operating simultaneously in
parallel.

Dual pumps providing high static pressure with expansion v essel
and safety valve. The two pumps operating simultaneously in
parallel.

Double pumps providing low static pressure with expansion vessel
and safety valve. One pump operates and the second pump is in
backup with balancing operation time.

Double pumps providing high static pressure with expansi on
vessel and safety valve. One pump operates and the second pump
is in backup with bal ancing operation time.

Water tank

Water tank on col d use (4 pipes) / reversible use (2 pipes)

Water tank on hot us e (4 pipes or 2 pipes)

Water tank volume :

- 200 litres for si zes 041-051

- 220 litres for sizes 061-071-081

- 340 litres for si zes 094-104

- 600 litres for sizes 124-144-164-194-214-244

- 765 litres for sizes 274-294-324

AQUA4–AGU-1405-E - 7 -

Options

Features and Benef its

Antifreeze protection

Antifreeze protection on exchangers and pipes

Antifreeze protection on exchanger s, pipes, pump(s ) and
expansion vessel

Antifreeze protection on exchanger s, pipes, pump(s ), expansion
vessel and water tank

Condensing control
Electronically controlled modul ating fan speed with EC motors

Remote Control

Remote display (s upplied loose)

Control interf ace

Electrical trace heating and reinforced insulation on the both braze
plate heat exchangers and pipes.

Electrical trace heating and reinforced insulation on the brazed
plate heat exchangers, pipess, pump(s) and the expansion vessel.

Electrical trace heating and reinforced insulation on the both
brazed plate heat exchangers, pipes, pump(s), expansion ves sel
and the water tank.

PGD1 user interf ace allows performanc e of all operations of the
program, displaying the status of the unit and changing settings. It
can be located up to a maximum of 50 meters from the unit with a
standard telephone cable and up to a maximum of 200 meters
from the unit with a shielded cable.

Modbus communic ation interface RS485

LonWorks® communication interface FTT10

pCOweb - Modbus/BACnet/SNMP communication interfac e
TCP/IP

Anti-vibration i solation

Rubber anti-vibr ation mounts (supplied loose)

Spring anti-vibration mounts (s upplied loose)

Communication card using ModBus or Carel protocol RS485.
Communication int erface with a buildi ng management system.

Communication card using LonWorks® FTT10. Communication
interface wit h a building management system.

Communication card using Modbus/BACnet®/SNMP TCP/IP.
Communication int erface with a buildi ng management system.

4 or 8 rubber anti-vibration isolator s are supplied depending on the
type of unit. They wil l be inserted between the floor and the unit to
prevent vibration.

4 or 8 spring anti-vibration isolators are supplied depending on the
type of unit. They wil l be inserted between the floor and the unit to
prevent vibration.

AQUA4–AGU-1405-E - 8 -

Accessories

Features and Benef its

Accessories

Power factor Cor rection

Capacitors f itted into unit. Cos phi correction up to 0.95 t o reduce
current and energy consumption.

Electronic soft starter included in the contr ol panel. Reduces t he
peak starting current by up to 40%. T hey also partici pate in the

Soft starter

installation design optimization of the electric al cables and reduce
the mechanical stresses on the compr essors. In addition, they
assure that the unit will not start operating in case of overvoltage,
under voltage, phase reversal fault or phase failure.

Victaulic coupl ing parts (x4) Four Victaulic couplings (suppli ed loose)

Set point and temper ature offset and display. Allows to offset

External temperatur e sensor for set point offset

chilled water set point temperature based on either outside air,
chilled water return or zone temperature.

Pressure gauges LP / H P Reading low and high pressures with gauges.
Filter dryer maintenance kit

This kit includes one solenoid valve and ball valve per circuit for
maintenance of dryer filters.

Two lifting tubes are supplied to be inserted in the round holes on
the base frame identified by sticker s.

- 2 x tubes Ø1"1/2 (38mm), thickness =2,9m m , Length=1370mm

Lifting tubes ( x2)

on size 041 to 104

- 2 x tubes Ø1"1/2 (38mm), thickness =2,9m m , Length=1840mm
on size 124 to 324
+ 4 x bolt M16 Inox (as stops at the end of the tube)

Coils protecti on guards

Water Y filters (x2) (supply loose)

The condenser coi l protection grills prevent light damage to the coil
when shipping, installation and oper ation.

This option incl udes two Y water filters supplied loose:

- 2'' GAS (screwed) on size 041 to 104

- 3'' GAS (screwed) on size 124 to 194

- 4'' Flange on size 214 t o 324
Note that the connec tions of the units are victaulic.
We can supply the adapt ers : Victaulic / Gas or Victaulic / Flange
via a Non Standard Request

AQUA4–AGU-1405-E - 9 -

Cooling

Circuit 1

Heating

Hot water

Cooling + Hot
water (DHW)

Heating + Hot
water (DHW)

Circuit 1

Circuit 2

Circuit 2

Circuit 2
Circuit 1

Circuit 1

A B D

C

B+D

6 Application

The AQUA4 units allow creating installations with 2 or 4 pipes. The designation 2 or 4 pipe refers to the system of the water distribution
for each building system.
A 2 pipe system comprises a single supply and a single hydraulic line back to the unit. The terminal units of a system to 2 pi pes are
characterized by a single exchanger having the coil function of heating or cool ing depending on the op erating mode.
The 4 pipe configur ation includes hot water supply (wi th the corresponding return lines) and col d w ater (with the corresponding return
lines) simultaneously.

Operating modes available for AQUA

- Circuit 1, reversible system: produc tion of chilled wat er for cooling or hot water for heating.

- Circuit 2, hot water per production or total heat recovery for hot water sanitary type for example.

4

M units can be mounted on a 2-pipe system:

production (DHW)

AQUA4–AGU-1405-E - 10 -

Example of 2 pipe installation for H otel and Hospital:

AQUA4–AGU-1405-E - 11 -

Cooling

Heating

Circuit 1

Circuit 2

Cooling + Heating
Circuit 1

Circuit 2

A D

C

Operating modes available for AQUA4 P units will all ow provision of hot and cold water simultaneously.

- Circuit 1: Production of cold water for cooling

- Circuit 2: Hot water production or total heat recover y for heating or preheating hot water for example.

AQUA4–AGU-1405-E - 12 -

Example of 4 pipe ins tallation for office or residential buildings:

Below is shown an example of an inertial tank with double cycle inversion (on demand) for winter and sum mer air conditioning, in
combination with a 2-pipe heating system. The double cycle inversion valve ( automatically c ontrolled by onboard microprocessor)
provides the best performance as i t favours tank strati fication in both summer and winter modes.

AQUA4–AGU-1405-E - 13 -

o 100% Cooling

o 25% Cooling

o 100% Heating

o 25% Heating

o 100% Cooling + 50% to 100% DHW

o 25% Cooling + 25% to 75% DHW

o 100% DHW

o 25% DHW

o 100% DHW

o 25% DHW

o

7 Operating combination depending on the thermal load:

The following tables show the possible operating regimes of the AQUA4 units at partial loads. The units ar e equipped with two
thermodynamic circuits and two or four compressors that combine their operations t o m eet the changing demands of the heating
system. For example, in heating mode, the units AQUA
domestic hot wat er.

- AQUA M (2 pipe) units : 2 compressors / 2 thermodynamic circuits :

Summer: Cooling mode Winter : Heating m ode

o 100% Cooling
o 50% Cooling

4

M (2 pipe) are able to shar e their heating capac ity with 50% heating and 50%

o 100% Heating
o 50% Heating

o 100% Cooling + 50% to 100% DHW
o 50% Cooling + 50% to 100% DHW

o 100% DHW
o 50% DHW

- AQUA M (2 pipe) units : 4 compressors / 2 thermodynamic circuits :

Summer: Cooling mode Winter : Heating m ode

o 75% Cooling
o 50% Cooling

o 75% Cooling + 25% to 75% DHW
o 50% Cooling + 25% to 100% DHW

o 75% DHW
o 50% DHW

- AQUA P (2 pipe) units : 2 compressors / 2 thermodynamic circuits :

All the year : Summer to winter

o 50% Heating + 50% DHW

o 100% DHW
o 50% DHW

o 75% Heating
o 50% Heating

o 25% Heating + 25% to 50% DHW
o 50% Heating + 25% to 50% DHW

o 75% DHW
o 50% DHW

AQUA4–AGU-1405-E - 14 -

o 100% Cooling
o 50% Cooling

o 100% Cooling + 50% to 100% Heating
o 50% Cooling + 50% to 100% Heating

o 100% Heating

50% Heating