Lennox CWC 020, CWC 030, CWC 040, CWC 050 Maintenance Manual

CHILLED
WATER
CASSETTE
INSTALLATION-OPERATION
&
MAINTENANCE MANUAL
CONTENTS
• PRODUCT RANGE
• GENERAL INFORMATION
• SPECIFICATION
• ELECTRICAL CONNECTIONS
• UNIT DIMENSIONS
• DRAIN PIPEWORK
• INSTALLATION
• CONTROL PANEL
• INSTALATION OF DIFFUSER AND INLET GRILLE
• MAINTENANCE
• AIR DISTRIBUTION
• OPTIONS
• FAULT ANALYSIS
• POINTS TO KEEP IN MIND
PAGE
2 3
4-5
5 6 7
7-8
9
10
11-12
12
13-14
14 15
TABLE OF CONTENTS
Congratulations, you have made a wise choice with the purchase of your Lennox chilled water ceiling
cassette.
This product has been designed, assembled and supplied in one of our world class manufacturing facilities
and we feel sure that it will meet your expectations.
Lennox an international organisation with world wide distribution takes pride in supplying you with this
product.
PACKING CONTENT
PRODUCT RANGE
MODEL V / Ph / 50 Hz
NOMINAL CAPACITY KW
2,0
2,8
6,0
230 V - 1Ph
CWC 020
230 V - 1Ph
230 V - 1Ph
230 V - 1Ph
CWC 030
CWC 040
CWC 050
COOLING
HEATING
3,5
4,4
5,2
4,4
5,1
Cassette unit
Diffuser panel
Installation manual
Hanging bracket insulation
Screws and washers
MANUAL DE FUNCIONAMIENTO
LENNOX
Setting up
template
(*)
(*) Packed separately
GENERAL INFORMATION
The CEILING CASSETTES are designed to operate with chilled and hot water. They provide both cooling and dehumidification in cooling mode and heating in the latter, cleaning and filtering the air in the process. Electrical heating elements are available as an option on all units excluding the CW050. The units are available with cooling capacities of 2000 to 5200 W and heating capacities of 2800 W to 6000 W.
The unit chassis is made of galvanised steel and is fully insulated both inside and out.
Made of copper tubes and aluminium fins. Coils have been designed and manufactured to ensure maximum efficiency.
The units are supplied with a 3 speed centrifugal fan. The impellor blades have been designed specifically for this type of units ensuring exceptionally low sound levels and the motor is protected with internal thermal protection.
The air discharge louvres change position in automatic or manual mode, (according to versions). In the case that this function has not been incorporated the position of the louvres can be adjusted manually.
The unit is designed, with serviceability in mind, and all components are easily accessible. A drip tray collects condensate which is removed by means of a condensate pump.
Made in decorative plastic, with a smooth finish. Internal insulation prevents condensation from forming. Four louvres ensure air distribution.
A polypropylene washable air filter is incorporated in the unit it is easily accessible for maintenance.
CABINET
ELECTRIC CIRCUIT
HEAT INTERCHANGE
INTERNAL COMPONENTS
OPTIONS
FAN
AIR DISTRIBUTION
The electrical panel is provided with a terminal block which provides connection of mains power or to a control box. A fused isolator is not included and where required shall be installed by others.
-Electric heater. (Excluding CW-050)
-Fresh air kit. Duct connection. Fresh air fan. Duct supports.
-Discharge of air to an adjacent room kit. Duct connection. Duct supports.
-Water control valve kit with 2 way or 3 way
proportional control valves.
-Auxiliary drip tray.
DIFFUSER PANEL
AIR FILTER
4
(1)Inlet air temperature:: 27ºC BS / 19ºC BH (2)Inlet air temperature: 20ºC BS (3)Inlet air temperature: 20ºC BS (4)Fan high speed. Power supply 230V-1ph-50Hz 230V-1ph-50Hz (*)Sound level has been tested at a distance of 2 m from the unit, at standard conditions
CORRECTION FACTORS FOR MEDIUM AND LOW SPEED The given values have been calculated for a high-speed fan. For a different speed, the given values must be
multiplied by the following correction factors.
Low speed Medium speed High speed
Air flow
Heating capacity
Cooling capacity
Water temperature: 7/12º C Water temperature: 50º C Water temperature: 70/60º C
m /h
3
SPECIFICATIONS
UNIT
Total cooling capacity Sensible total capacity Chilled water flow rate
Water content
Heating capacity Hot water flow rate
Air flow (max. / min)
Fan power consumption Running current Electric heater power consumption
Running current with electric heater
2 PIPES SYSTEM
Heating capacity Hot water flowrate
Hot water pressure drop
Pipe connections
Sound level (Lp)
Diffuser dimensions Cassette dimensions Diffuser weight
Cassette weight
5200
3750
900
22
CWC 050
2000 3500
kPa(1)
W(1)
l
4400
1650 2750 3400
345 600 745
11 17 26
CWC 020 CWC 030 CWC 040
W(1)
l/h(1)
2,20,7 1,2 1,5
6000
900
22
2800 4400
kPa(2)
5100
345 600 745
11 17 26
W(2) l/h(2)
9446 46 69
0,5
----
----
A
A(4)
0,2 0,2 0,3
1,5 2 2 6,5 8,7 8,7
W(4)
W
9600
825
18
920/650
4700 7000
kPa(3)
7900
404 600 680
13 17 22
650/445 650/445 880/600
W(3) l/h(3)
F 1/2'' GF 1/2'' GF 1/2'' GF 1/2'' G
dB(A)(*)
40/32 44/3840/32 48/39
3
Kg
298x575x575
3 3 3
24
Kg
21 22 23
HxLxW(mm) HxLxW(mm)
48x720x720 48x720x720 48x720x720 48x720x720
298x575x575 298x575x575 298x575x575
0,8
0,68
0,77
0,9
0,85
0,86
1
1
1
Chilled water pressure drop
Hot water pressure drop
10%
x 1,07
20%
x 1,12
30%
x 1,20
MODEL
COOL WATER
COOL AND HOT WATER
VOLTAGE
50Hz
CWC020 / CWC030 CWC040 / CWC050
FLOW RATE
l/h
PRESSURE DROP
CWC 020 CWC 030 CWC 050CWC 040
250
400
345
450 500
300
550
650 700 745
600
800
1000
900 950
850
6
8,3
11
13,6
17 9,8
12 14 17 17,8 19 20,5 21 23 14 24 26 16
29,5 17,5
33 19.5
36,3
22 24 26----
----
----
----
----
----
----
---- ----
--------
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
----
5 7 81 2 3
0 1 2 3 42 51 2
230V/50HZ 1Ph + N
4 6
6 7 8
1
1
2
2
THERMOSTAT
CASSETTE UNIT
CHILLED WATER
CHILLED WATER AND HOT WATER
1
1
2
2
CWC
5 7 81 2 3
0 1 2 3 42 51 2
230V/50HZ 1Ph + N
4 6
6 7 8
ELECTRIC WIRING DIAGRAM
For electrical connection refer to wiring diagram
in the unit.
SPECIFICATIONS
Ethylene glycol %
Pressure drop
ELECTRICAL CONNECTIONS
WATER PRESSURE DROP
Nº OF WIRES X SECTIÓN
230 V / 1Ph
Power supply
Thermostat connections
As the percentage of glycol increases the standard pump flow decreases due to the increased pressure characteristics. This means that the cooling and heating duties will decrease. As a result the pressure drop must be multiplied by the coefficient shown in the table below.
POWER SUPPLY WIRING
This equipment must be installed in accordance
with national regulations. A suitable means of
disconnecting all supply poles must be provided in the power supply wiring. The power supply must incorporate suitably rated fused or circuit breaker
protection.
2
3 X 1,5mm
2
3 X 1,5mm
2
7 X 1,5mm
2
8 X 1,5mm
23,5
91
121
247
32
72
40
Air vent
Outlet water connection 1/2” G
Inlet water connection 1/2” G
4 x hanging brackets (M 8)
Electrical cable entry point
Condensate pump flexible hose 10mm ID 15mm OD
Drain tube 16mm OD
O 150
575
284
123
143
196
273
Fresh air knockout panel for branch duct.
CASSETTE UNIT
DIFFUSER PANEL
298
Branch duct knockout hole, to supply air into adjacent area.
O 68
O 150
UNIT DIMENSIONS (mm.)
DETAIL A
30
720
489,74
540
720
DETAIL A
30,6
54,66
17,5
17,5
489,74
54,66
30,6
(**)
INSTALLATION CLEARANCES
2%
Máx.200mm
DRAIN PIPEWORK
INSTALLATION METHOD
2. Ensure there is sufficient space around the unit to service it. Where there is a false ceiling ensure that there is enough space to provide access. Where there is a false, panelled ceiling ensure that there is sufficient space adjacent to remove the panels.
1. The unit should be positioned centrally within the room. The ceiling must be horizontal to ensure that the condensate water can drain away thoroughly. The unit must be installed in a position where there is sufficient strength in the structure to support the weight of the unit.
CONDENSATE PUMP FLEXIBLE HOSE
DRAIN TUBE
DRAIN TUBE
• The drain tube is connected to drip tray.
• This drain tube is supplied with a cap; the cap can be removed when it is necessary to remove any water that accumulates in the drip tray.
• The unit is fitted with a condensate pump to ensure condensate removal.
• To insure that there is condensate flow, the drain tube must be installed with a fall of 2 % without obstructions, or without rising sections.
• To avoid any unpleasant odours from the drainage system a trap must be fitted with a trap depth of no less than 50 mm.
• The condensate pump has a maximum lift of 200 mm. The rising tube must always be vertical.
• On completion the drain line must be insulated.
CONDENSATE PUMP FLEXIBLE HOSE
298
720
720
Min. 500 (**)
Min. 500 (**)
2%
50
Cassette
unit
Diffuser panel
308
Setting up
template
489,74
489,74
54,66
30,6
575
25
25
30,6
54,66
540
17,5
17,5
575
Cassette
unit
Diffuser panel
Suspension rots M-8
1
2
1 1
2
1
2
Nut whasers
Fixing points
INSTALLATION METHOD (CONTINUED)
8. The cassette brackets hook over the washer. Tighten the cassette, with the lower nuts.
7. When lifting the cassette into position care should be taken not to lift the unit by, the drip tray, water connection, drain tube; which could be damaged. The cassette should be lifted by the hanging brackets. The hanging brackets should be insulated, with the supplied insulation.
9. Check to ensure the unit is level. The drain will then automatically be lower than the rest of the drip tray.
10. Tighten the nuts on the suspended rods to ensure a distance of 25 mm between the bottom face of the body of the unit and false ceiling.
4. Install the suspension rods to the ceiling, the rods should have three nuts and two washers, as in next figure. The setting up template can be used to indicate the position for the suspension rods.
5. The condensate connections should be positioned, before that the unit is installed.
NOTE: Before marking the fixing points to the ceiling, ensure that the unit is positioned in the correct orientation taking into account of where the electrical cabinet is required. Ensure that water pipes can be run easily. When the unit is fixed it is not easy to change position.
6. To facilitate the connections of water pipes and the drain tube is advisable to disassemble the supporting bracket situated on this corner. Once the installation is completed; the bracket must be reassembled.
3. Cut the false ceiling, to a maximum dimension of 625x625 mm. For a panelled ceiling removes one panel of 600x600 mm.
WARNING
Electric shock hazard can cause injury or death. Before attempting to perform any service or maintenance on the unit, turn OFF the electrical power, and check that the fan has stopped.
Cover plate for electrical board
Terminal plate cover
2
3
1
CONTROL PANEL
Removing the corresponding plate cover screws gives access to the electrical board and terminal plate, as indicated
on the drawing.
For electrical connection refer to wiring diagram in the unit.
ELECTRICAL WIRING DIAGRAM
ACCESS TO THE ELECTRICAL COMPONENTS OF THE UNIT
Electrical inlets, power supply and remote controller
Terminal plate
Electrical connections (it depends on versions)
1
2
3
10
Insulation
WARNING
Electric shock hazard can cause injury or death. Before
attempting to perform any service or maintenance on the unit,
turn OFF the electrical power, and check that the fan has
stopped.
Display unit holder
Diffuser panel
INSTALLATION OF DIFFUSER AND INLET GRILLE
Depending on the control type, the display holder will either include both the infrared receiver and indicator or be empty. (Refer to the corresponding infrared controller manual)
The display unit holder is mounted by two screws, on any side of the diffuser panel.
Check that the position in which the diffuser is mounted is the right one.
1. - Release the air intake grille.
2. - The diffuser panel can then be provisionally positioned on the cassette using the fixing clips.
3. - The diffuser is fastened with the four bolts supplied.
4. - Make sure that the frame has not been deformed in the installation, by an excessive tighten of the bolts. There must be no recirculation of air between intake and outlet air paths.
The diffuser panel is sealed with insulation to avoid air gaps between the unit and the air panel. The insulation can be compressed from 8 mm to 3 mm, allowing the panel to be tightened to the cassette by up to 5 mm.
MOUNTING THE DIFFUSER PANEL TO THE UNIT
IINSTALLATION OF DISPLAY UNIT HOLDER
MOUNTING THE AIR INTAKE GRILLE AND FILTER ASSEMBLY
The position in which the grill is mounted depends on the position of the display unit holder.
1.- The grill fixing hooks should be fitted into the holes provided.
2.- The stays need to be placed between the diffuser and the inlet grille.
3.- The grille is mounted on the diffuser via two hand triggers. Initially pull off the hand triggers, then insert the grille into the diffuser and release the hand triggers. When this operation is completed the grille is attached to the diffuser.
Cassette unit
Air grille and filter
Diffuser panel
Air grille and
filter
11
WARNING
Electric shock hazard can cause injury or death. Before attempting to
perform any service or maintenance on the unit, turn OFF the electrical
power, and check that the fan has stopped.
A
DETAIL A
HAND TRIGGERS
HOOKS
STAYS
AIR FILTER
AIR INTAKE
GRILLE
TERMINAL PLATE
COVER
ELECTRICAL PANEL
COVER
MAINTENANCE
Access to terminal plate
The terminal plate can be accessed by removing the air intake grille and unscrewing the terminal cover.
Access to electrical panel
To gain access to the electrical board follow these instructions:
1.- Disconnect the display unit, and the swing motor wire. (Depending on cassette version.)
2.- Disassemble the diffuser panel by removing the four screws that attaches it to the unit.
3.- Remove the cover of the electrical panel, where is the PCB, (Depending on cassette version.)
4.- The PCB can be checked or replaced, by loosening the screws that hold it.
CLEANING THE AIR FILTER
INSTALL THE FILTER
If the unit operates without the filter, there is
a risk of damaging the unit through dust
contamination.
ACCESS TO ELECTRICAL COMPONENTS
1.- Stop the unit.
2.- Open the air intake grille on the unit.
Open the grille by way of two hand triggers, which are close to the display unit holder. The grille will swing down supported by the stays and the hooks.
3.-Relese the air intake grille from de unit.
To release the grille pull it down until the stays can be unlock from the diffuser, then pull it back to an angle greater of 90º and lift it lightly, finally the grille hooks will come away from the diffuser.
4.-Remove the air filter once the air intake grille have been released
Clean the air filter depending on the operation conditions and working time, (approximately once every 6 months). Use a vacuum cleaner to clean dust off. If the filter is too dirty, wash it with water and neutral detergent. Dry the filter before re­fitting.
5.-Replace the filter in the right position.
6.- Close the air intake grille.
Place the hand triggers on position again.
12
1 2 3
4
WARNING
Electric shock hazard can cause injury or death. Before attempting
to perform any service or maintenance on the unit, turn OFF
the electrical power, and check that the fan has stopped.
2
3
4
1
MAINTENANCE
AIR DISTRIBUTION
1
2
Louvre position for correct air flow in heating mode.
Louvre position for correct air flow in cooling mode.
When checking or replacing any internal component of the unit eg coil, fan motor, condensate pump, float switch, the drip tray and volute must be removed.
• Remove the air intake grille and filter.
• Disconnect the display unit
• Disassembly the diffuser panel by removing the four screws that attach it to the unit.
• Detach the volute by removing its three screws, and the electrical panel cover.
• The drip tray can be taken apart by removing its three screws. As shown in the figure.
Louvres change position to distribute air according to heating or cooling operation.
• In cooling operation the louvres are positioned to distribute air outwards from the discharge, which allow airflow close to the ceiling.
• In heating mode the louvres are repositioned to blow air in a downward direction. The air should flow towards to the floor to prevent layers or stationary hot air forming in the upper part of the room.
Depending on the control, the louvres may be set on intermediate positions; as well the louvres may be set to move continuously, sweep mode. (For more information, see the remote control manual.) When the Electro-mechanical thermostat is used the louvres movement is manual, louvres should be positioned manually.
IMPORTANT:
Do not try to move the louvres, when
they are connected to a motor.
ACCESS TO INTERNAL COMPONENTS
DISASSEMBLING DRIP TRAY
Drip tray
Volute
Coil Fan motor Condensate pump Float switch (in option)
1
2
13
Duct connection O 150mmflange and clip(*)
Duct connection Ø75 mm(*)
Reduction 125-75mm(*)
Duct Ø125mm
(*)Elements included in optional kit
Fan(*)
Insulated flexible
duct Ø150
Air inlet grille
Air inlet grille and filter
Air intake
OPTIONAL ELECTRIC HEATER TECHNICAL DATA
m /h
3
Air flow supplied to an adjacent room in m /h, fresh air fan at high speed.
3
POWER
230 V 1Ph -50Hz
1,5 kW
• Remove the 150 mm insulation material and cut out the prepunched side knockouts. The two prepunched side knockouts must not be used at the same time to provide conditioned air to an adjacent room.
• Cut away the polystyrene around the inside edge of the opened panel, remove the polystyrene.
• Use a duct connection flange and a suitable duct.
• Air supply to an adjacent room requires that outlet corresponding
with the duct is closed.
• An air inlet grille must be fitted (if possible near the floor)
between the air conditioned room (where the unit is situated) and the adjacent room.
• Conduits can be of flexible polyester type or corrugate aluminium,
externally covered with anti-condensate material. The duct length can be calculated by taking into account the pressure drop through the unit, using the following table.
• Side knockouts panel are provided. One to connect a fresh air inlet duct, and another to connect an air distribution duct to deliver air to an adjacent room.
MODELS 020
OPTIONS
AIR SUPPLY TO AN ADJACENT ROOM
FRESH AIR MAKE UP
INSTALLATION
INSTALLATION
• Remove the 68 mm insulation material and cut out the prepunched side knockouts.
• Secure the duct connection flange to the unit. Conduits can be of flexible polyester type or corrugate aluminium, externally covered with anti-condensate material.
• Install a supplementary fresh air fan for the introduction of fresh air into the unit. The fan motor must be controlled by an ON-OFF switch.
• Fresh air flow must be less than 10% of the total air flow, to avoid operating problems. A speed controller should be installed in the supplementary fan motor, for adjusting the air flow.
Air flow
CWC 020- CWC 030
175
UNIT/MODELS
Available pressure
100 25
0
8 15
CWC 040
200
100 25
0
10
20
CWC 050
250
125 25
0
20 30
Pa.
2 kW
MODELS 030-040
14
Drain tube from auxiliary drip tray
Connecting flexible hose
Auxiliary drip tray
Drain tube from drip tray
Main cable
Air vent
Condensate pump flexible hose
Auxiliary drip tray
Water control valve
NOTE THE CORRECT POSITION OF THE WATER CONTROL VALVE
• Install the auxiliary drip tray as shown in the illustration.
• Connect the drain tube from drip tray to the auxiliary drip tray.
• The condensate drains from auxiliary drip tray will be pumped away.
OPTIONS
WATER CONTROL VALVE KIT (2 AND 4 WAYS, ON/OFF AND PROPORTIONAL)
AUXILIARY DRIP TRAY
PROBLEM
ACTION
FAULT ANALYSIS
1.- Unit not operating
• Check power is available at unit.
• Check wiring.
• Check remote control is functioning and set properly ( if any).
2.- Indoor unit fan running to fast without apparent speed change
• Check the indoor unit filter is clean.
• Check wiring
• If problem persists then motor may be faulty.
3.- Condensate overflowing
• Check drip tray for blockage, and condensate drains away.
• Check unit is level.
• Check condensate pump is working.
• Check service drain pipework.
Coupling
Water control valve (4 ways)
15
The air filter cleaning operations do not require technical service; however when an electrical or mechanical operation is required call an Engineer.
WARNING
Electric shock hazard can cause injury or death. Before attempting to perform any service or maintenance on the unit, turn OFF the electrical power, and check that the fan has stopped.
FILTER CLEANING
Check the air filter and make sure it is not blocked with dust or dirt.
If the filter is dirty, wash it in a bowl with neutral soap and water, drying it in the shade before inserting it in the unit.
Standard Guidelines to Lennox Refac equipment
All technical data contained in these operating instructions including the diagrams and technical description remains the property of Lennox Refac and may not be used (except for the purpose of familiarising the user with the equipment), reproduced, photocopied, transferred or transmitted to third parties without prior written authorisation from Lennox Refac.
The data published in the operating instructions is based on the latest information available. We reserve the right to make modifications without notice.
We reserve the right to modify our products without notice without obligation to modify previously supplied goods.
These operating instructions contain useful and important information for the smooth operation and maintenance of your equipment.
The instructions also include guidelines on how to avoid accidents and serious damage before commissioning the equipment and during its operation and how to ensure smooth and fault-free operation. Read the operating instructions carefully before starting the equipment, familiarise yourself with the equipment and handling of the installation and carefully follow the instructions. It is very important to be properly trained in handling the equipment. These operating instructions must be kept in a safe place near the equipment.
Like most equipment, the unit requires regular maintenance. This section concerns the maintenance personnel and management. If you have any queries or would like to receive further information on any aspect relating to your equipment, do not hesitate to contact us.
Risk of injury with
rotating objects
Low
temperatures
High
temperatures
Risk of injury with
moving objects
Electrical
voltage
Abrasive surfaces
POINTS TO KEEP IN MIND
GREAT BRITAIN,
IRELAND:
BELGIUM :
CZECH REPUBLIC :
FRANCE :
GERMANY:
NETHERLANDS :
POLAND :
PORTUGAL :
RUSSIA :
SLOVAKIA :
SPAIN:
UKRAINE :
OTHER EUROPEAN COUNTRIES,
AFRICA,
MIDDLE-EAST :
LENNOX INDUSTRIES LTD tél. : + 44 1604 59 9400 fax : + 44 1604 594200 e-mail : marketing lennoxind.com
LENNOX BENELUX N.V./S.A. tél. : + 32 3 633 30 45 fax : + 32 3 633 00 89 e-mail : inf.beo lennoxbenelux.com
JANKA RADOTIN AS tél. : + 420 2 510 88 111 fax : + 420 2 579 10 393 e-mail : janka janka.cz
LENNOX FRANCE tél. : + 33 1 60 17 88 88 fax : + 33 1 60 17 86 58 e-mail : accueil lennoxfrance.com
LENNOX DEUTSCHLAND Gmbh tél. : + 49 69 42 0979 0 fax : + 49 69 42 0979 40 e-mail : info lennoxdeutschland.com
LENNOX BENELUX B.V. tél. : + 31 33 2471 800 fax : + 31 33 2459 220 e-mail : info lennoxbenelux.com
LENNOX POLSKA SP z o.o. tél. : + 48 22 832 26 61 fax : + 48 22 832 26 62 e-mail : lennoxpolska inetia.pl
LENNOX CLIMATIZAÇAO LDA. tél. : + 351 22 999 84 60 fax : + 351 22 999 84 68 e-mail : marketing lennoxportugal.com
LENNOX DISTRIBUTION MOSCOW tél. : + 7 095 246 07 46 fax : + 7 502 933 29 55 e-mail : lennox.dist.moscow co.ru
LENNOX SLOVAKIA tél. : + 421 7 44 88 92 16 fax : + 421 7 44 88 16 88
LENNOX REFAC S.A. tél. : + 34 902 400 405 fax : + 34 91 542 84 04 e-mail : marketing lennox-refac.com
LENNOX DISTRIBUTION KIEV tél. : + 380 44 213 14 21 fax : + 380 44 213 14 21 e-mail : jankauk uct,kiev,ua
LENNOX DISTRIBUTION tél. : + 33 4 72 23 20 14 fax : + 33 4 72 23 20 28 e-mail :marketing lennoxdist.com
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