Lennox KVHK 22E, KVCK 28E, KVHA 22E, KVHA 24E, KVHK 28E Installation, Operation & Maintenance Manual

...
Page 1
COMPACTAIR
KVCK / KVHK
English/04-2004
INSTALLATION OPERATION & MAINTENANCE MANUAL
Page 2
2.- INSTALLATION
PAGE
PAGE
PAGE
22
22
23
24
25
25
26-30
31-36
37
38
39
40
41
2.1.- INSTALLATION GUIDELINES
2.2.- UNIT INSTALLATION
2.3.- OPTIONAL TASK PRIOR TO UNIT INSTALLATION:
FLOW REGULATION IN THE FANS
2.4.- UNIT LOCATION
2.5.- INSTALLATION CLEARANCES
2.6.- DRAINS
2.7.- REFRIGERANT CONNECTIONS
2.8.- ELECTRICAL CONNECTIONS
DATA PAGE FOR UNIT COMMISSIONING
PAGE
4
5-6
7-8
9
10-19
20-21
PAGE 3
PAGE 2
POINTS TO KEEP IN MIND
TABLE OF CONTENTS
1.- GENERAL CHARACTERISTICS
1.1.- PHYSICAL DATA
1.2.- FAN PERFORMANCES
1.3.-
ELECTRICAL DATA
1.4.- OPERATING LIMITS
1.5.- UNIT DIMENSIONS
1.6.- AVAILABLE OPTIONS
4.- MAINTENANCE
4.1.- PREVENTIVE MAINTENANCE
4.2.- CORRECTIVE MAINTENANCE
4.3.- FAILURE DIAGNOSIS
3.- COMMISSIONING AND OPERATION
3.1.- PRELIMINARY CHECKS
3.2.- STEPS TO FOLLOW FOR COMMISSIONING THE UNIT
Page 3
Risk of injury with
rotating objects
Low
temperatures
High
temperatures
Risk of injury with
moving objects
Electrical
voltage
Abrasive surfaces
Standard Guidelines to Lennox equipment
All technical data contained in these operating instructions including the diagrams and technical description remains the property of Lennox and may not be used (except for the purpose of familiarizing the user with the equipment), reproduced, photocopied, transferred or transmitted to third parties without prior written authorization from Lennox .
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, familiarize 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.
POINTS TO KEEP IN MIND
Page 4
High pressure:
Low pressure:
circuit 1 circuit 2
circuit 1 circuit 2
Air intake temperature to the outdoor coil:
Air output temperature to the outdoor coil:
High pressure:
Low pressure:
circuit 1 circuit 2
circuit 1 circuit 2
Air intake temperature to the outdoor coil:
Air output temperature to the outdoor coil:
Options installed:
Comments:
ELECTRIC POWER CONSUMPTION (Amps)
ºC
1
ºC
2
ºC
1
2
ºC
1
ºC
2
ºC
Fan outdoor section 1
Fan outdoor section 1
Fan outdoor section 2
Fan outdoor section 2
ºC
1
ºC
2
Compressor 1 Compressor 2
Compressor 1 Compressor 2
UNIT:
SERIAL Nr.:
INSTALLATION ADDRESS:
INSTALLER:
INSTALLER TEL.:
CHECKS:
SUPPLY VOLTAGE:
DATA INPUT:
DATE OF COMMISSIONING:
INSTALLER ADDRESS:
RATED VOLTAGE OF THE UNIT:
YES NO
GENERAL POWER SUPPLY CONNECTION
CONTROL PANEL CONNECTION
COOLING CYCLE
HEATING CYCLE
COMPRESSOR OIL LEVEL INDICATOR
UNIT ON SHOCK ABSORBERS
DRAINAGE WITH TRAP
CONTROL PANEL IDENTIFICATION CODE
DATA PAGE FOR UNIT COMMISSIONING
Page 5
COMPRESSOR
Nr. / Type
NET WEIGHT
Cooling only units KVC
Heat pump units KVH
UNIT MODEL
REFRIGERANT CHARGE
COMPRESSOR
No. / Type
NET WEIGHT
Cooling only units KVC
Heat pump units KVH
UNIT MODEL
REFRIGERANT CHARGE
Kg
Kg
Kg
Kg
1 / Scroll
22E
205
1 / Scroll
24E
265
1 / Scroll
28E
275
1 / Scroll
32E
280
1 / Scroll
38E
360
2 / Scroll
520
2 / Scroll
540
2 / Scroll
545
2 / Scroll
670
48D/D2
56D/D2
76D/D2
NITROGEN (*)
NITROGEN (*)
210 270 280 285 365
530 550 555 680
2 / Scroll
44D/D2
400
410
2 / Scroll
850
4 / Scroll
900
100D/D2
860 910
64D/D2
86D/D2
KV C K
Type of unit
outdoor
COMPACTAIR
24 VFC
VFC: Voltage free contact unit version.
------: Standard unit version.
E
E: one circuit D: two circuits D2: Units multi-spilt 2 indoor units
KVHA: Heat pump unit R-22 KVCK: Cooling only unit R-407C KVHK: Heat pump unit R-407C
Application C: Cooling only H: Heat pump
Type of Refrigerant A: R-22 K: R-407C
Approximate cooling capacity in Kw
1.- GENERAL CHARACTERISTICS
1.1.- PHYSICAL DATA
(*) The units are supplied with nitrogen gas, this must be removed and charge the unit with refrigerant R-22 or R-407C, depends on unit model. (See pages 29 and 30, to calculate model refrigerant charge)
Page 6
1.2.- STANDARD FAN PERFORMANCES.
STATIC PRESSURE AVAILABLE Pa.
WRONG STATUS ON ACCOUNT OF MOTOR POWER LIMIT
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
22E
24E
28E
32E
38E
5600 6325
7350
5600 6325
7550
AVAILABLE STATIC PRESSURE Pa
AVAILABLE STATIC PRESSURE Pa
AVAILABLE STATIC PRESSURE Pa
AVAILABLE STATIC PRESSURE Pa
AVAILABLE STATIC PRESSURE Pa
AVAILABLE STATIC PRESSURE Pa
AIR FLOW M3/H
AIR FLOW M3/H
AIR FLOW M3/H
AIR FLOW M3/H
AIR FLOW M3/H
9000 9600 10300 11000
7050
6800
5600 6125
7100
6650
6500 7000 7500 8000
13000
14000
15000
16000
18000 19200
20600
22000
44D/D2
64D/D2
76D/D2
AIR FLOW M3/H
11.200 12.650
15.100
14.100
48D/D2
11.200 12.650
14.700
13.600
56D/D2
11.200 12.250
14.200
13.300
21000
23000
25000
26000
23000 24600
26200
28000
86D/D2
100D/D2
AIR FLOW
AIR FLOW
AIR FLOW
140 90 50 0
160 110 50 0
170 120 50 0
1000
300*
250*
270*
200*
160* 120*
90* 40*
930
870
800
165*
70*
0*
25*
___
110*
1140
300*
230*
275*
200*
175* 140*
115* 75*
1070
995
920
225*
140*
75*
20*
25*
___
1140
1070
995
920
300*
230*
275*
200*
225*
140*
175*
140*
75*
115*
75*
20*
25*
___
1000
930
870
800
300*
250*
270*
200*
165*
160*
120*
70*
90*
40*
0*
110*
25*
___
170 120 50 0
160 110 50 0
140 90 50 0
1010
995
900
845
270*
190*
205*
125*
135*
55*
140*
70*
0*
85*
15*
__
__
1120
1080
1030
980
360*
290*
305*
245*
240*
190*
230*
170*
110*
180*
120*
60*
100*
20*
0*
25*
__
85*
85*
165*
(*) ( )
1.- GENERAL CHARACTERISTICS
NOTE: The unit leaves factory with pulley two turns opened.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
Page 7
1.2.- FAN PERFORMANCES WITH KIT HIGH STATIC PRESSURE TO 350Pa (OPTION)
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
1 TURN
PULLEY CLOSED
PULLEY
POSITION
2 TURNS
3 TURNS
22E
24E
5600 6325 6800 7350
5600 6325 7050 7550
5600
6125
6650
7100
11200 12650
14100
15100
28E
44D/D2
11200
12650
13600
14700
11200 12250
13300
14200
48D/D2
56D/D2
AIR FLOW
AIR FLOW
AIR FLOW
1140
365*
290*
325*
250*
240* 190*
185* 140*
1070
995
920
290*
210*
165*
105*
135*
70*
195*
1140
365*
290*
330*
255*
240* 195*
185* 145*
1070
995
920
290*
210*
165*
105*
135*
70*
1140
1070
995
920
365*
290*
325*
250*
290*
210*
240*
190*
165*
185*
140*
105*
135*
70*
1140
1070
995
920
365*
290*
330*
255*
210*
240*
195*
165*
185*
145*
105*
135*
70*
1140
1070
995
920
365*
290*
330*
255*
290*
210*
240*
195*
165*
185*
145*
105*
135*
1140
1070
995
920
365*
290*
330*
255*
290*
210*
240*
195*
165*
185*
145*
105*
195*
135*
70*
70*
195*
270*
195*
(*) ( )
STATIC PRESSURE AVAILABLE Pa.
WRONG STATUS ON ACCOUNT OF MOTOR POWER LIMIT
1.- GENERAL CHARACTERISTICS
NOTE: The unit leaves factory with pulley two turns opened.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
M3/H
R.P.M.
Page 8
V/f (50 Hz)
Kw
Kw
Kw
A
A
A
A
V/f (50 Hz)
Kw
Kw
Kw
A
A
A
A
Maximum absorbed power
Voltage
Maximum current
Total current
Start up current
UNIT MODELS
Fan
Compressor
Fan
Compressor
Maximum absorbed power
Voltage
Maximum current
Total current
Start up current
UNIT MODELS
Fan
Compressor
Fan
Compressor
Total power
Total power
KVCK 48D KVHK 48D KVHA 48D
KVCK 56D KVHK 56D KVHA 56D
KVCK 64D KVHK 64D KVHA 64D
KVCK 76D KVHK 76D KVHA 76D
KVCK 22E KVHK 22E KVHA 22E
KVCK 24E KVHK 24E KVHA 24E
KVCK 28E KVHK 28E KVHA 28E
KVCK 32E KVHK 32E KVHA 32E
KVCK 38E KVHK 38E KVHA 38E
230V-400V/ 3Ph
22,4/12,9
28,8/16,6
184,4/104,7
6,4/3,7
2,2
7,6
9,8
6,4/3,7
2,2
8,62
10,8
24,3/14
30,7/17,7
172,4/102,7
6,4/3,7
2,2
11,15
13,4
28,5/16,4
34,9/20,1
216,4/126,7
2,5
12,9
15,4
36,5/21
45,3/26,1
232,8/132,1
8,8/5,1
2,8
15,55
18,4
46,1/25,6
58,6/32,8
291,5/165,2
12,5/7,2
KVCK 86D KVHK 86D KVHA 86D
KVCK 44D KVHK 44D KVHA 44D
44,8/25,8
57,6/33,2
213,2/121,3
12,8/7,4
4,4
15,2
19,6
KVCK 100D KVHK 100D KVHA 100D
230V-400V/ 3Ph
48,6/28
61,4/35,4
203,1/120,4
12,8/7,4
4,4
17,24
21,6
12,8/7,4
4,4
22,3
26,7
57/32,8
69,8/40,2
251,3/146,8
17,6/10,2
5
25,8
30,8
73/42
90,6/52,2
278,1/158,2
5,6
31,1
36,7
92,2/51,2
117,1/65,6
350,0/198,0
24,9/14,4
8
38,14
46,1
106,6/60
138,1/78,2
414,5/237,2
31,5/18,2
114/65,6
155,2/89,4
337,2/195,8
41,2/23,8
10
44,6
54,6
1.3.- ELECTRICAL DATA
R-407C
R-22
1.- GENERAL CHARACTERISTICS
Page 9
V/f (50 Hz)
Kw
Kw
Kw
A
A
A
A
Maximum absorbed power
Voltage
Maximum current
Total current
Start up current
UNIT MODELS
Fan
Compressor
Fan
Compressor
Total power
KVCK KVHK KVHA
48D2
KVCK KVHK KVHA
56D2
KVCK KVHK KVHA
64D2
KVCK KVHK KVHA
76D2
230V-400V/ 3Ph
12,8/7,4
4,4
17,24
21,6
48,6/28
61,4/35,4
203,1 120,4
12,8/7,4
4,4
22,3
26,7
57/32,8
69,8/40,2
251,3 146,8
5
25,8
30,8
73/42
90,6/52,2
278,1 158,2
17,6/10,2
5,6
31,1
36,7
92,2/51,2
117,1/65,6
350,0 198,0
24,9/14,4
KVCK KVHK KVHA
86D2
8
38,14
46,1
106,6/60
138,1/78,2
414,5 237,2
31,5/18,2
KVCK KVHK KVHA
100D2
10
44,6
54,6
114/65,6
155,2/89,4
337,2 195,8
41,2/23,8
KVCK KVHK KVHA
44D2
44,8/25,8
57,6/33,2
213,2 121,3
12,8/7,4
4,4
15,2
19,6
R-407C
1.3.- ELECTRICAL DATA
1.- GENERAL CHARACTERISTICS
R-22
Page 10
9
MODELS
With rated outdoor flow
With minimum outdoor flow
MODELS
With rated outdoor flow
With minimum outdoor flow
DEPENDING ON MODEL
(TABLE 1)
32º C DB / 23ºC WB
21º C DB / 15ºC WB
27º C DB
15ºC DB
24º C DB / 18ºC WB
-10º C DB / -11ºC WB
DEPENDING ON MODEL
(TABLE 1)
INDOOR
TEMPERATURE
MAXIMUM TEMPERATURES MINIMUM TEMPERATURES
32º C DB / 23ºC WB
COOLING CYCLE
OPERATION
21º C DB / 15ºC WB
OUTDOOR
TEMPERATURE
+19º C STANDARD UNIT
0º C WITH OPTIONAL CPC ON/OFF
-10ºC (*)
+19º C STANDARD UNIT
0º C WITH OPTIONAL CPC ON/OFF
-10ºC (*)
INDOOR
TEMPERATURE
MAXIMUM TEMPERATURES MINIMUM TEMPERATURES
COOLING CYCLE
OPERATION
OUTDOOR
TEMPERATURE
INDOOR
TEMPERATURE
HEATING CYCLE
OPERATION
OUTDOOR
TEMPERATURE
1.4.- OPERATING LIMITS
(To install with LECK - LEHA - LEHK units)
OPERATING LIMITS FOR (COOLING ONLY) UNITS
22E
45
43
24E
45
43
28E
43
41
32E
43
40
38E
42
39
44D
44D2
45
43
48D
48D2
45
43
56D
56D2
43
41
64D
64D2
43
40
76D
76D2
42
39
86D
86D2
42
39
100D
100D2
41
38
22E
48
46
24E
48
45
28E
46
44
32E
46
44
38E
45
42
44D
44D2
48
46
48D
48D2
48
45
56D
56D2
46
44
64D
64D2
46
44
76D
76D2
45
42
86D
86D2
45
42
100D
100D2
44
41
(*) With kit hot gas by pass or proportional winter control (options).
(*) With kit hot gas by pass or proportional winter control (options).
OPERATING LIMITS FOR (HEATING PUMP) UNITS
1.- GENERAL CHARACTERISTICS
DB.- Dry Bulb Temperature WB.- Wet Bulb Temperature
TABLE 1-COOLING CYCLE MAXIMUM OUTDOOR OPERATING TEMPERATURES
MODELS WITH REFRIGERANT R-407C
MODELS WITH REFRIGERANT R-22
Page 11
10
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Electrical box
Drainage outside
thread 3/4''
Power supply
Power
supply
Control panel connection
Ø 14 (x 4)
20
33
978
99
888
47
348
118
100
25
1350
1.195
550
100
1.255
15
15
1375
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNITS DIMENSIONS MODELS 22E-24E-28E-32E
1.- GENERAL CHARACTERISTICS
Page 12
11
Ø 14 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Drainage outside
thread 3/4''
Power supply
Power
supply
25
1415
1.320
100
550
100
1.380
15
15
1445
20
33
1.103
99
888
47
413
118
The dimensions referred
to the center of the drill holes for the supports.
1.- GENERAL CHARACTERISTICS
1.5.- UNIT DIMENSIONS MODEL 38E
Page 13
12
1.- GENERAL CHARACTERISTICS
Ø 16 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Ø 16 (x 4)
Drainage outside
thread 3/4''
Power supply
Power supply
888 348
47
33
119
56
978
119
978
30
1.350
2250
100
550
100
30
15
15
2310
1.380
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNITS DIMENSIONS MODELS 44D-48D-56D-64D
44D2-48D2-56D2-64D2
Page 14
13
1.- GENERAL CHARACTERISTICS
Ø 16 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Ø 16 (x 4)
Drainage outside
thread 3/4''
Power supply
Power supply
1.415
2.260
2.500
100
550
100
30
15
15
2.560
1.445
56
119
888
1.103
413
47
1.103
33
30
119
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNITS DIMENSIONS MODELS 76D-76D2
Page 15
14
1.- GENERAL CHARACTERISTICS
Refrigerant
connections
Refrigerant connections
SLAVE SECTION
MASTER SECTION
DETAIL
Drain pipe G 3/4''
Drain pipe G 3/4''
Electrical box
Electrical connection between outdoor units
DETAIL
SLAVE SECTION
MASTER SECTION
Power supply
Power supply
1570
100
100
550
25
1440
1406
119
45
45
1406
119
413
888
47
33
1570
1440
1.5.- UNITS DIMENSIONS MODELS 86D-100D-86D2-100D2
15
550
1540
Page 16
15
1.- GENERAL CHARACTERISTICS
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Ø 14 (x 4)
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Drainage outside
thread 3/4''
Power supply
Power
supply
20
33
978
99
888
47
348
118
347
4
01
376.5
25
73.5
416.5
327
25
1350
1.195
100
550
100
1.255
15
15
1375
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNITS DIMENSIONS MODELS 22E-24E-28E-32E WITH KIT VERTICAL DISCHARGE FOR OUTDOOR UNITS (OPTION)
Page 17
16
1.- GENERAL CHARACTERISTICS
Ø 14 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Drainage outside
thread 3/4''
Power supply
Power supply
410
4
77
421,5
25
74
4
21,5
266
25
1415
1.320
100
550
100
1.380
15
15
1440
20
33
1.103
99
888
47
413
118
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNIT DIMENSIONS MODEL 38E WITH KIT VERTICAL DISCHARGE FOR OUTDOOR UNITS (OPTION)
Page 18
17
1.- GENERAL CHARACTERISTICS
Ø 16 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Ø 16 (x 4)
Drainage outside
thread 3/4''
Power supply
Power supply
888 348
47
33
119
56
978
119
978
1.380
1.350
2250
100
550
100
30
15
15
2310
401
406
347
401
636
25
305
406
98
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNITS DIMENSIONS MODELS 44D-48D-56D-64D-44D2-48D2-56D2-64D2 WITH KIT VERTICAL DISCHARGE FOR OUTDOOR UNITS (OPTION)
Page 19
18
1.- GENERAL CHARACTERISTICS
Power supply connection
Power supply connection
Control panel connection
Control panel connection
Electrical box
Ø 16 (x 4)
Drainage outside
thread 3/4''
Refrigerant
connections
Refrigerant
connections
Ø 16 (x 4)
Drainage outside
thread 3/4''
Power supply
Power supply
56
119
888
1.103
413
47
1.103
33
1.415
2.260
2.500
100
550
100
30
15
15
2.560
477
432
410
477
682
25
305
432
35
1445
119
The dimensions referred
to the center of the drill holes for the supports.
1.5.- UNIT DIMENSIONS MODEL 76D-76D2 WITH KIT VERTICAL DISCHARGE FOR OUTDOOR UNITS (OPTION)
Page 20
19
1.- GENERAL CHARACTERISTICS
Refrigerant
connections
Refrigerant connections
SLAVE SECTION
MASTER SECTION
DETAIL
Drain pipe G 3/4''
Drain pipe G 3/4''
Electrical box
Electrical connection between outdoor units
DETAIL
SLAVE SECTION
MASTER SECTION
Power supply
Power supply
477
580
513
1406
119
45
45
1406
119
413
888
33
47
1570
100
100
550
25
1440
35
410
305
477
513
580
750
1570
1440
25
1.5.- UNITS DIMENSIONS MODELS 86D-100D-86D2-100D2 WITH KIT VERTICAL DISCHARGE FOR OUTDOOR UNITS (OPTION)
15
550
1540
Page 21
20
1.- GENERAL CHARACTERISTICS
(*) Add to the unit's weight.
MODELS
DIMENSIONS
A
B
22E-24E-28E-32E
122,5
38E
122,5
44D-48D-56D-64D
150,5
76D
150,5
86D-100D
WEIGHTS kg (*)
15
20
30
40 50
102,5
102,5
150,5
150,5
970
1095
1949
2199
C
165
165
165
165
D
342
407
342
407
E
996,5
996,5
996,5
996,5
F
5050
80,5
150,5
1339
165
407
996,5
D
A
C
B
E
F
DAMPER
DAMPER
ACTUATOR
Check to make sure that the main switch is large enough to handle the current for the unit if electric heaters are installed.
PHASE SEQUENCER
The phase sequencer is located in the electrical box in the outdoor section, thus assuring that the unit will not begin operation while the phase connection of the compressor is not correct. Should this occur, then just switch two phase connections.
ON/OFF CONDENSATION PRESSURE CONTROL
The condensation pressure control consists of one or two pressure switches, which starts and stops the outdoor fan regulating the condensation temperature, thus the unit will be able to operate in the cooling cycle when the outdoor temperature is below 19ºC, (Until 0ºC).
CRANK CASE HEATER (COOLING-ONLY UNITS)
The purpose of the heater is to keep the oil in the compressor at the correct temperature while the compressor is stopped so that it can be properly lubricated when started again. When the unit is operating at low outdoor temperatures ( below 19ºC), it is advisable to fit a crank case heater.
HOT GAS BYPASS VALVE
The purpose of the BYPASS valve is to make it possible for the unit to operate at low outdoor temperatures (until -10°C), to be used in cooling-only and head-pump units. It regulates the capacity of the compressor by injecting hot gas from the compressor discharge side to the coil.
Based on one or two dampers located on the outdoor unit discharge air, which lets you controls condensation temperature through the air flow. The damper is moving by a servomotor, which receives a proportional signal through a pressure detector.
PROPORTIONAL CONDENSING PRESSURE CONTROL BY DAMPERS
Thus the unit will be able to operate in the cooling cycles when the outdoor temperature is until -10ºC.
This kit is not available with kit vertical discharge outdoor unit at the same time.
MAIN SWITCH
The main switch is located on the access panel to the electrical box of the outdoor unit. (Except 86D-100D models) The main switch is endowed with a clutch gadget, which allows open the panel of the electrical box, when it is on OFF position.
WITH MAIN SWITCH ON. DO NOT REMOVE THE PANEL
ATTENTION!
1.6.- AVAILABLE OPTIONS
Dimensions of dampers for this kit:
Page 22
21
1.- GENERAL CHARACTERISTICS
MODELS
22E-24E-28E-32E-38E
44D-48D-56D-64D-76D-86D
WEIGHTS (*)
3
6
(*) Add to the unit data.
(*) Add to the unit's weight.
CONTROL USING A PROGRAMMABLE CONTROLLER
With the programmable controller option, the desired temperature can be programmed in the area 24 hours a day, 7 days a week.
REMOTE AMBIENT SENSOR AND REMOTE DUCT SENSOR
This sensors may be used in conjunction with remote controller or allowing the controller to be mounted in a room away from the conditioned space.
- REMOTE DUCT SENSOR: The sensor will be located in the return-air duct, detecting the air temperature of the air being air-conditioned.
- REMOTE AMBIENT SENSOR: The sensor will be placed in the area to be air-conditioned.
MODELS KVC / H
MAXIMUM CURRENT
(A)
230 / III
400/ III
POWER Kw
WEIGHTS Kg (*)
22E
0,4
1,0
0,6
15
24E
0,6
1,5
0,9
15
28E
0,8
2,0
1,2
15
32E
__
__
__
__
38E
__
__
__
__
44D
0,8
2,0
1,2
30
48D
1,2
3,0
1,7
30
56D
1,6
4,0
2,3
30
64D
__
__
__
__
76D
__
__
__
__
86D
__
__
__
__
100D
__
__
__
__
KIT MORE STATIC PRESSURE OF AIR DISCHARGE
It is an specific fan to obtain mores static available pressure up to 350Pa. See air flow data section for optional fan performances. Electrical data for these optional fans:
KIT VERTICAL DISCHARGE FOR OUTDOORS UNITS, (only for split and multi-split systems)
It is a set of accessories to adapt casing, making the outdoor air discharge become vertical See dimensions section for performances.
COMPRESSOR STARTING CURRENT CONSTRAINED (SOFT STARTER) 400V-III
Is an electronic element, which reduce the pick compressor starting current up to 40% (see pages of electrical data without soft starter) Not available for 100D units. Only available for 400V-III units.
This kit is not available with kit proportional condensing pressure control at the same time.
Placement standard
Placement optional
1.6.- AVAILABLE OPTIONS
Page 23
22
The unit must be transported in a VERTICAL POSITION on its metal bedplate profiles. Any other position may cause serious damage to the machine. When the unit is received, it should be checked to assure that there are no bumps or other damage, following the instructions on the packaging. If there is damage, the unit may be rejected by notifying the LENNOX Distribution Department and reporting why the machine is unacceptable on the transport agents delivery notice. Any later complaint or claim made to the LENNOX Distribution Department, for this type of anomaly, cannot be considered under the Guarantee.
Sufficient space must be allowed to facilitate placement of the unit.
The unit may be mounted outdoors. There should be NO possibility of flooding if floor mounted.
All the units have Metal Bedplate Profiles.
All INSTALLATION, SERVICE and MAINTENANCE operations
must be carried out by QUALIFIED PERSONNEL.
When positioning the unit, be sure that the Rating Plate will always be visible since this
data will be necessary to assure proper maintenance.
The units are designed to be installed with ducts, calculated by qualified technical staff. The joints to be used between ducts and the openings to the unit should be Elastic Joints. Avoid the use of BYPASS joints between the extraction air and input air in both the outdoor and indoor sections. The structure where the unit is placed must be able to support the weight of the unit during operation.
2.- INSTALLATION
If unloading and placement require the use of a crane, then secure the suspension cables as shown in the figure.
How to hoist the unit
Use
separators
2.1.- PRELIMINARY PREPARATIONS
2.2.- UNIT RECEPTION
Page 24
23
FLOW REGULATION IN THE FANS
The fan in the outdoors units KVCK/ KVHK/ KVHA 32E- 38E- 64D- 76D- 86D- 100D have a variable pulley incorporated into the activating motor, by which it is possible to vary, when the fan is off its diameter to modify the air flow of the unit, as required.
1. Fixed part
2. Mobil part
3. Fixing screw
CLOSE PULLEY: To increase the fan flow, turn the mobil part in direction "B" (Clock wise). OPEN PULLEY: To reduce the flow, turn in direction "A" (Unclock wise).
TENSION OF BELTS
The belts can be easily tensioned through the tensing screw incorporated into the bases of the motor of the transmitting units which also enables a good servicing to be carried out.
When the tensing screw is moved, the motor fan is moved to the sides in order to tension the pulley.
2.- INSTALLATION
A
B
3
1
2
A
B
3
2
1
2
SIMPLE PULLEY
DOUBLE PULLEY
7
6
7
3
2
4
1
5
DISPLACEMENT
VARIABLE PULLEYS
1.- Centrifugal fan ( single or double).
2.- Activating motor.
3.- Fixed pulley at the fan.
4.- Adjustable pulley at the motor fan.
5.- transmission pulley or pulleys.
6.- Base of the motor with displacement system for tensioning of belts.
7.- Tensing screw.
THE VENTILATION FOR KVCK- KVHA- KVHK 32E-38E-64D-76D-86D-100D UNITS IS FORMED BY:
2.3.- OPTIONAL OPERATIONS PRIOR TO UNIT INSTALLATION:
Page 25
24
UNIT INSTALLED ON SHOCK ABSORBERS
- The unit is able to work in normal radioelectronics conditions for commercials and residential installations. For any other conditions please consult.
- If the outside temperature in the area where the heat pump unit is to be installed is low or the cycle functioning are too long, it may necessary to install a electrical heater, below the likely coils on the drip tray, which avoid the causing of ice in the coil during defrost cycle.
- If the outdoor unit is going to be installed outside. It may be recommended to install isolation around the panel of electrical box, to make sure it became hermetic.
- The bedplate is made up of two metal channels, capable of with standing the weight of the units whether hung from the ceiling or mounted on the floor.
- If the unit is floor mounted, then the profiles should be isolated with shock absorbing material such as anti-vibration or pads. Keep in mind that fans rotate at approximately 850 rpm. For the ones with variable pulley belts, see performances tables.
2.- INSTALLATION
Floor supports
(shock absorbers)
2.4.- UNIT LOCATION
Page 26
25
Clearance around the unit for service and maintenance
Also slightly tip the unit (2%) toward the drainage side. Check that the condensation trays are clean and free from dirt and other debris from the works and that water drains correctly.
All the indoor and outdoor sections of these units have a 3/4 steel threaded drain pipe welded to the condensation tray.
SERVICE SPACE Space should be left free for access or servicing, to case the installation of cables, drainage connections, electric installation and cleaning filters, as well as easy access to the unit.
Drainage pipes will be fitted for each tray through a siphon with a height difference of 80 mm. to avoid drainage problems from the depression formed by the fans. The pipes should have an inclination of 2% to ease drainage of condensation.
Inspection and cleaning stopper.
LOCATION The unit can be installed outside. If it is installed, air entry and exit ducts should be fitted. Both the interior and exterior unit should be assembled on bases previously made and stood on absorbent and antivibrating material to avoid the vibrations being transmitted to the structure of the building.
2.- INSTALLATION
2%
Min. 80 mm.
2 %
UNIT
1 m.
1 m.
1 m.
1 m.
2.5.- INSTALLATION CLEARANCE
2.6.- DRAINS
Page 27
26
The unit is supplied with gas and liquid lines sealed with copper covers inside the casing with possibility to install pipe lines horizontal or vertical.
THE UNITS ARE SUPPLIED WITH NITROGEN GAS, THIS MUST BE REMOVED AND THEN PROCEED
AS FOLLOW:
2.- INSTALLATION
2.7- REFRIGERANT CONNECTIONS
brazing
cupper cover
Horizontal pipe lines
Vertical lines pipe
During installation operations, keep gas and liquid pipes covered, in order to prevent humidity and dirt, get into them. Take special concern about refrigerant pipes are isolated. Avoid collapse on pipe lines installation.
1º Remove the nitrogen gas, through the high and low 1/4 service ports locate inside, from both indoor and outdoor units. 2ª Remove the covers from connecting lines. 3ª Braze the piping connection lines. Refer to installation manual to select the diameter of the lines. (When brazing refrigerant pipes, is necessary to supply nitrogen gas through the service ports into the pipes to remove the air) 4º Leak test:
- Add nitrogen gas and check 5 kg/cm
2
pressure has been reached, and verify there are not leaks in the circuit or brazing, applying soapy water on pipes, because the leaks cause soapy water to form bubbles. To detect small leaks proceed as follow: Add nitrogen gas and check 32 kg/cm2 pressure has been reached, there is not leak if pressure remains the same at least during 24 hours and final pressure is not less than 10% from the initial pressure. 5º Be sure gas line is isolated. 6º Vacuuming. Remove the nitrogen gas, connect the gauge manifold and vacuum pump to both liquid and gas lines, fully open the valve of the gauge manifold and switch on the vacuum pump. Check to make sure the gauge shows a pressure level of -750mm Hg, after a level of -750mm Hg is reached, keep on the vacuum pump at least during an hour. 7º Refrigerant charge:
- Refer to installation manual to verify amount and type of refrigerant which must be charged, and the total amount to be added must be calculated considering the refrigerant charge of the unit, and also the length and sizes of the refrigerant piping.
- Disconnect the vacuum pump and connect to the refrigerant-charging cylinder. Open the charging cylinder and purge the air from the hose at the gauge manifold.
- Set up the amount of additional refrigerant on the weighing scale, open the high pressure (liquid) and low pressure side (suction) of the gauge valve to start the process of refrigerant from outdoor unit. If the total amount of refrigerant charge has not been reached, because balance pressure, turn off the high side of the gauge manifold, turn on the unit, and add slowly through low side of the gauge the remain amount of the refrigerant charge needed.
(With R-407C refrigerant, the charging cylinder must be on horizontal position and it is important to charge in liquid state).
Close the sides of gauge valve from service port of the unit, put the covers on service ports. Then the unit is ready to work.
Page 28
UNIT - MODEL
TABLE 1: REFRIGERANT LINES SELECTION
27
2.- INSTALLATION
- THE GAS LINE MUST BE ALWAYS INSULATED.
- THE HORIZONTAL LINES MUST BE TYPED AT LEAST 2% TOWARD THE OUTDOOR UNIT.
- THE MAXIMUM SPEED INSIDE LINES SHOULD NOT BE MORE THAN 15 m/seg.
Between length of 30 and 50 m superior you have to make a recalculation according to our technical commercial department or distribution itself to maintain determinated aspects how to make the installation (additional charge of oil, solenoid valves, etc.
L
L
L
2
1
2.7- REFRIGERANT CONNECTIONS
A
B
2%
2%
To locate the outdoor and the indoor units, refer to the following information:
A,B,C : Unit positions
L : Total length 1 = Gas line 2 = Liquid line
Liquid
Gas
Liquid
Gas
Liquid
Total
line
length
0 to 10 m.
Gas
30 to 50 m.
Unit connections
REFRIGERANT LINES
Maximum vertical line length (m)
Maximum number of bends
0 to 30 m.
Liquid
Gas
2%
2%
OUTDOOR UNIT
INDOOR UNIT
C
22E
3/4"
1-3/8"
2x5/8''
2x
7/8"
2x5/8''
2x
1-1/8"
5/8"
1-1/8"
5/8"
7/8"
5/8"
1-1/8"
5/8"
1-1/8"
2x5/8''
2x
1-1/8"
2x5/8''
2x
1-1/8"
2x3/4"
2x
1-3/8"
24E 28E 32E 38E
44D
44D2
48D
48D2
56D
56D2
64D
64D2
76D
76D2
2x7/8''
2x
1-5/8"
86D
86D2
2x7/8''
2x
1-5/8"
100D
100D2
3/4"
1-3/8"
2x5/8''
2x
7/8"
2x5/8''
2x
1-1/8"
5/8"
1-1/8"
5/8"
7/8"
5/8"
1-1/8"
5/8"
1-1/8"
2x5/8''
2x
1-1/8"
2x5/8''
2x
1-1/8"
2x3/4"
2x
1-3/8"
2x7/8''
2x
1-5/8"
2x7/8''
2x
1-5/8"
5/8" 3/4" 3/4" 3/4" 7/8" 2x5/8'' 2x3/4''
2x
1-1/8"2x1-3/8"
1-5/8"1-3/8"1-1/8" 1-3/8" 1-3/8"
16 16 16 16 16 16 16
12 12 12 12 12 12 12
2x3/4''
2x
1-3/8"
16
12
2x3/4''
2x
1-3/8"
16
12
2x7/8''
2x
1-5/8"
16
12
2x7/8''
2x
2-1/8"
16
12
2x1-1/8''
2x
2-1/8"
16
12
7/8"
1-5/8"
2x5/8''
2x
1-1/8"
2x5/8''
2x
1-1/8"
3/4"
1-3/8"
5/8"
1-1/8"
5/8"
1-1/8"
5/8"
1-1/8"
2x5/8''
2x
1-1/8"
2x3/4''
2x
1-3/8"
2x7/8"
2x
1-5/8"
2x7/8''
2x
1-5/8"
2x7/8''
2x
1-5/8"
2
1
OUTDOOR UNIT
INDOOR UNIT
OUTDOOR UNIT
INDOOR UNIT
2
1
2%
POSITION A : A syphon suction must be installed on the vertical line of the gas line 1 , and syphons must be
installed every 8 meters upward. The minimum speed suction must not be below 6m/s.
POSITION B : Tip the lines toward the outdoor unit. Make special atention to line length longer than 10m and
avoid collapse on pipe lines installation.
POSITION C : Install a siphon at the base of the vertical of the gas line; no more siphons are necessary.
Page 29
28
If R-407C Refrigerant is used in the unit, the following precautions characteristic of this gas should
be taken:
- The Vacuum Pump must have a Check Valve or Solenoid Valve.
- Pressure Gauges and Hoses for the exclusive use with R-407C Refrigerant should be used.
- The charge should be carried out in the Liquid Phase.
- Always use scales to weight-in charge- Use the Leak Detector exclusive for R-407C Refrigerant.
- Do not use mineral oil, only synthetic oil to ream, expand or make connections.
- Keep pipes wrapped before using them and be very thorough about any possible dirt (dust, filings,
burrs, etc.).
- When there is a leak, gather what is left of the charge, create a vacuum in the unit and completely
recharge with new R-407C Refrigerant.
- Brazing should always be carried out in a nitrogen atmosphere.
- Reamers should always be well sharpened.
2.- INSTALLATION
2.7.-REFRIGERANT CONNECTIONS
PRECAUTIONS TO BE TAKEN IN THE USE OF R-407C Refrigerant
Page 30
29
2.- INSTALLATION
Indoor and outdoor units are factory pre-charged with Nitrogen (N2). The installer should remove this gas and charge the units with the refrigerant R-22 or R-407C shown on the following table and also the charge per meter line on table 4.
Charge of refrigerant (gr) R-22 for 0 meters of line KVHA + LEHA
22E
6000
24E
6800
28E
7900
32E
9100
38E
11300
44D
12000
48D
13600
56D
15800
64D
18200
86D
24400
76D
22600
100D
27000
22E 24E 28E 32E 38E 44D 48D 56D 64D 86D
21000
76D 100D
23400
Charge of refrigerant (gr) R-407C for 0 meters of line KVCK + LECK
22E 24E 28E 32E 38E 44D 48D 56D 64D 86D
23400
76D 100D
26000
Charge of refrigerant (gr) R-407C for 0 meters of line KVHK + LEHK
32E 38E
Indoor and outdoor units are factory pre-charged with Nitrogen (N2). The installer should remove this gas and charge the units with the refrigerant R-22 or R-407C shown on the following table and also the charge per meter line on table 4.
Charge of refrigerant (gr) R-22 KVHA + 2 x LEHA
44D2
2 x 6000
48D2
2 x 6800
56D2
2 x 7900
64D2
2 x 9100
76D2
2 x 11300
86D2
2 x 12200
100D2
2 x 13500
Charge of refrigerant (gr) R-407C KVCK + 2 x LECK
44D2
2 x 5000
48D2
2 x 5700
56D2
2 x 6650
64D2
2 x 7600
76D2
2 x 9450
86D2
2 x 10500
100D2
2 x 11700
Charge of refrigerant (gr) R-407C KVHK + 2 x LEHK
44D2
2 x 5500
48D2
2 x 6300
56D2
2 x 7400
64D2
2 x 8500
76D2
2 x 10500
86D2
2 x 11700
100D2
2 x 13000
5000 5700 6650 7600 9450 10000 11400 13300 15200 18900
5500 6300 7400 8500 10500 11000 12600 14800 17000 21000
2.7.- REFRIGERANT CONNECTIONS
TABLE 3: CHARGE OF REFRIGERANT FOR MULTI-SPLIT SYSTEM
TABLE 2: CHARGE OF REFRIGERANT FOR OUTDOOR UNIT + INDOOR UNIT LE
Page 31
30
2.- INSTALLATION
CHARGE OF REFRIGERANT FOR THE SET: EXAMPLE: To install a KVHK 38E + LEHK 38E set, with a 22m refrigerant line length between outdoor and indoor unit, then the refrigerant charge must be calculated as follow: 1º Type of refrigerant R-22 or R-407C, in this case, R-407C . 2º The TABLE 4 shows, that for 22m of line length between indoor unit and outdoor unit, the line sizes are, liquid 7/8", and gas 1-5/8". 3º TABLE 4 shows, for line sizes of 7/8"- 1-5/8", the charge per meter line is: 327 gr/m. 4º TABLE 2 shows, charge of refrigerant for the set with 0m of line length is 10.500gr. 5º To determine the charge of the set: Add charge of the refrigerant lines + charge of refrigerant indoor unit and outdoor unit.
Total charge for the set: (327 gr/m) x 22m + 10.500 gr = 17.694 gr
MODEL 22E MODEL 24E
MODEL 28E
MODEL 32E
MODEL 38E
MODEL 44D / D2 MODEL 48D / D2
5/8"
5/8" 5/8"
7/8"
1-1/8" 1-3/8"
151 155 155 155 232 151 155
1-1/8" 1-1/8"
2x7/8"
2x1-1/8"
5/8"
3/4"
2x5/8" 2x5/8"
3/4"
3/4"
1-3/8"
155 232 232 232 327 155 232
1-3/8"
3/4"
1-1/8" 1-3/8"
1-5/8"
2x1-1/8" 2x1-3/8"
5/8"
7/8"
2x5/8" 2x3/4"
Suction Liquid Suction Liquid
FROM 0 TO 10M
FROM 30 TO 50M
gr/m gr/m
MODEL 56D / D2
155
2x1-1/8"
2x5/8" 2322x1-3/8" 2x3/4"
MODEL 64D / D2
1552x1-1/8" 2x5/8" 2322x1-3/8" 2x3/4"
MODEL 76D / D2
2322x1-3/8" 2x3/4" 3272x1-5/8" 2x7/8"
MODEL 86D / D2
3272x1-5/8" 2x7/8" 3402x2-1/8" 2x7/8"
5/8"
5/8" 3/4"
1-1/8"
1-3/8" 1-5/8"
155 155 155 232 327 155 155
1-1/8" 1-1/8"
2x1-1/8" 2x1-1/8"
5/8"
7/8"
2x5/8" 2x5/8"
Suction Liquid
FROM 10 TO 30M
gr/m
155
2x1-1/8"
2x5/8"
2322x1-3/8" 2x3/4" 3272x1-5/8" 2x7/8" 3272x1-5/8" 2x7/8"
MODEL 100D / D2
3272x1-5/8" 2x7/8" 5812x2-1/8" 2x1-1/8"3272x1-5/8" 2x7/8"
2.7.-REFRIGERANT CONNECTIONS
TABLE 4: WEIGHT OF REFRIGERANT R-22 R-407C PER METER LINE OF LINE
Page 32
31
Printed circuit
board
Electrical box
1 2
3
Power supply. Electrical connection between outdoor units. Indoor motor fan electrical connection.
Thermostat connection
Thermostat connection
Printed circuit
board
Electrical box
PE L1 L2 L3 N
X1
3N ~ 400V - 50 Hz + PE
PE L1 L2
X1
L3
3 ~ 230V - 50 Hz + PE
UNIT
MODEL
POWER SUPPLY
230V THREE-PHASE UNITS
Power supply
WITHOUT
electrical heater.
Power supply
WITH electrical
heater.
Nr. OF CABLES x SECTION (mm )
2
1
1
28E
24E
32E
22E
38E
48D
44D
56D
76D
64D
2
Electrical connection
between outdoor units.
3
Indoor motor
fan electrical connection.
86D
COOLING
HEATING
100D
1
1
28E
24E
32E
22E
38E
48D
44D
56D
76D
64D
2
3
86D
100D
Electrical connection
between outdoor units.
Indoor motor fan electrical
connection.
UNIT
MODEL
POWER SUPPLY
400V THREE-PHASE UNITS
Power supply
WITHOUT
electrical heater.
Power supply
WITH electrical
heater.
Nr. OF CABLES x SECTION (mm )
2
COOLING
HEATING
4 x 1,5
4 x 1,5
4 x 1,5
4 x 1,5 4 x 1,5 4 x 2,5 4 x 2,5
4 x 2,5 4 x 2,5 4 x 2,5
4 x 95
4 x 2,5
4 x 16 10 x 1
4 x 2,5
4 x 2,5
4 x 16 14 x 1
4 x 95
4 x 2,5
4 x 2,5
8 x 6
16 x 1
4 x 2,5
8 x 6
20 x 1
4 x 25
4 x 25
4 x 35 4 x 35 4 x 70 4 x 70
4 x 70 4 x 95 4 x 95
4 x 25
4 x10 4 x 10 4 x 10
4 x 16 4 x 16 4 x 25 4 x 25
4 x 35 4 x 50 4 x 50
4 x 1,5
4 x 1,5
4 x 1,5
4 x 1,5 4 x 1,5 4 x 2,5 4 x 2,5
4 x 2,5 4 x 2,5 4 x 2,5
5 x 35
5 x 50
5 x 70
4 x 2,5
4 x 6
10 x 1
4 x 2,5
4 x 2,5
4 x 6
14 x 1
5 x 50
4 x 2,5
4 x 2,5
8 x 4
16 x 1
4 x 2,5
8 x 4
20 x 1
5 x 10
5 x 10
5 x 16 5 x 16 5 x 25 5 x 25
5 x 35 5 x 35 5 x 50
5 x 10
5 x 4 5 x 4 5 x 6
5 x 6
5 x 10 5 x 10 5 x 10 5 x 16 5 x 25 5 x 25
4 x 120
4 x 150
- BEFORE MAKING ANY ELECTRICAL CONNECTIONS, BE SURE THAT ALL CIRCUIT BREAKERS ARE OPEN.
- IN ORDER TO CARRY OUT THE ELECTRICAL CONNECTIONS, FOLLOW THE ELECTRICAL DIAGRAM SUPPLIED WITH THE UNIT.
- Connect the power supply cables to the terminals in the electric box through the grommet.
- The sections have been calculated for a length no longer than 50m and a voltage drop of 10V. Do not start the unit if the drop is greater than this.
- The wiring and circuit breakers to be mounted in the installation must comply with the Regulations in force.
- Ground wires must be properly connected and have a greater length than the phase wires
.
FOR UNITS MODELS:
22E-24E-28E-32E-38E 44D-48D-56D-64D-76D
86D-100D
INDOOR
SECTION
OUTDOOR
SECTION
MASTER
OUTDOOR SECTION
SLAVE
OUTDOOR SECTION
INDOOR
SECTION
2.- INSTALLATION
2.8.- ELECTRICAL CONNECTION
1
1
3
2
3
Page 33
32
1 2
3
Power supply. Electrical connection between outdoor units. Indoor motor fan electrical connection.
Printed circuit
board
Electrical box
Thermostat connection
Thermostat connection
Printed circuit
board
Thermostat connection
Thermostat connection
Electrical box
PE L1 L2 L3 N
X1
3N ~ 400V - 50 Hz + PE
PE L1 L2
X1
L3
3 ~ 230V - 50 Hz + PE
MODELS VOLTAGE
LIMIT
28E/56D
24E/48D
32E/64D
22E/44D
38E/76D
86D
86D
100D
100D
1
1
48D2
44D2
56D2
76D2
64D2
2
3
86D2
100D2
1
1
48D2
44D2
56D2
76D2
64D2
2
3
86D2
100D2
Electrical connection
between outdoor units.
Indoor motor fan electrical connection.
Indoor motor fan electrical
connection.
UNIT
MODEL
POWER SUPPLY
230V THREE-PHASE UNITS
Power supply
WITHOUT
electrical heater.
Power supply
WITH electrical
heater.
Nr. OF CABLES x SECTION (mm )
2
COOLING
HEATING
UNIT
MODEL
POWER SUPPLY
400V THREE-PHASE UNITS
Power supply
WITHOUT
electrical heater.
Power supply
WITH electrical
heater.
Nr. OF CABLES x SECTION (mm )
2
COOLING
HEATING
Electrical connection
between outdoor units.
230 V-3Ph-50Hz 230 V-3Ph-50Hz
230 V-3Ph-50Hz
400 V-3Ph-50Hz
400 V-3Ph-50Hz
198-264 V -3Ph- 50Hz 180-242 V -3Ph- 50Hz 342-462 V -3Ph- 50Hz 198-264 V -3Ph- 50Hz 342-462 V -3Ph- 50Hz
230 V-3Ph-50Hz
230 V-3Ph-50Hz
400 V-3Ph-50Hz
400 V-3Ph-50Hz
198-264 V -3Ph- 50Hz 342-462 V -3Ph- 50Hz 180-242 V -3Ph- 50Hz 342-457 V -3Ph- 50Hz
4 x 1,5 4 x 1,5 4 x 1,5 4 x 1,5 4 x 1,5
4 x 95
4 x 2,5
4 x 16 10 x 1
4 x 2,5
4 x 2,5
4 x 16 14 x 1
4 x 95
4 x 2,5
4 x 2,5
8 x 6
16 x 1
4 x 2,5
8 x 6
20 x 1
4 x 70 4 x 70 4 x 70 4 x 95 4 x 95
4 x 25 4 x 25 4 x 35 4 x 50 4 x 50
4 x 1,5 4 x 1,5 4 x 1,5 4 x 1,5 4 x 1,5
5 x 35
4 x 2,5
4 x 6
10 x 1
4 x 2,5
4 x 2,5
4 x 6
14 x 1
5 x 50
4 x 2,5
4 x 2,5
8 x 4
16 x 1
4 x 2,5
8 x 4
20 x 1
5 x 25 5 x 25 5 x 35 5 x 35 5 x 50
5 x 10 5 x 10 5 x 16 5 x 25 5 x 25
4 x 120
4 x 150
5 x 50
5 x 70
VOLTAGE OPERATING LIMITS
- Connect the power supply cables to the terminals in the electric box through the grommet.
- The sections have been calculated for a length no longer than 50m and a voltage drop of 10V. Do not start the unit if the drop is greater than this.
- The wiring and circuit breakers to be mounted in the installation must comply with the Regulations in force.
- Ground wires must be properly connected and have a greater length than the phase wires.
FOR UNITS MODELS:
44D2-48D2
56D2-64D2-76D2
86D2-100D2
INDOOR
SECTION
MASTER
OUTDOOR SECTION
SLAVE
OUTDOOR SECTION
INDOOR
SECTION
OUTDOOR
SECTION
2.- INSTALLATION
2.8.- ELECTRICAL CONNECTION
1
3
1
3
3
3
2
Page 34
33
CONTROL PANEL
ELECTRICAL CONNECTION DIGITAL THERMOSTAT, FOR STANDARD UNIT VERSION
- For securing and connecting the Control Panel, consult the control Panel Manual supplied with the unit.
- Keep in mind that the Control Panel cable is a SHIELDED CABLE and the wire mesh is only grounded through the electric box.
- The T+ and T- polarity must strictly agree with the electrical diagram supplied with the unit.
IMPORTANT
THE SHIELDED CONNECTION CABLE BETWEEN THE CONTROL PANEL AND THE UNIT MUST
BE SEPARATE FROM ANY OTHER TYPE OF ELECTRICAL WIRING.
CONNECT IT TO THE ELECTRIC BOX LOCATED IN THE OUTDOOR UNIT.
Since this type of control panel is factory-configured for each application, an identification code located on the control panel of the terminal itself has been given to each panel. Any query or request for a replacement of the control panel must be accompanied by this identification code.
IDENTIFICATION CODE FOR THE CONTROL PANEL
Type of control
Nr. of speeds of the indoor fan
Nr. of cooling stages
Nr. of heating stages
Application C: Cooling only H: Heat pump
Configuration Version
BASIC TERMINAL NAME ACCESSORIES
P: Programmable
(Programming schedule)
(INTERNAL FACTORY CODES)
Ground connection for the wire
mesh of the shielded cable
T + T
-
PE 1
90 91
PE
PE
X1
CONTROL
PANEL
UNIT
ELECTRIC
BOX
Shielded cable,
two connection wires
A111
2.- INSTALLATION
2.8.- ELECTRICAL CONNECTION
Page 35
34
ELECTRICAL CONNECTION DIGITAL THERMOSTAT, FOR VFC UNIT VERSION
- For securing and connecting the Control Panel, consult the control Panel Manual supplied with the unit.
111
MODELS: COOLING ONLY UNITS
22E-24E-28E-32E-38E
MODELS: HEAT PUMP UNITS
22E-24E-28E-32E-38E
MODELS: COOLING ONLY UNITS
44D-48D-56D-64D-76D-86D-100D
MODELS: HEAT PUMP UNITS
44D-48D-56D-64D-76D-86D-100D
CONTROL PANEL
IDENTIFICATION CODE FOR THE CONTROL PANEL
Nr. of speeds of the indoor fan
Nr. of cooling stages
Nr. of heating stages
Application F: Cooling only B: Heat pump
Version
BASIC TERMINAL NAME
(INTERNAL FACTORY CODES)
A B C D E F G H C R T G O
Y1Y2W3
A B C D E F G H C R T G O
Y1Y2W3
Y2
O
W1
Y1
G R
24V
B
W1
Y1
24V
G R
24V(c)
Y2
W2
W1
Y1
G R
24V
24V(c)
24V(c)
24V(c)
W1
Y1
24V
G R
O
B
2.- INSTALLATION
2.8.- ELECTRICAL CONNECTION
PCB(In the unit electrical box)
PCB(In the unit electrical box)
PCB(In the unit electrical box)
PCB(In the unit electrical box)
RC 111F-300
RC 122F-700
RC 112B-450
RC 123B-600
Page 36
35
SINGLE CIRCUIT UNIT, STANDARD VERSION
C FM FM CM EH
Dirty
filter
alarm
SINGLE CIRCUIT UNIT, VFC VERSION
REMOTE
ON/OFF
Power
supply
Common
Fan
Heat/ Cool
(**)
E. HEATER
Compressor
C FM FM CM EH
Dirty
filter
alarm
CM
DOUBLE CIRCUIT UNIT, STANDARD VERSION
C FM
FM CM1 EH1
Dirty
filter
alarm
CM1 CM2
CM2 EH2
DOUBLE CIRCUIT UNIT, VFC VERSION
Power supply
Common
Fan
Heat / Cool (Second stage
electrical heater (**)
CM2
CM1
Cooling only unit
First stage
electrical heater
C FM
FM CM1 EH1
Dirty
filter
alarm
CM1 CM2
CM2 EH2
Cooling only unit
REMOTE
ON/OFF
ELECTRICAL BOX OF THE UNIT
ELECTRICAL BOX OF THE UNIT
ELECTRICAL BOX
OF THE UNIT
ELECTRICAL BOX OF THE UNIT
When unit switch off, the system will show CM, CM1 Y CM2 failure signal.
* Remove wire, if ON/OFF remote is used.
*
*
*
*
90 91 92 93
REMOTE
ON/OFF
60 61 64 65 67 69
Alarm and
failure signals
Unit's functioning mode signals
92
93
A
BCDEFGH
60 61 64 65 67 69
Alarm and
failure signals
Unit's functioning mode signals
62
90 91 92 93
REMOTE
ON/OFF
60 61 64 65 67 69
Alarm and
failure signals
Unit's functioning mode signals
62 63 66 68
C
RGOY1Y2W3
60 61 64 65 67 69
Alarm and
failure signals
Unit's functioning mode signals
62 63 66 68
68
68
92
93
The electrical box of all the range, lets you obtain the following functions:
- Remote ON / OFF.
- Alarm and failure signals for the unit's components: FM, CM.
- The unit's functioning mode signals: FM,CM, EH.
- Dirty air filter indication (option).
- Manage the unit operation, through the supplied thermostat or through the digital inputs for a BMS system (Only for VFC unit version).
Optional
Optional
Optional
Optional
T + T
-
T + T
-
Thermostat connection
Thermostat connection
** Heat
pump
** Cooling
only
C: Common FM: Indoor fan CM: Compressor CM1: Compressor 1 CM2: Compressor 2
Ambient thermostat
signals or digital
inputs BMS system
Ambient thermostat
signals or digital
inputs BMS system
EH1: Electrical heater 1 EH2: Electrical heater 2
ELECTRICAL CONNECTION " REMOTE SIGNALS"
2.- INSTALLATION
2.9.- ELECTRICAL CONNECTION
Page 37
Power
supply
Common
Fan
Heat/ Cool
(**)
E. HEATER
Compressor
A BCDEFGH
Power
supply
Common
Fan
Heat/ Cool
(**)
E. HEATER
Compressor
A BCDEFGH
36
*
*
Dirty
filter
alarm
REMOTE
ON/OFF
Dirty
filter
alarm
ELECTRICAL BOX OF THE UNIT
ELECTRICAL BOX OF THE UNIT
STANDARD VERSION UNIT MULTI-SPLIT SYSTEM
C FM1 FM2
FM1 EH1
CM1 FM2
CM2
EH2
C
FM1 FM2
FM1 EH1
CM1 FM2
CM2
EH2
CM1
CM2
VFC VERSION UNIT MULTI-SPLIT SYSTEM
When unit switch off, the system will show, CM1 Y CM2 failure signal.
* Remove wire, if ON/OFF remote is used.
REMOTE
ON/OFF
Alarm and
failure signals
Unit's functioning mode signals
Alarm and
failure signals
Unit's functioning mode signals
Optional
Optional
Thermostat connection
(**) Heat
pump
90 91 92 93
60 61 63 65 67 69
92
93
66 68
T + T
-
94 95
70 7371
Ambient thermostat
signals or digital
inputs BMS system
60 61 63 65 67 6966 68
64
62
70
7371
Ambient thermostat
signals or digital
inputs BMS system
C: Common FM: Indoor fan CM1: Compressor 1 CM2: Compressor 2 EH1: Electrical heater 1 EH2: Electrical heater 2
ELECTRICAL CONNECTION " REMOTE SIGNALS" MULTI-SPLIT SYSTEMS
2.9.- ELECTRICAL CONNECTION
2.- INSTALLATION
T + T
-
Page 38
37
CONTROL PANEL
INLET AIR DUCT OUTDOOR SECTION
OUTDOOR SECTION
OUTDOOR FAN ACCESS
AIR INTAKE DUCT OUTDOOR SECTION
TRAP
DRAIN PIPE
FIGURE FOR THE STANDARD UNIT CONFIGURATION FOR MODELS
44D-48D-56D-64D-76D
DISCHARGE IN THE DOUBLE CIRCUIT UNITS
Always to be done through a common duct or plenum.
Check that drain pipe connections and their fixtures are secure and that the level of the unit is tipped toward the drain. Inspect the state of the ducts and grilles (clean and open grilles, no breaks in the duct, etc.). Check that the power supply is the same as stated on the Rating Plate which is in agreement with the electrical diagram for the unit and that cable sizes are correct. Check that tightness of the electrical connections to their terminals and to ground. Check the control panel connections. (If the connection is wrong, the unit will not operate and the control panel display will not light). Check with your hand that the fans turn freely.
1
2 3
4
5
LOCATION The unit can be installed outside. If it is installed, air entry and exit ducts should be fitted. The outdoor unit should be assembled on bases previously made and stood on absorbent and antivibrating material to avoid the vibrations being transmitted to the structure of the building.
FLEXIBLE JOINT AT OPENINGS
3.- COMMISSIONING AND OPERATION
3.1.- PRELIMINARY CHECKS
Page 39
38
- On the heat pump units, the compressor has a single phase electric heating element to assure a separation between the Refrigerant and the oil in the housing. This heater is activated when the compressor is off and stops working when the compressor is on. About eight hours before start up or after a long shutdown period, voltage should be supplied to the unit so that this heater will be activated.
- To start the unit, follow the instructions given in the Control Panel Manual supplied with the unit (requesting operation in any of the modes, cooling, heating, or automatic). After a time lapse, the unit will start.
- With unit operating, check that the fans are turning freely and in the proper direction.
- Check compressor oil level, sight glass included (on the sides of the compressor, the level should be between 1/4 and 3/4 in the sight glass, while during operation the level should be between 3/4 and full).
- Connect high and low pressure gauges and check that operating pressure values are normal.
- Measure electrical consumption for the unit and check that it is near what is indicated on the Rating Plate.
- Check the electrical consumption of the compressor and the fans with what is specified in the physical data sheets.
- In the case of a Heat Pump unit, make a cycle change on the Control Panel checking that the 4-way valves make the change correctly. Check the pressure values in the new cycle.
- Remember the low pressure switch is reset automatically and the high pressure switch is reset electronically.
- Check that pressure switches stop the unit: FOR THE COOLING CYCLE UNIT: Stop the outdoor fan by disconnecting it. The high pressure should rise and the high pressure switch should stop the compressor at 27.5 kg/cm . Reconnect the fan and electrically reset the pressure switch by pressing the RESUME button on the Control Panel for 5 seconds for standard unit version, and press "OFF" for VFC version units and wait for the anti-cycle time (5 minutes), afterwards, the unit will start-up again. Stop the indoor fan by disconnecting it. The low pressure should drop and the unit should stop when the pressure gauge reaches 1 kg/cm . The unit will start up again when the pressure rises and the pressure gauge indicates 2 kg/cm . Once this has been carried out, stop the unit and reconnect the fan.
- Start the unit again and when everything is operating normally, take a reading of all the data and fill out the
Commissioning Sheet.
Scroll type compressors only compress in one direction of the rotation. Single phase models are always started up in the proper direction; however, the three phase models, turn in either direction depending on the order of the power supply phases. Therefore, it is essential that the phase connection for scroll-type three-phase compressors be carried out correctly (the correct direction of rotation can be checked when the pressure on the suction side decreases and the pressure on the discharge side increases when the compressor is activated). If the connection is wrong, the rotation will be reversed causing a high noise level and a reduction in the amount of current consumed. If this occurs, the compressors internal protection system will kick in shutting down the unit. The solution is to disconnect, switch the wires between two of the phases and connect again).
REMEMBER THAT THE COMPRESSOR IS A SCROLL TYPE COMPRESSOR:
3.- COMMISSIONING AND OPERATION
3.2.- STEPS TO FOLLOW FOR COMMISSIONING THE UNITS
2
2
2
Page 40
39
-GENERAL STATE OF THE CASING : Furniture, paint, deterioration due to bumps, rust spots, leveling and supporting, state of the shock absorbers, if installed, screwed panels, etc.
- ELECTRICAL CONNECTIONS : State of hoses, tightness of screws, grounding, current draw of the compressor and fans and checking that the unit is receiving the correct voltage.
- COOLING CIRCUIT : Check that pressure values are correct and that there are no leaks. Check that there is no damage to the pipe insulation, that the state of the batteries is correct and that there are no chips or clogs retained by the air flow, etc.
- COMPRESSOR : Inspect the oil level, if sight glass is present. Inspect the state of the silent block fixtures.
- DRAINS : Check that water drains correctly and that the drain trays are clean.
- FANS : Check that fans turn freely and in the correct direction without excessive noises.
- CONTROL : Check Set Points and normal operation.
4.1.- PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTS COSTLY REPAIRS.
BECAUSE OF THIS PERIODIC INSPECTIONS ARE REQUIRED.
4.- MAINTENANCE
Page 41
40
If some component in the cooling circuit must be replaced, follow these recommendations:
- Always use original replacement parts.
- Remove the entire refrigerant charge from the unit through the schrader valves located in the outdoor section. Create a slight vacuum as a safety measure.
- Regulation prohibits the release on the refrigerant into the atmosphere.
- If cuts must be made in the pipe work, use pipe cutters. Do not use saws or any other tools that produce filings.
- All brazing must be carried out in a nitrogen atmosphere to prevent corrosion from forming.
- Use silver alloy brazing rod.
- Take special care that the flame from the torch is aimed in the opposite direction from the component to be welded and is covered with a wet rag in order to avoid overheating.
- Take very special care if 4-way check valves are to be replaced since these have internal components that are very heat-sensitive such as plastic, teflon, etc.
- If a compressor must be replaced, disconnect it electrically and un-braze the suction and discharge lines. Remove the securing screws and replace the old compressor with the new one. Check that the new compressor has the correct oil charge, screw it to the base and connect the lines and electrical connections.
- Carry out the vacuum above and below through the schrader valves of the outdoor unit until -750 mm Hg is reached. Once this level of vacuum has been reached, keep the pump in operation for at least one hour. DO NOT USE
THE COMPRESSOR AS A VACUUM PUMP.
- Charge the unit with refrigerant according to the data on the Rating Plate for the unit and check that there are no leaks.
IMPORTANT
MAKE SURE THAT THE UNIT IS COMPLETELY DISCONNECTED FROM THE POWER SUPPLY
WHEN CARRYING OUT ANY TYPE OF WORK ON THE MACHINE
If R-407C Refrigerant is used in the unit, the following precautions characteristic of this gas should be taken:
- The Vacuum Pump must have a Check Valve or Solenoid Valve.
- Pressure Gauges and Hoses for the exclusive use with R-407C Refrigerant should be used.
- The charge should be carried out in the Liquid Phase.
- Always use scales to weight-in charge.
- Use the Leak Detector exclusive for R-407C Refrigerant.
- Do not use mineral oil, only synthetic oil to ream, expand or make connections.
- Keep pipes wrapped before using them and be very thorough about any possible dirt (dust, filings, burrs, etc.).
- When there is a leak, gather what is left of the charge, create a vacuum in the unit and completely recharge with new R-407C Refrigerant.
- Brazing should always be carried out in a nitrogen atmosphere.
- Reamers should always be well sharpened.
PRECAUTIONS TO BE TAKEN IN THE USE OF R-407C Refrigerant
Direction of the flame
Silver alloy welding rod
Wet rag
Component to be welded
Nitrogen
4.- MAINTENANCE
4.2.- CORRECTIVE MAINTENANCE
Page 42
41
FAILURE
POSSIBLE CAUSES POSSIBLE SOLUTIONS
UNIT DOES NOT START
Failure in the power supply, or insufficient voltage.
UNIT STOPS DUE TO HIGH PRESSURE DURING THE COOLING CYCLE
The same causes and solutions as the Cold Cycle but with reference to the batteries and Indoor Fan.
UNIT STARTS AND STOPS IN SHORT CYCLES
Compressor overcharged.
Inspect suction and discharge pressure values and correct.
UNIT STOPS DUE TO HIGH PRESSURE DURING THE HEATING CYCLE
UNIT STOPS DUE TO LOW PRESSURE
LOAD AND ABNORMAL NOISE IN THE COMPRESSOR (SCROLL)
WATER LEAKS
Circuit breakers have opened.
Power cable or Control Panel cable is defective.
Connect the power supply or check the voltage.
Reset.
Inspect and Correct.
High Pressure switch is defective.
Outdoor fan is not working.
Outdoor Fan turns in the wrong direction.
Outdoor Coil is dirty or clogged for passing air
Check Cut-off Pressure or change Pressure Switch if necessary.
Check for voltage, inspect the motor and turbine or replace if necessary.
Switch the power phases.
Inspect and Clean.
Low pressure switch defective.
Check the Cut-off Pressure with a pressure gauge and change the Pressure switch if necessary.
Indoor Fan is not working.
Check for voltage and inspect the motor, turbine and replace if necessary.
Indoor Fan turns in the wrong direction.
Switch the power phases.
Lack of refrigerant. Leak. Correct leak, create vacuum and charge.
Dirty Air Filter Inspect and Clean.
Clogged Cooling Circuit. Dirty filter drier.
Compressor cuts off due to Klixon.
Inspect input voltage and voltage drop.
Lack of Refrigerant. Correct leak and replace.
Power supply phases inverted (three-phase compressor).
Inspect and switch power phases.
Clogged drainage.
Inspect and Clean.
Loose drainage pipe connections.
Correct connection.
Inspect and Correct or Change the Filter drier.
Excess charge of the Refrigerant.
Remove the charge and charge according to the data on the Rating Plate.
In case of failure or malfunction of the unit, the Display on the Control Panel will show an Error or Alarm warning explained in the Control Panel Manual. Nevertheless, whenever there is a unit failure, the unit should be shut down and our Service Technicians consulted.
Dirty and overflowing trays.
Inspect and Clean.
4.- MAINTENANCE
4.3.- FAILURE DIAGNOSIS
Page 43
42
NOTES
Page 44
COD: MIL65E-0701 04-2004
www.lennoxeurope.com
Due to Lennox's ongoing commitment to quality, Specifications, Ratings and Dimensions subject to change without notice and without incurring liability. Improper installation, adjustment, alteration, service or maintenance can cause property damage or personal injury. Installation and service must be performed by a qualified installer and servicing agency.
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tél. : + 420 2 510 88 111 fax : + 420 2 579 10 393 e-mail : janka@janka.cz
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