Installation, operating and maintenance

110 Pages·2013·4.86 MB·English

Installation, operating
and maintenance
BALTIC Air cooled and water cooled
rooftop packaged units
20 - 85 kW
BALTIC-IOM-1305-E

TABLE OF CONTENTS
BALTIC
Installation, operating and
maintenance
Ref : BALTIC-IOM-1305-E
INsTALLATION MANUAL 1
sERVICE MANUAL 37
CONTROL MANUAL 83
CERTIfICATEs 103

All the technical and technological information contained in this manual, including any drawing and technical descriptions provided by us,
remain the property of Lennox and must not be utilised (except in operation of this product), reproduced, issued to or made available to third
parties without the prior written agreement of Lennox.
BALTIC-IOM-1305-E

TABLE OF CONTENTS
BALTIC
INSTALLATION MANUAL
Ref : BALTIC_Installation-IOM-1305-E
INTRODUCTION
Safety codes & regulations 3
TRANSPORT & HANDLING
Mandatory handling devices 8
LIFTING THE UNITS
Machine dimensions and weights 9
Minimum clearance around the unit installation 11
Fork lifting the unit 11
Removing the forklift protection located under the machine 12
Lifting the unit with a crane 13
Lifting the roof curbs 14
DELIVERY CHECKS
Rating plate 16
Storage 16
Maintenance key 16
Condensate drains 17
Preliminary checks 17
Installation requirements 17
Connections 17
INSTALLATION ON A ROOF MOUNTING FRAME
Roof opening dimensions 18
Sealing checks 18
Leveling adjustable roofcurbs 18
Positioning the rooftop on adjustable roofcurbs 19
NON ADJUSTABLE NON ASSEMBLED ROOFCURB INSTALLATION
Frame parts packing 20
Installation 21
Assembly 21
Securing the frame 21
Sealing checks 22
Curbing and fl ashing 22
DUCT CONNECTIONS 23
WATER COOLED UNITS 24
HEAT RECOVERY
General description 28
Plate heat recovery - Confi gurations 29
Plate heat recovery - Installation 30
Thermodynamic heat recovery - Confi gurations 32
Thermodynamic heat recovery - Installation 33
Thermodynamic heat recovery - Control 35
BALTIC-IOM-1305-E / Installation manual • 1 •
GLOSSARY
EBHO Horizontal extraction box
ERVF Vertical fl ow exhaust roofcurb
HRMH Horizontal heat recovery module
HRMV Vertical heat recovery module
TRMO Thermodynamic heat recovery module
HRHS Horizontal return - Horizontal Supply
HRVS Horizontal return - Vertical Supply
VRHS Vertical return - Horizontal Supply
VRVS Vertical return - Vertical Supply
• 2 • BALTIC-IOM-1305-E / Installation manual
INTRODUCTION
The present manual applies to the following rooftop versions
Heating capacity
Net cooling capacity Heating capacity
Item (kW - Eurovent conditions)
(kW - Eurovent conditions) (KW) GAS
HeatPump
COOLING ONLY
BAC 024 SNM 3M 23,4 - -
BAC 030 SNM 3M 29,2 - -
BAC 038 SNM 3M 37,1 - -
BAC 042 SNM 3M 39,4 - -
BAC 045 DNM 3M 43,9 - -
BAC 052 DNM 3M 49,8 - -
BAC 057 DNM 3M 55,2 - -
BAC 065 DNM 3M 62,6 - -
BAC 075 DNM 3M 74,1 - -
BAC 085 DNM 3M 80,7 - -
HEAT PUMP
BAH 024 SNM 3M 23,4 20,7 -
BAH 030 SNM 3M 29,2 26,2 -
BAH 038 SNM 3M 37,1 34,8 -
BAH 042 SNM 3M 39,4 38,0 -
BAH 045 DNM 3M / BWH 045 DNM 3M 43,9 / 46,3 40,8 / 56,7 -
BAH 052 DNM 3M / BWH 052 DNM 3M 49,8 / 53,3 46,2 / 65,9 -
BAH 057 DNM 3M / BWH 057 DNM 3M 55,2 / 61,9 54,4 / 78,4 -
BAH 065 DNM 3M / BWH 065 DNM 3M 62,6 /73,6 62,2 / 91,1 -
BAH 075 DNM 3M / BWH 075 DNM 3M 74,1 / 87,8 73,5 / 105,3 -
BAH 085 DNM 3M / BWH 085 DNM 3M 80,7 / 91,6 80,1 / 112,8 -
GAS ONLY - STD HEAT
BAG 024 SSM 3M 23,3 - 20
BAG 030 SSM 3M 28,9 - 20
BAG 038 SSM 3M 36,8 - 20
BAG 042 SSM 3M 39,1 - 20
BAG 045 DSM 3M 43,7 - 33
BAG 052 DSM 3M 49,5 - 33
BAG 057 DSM 3M 54,7 - 33
BAG 065 DSM 3M 61,9 - 33
BAG 075 DSM 3M 73,4 - 60
BAG 085 DSM 3M 79,8 - 60
GAS ONLY - HIGH HEAT
BAG 024 SHM 3M 23,3 - 46
BAG 030 SHM 3M 28,9 - 46
BAG 038 SHM 3M 36,8 - 46
BAG 042 SHM 3M 39,1 - 46
BAG 045 DHM 3M 43,7 - 60
BAG 052 DHM 3M 49,5 - 60
BAG 057 DHM 3M 54,7 - 60
BAG 065 DHM 3M 61,9 - 60
BAG 075 DHM 3M 73,4 - 120
BAG 085 DHM 3M 79,8 - 120
DUAL FUEL - STD
BAM 024 SSM 3M 23,3 20,8 20
BAM 030 SSM 3M 28,9 26,5 20
BAM 038 SSM 3M 36,8 35,1 20
BAM 042 SSM 3M 39,1 38,4 20
BAM 045 DSM 3M / BWM 045 DSM 3M 43,7 / 46,3 41,0 / 56,7 33
BAM 052 DSM 3M / BWM 052 DSM 3M 49,5 / 53,3 46,6 / 65,9 33
BAM 057 DSM 3M / BWM 057 DSM 3M 54,7 / 61,9 54,9 / 78,4 33
BAM 065 DSM 3M / BWM 065 DSM 3M 61,9 / 73,6 62,8 / 91,1 33
BAM 075 DSM 3M / BWM 075 DSM 3M 73,4 / 87,8 74,2 / 105,3 60
BAM 085 DSM 3M / BWM 085 DSM 3M 79,8 / 91,6 81,0 / 112,8 60
DUAL FUEL - HIGH
BAM 024 SHM 3M 23,3 20,8 46
BAM 030 SHM 3M 28,9 26,5 46
BAM 038 SHM 3M 36,8 35,1 46
BAM 042 SHM 3M 39,1 38,4 46
BAM 045 DHM 3M / BWM 045 DHM 3M 43,7 / 46,3 41,0 / 56,7 60
BAM 052 DHM 3M / BWM 052 DHM 3M 49,5 / 53,3 46,6 / 65,9 60
BAM 057 DHM 3M / BWM 057 DHM 3M 54,7 / 61,9 54,9 / 78,4 60
BAM 065 DHM 3M / BWM 065 DHM 3M 61,9 / 73,6 62,8 / 91,1 60
BAM 075 DHM 3M / BWM 075 DHM 3M 73,4 / 87,8 74,2 / 105,3 120
BAM 085 DHM 3M / BWM 085 DHM 3M 79,8 / 91,6 81,0 / 112,8 120
BALTIC-IOM-1305-E / Installation manual • 3 •
INTRODUCTION
Safety codes & regulations
THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE
USED IN WELL VENTILLATED AREA.
PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING THIS UNIT.
INSPECTIONS AND REQUALIFICATION ACCORDING PRESSURE EQUIPMENT DIRECTIVE MUST FOLLOW THE LOCAL
REGULATIONS WHERE THE UNIT IS INSTALLED.
All units are compliant with the PED directive 97-23/CE
EMC DIRECTIVE COMPLIANCE
WARNING:
This equipment is an “A class“ according CEM Directive. In an industrial environment, this device can create radio electrical noise. In
this case, the owner can be asked to take appropriated actions
This applies to all machine installed with nominal amps below <75A:
• The short-circuit rate Rsce=33 is defi ned in the EN61000-3-12 standard relative to the harmonics readings on the supply network.
The appliances compliant with the harmonic current limits equivalent to Rsce=33 can be connected in whatever connection point
of the main supply system.
• The maximal allowable impedance of the main supply system Zmax=0.051W is defi ned by EN 61000-3-11 standard relative to
the voltage variation, fl uctuation and fl icker readings. The connection to the supply is a conditional connection submitted to the
preliminary agreement of the power supply local provider.
Important note for unit fi tted with gas burner:
THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FOLLOWING CODES:
GB IR GR DA NO FI IS
In case these symbols are not displayed on the unit, please refer to the technical documentation which will eventually detail any
modifi cations required to the installation of the unit in a particular country.
• If machine is including gas burner, minimum clearance around the unit must be at least 8 m to allow a proper gas fl ue dilution. If
not possible, the fresh air intake must be ducted at least 8 m away from the gas burner exhaust.
• The gas burner air intake and exhaust chimney must not be modifi ed or ducted.
• Before commissioning this type of unit, it’s mandatory to ensure that the gas distribution system is compatible with the adjustments
and settings of the unit.
• Gas module can only be used for outdoor installations.
• Any work on gas module must be carried out by qualifi ed engineer.
• 4 • BALTIC-IOM-1305-E / Installation manual
INTRODUCTION
F-Gas REGULATION
EC Regulation No 842/2006 on fl uorinated greenhouse gases
Operators of refrigeration equipments must comply with the 6 main obligations defi ned in the F Gas Regulation
OBLIGATION APPLICABILITY
Recovery of F gases during plant servicing and maintenance and at the end of plant life. All stationary systems
Use adequately trained staff to carry out installation, servicing and maintenance and leakage
All stationary systems
checking.
NEW equipment shall be labelled. All stationary systems
Take steps to prevent F gas leakage and repair detected leakage as soon as possible. All stationary systems
Regularly check for leakage.
06 kg or more : at least once every 12 months Hermetically sealed systems >
30 kg or more : at least once every 6 months 6kg
300 kg or more : at least once every 3 months
Keep certain records about refrigeration plant that uses F gases. (refer to the start up and
Stationary systems > 3kg
Maintenance Log book at the end of this document)
Fit and check automatic leak detection system. Stationary systems > 300kg
Non compliance with these requirements is an offence and liable of fi nancial penalties.
Moreover, in case of problem it is mandatory to prove to the insurance company that the equipment complies
with the F gas Regulation.
WARRANTY
The warranty of the unit is subject to the warranty defi nitions as agreed upon in the order.
It is expected that the design and installation of the unit utilises good working practices.
The warranty will be legally null and void if:
• Service and maintenance have not been executed in accordance with the regulations; repairs have not been carried out
by LENNOX personnel or have been implemented without prior written permission by LENNOX.
• Modifi cations have been made to the equipment without prior written permission by LENNOX.
• Settings and protections have been modifi ed without prior written permission by LENNOX.
• Non-original or other than the prescribed refrigerants or lubricants are used.
• The equipment has not been installed and/or connected in accordance with the installation instructions.
• The equipment is being used improperly, incorrectly, negligently or not in accordance with its nature and/or purpose.
• A fl ow protection device is not fi tted.
In these circumstances LENNOX is indemnifi ed from any product liability claims from third parties.
In the event of a warranty claim the machine serial number and LENNOX order number must be quoted.
WARNING - All the technical and technological information contained in this manual, including any drawing and technical descriptions
provided by us, remain the property of LENNOX and must not be utilised (except in operation of this product),reproduced, issued to or
made available to third parties without the prior written agreement of LENNOX. The technical information and specifi cations contained
in this manual are for reference only. The manufacturer reserves the right to modify these without warning and without obligation to
modify equipment already sold.
BALTIC-IOM-1305-E / Installation manual • 5 •
INTRODUCTION
SAFETY
The safety information contained in this manual is provided as a guide for the safe handling of this installation. LENNOX
does not vouch for the completeness of this information and can therefore not accept liability for any possible omissions.
In the roof tops, heat is being transported by a pressurised refrigerant, with changes in pressure and temperature. For air cooled roof
tops, fans have been provided to discharge heat into the environment. The protection of operating and maintenance personnel was
central in the design of the roof top. Safety features have been included to prevent excessive pressure in the system. Sheet metal
parts have been fi tted to prevent inadvertent contact with (hot) pipes. For air cooled roof tops, the fans are equipped with protective
grids and the electrical control panel is completely touch-proof. This excludes some parts operating at a safe voltage (< 24 Volt). The
service panels can only be opened using tools.
The electrical control panel is completely touch-proof. This excludes some parts operating at a safe voltage (< 50 Volt). The service
panels can only be opened using tools.
Notwithstanding that the roof tops are equipped with extensive safety and protection features, the utmost care and attention
is needed when carrying out operations on the machine. Furthermore, ear protection should be worn when working on or
in the vicinity of the roof tops. Operations on the cooling circuit or electrical equipment should be carried out by authorised
personnel.
It is essential to follow non exhaustive recommendations hereunder:
• Never work on a unit that is still energized.
• Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualifi ed and authorised engineer. These procedures
must be carried out with the unit shut-down.
• Never work on any of the electrical components, until the general power supply to the unit has been cut. During any maintenance
operations on the unit, lock the power supply circuit in the open position ahead of the machine. If the work is interrupted, check the
lock before resuming the work.
WARNING: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuit disconnect switch
is open. Refer to the wiring diagram for further details.
• For some units, a separate 220V power supply may exist, check the electrical wiring for more informations
• In case of maintenance operations on fans (grills replacement …) ensure that the power is shut off to avoid automatic restart.
• Before the opening of the refrigerant circuit, check the pressure with manometers or pressure sensors.
• Never leave a unit stopped with valves closed on the liquid line, refrigerant could be trapped and the pressure would rise.
• All installation parts must be maintained by the personnel in charge, in order to avoid material deterioration and injuries to people.
Faults and leaks must be repaired immediately. The authorized technician must have the responsibility to repair the fault immediately.
Each time repairs have been carried out to the unit, the operation of the safety devices must be re-checked.
• Follow guidance and recommendations given in safety and machine standards such as EN378, ISO5149, etc
• Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and
other common substances.
• Never exceed the specifi ed maximum operating pressures. Verify the allowable maximum high- and low-side test pressures by
checking the instructions in this manual and the pressures given on the unit name plate.
• Do not use air for leak testing. Use only refrigerant or dry nitrogen.
• Do not unweld or fl ame cut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and vapour) has
been removed from roof top. Traces of vapour should be displaced with dry air nitrogen. Refrigerant in contact with an open fl ame
produces toxic gases.
• Do not siphon refrigerant
• Avoid spilling liquid refrigerant on skin or splashing it into the eyes. Use safety goggles. Wash any spills from the skin with soap and
water. If liquid refrigerant enters the eyes, immediately and abundantly fl ush the eyes with water and consult a doctor.
Safety defi nition
The roof tops meet the following safety defi nitions:
• Pr-EN-378-1.
• 2006/42/CE (“Machine Directive”).
• EN-60204-1.
• 2004/108/CE “EMC Directive”.
• Pressure Equipment Directive 97/23/CE.
• Gaz equipment Directive 90/396/CEE
And is provided with CE markings (on the condition that the necessary options are present) (for further information see CE declaration).
Warning labels
The roof top is marked with the following warning labels to alert to potential hazards (on or near the potentially hazardous part).
High temperatures Electrical Voltage Rotating parts Sharp parts
Regularly check that the warning labels are still in the correct positions on the machine and replace them if necessary.
• 6 • BALTIC-IOM-1305-E / Installation manual