Lennox SW 036 User manual

12/11

*2P1211*

506671-01

*P506671-01*

2011

Litho U.S.A. RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

WARNING

Improper installation, adjustment, alteration, ser

vice or maintenance can cause property damage,

personal injury or loss of life. Installation and ser

vice must be performed by a qualified installer or

service agency.

INSTALLATION

INSTRUCTIONS

SW 036 ( 3 TON)

SW 060 ( 5 TON)

SW 120 (10 TON)

SW 240 (20 TON)

506671-01

12/2011

Supersedes 1/2011

WATER SOURCE HEAT PUMP UNITS

Table Of Contents

Parts Arrangement Page 2.....................

Dimensions Page 3............................

Shipping And Packing List Page 6...............

General Page 6...............................

Safety Page 6................................

Unit Support Page 7...........................

Duct Connection Page 7.......................

Rigging Unit For Lifting Page 7..................

Condensate Drains Page 8.....................

Water Supply Connections Page 8...............

Water Bypass Loop Page 11.....................

Bleed Air From Water Lines Page 11..............

Factory-Installed Options Page 12................

Electrical Connections Page 14..................

Blower Operation and Adjustment Page 16........

Cooling Start-Up Page 24.......................

Water Circuit Operation Page 28.................

Freeze Protection Page 28......................

Water Quality Guidelines Page 30................

Service Page 30...............................

SW 036 & 060 Parts Arrangement

INDOOR

COIL

WATER TO

REFRIGERANT

COIL

COMPRESSOR

BLOWER

FILTERS

(FOUR - 16 X 20 X 2”)

WATER INLET

CONNECTION

REVERSING

VALVE

IMC UNIT

CONTROLLER

BOTTOM

POWER ENTRY

WATER OUTLET

CONNECTION

BOTTOM

WATER ENTRY

WATER FLOW

CONTROL VALVE

(SEE FIGURE 6)

CHARGE

COMPENSATOR

BLOWER

MOTOR

Page 2

SW 120 Parts Arrangement

INDOOR

COIL

COMPRESSOR 1

BLOWER

FILTERS

(SIX - 16 X 25 X 2”)

ECONOMIZER

DAMPERS (OPTIONAL)

CHARGE

COMPENSATOR 1

REVERSING

VALVE 2

IMC UNIT

CONTROLLER

WATER INLET

CONNECTION

WATER OUTLET

CONNECTION

BOTTOM

WATER ENTRY

STG. 1 WATER FLOW

CONTROL VALVE

(SEE FIGURE 7)

STG. 1 WATER TO

REFRIGERANT COIL

(SEE FIGURE 7)

COMPRESSOR 2

BLOWER

MOTOR

REVERSING

VALVE 1

CHARGE

COMPENSATOR 2

STG. 2 WATER TO

REFRIGERANT COIL

(SEE FIGURE 7)

STG. 2 WATER FLOW

CONTROL VALVE

(SEE FIGURE 7)

SW 240 Parts Arrangement

STG. 1 WATER

FLOW CONTROL VALVE

(SEE FIGURE 8)

STG. 2 WATER

FLOW CONTROL VALVE

(SEE FIGURE 8)

INDOOR

COIL

BLOWER MOTOR

COMPRESSOR 1

BLOWER

FILTERS

(TWELVE - 20 X 20 X 2”)

ECONOMIZER

DAMPERS (OPTIONAL)

STG.1 WATER TO

REFRIGERANT COIL

(SEE FIGURE 8)

WATER INLET

CONNECTION

REVERSING

VALVES

IMC UNIT

CONTROLLER

WATER OUTLET

CONNECTION

BOTTOM

WATER ENTRY

CHARGE

COMPENSATOR 1

CHARGE

COMPENSATOR 2

COMPRESSOR 2

STG.2 WATER TO

REFRIGERANT COIL

(SEE FIGURE 8)

Page 3

SW 036 & 060 Dimensions

FRONT VIEWSIDE VIEW

FORKLIFT

SLOTS

BLOWER

INDOOR COIL

BOTTOM

POWER

ENTRY

FILTERS

BOTTOM POWER

ENTRY

5 x 8 inches

(127 x 203 mm)

RETURN AIR

OPENINGS

SUPPLY AIR

OPENING

COMPRESSOR

CONDENSATE DRAIN

ECONOMIZER

DAMPERS

(Factory Installed

Option)

INDOOR COIL

FILTERS

BLOWER

OUTDOOR AIR HOOD

(Factory Installed Option)

TOP VIEW

TOP VIEW BASE SECTION

LIFTING HOLES

(For Rigging

Front and Back)

(711)

15 (381)

(457)

14-1/4

(362)

(102)

(2057)

82-7/8

(2105)

28‐7/8

(733)

5-1/4

(133)

41‐3/8

(1050)

3‐1/2

(89)

37‐7/8

(962)

53-1/8

(1350)

12‐1/2

(318)

OUTDOOR

AIR

CIRCUIT

BREAKER

COVER

4‐1/4

(108)

ECONOMIZER DAMPERS

(Factory Installed Option)

(25)

12‐1/2

(318)

(457)

5‐1/4

(133)

1‐1/2

(38)

CONTROL

BOX

15-1/4

(387)

OUTDOOR AIR HOOD

FORKLIFT

SLOTS

115V OUTLET (FACTORY-

INSTALLED INSIDE UNIT;

FIELD WIRING REQUIRED)

WATER TO

REFRIGERANT

COIL

CHARGE

COMPENSATOR

COMPRESSOR

3 X 12 (76 X 305)

BOTTOM WATER

ENTRY

AA BB

DD CC

CENTER OF

GRAVITY

4-3/8

(111)

4-1/2

(114)

Unit Corner Weight - lbs. (kg) Center of Gravity - in. (mm)

AA BB CC DD EE FF

036 239 (108) 249 (113) 265 (120) 253 (115) 39-3/4 (1010) 28-3/4 (730)

060 244 (110) 255 (115) 272 (123) 259 (117) 39-3/4 (1010) 28-3/4 (730)

Weight with all options installed.

Page 4

SW 120 Dimensions

FORKLIFT

SLOTS

BLOWERS

INDOOR COIL

BOTTOM

POWER

ENTRY

FILTERS

SUPPLY AIR

OPENINGS

RETURN AIR

OPENING

COMPRESSORS (2)

CONDENSATE

DRAIN

ECONOMIZER

DAMPERS

(Factory Installed

Option)

INDOOR COIL

FILTERS

BLOWER

OUTDOOR AIR HOOD

(Factory Installed Option)

FRONT VIEW

TOP VIEW

SIDE VIEW

TOP VIEW BASE SECTION

LIFTING HOLES

(For Rigging

Front and Back)

(1016)

15 (381)

20 (508)

(711)

18 (457)

90‐1/4

(2292)

92-1/8

(2340)

31-3/16

(792)

5‐3/8

(137)

51‐3/8

(1305)

3‐1/2

(89)

47-7/8

(1216)

77‐5/16

(1964)

12‐3/8

(314)

12‐3/8

(314)

13-3/8

(340)

OUTDOOR

AIR

CIRCUIT

BREAKER

COVER

4‐1/4

(108)

ECONOMIZER DAMPERS

(Factory Installed Option)

OUTDOOR AIR HOOD

(For Outdoor Air Dampers)

(102)

BOTTOM POWER

ENTRY

5 x 8 inches

(127 x 203 mm)

115V OUTLET (FACTORY-

INSTALLED INSIDE UNIT;

FIELD WIRING REQUIRED)

FORKLIFT

SLOTS

5-1/4

(133)

1-1/2

(38)

FORKLIFT

SLOTS

BOTTOM

WATER ENTRY

CHARGE

COMPENSATORS

(2)

WATER TO

REFRIGERANT

COIL

CENTER OF

GRAVITY

DD CC

AA BB

OUTDOOR AIR HOOD

(With Economizer)

15-3/4

(400)

3 X 12 (76 X 305)

BOTTOM WATER

ENTRY

8-11/16

(221)

5-5/8

(143)

Corner Weight - lbs. (kg) Center of Gravity - in. (mm)

AA BB CC DD EE FF

416 (189) 417 (189) 474 (215) 473 (215) 41 (1041 38-3/4 (984)

Weight with all options installed.

Page 5

SW 240 Dimensions

Note: Optional equipment shown for information only. See

Engineering Handbook for standard and optional features.

BOTTOM

POWER

ENTRY

CONTROL

BOX

BLOWER

INDOOR COIL

FILTERS

BLOWER

FRONT VIEW

TOP VIEW

FORKLIFT SLOTS

(Front and Left

Side Only)

3‐1/4

(83)

120-1/2

(3061)

145-1/4

(3689)

65-3/16

(1656)

(1573)

LIFTING HOLES

(For Rigging

Front and Back)

BOTTOM POWER

ENTRY 5 X 8 inches

(127 X 203 mm)

BOTTOM SUPPLY

AIR OPENINGS

BOTTOM RETURN

AIR OPENING

4‐1/4

(108)

4‐1/2

(114)

(711)

4 (102)

9 (229)

20 (508) 20 (508)

15 (381)

18 (457)

60-1/2 (1537)

9-1/4

(235)

OPTIONAL

ECONOMIZER DAMPERS

(Factory or Field Installed)

OPTIONAL OUTDOOR AIR HOOD

(Factory or Field Installed)

COMPRESSOR

1-3/4

(45)

BOTTOM

WATER ENTRY

WATER TO

REFRIGERANT

COIL

17-3/8

(440)

CENTER OF

GRAVITY

3 X 12 (76 X 305)

BOTTOM WATER

ENTRY

23-7/8

(606)

5-1/2

(140)

17-3/8

(440)

CHARGE

COMPENSATOR

COMPRESSOR

CHARGE

COMPENSATOR

BLOWERS

(2)

61‐15/16

(1573)

EVAPORATOR

COIL

FILTERS

SIDE VIEW

OUTDOOR

AIR

90‐1/4

(2292)

30‐7/8

(784)

91-1/2

(2324)

ECONOMIZER DAMPERS

(Factory Installed Option)

25-1/2

(648)

OUTDOOR AIR HOOD

(With Economizer)

CONDENSATE

DRAIN

5‐3/8

(137) 3‐1/4

(83)

FORKLIFT

SLOTS

65‐3/16

(1656)

TOP VIEW BASE SECTION

115V OUTLET

(FACTORY-INSTALLED

INSIDE UNIT; FIELD

WIRING REQUIRED)

CIRCUIT

BREAKER

COVER

Corner Weight - lbs. (kg) Center of Gravity - in. (mm)

AA BB CC DD EE FF

684 (310) 684 (310) 750 (340) 750 (340) 40 (1016) 60 (1524)

Weight with all options installed.

Page 6

Shipping and Packing List

Package 1 of 1 contains:

1- Assembled unit

Check unit for shipping damage. Receiving party should

contact last carrier immediately if shipping damage is found.

General

These instructions are intended as a general guide and

do not supersede local codes in any way. Authorities

having jurisdiction should be consulted before

installation.

Requirements

The unit is ETL certified for outdoor installations only at

the clearances to combustible materials listed on unit

nameplate and in figures 1 and 2.

ÉÉÉÉÉÉÉÉÉÉ

(1524)

60 (1524) 10 TON

48 (1219) 3 & 5 TON

RECOMMENDED SERVICE CLEARANCES IN (mm)

036, 060, AND 120 UNITS

TOP CLEARANCE UNOBSTRUCTED

FIGURE 1

BLOWER

36 (914) 3 & 5 TON

48 (1219) 10 TON

(1524)

SERVICE CLEARANCES IN (mm) - 240 UNITS

TOP CLEARANCE UNOBSTRUCTED

FIGURE 2

ÇÇÇÇÇÇÇ

ÇÇÇÇ

(2438) 48

(1219)

(1829)

60 (1524)

NOTE- ENTIRE PERIMETER OF UNIT BASE REQUIRES SUP

PORT WHEN ELEVATED ABOVE MOUNTING SURFACE.

*66 inches (1676mm)

recommended

service clearance for

blower deck removal.

CAUTION

Danger of sharp metallic edges. Can cause injury.

Take care when servicing unit to avoid accidental

contact with sharp edges.

Installation of heat pumps must conform with standards in

National Fire Protection Association (NFPA) “Standard

for Installation of Air Conditioning and Ventilating

Systems NFPA No. 90A,” “Standard for Installation of

Residence Type Warm Air Heating and Air conditioning

Systems NFPA No. 90B,” local municipal building codes

and manufacturer's installation instructions.

The National Electric Code (ANSI/NFPA No. 70-1984) is

available from:

National Fire Protection Association

1 Batterymarch Park

PO Box 9101

Quincy, MA 02269-9101

The unit is ETL certified as a heat pump with cooling and

with or without auxiliary electric heat for non-residential

use only at the clearances to combustible materials as

listed on the unit nameplate and in figures 1 and 2.

Installation of ETL certified units must conform with current

standard C273.5 “Installation Requirements for Heat

Pumps” and applicable local codes. Authorities having

jurisdiction should be consulted before installation.

Use of this unit as a construction heater or air conditioner

is not recommended during any phase of construction.

Very low return air temperatures, harmful vapors and

operation of the unit with clogged or misplaced filters will

damage the unit.

If this unit has been used for heating or cooling of

buildings or structures under construction, the following

conditions must be met or the warranty will be void:

 A room thermostat must control the unit. The use of

fixed jumpers that will provide continuous heating or

cooling is not allowed.

 A pre-filter must be installed at the entry to the return

air duct.

 The return air duct must be provided and sealed to

the unit.

 Return air temperature range between 55°F (13°C)

and 80°F (27°C) must be maintained.

 Air filters must be replaced and pre-filter must be

removed upon construction completion.

 The unit components, duct system, air filters and

evaporator coil must be thoroughly cleaned following

final construction clean-up.

 The unit operating conditions (including airflow,

cooling operation, and heating operation) must be

verified according to these installation instructions.

Page 7

WARNING

Electric shock hazard and danger of

explosion. Can cause injury, death or

product or property damage. Turn off

electrical power to unit before

performing any maintenance or

servicing operations on the unit.

IMPORTANT

The Clean Air Act of 1990 bans the intentional vent

ing of refrigerant (CFC's and HCFC's) as of July 1,

1992. Approved methods of recovery, recycling or

reclaiming must be followed. Fines and/or incar

ceration may be levied for non-compliance.

Unit Support

In downflow discharge installations, install the unit on a

non-combustible surface only.

NOTE - Securely fasten roof frame to roof per local codes.

Downflow Discharge Application

Roof Mounting with S1 / S6 / S7CURB

1- The S1 / S6 / S7CURB roof mounting frame must be

installed, flashed and sealed in accordance with the

instructions provided with the frame.

2- The S1 / S6 / S7CURB roof mounting frame should

be square and level to 1/16” per linear foot (5mm per

linear meter) in any direction.

3- Duct must be attached to the roof mounting frame

and not to the unit; supply and return plenums must

be installed before setting the unit.

Installer's Roof Mounting Frame

Many types of roof frames can be used to install the unit

depending upon different roof structures. Items to keep

in mind when using the building frame or supports are:

1- The base is fully enclosed and insulated, so an

enclosed frame is not required.

2- The frames or supports must be constructed with

non-combustible materials and should be square and

level to 1/16” per linear foot (5mm per linear meter)

in any direction.

3- Frame or supports must be high enough to prevent any

form of moisture from entering unit. Recommended

minimum frame height is 14” (356mm).

4- Duct must be attached to the roof mounting frame

and not to the unit. Supply and return plenums must

be installed before setting the unit.

5- Units require support along all four sides of unit base.

Supports must be constructed of steel or suitably

treated wood materials.

NOTE-When installing a unit on a combustible surface for

downflow discharge applications, an S1 / S6 / S7CURB

roof mounting frame is required.

Duct Connection

All exterior ducts, joints and openings in roof or building

walls must be insulated and weather-proofed with

flashing and sealing compounds in accordance with

applicable codes. Any duct passing through an

unconditioned space must be insulated.

CAUTION

In downflow applications, do not drill or punch

holes in base of unit. Leaking in roof may occur if

unit base is punctured.

Rigging Unit For Lifting

Rig unit for lifting by attaching four cables to holes in unit

base rail. See figure 3.

1- Detach wooden base protection before rigging.

2- Connect rigging to the unit base using both holes in

each corner.

3- All panels must be in place for rigging.

4- Place field‐provided H‐style pick in place just above

top edge of unit. Frame must be of adequate

strength and length. (H-style pick prevents damage

to unit.)

FIGURE 3

CAUTION - Do not

walk on unit.

IMPORTANT - ALL

PANELS MUST BE IN

PLACE FOR RIGGING.

RIGGING

LIFTING POINT SHOULD

BE DIRECTLY ABOVE

CENTER OF GRAVITY

*Maximum weight with all available

factory-installed accessories.

1030

1752

2720

036, 060

120

240

467

795

1256

Unit *Weight

Lbs. Kg.

Page 8

Condensate Drains

Remove cap and make drain connection to the 1” N.P.T.

drain coupling provided on unit. A trap must be installed

between drain connection and an open vent for proper

condensate removal. See figure 4. Always route

condensate line to a drain; condensate can damage

roofing material. The condensate line must be vented.

Check local codes concerning condensate disposal.

Refer to dimensions in the front of this manual for

condensate drain location.

FIGURE 4

UNIT

Minimum Pitch

1” (25 mm) per

10' (3 m) of line

MOUNTING

FRAME

OPEN VENT

CONDENSATE DRAIN CONNECTION

NOTE - Allow clearance to

open doors when installing

condensate piping. CAULK AROUND

CONDENSATE

COUPLING

Water Supply Connections

Supply and return water connections are to be made with

black iron pipe suitable for use in water systems. Lines

must enter the unit through the opening in the base.

Field-provided dielectric unions and flexible steel braided

hose should be installed between the black iron pipe and

the supply and return water connections. See dimensions

in the front of this manual.

1- Remove two-piece cover and install black iron pipes

through openings in base. Extend pipes 3-6in.

(76-152mm) above the opening. Use the following

diameter black iron pipe with NPT male threads:

036 - 1” diameter

060 - 1-1/4” diameter

120 - 1-1/2” diameter

240 - 2” diameter

2- Install the field-provided dielectric unions and flexible

steel braided hoses between the black iron pipe and

unit water in/out connections.

3- Apply a thread sealing compound to threaded

connections. Use only thread sealing compounds

compatible with water systems. Make sure hoses are

not kinked; this may indicate incorrect black iron pipe

height.

4- Cut half-round openings in the cover to fit around the

black iron pipe. See figure 5. Secure two-piece cover

to flanges and apply mastic sealant around openings.

IMPORTANT - Make sure flexible steel hoses are not

kinked. Kinked hoses may increase pressure drop and

reduce system performance.

Verify air vents are closed and that three-way water

inlet/outlet valves are in bypass position before pressure

testing the building system with air to avoid a

false-positive leak check. See figure 6, 7, or 8. Do not

pressurize the hose kits with more than 300 psi.

Page 9

INSTALL COVER

FIGURE 5

TWO-PIECE

COVER

CUT FOUR SEMI-

CIRCLES TO FIT

AROUND BLACK

IRON PIPES

BLACK

IRON PIPES

SECURE WITH

FOUR SCREWS

FIGURE 6

WATER-TO-REFRIGERANT CIRCUIT - SW 036, 060

WATER

MANUAL

AIR VENT

WATER TO

REFRIGERANT

COIL

WATER

OUT

B39 WATER FLOW

CONTROL VALVE

(ON/OFF)

STRAINER

THREE-WAY

VALVE IN BYPASS

POSITION

THREE-WAY

VALVE IN MAIN

LOOP POSITION

FLEXIBLE

MESH BY

PASS HOSE

AUTOMATIC

FLOW

REGULATOR

DRAIN VALVE

WITH HOSE END

CONNECTION

Page 10

FIGURE 7

WATER-TO-REFRIGERANT CIRCUIT - SW 120

WATER TO

REFRIGERANT

COIL STG. 1

B39 STG. 1 WATER

FLOW CONTROL

VALVE (ON/OFF) MANUAL AIR

VENTS

WATER

IN WATER

OUT

STRAINER

THREE-WAY

VALVE IN MAIN

LOOP POSITION

WATER TO

REFRIGERANT

COIL STG. 2

B42 STG. 2 WATER

FLOW CONTROL

VALVE (ON/OFF)

THREE-WAY

VALVE IN BY

PASS POSITION

AUTOMATIC

FLOW

REGULATORS

FLEXIBLE

MESH BY

PASS HOSE

DRAIN VALVE

WITH HOSE END

CONNECTION

FIGURE 8

WATER-TO-REFRIGERANT CIRCUIT - SW 240

WATER-TO-

REFRIGER

ANT COIL

STG. 1

B39 STG. 1 WATER

FLOW CONTROL

VALVE (ON/OFF) MANUAL

AIR VENTS

WATER

OUT

STRAINER

THREE-WAY

VALVE IN BYPASS

POSITION

THREE-WAY

VALVE IN

MAIN LOOP

POSITION

THREE-WAY

VALVE IN MAIN

LOOP POSITION

WATER TO

REFRIGERANT

COIL STG. 2

B42 STG. 2 WATER

FLOW CONTROL

VALVE (ON/OFF)

THREE-WAY

VALVE IN BY

PASS POSITION

AUTOMATIC

FLOW REGULATORS

FLEXIBLE

MESH BY

PASS HOSE

DRAIN VALVE

WITH HOSE END

CONNECTION

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