Lennox FCM 85 User manual

Providing indoor climate comfort

FLEXY II

FLEXYII-IOM-0308-E

Installation, operating

and maintenance

IOM –FLEXY II –0308 –E Page 1

INSTALLATION

OPERATION

MAINTENANCE MANUAL

Ref. FLEXYII_IOM/0308-E

The present manual applies to the following ROOFTOP versions:

FCM 85 -FCM 100 -FCM 120 -FCM 150 -FCM 170 -FCM200 -FCM 230

FHM 85 -FHM 100 -FHM 120 -FHM 150 -FHM 170 -FHM200 - FHM 230

FDM 85 -FDM 100 -FDM 120 -FDM 150 -FDM 170 -FDM200 -FDM 230

FGM 85 -FGM 100 -FGM 120 -FGM 150 -FGM 170 -FGM 200 -FGM 230

FXK 25 -FXK 30 -FXK 35 -FXK 40 -FXK 55 -FXK 70 -FXK 85 -FXK 100 -FXK 110 -FXK 150 -FXK 170

NOTES FOR UNIT FITTED WITH GAS BURNER:

LENNOX have been providing environmental solutions since 1895, our range of Baltic TM rooftop continues to meet the

standards that have made LENNOX a household name. Flexible design solutions to meet YOUR needs and uncompromising

attention to detail. Engineered to last, simple to maintain and Quality that becomes a standard. Further Information on

www.lennoxeurope.com.

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 used (except in operation of this product), reproduced,

issued to or made available to third parts without the prior written agreement of Lennox.

The technical informationsand specifications 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.

CONTENTS

THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL

SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL

VENTILATED AREA.

PLEASE READ CAREFULLY THE MANUFACTURER'S INSTRUCTIONS

BEFORE STARTING THIS UNIT.

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 modifications required to the

installation of the unit in a particular country.

Switchgear must be installed on each unit in accordance with the Machine

Directive and the standard NF EN 60204.

IOM –FLEXY II –0308 –E Page 2

COMMISSIONING SHEET..............................................................................................................................6

INSTALLATION

Transport -Handling.................................................................................................................................10

Dimensions and weights...........................................................................................................................12

Lifting the units.........................................................................................................................................14

Preliminary checks...................................................................................................................................15

Minimum clearance around the unit...........................................................................................................16

Installation on roof mounting frame ..........................................................................................................17

Curbing and flashing ................................................................................................................................18

Duct connections......................................................................................................................................19

Non-adjustable non-assembled roof curb installation.................................................................................20

Non-adjustable non-assembled roof curb installation instructions...............................................................21

Adjustable roof curb .................................................................................................................................22

Non-adjustable Non-assembled roof curb .................................................................................................23

Multidirectional roof curb ..........................................................................................................................24

Return roof curb ......................................................................................................................................25

Return horizontal roof curb .......................................................................................................................26

Transition roof curb ..................................................................................................................................27

Energy Recovery......................................................................................................................................28

Economiser and extraction .......................................................................................................................29

COMMISSIONING

Before connecting the power ....................................................................................................................30

CLIMATIC................................................................................................................................................31

Powering the unit .....................................................................................................................................31

Run test...................................................................................................................................................32

VENTILATION

Belt tension ....................................................................................................................................................33

Mounting ans adjusting pulleys......................................................................................................................34

Airflow balancing............................................................................................................................................35

Filters .............................................................................................................................................................43

Air sock control.........................................................................................................................................44

UV Light...................................................................................................................................................45

HEATING OPTIONS

Hot water coils .........................................................................................................................................46

Electric heater..........................................................................................................................................48

Gas burners.............................................................................................................................................49

Modulating gas burners............................................................................................................................60

CONTENTS

IOM –FLEXY II –0308 –E Page 3

ELECTRICAL DATA: WIRING DIAGRAMS

Diagram reference legend ........................................................................................................................69

Main current diagram TRI/400V/50Hz + T……………………………………………………. ............................70

CLIMATIC 50 controller………………………………………………………………………….............................72

CLIMATIC 50 input……………………………………………………………………………………......................73

CLIMATIC 50 output…………………………………………………………………………………. ......................74

DAD smoke detector……………………………………………………………………………… ..........................75

General customer connection (TCB..........................................................................................................76

General customer connection with Advanced Control Pack (ADC) .............................................................77

Gas burner 60 kW and hot water coil.........................................................................................................78

Gas burner 120 kW .................................................................................................................................79

Gas burner 180/240 kW............................................................................................................................80

Electric heater..........................................................................................................................................81

General customer connection diagram......................................................................................................82

Electrical data control variables.................................................................................................................83

REFRIGERATION CIRCUIT

R410A .....................................................................................................................................................84

Advanced scroll temperature protection (ASTP)........................................................................................85

Principle sketches....................................................................................................................................86

HOT WATER COIL.........................................................................................................................................90

MAINTENANCE DIAGNOSTIC.......................................................................................................................91

MAINTENANCE PLAN...................................................................................................................................94

WARRANTY...................................................................................................................................................97

CERTIFICATES..............................................................................................................................................98

CONTENTS

IOM –FLEXY II –0308 –E Page 4

All FLEXY II Units are compliant with the PED directive 97-23/CE

The following note must be followed carefully

All work on the unit must be carried out by a qualified and authorised employee.

Non-compliance with the following instructions may result in injury or serious accidents.

Work on the unit:

The unit shall be isolated from the electrical supply by disconnection and locking using the main isolating switch.

Workers shall wear the appropriate personal protective equipment (helmet, gloves, glasses, etc.).

Work on the electrical system:

Work on electric components shall be performed with the power off by employees having valid electrical qualification and

authorisation.

Work on the refrigerating circuit(s):

Monitoring of the pressures, draining and filling of the system under pressure shall be carried out using connections provided

for this purpose and suitable equipment.

To prevent the risk of explosion due to spraying of coolant and oil, the relevant circuit shall be drained and at zero

pressure before any disassembly or unbrazing of the refrigerating parts takes place.

There is a residual risk of pressure build-up by degassing the oil or by heating the exchangers after the circuit has been

drained. Zero pressure shall be maintained by venting the drain connection to the atmosphere on the low pressure side.

The brazing shall be carried out by a qualified brazier. The brazing shall comply with standard NF EN1044 (minimum 30%

silver).

Replacing components:

In order to maintain CE marking compliance, replacement of components shall be carried out using spare parts, or using

parts approved by Lennox.

Only the coolant shown on the manufacturer’s nameplate shall be used, to the exclusion of all other products (mix of

coolants, hydrocarbons, etc.).

CAUTION:

In the event of fire, refrigerating circuits can cause an explosion and spray coolant gas and oil.

TRANSPORT –HANDLING:

- Never lift the unit without forklift protections

- Remove the forklift protection before installation

- An approach ramp must be installed if the unit’s installation requirements tell that it's necessary to reach the main switch.

This recommendation is valid for installations in general and in particular for return and curbs. It’s also valid to reach other

parts of the unit: filters, refrigerant circuit, etc…

- It’s advised to fix curbs and roofcurbs to the unit

- Whatever the supply configuration is, respect a minimal duct’s length of 2m before any elbow or any duct’s section change.

COMMISSIONING:

- It must only be carried out by trained refrigeration engineers.

- Don’t forget to open the insulation valve on the liquid line before starting the unit

FILTERS:

- Do the filters fire classification’s choice according to local regulations.

FANSTART:

- Any adjustment has to be done power stopped.

GAS:

- Any work on gas modulemust be carried out by qualified personnel

- A unit with gas module must be installed in accordance with local safety codes and regulations and can only be used in

planed installation conditions for outdoor.

- Before commissioning this type of unit, it’s mandatory to ensure that the gas distribution system is compatible with the

adjustment and settings of the unit.

IMPORTANT NOTICE –Safety instructions

IOM –FLEXY II –0308 –E Page 5

UV LIGHT :

- The UV lamp emits shortwave UV-C ultraviolet radiation which is harmful to skin and eyes

- It can cause serious skin burns and eye inflammation within ONE SECOND of exposure

- Do not enter the machine while UV are switched on

- Make sure the UV light circuit breaker is OFF when opening the return air section door and the supply air section doors

- The following logo will appear to inform about the UV-C radiation risk

IMPORTANT NOTICE –Safety instructions

IOM –FLEXY II –0308 –E Page 6

Site details

Site

Unit Ref

Installer

………………………………………

……………………………………....

………………………………………

Controller

Model

Serial No

Refrigerant

………………………………….

……………….…………………

…………………………………

(1) ROOF INSTALLATION

Sufficient Access OK

Yes No Condensate drain fitted

Yes No Roofcurb

OK Not OK

(2) CONNECTIONS CHECK

Phase checkYes No Voltage between

Phases 1 / 2

………………. 2 / 3

………………. 1 / 3

……………….

(3)CLIMATIC CONFIGURATION CHECK

CLIMATIC 50 Configured according to the Options and Specifications:

Yes No

(4) SUPPLY BLOWER SECTION

Type :

Power displayed on plate:

Voltage displayed on plate:

Current displayed on plate:

N°1

……………………

N°2

……………………

Fan Type : Forward

Backward Forward

Backward

Displayed Belt Length : mm …………………… ……………………

Tension Checked: Yes No Yes No

Alignment Checked : Yes No Yes No

Motor Pulley Diameter: DMmm …………………… ……………………

Fan Pulley Diameter: DPmm …………………… ……………………

Fan Speed = Motor rpm x DM/ DP

Averaged Measured Amps : rpm

A ……………………

…………………… ……………………

……………………

Shaft Mechanical Power (Refer to airflow balancing) W …………………… ……………………

Operating point checked : Yes No Yes No

Estimated Airflow m3/h …………………… ……………………

(5) AIRFLOW PRESS. SENSOR CHECK

Measured pressure drop…………………………… mbar Set Points Adjusted: Yes No

If Yes enter new values:

3410: ………… 3411: ………… 3412: …………

(6) EXTERNAL SENSOR CHECKS Check and record temp. in menu 2110

Yes Non

Check electrical connections :

Yes No 100% Fresh Air 100% return Air

Supply Temperature ………………………..°C ………………………..°C

Return Temperature ………………………..°C ………………………..°C

Outdoor Temperature ………………………..°C ………………………..°C

(7) MIXING AIR DAMPERS CHECKS

Dampers open & close freely

OK % Minimum FA: Power exhaust checked Enthalpy sensor(s) checked

Yes No ……………..% Yes No Yes No

COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 7

(8) REFRIGERATION SECTION

Outdoor Fan Motor Current: Check Rotation

Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Yes No

Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Yes No Compressor Voltage

Motor 3 / Moteur 3 L1 ……..A L2 ……..A L3 ……A Yes No Comp1: …….. V

Motor 4 / Moteur 4 L1 ……..A L2 ……..A L3 ……A Yes No Comp2: …….. V

Motor 5 / Moteur 5 L1 ……..A L2 ……..A L3 ……A Yes No Comp3: …….. V

Motor 6 / Moteur 6 L1 ……..A L2 ……..A L3 ……A Yes No Comp4: …….. V

Compressor Amps COOLING Pressures & Temperatures

Temperatures Pressures

Phase 1 Phase 2 Phase 3 Suction Discharge LP/ BP HP / HP

Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Check Reversing valves :

Valve1: Yes No

Valve2: Yes No Valve3: Yes No

Valve4: Yes No

Compressor Amps HEATING Pressures & Temperatures

Temperatures Pressures

Phase 1 Phase 2 Phase 3 Suction Discharge LP/ BP HP / HP

Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

HP cut out ……Bar LP cut out ………..…... Bar

Refrigerant charge C1 : ………..kg C2 : ………..kg C3 : ………..kg C4 : ………..kg

(8)ELECTRIC HEATER SECTION

Type : …………………………………………………. Serial No.:………………………..

AMPS 1st stage (Baltic) AMPS 2nd stage (Baltic)

1 ………………. 2 ………………. 3 ………………. 1 ………………. 2 ………………. 3 ……………….

(9) HOT WATER COIL SECTION

Check Three Way Valve Movement : Yes No

(10) GAS HEATING SECTION

Gas Burner N°1 Gas Burner N°2

Size :

………………………. Valve type :

……………………. Size :

………………………. Valve type :

…………………….

Pipe size: Gas type : G……. Pipe size Gas type : G…….

Line pressure :

……………………… Drop test

Yes No line pressure :

……………………… Drop test

Yes No

Check manifold pressure:

High fire …….…Low fire ……….. Check manifold pressure:

High fire …….…... Low fire ………..

Pressure cut out airflow press switch :

……………………mbar /Pa Pressure cut out airflow press switch :

……………………mbar /Pa

Motor amps :

……….A

Flue temp.

……… °C

CO2 %:

………%

CO ppm:

………%

Motor Amps:

……….A

Flue temp.

………. °C

CO2 %:

………%

CO ppm:

………%

(11) REMOTE CONTROL BMS CHECK

Type :

………………………….. Sensor type

……………………………….. KP07 KP/17 checked:

Yes No Interconnect wiring checked:

Yes No

COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 8

It is recommended that you fill the two tables below before transferring the zone settings to the Climatic 50 controller.

Refer to control section page 55 / Se référer à la section régulation page 55

Time Zones / Zones Horaires

Hour 0

2 3 4

7 8 9 10

13 14

17 18

Example UNO

7h15

11h00 ZB

14h00 ZC

19h00 UNO

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

Variables to adjust for each time zone / Consignes à renseigner pour chaque zone horaire

Start z.A Start z.B Start z.C Start UNO

hour (3211)

min (3212)

hour (3213)

min (3214)

hour (3215)

min (3216) hour (3217)

min (3218)

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

Description

Unit

Min Max Zone A Zone B Zone C UNOC

Sp Room °C 3311 8 35

Mini.Air % 3312 0 100

Sp Dyna °C 3321 0 99.9

Sp Cool °C 3322 8 35

Sp Heat °C 3323 8 35

Swap Heater On/Off

3324 ~ ~

Activation On/Off

3331 ~ ~

Swap Heater On/Off

3332 ~ ~

Sp.Dehu % 3341 0 100

Sp.Humi % 3342 0 100

Fan On/Off On/Off

3351 ~ ~

Fan Dead On/Off

3352 ~ ~

F.Air On/Off

3353 ~ ~

CO2 On/Off

3354 ~ ~

Comp.Cool. On/Off

3355 ~ ~

Comp.Heat. On/Off

3356 ~ ~

AuxHeat On/Off

3357 ~ ~

Humidif. On/Off

3358 ~ ~

Low Noise On/Off

3359 ~ ~ N/A N/A N/A

COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 9

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COMMISSIONING REPORT

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