Lennox FCA 50, FCA 60, FCA 85, FCA 70, FCA 100 Installation Operating & Maintenance Manual

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Page 1

INSTALLATION OPERATING & MAINTENANCE MANUAL

ROOFTOP FLEXY

English Sept 2001

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IOM / ROOF-TOP FLEXY™ Series - Page 1

CONTENTS

The present manual applies to the following ROOFTOP versions :

FCA 50 - FCA 60 - FCA 70 - FCA 85 - FCA 100 - FCA 120 - FCA 140 - FCA 160 - FCA 190 FCK 50 - FCK 60 - FCK 70 - FCK 85 - FCK 100 - FCK 120 - FCK 140 - FCK 160 - FCK 190 FHA 50 - FHA 60 - FHA 70 - FHA 85 - FHA 100 - FHA 120 - FHA 140 - FHA 160 - FHA 190 FHK 50 - FHK 60 - FHK 70 - FHK 85 - FHK 100 - FHK 120 - FHK 140 - FHK 160 - FHK 190 FDA 50 - FDA 60 - FDA 70 - FDA 85 - FDA 100 - FDA 120 - FDA 140 - FDA 160 - FDA 190 FDK 50 - FDK 60 - FDK 70 - FDK 85 - FDK 100 - FDK 120 - FDK 140 - FDK 160 - FDK 190 FGA 50 - FGA 60 - FGA 70 - FGA 85 - FGA 100 - FGA 120 - FGA 140 - FGA 160 - FGA 190 FGK 50 - FGK 60 - FGK 70 - FGK 85 - FGK 100 - FGK 120 - FGK 140 - FGK 160 - FGK 190

FXA 25 - FXA 30 - FXA 35 - FXA 40 - FXA 55 - FXA 70 - FXA 85 - FXA 100 - FXA 110 - FXA 140 - FXA 170 FXK 25 - FXK 30 - FXK 35 - FXK 40 - FXK 55 - FXK 70 - FXK 85 - FXK 100 - FXK 110 - FXK 140 - FXK 170

The technical information and 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.

Ref. IOM-RT F-0901-E

IOM MANUAL

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CONTENTS

INSTALLATION

TRANSPORT - HANDLING .............................................................................................. 3

INSTALLATION............................................................................................................... 10

INSTALLATION ON ROOF MOUNTING FRAME ........................................................... 11

INSTALLATION ON POSTS ........................................................................................... 13

COMMISSIONING .......................................................................................................... 14

OPERATION

AIR FLOW BALANCING ................................................................................................ 15

AIRFLOW BALANCING - FXA/FXK .............................................................................. 24

FILTERS .........................................................................................................................25

HOT WATER COILS....................................................................................................... 26

GAS BURNERS.............................................................................................................. 27

BEL T TENSIONING........................................................................................................ 34

PULLEYS........................................................................................................................ 35

CONTROL FUNCTIONS

USING THE KP 17 COMFORT DISPLA Y ...................................................................... 36

USING THE KP02 MAINTENANCE DISPLA Y ............................................................... 37

USING THE KP07 REMOTE GRAPHICAL DISPLA Y .................................................... 47

BMS CONT ACTS KIT ..................................................................................................... 56

CLIMATIC™ PARAMETERS .......................................................................................... 57

WIRING DIAGRAMS

ELECTRICAL WIRING DIAGRAMS ............................................................................... 63

ELECTRICAL WIRING DIAGRAMS LIST OF ITEMS .................................................... 74

TROUBLESHOOTING

SAFETY AND ERROR CODES ..................................................................................... 77

BEFORE CALLING FOR ASSIST ANCE ........................................................................ 82

PLANNED MAINTENANCE............................................................................................ 84

WARRANTY ................................................................................................................... 87

CERTIFICATES

AFAQ CERTIFICATION .................................................................................................. 88

CE CERTIFICA TION OF CONFORMITY........................................................................ 89

FILTERS FIRE CLASS ................................................................................................... 90

33 KW GAS BURNER CE CERTIFICA TION OF CONFORMITY................................... 91

60 KW GAS BURNER CE CERTIFICA TION OF CONFORMITY................................... 92

120 KW GAS BURNER CE CERTIFICA TION OF CONFORMITY................................. 93

180 kW GAS BURNER CE CERTIFICA TION OF CONFORMITY ................................. 94

INSULATION FIRE CLASS ............................................................................................ 95

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TRANSPORT - HANDLING

DELIVERY CHECKS

The equipment is shipped at the customers risk, and whose responsiblity it is to ensure that the products are in good working order on receipt by checking the following :

- The exterior has not been damaged in any way.

- The lifting and handling equipment are suitable for the equipment and comply with the specifications of the handling instructions enclosed herein.

- Accessories ordered for on site installation have been delivered and are in good working order.

- The equipment supplied corresponds with the order and matches the delivery note.

If the product is damaged, exact details must be confirmed in writing by registered post to the shipping company within 48 hours of delivery (working days). A copy of the letter must be addressed to Lennox and the supplier or distributor for information purposes. Failure to comply will invalidate any claim against the shipping company.

RA TING PLA TE

The rating plate provides a complete reference for the model and ensures that the unit corresponds to the model ordered. It states the electrical power consumption of the unit on startup, its rated power and its supply voltage. The supply voltage must not deviate beyond +10/-15 %. The start-up power is the maximum value likely to be achieved for the specified operational voltage. The customer must have a suitable electrical supply. It is therefore important to check whether the supply voltage stated on the unit's rating plate is compatible with that of the mains electrical supply. The rating plate also states the year of manufacture as well as the type of refrigerant used with the required volume capacity of each compressor circuit.

STORAGE

When units are delivered on site they are not always required immediately and are sometimes put into storage. In the event of medium to long-term storage, we recommend the following procedures :

- Ensure that there is no water in the hydraulic systems.

- Keep the heat exchanger covers in position (AKILUX cover).

- Keep protective plastic film in position.

- Ensure the electrical panels are closed.

- Keep all items and options supplied in a dry and clean place for future assembly before using the equipment.

MAINTENANCE KEY

On delivery we recommend that you keep the key which is attached to an eyebolt in a safe and accesible place. This allows you to open the panels for maintenance and installation work. The locks are ¼ turn + then tighter (figure 2).

Figure 2

Figure 1

N˚ SERIE SERIAL NUMBER

TYPE UNIT TYPE

Usine Dijon Z.I. LONGVIC 21600 LONGVIC FRANCE

ANNEE YEAR

ALIMENTATION ELEC. SUPPLY

A. MAXI MAX. AMP.

REFRIGERANT FLUIDE

Kg/CIRC

C1 C3C2 C4

I. DEMARR. START UP AMP.

C. COMMANDE. CONTROL CIR.

FCK 190

2000

215 900-01/01

400 3 50

140 269

111111 11

R407C

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Model Length Rain Width Height Weight

Cover

mm mm mm mm kg

FC*/FH* 050 downflow 2150 - 1780 1090 750 FC*/FH* 050 upflow 2150 - 1780 1120 750 FC*/FH* 050 horizontal flow 2150 - 1780 1120 750 FGA/FDA/FGK/FDK 050 2200 - 1900 1090 850 FC*/FH* 060 downflow 2821 629 2254 1410 1000 FC*/FH* 060 upflow 2821 629 2254 1410 1000 FC*/FH* 060 side discharge 2821 629 2254 1410 1000 FC*/FH* 060 centrif. condensing fan 2821 629 2254 2000 1100 FGA/FDA/FGK/FDK 060 2821 629 2254 1410 1100 FC*/FH* 070 downflow 2821 629 2254 1410 1000 FC*/FH* 070 upflow 2821 629 2254 1410 1000 FC*/FH* 070 side discharge 2821 629 2254 1410 1000 FC*/FH* 070 centrif. condensing fan 2821 629 2254 2000 1100 FGA/FDA/FGK/FDK 070 2821 629 2254 1410 1150 FC*/FH* 085 downflow 3781 629 2254 1495 1200 FC*/FH* 085 upflow 3781 629 2254 1495 1200 FC*/FH* 085 side discharge 3781 629 2254 1495 1200 FC*/FH* 085 centrif. condensing fan 3782 629 2254 2010 1430 FGA/FDA/FGK/FDK 085 2821 629 2254 1495 1300 FC*/FH* 100 downflow 3781 629 2254 1495 1200 FC*/FH* 100 upflow 3781 629 2254 1495 1200 FC*/FH* 100 side discharge 3781 629 2254 1495 1200 FC*/FH* 100 centrif. condensing fan 3782 629 2254 2010 1430 FGA/FDA/FGK/FDK 100 2821 629 2254 1495 1480 FC*/FH* 120 downflow 3582 629 2254 1410 1500 FC*/FH* 120 upflow 3582 629 2254 1410 1500 FC*/FH* 120 side discharge 3582 629 2254 1410 1500 FC*/FH* 120 centrif. condensing fan. 3582 629 2254 1910 1550 FGA/FDA/FGK/FDK 120 4030 629 2254 1410 1750 FC*/FH* 140 downflow 3582 629 2254 1410 1600 FC*/FH* 140 upflow 3582 629 2254 1410 1600 FC*/FH* 140 side discharge 3582 629 2254 1410 1600 FC*/FH* 140 centrif. condensing fan 3582 629 2254 1910 1650 FGA/FDA/FGK/FDK 140 4030 629 2254 1410 1950 FC*/FH* 160 downflow 3590 900 2254 2050 2000 FC*/FH* 160 upflow 3590 900 2254 2050 2000 FC*/FH* 160 side discharge 3590 900 2254 2050 2000 FC*/FH* 160 centrif. condensing fan 3590 900 2254 2050 2150 FGA/FDA/FGK/FDK 160 4040 900 2254 2050 2500 FC*/FH* 190 downflow 3590 900 2254 2050 2250 FC*/FH* 190 upflow 3590 900 2254 2050 2250 FC*/FH* 190 side discharge 3590 900 2254 2050 2250 FC*/FH* 190 centrif. condensing fan 3590 900 2254 2050 2350 FGA/FDA/FGK/FDK 190 4040 900 2254 2050 2750

TRANSPORT - HANDLING

DIMENSIONS AND WEIGHTS

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TRANSPORT - HANDLING

Model

Length Side Ventil. Width Height Weight

louver louver

mm mm mm mm mm kg

FX* 25 4070 490 600 1633 1055 950 FX* 30 4070 490 600 1633 1055 980 FX* 35 4750 490 600 2254 1290 1400 FX* 40 4750 490 600 2254 1290 1450 FX* 55 4750 490 600 2254 1290 1600 FX* 70 5050 890 600 2254 1725 1800 FX* 85 5050 890 600 2254 1725 1900 FX* 100 5050 890 600 2254 1725 2000 FX* 110 5650 860 2254 2000 2300 FX* 140 5650 860 2254 2000 2400 FX* 170 5650 860 2254 2000 2600

HANDLING

The equipment can be moved using the lifting holes on the top of the unit. The "sling" length is the value that we recommend for safe handling of the equipment.

Some units can only be supported by four slings at rightangles. Others require different lengths (see figure 3). It is essential that all lifting holes are used and that the slings are all of the same size to avoid damaging the equipment.

Sling length = 1580 mm for angle = 45°C

FC.../FH.../FD.../FG... 050

Sling length = 2210 mm for angle = 45°C

FC.../FH.../FD.../FG... 060 & 070

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TRANSPORT - HANDLING

Sling length = 1855 mm for angle = 45°C

FC.../FH.../FD.../FG... 060 & 070 with centrifugal fans

Sling length = 2590 mm for angle = 45°C

Sling length = 2330 mm for angle = 64,5°C

FC.../FH.../FD.../FG... 085 & 100

Sling length = 2430 mm for angle = 45°C

FC.../FH.../FD.../FG... 085 & 100 with centrifugal fans

Sling length = 3230 mm

for angle = 45°C

Sling length = 2830 mm

for angle = 45°C

Sling length = 1870

for angle = 45°C

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TRANSPORT - HANDLING

Sling length = 2080 mm for angle = 45°C

FC.../FH.../FD... 120 & 140

Sling length = 2700 mm for angle = 45°C

Sling length = 2410 mm for angle = 45°C

FC.../FH.../FD... 120 & 140 with centrifugal fans

Sling length = 2080 mm for angle = 45°C

FG... 120 & 140 with gas burner

Sling length = 2700 mm

for angle = 45°C

Sling length = 3000 mm

for angle = 45°C

Sling length = 1880 mm for angle = 45°C

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TRANSPORT - HANDLING

Sling length = 2700 mm for angle = 45°C

FG... 120 & 140 with gas burner and centrifugal fans

Sling length = 3300 mm

for angle = 45°C

Sling length = 2080 mm for angle = 45°C

Sling length = 2090 mm for angle = 45°C

FC.../FH.../FD... 160 & 190

FC.../FH.../FD... 160 & 190 with centrifugal fans

Sling length = 2700 mm

for angle = 45°C

Sling length = 2320 mm for angle = 45°C

FG... 160 & 190

FG... 160 & 190 with centrifugal fans

Sling length = 3000 mm

for angle = 45°C

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TRANSPORT - HANDLING

FX 25 & 30

Sling length = 3000 mm

FX 35 - 40 - 55

Sling length = 3700 mm

Sling length = 3900 mm

FX 70 - 85 - 100

Sling length = 4300 mm

FX 110 - 140 - 170

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PRELIMINARY CHECK

Before installing the equipment, the following items MUST be checked :

- Is there sufficient space for the equipment?

- Is the surface on which the equipment will be placed sufficiently solid to withstand its weight? A detailed study of the frame must be made beforehand.

- Do the supply and return ductwork openings excessively weaken the structure?

- Are there any obstructing items which could hinder the operation of the equipment?

- Does the electrical power available correspond to the equipment's electrical specifications?

- Does the noise level of the equipment meet the specification ?

- Is drainage provided for the condensate?

- Is there sufficient access for maintenance?

- Installation of the equipment could require different lifting methods which may vary with each installation (helicopter or crane). Have these been evaluated ?

- Ensure that the unit is installed in accordance with the installation instructions and applicable codes.

- Check to ensure that the refrigerant lines do not rub against the cabinet or against other refrigerant lines.

In general, make sure no obstacles (walls, trees or roof ledges) are obstructing the duct connections or hindering assembly and maintenance access.

INSINS

INS

ALLAALLA

ALLA

TIONTION

TION

Figure 4

INST ALLA TION DEVICE

The surface on which the equipment is to be installed must be clean and free of any obstacles which could hinder the flow of air to the condensers:

- Avoid uneven surfaces

- Avoid installing two units side by side or close to each other as this may restrict the airflow to the condensers.

Before installing a packaged rooftop unit it is important to understand :

- The direction and position of air flows.

- The external dimensions of the unit and the dimensions of the supply and return air connections.

- The arrangement of the doors and the space required to open them to access the various components.

Figure 4 shows the required clearances and dimensions.

CONNECTIONS DEVICE

- Ensure that all the pipework crossing walls or roofs are secured and insulated.

- To avoid condensation problems, be sure all pipes are insulated according to temperatures of fluids and type of rooms.

NOTE : The AQUILUX covers which protect the finned surfaces must be removed prior to unit commissioning.

MODELS A B C D FC/FH/FG/FD

50 1000 1000 1000 2000 60 è 140 1400 1000 1400 2300 160 & 190 2000 1000 2000 2300

FX 25 & 30 * 1100 * 1700 35 è 55 * 1300 * 2300 70 è 100 * 1700 * 2300 110 è 170 * 2000 * 2300

* : according to connection

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INSTALLATION ON A ROOFMOUNTING FRAME

As levels are adjustable, observe the following recommendations for correct installation of the equipment.

Above all, ensure that all the flaps are facing outward (1 - figure 5). They are sometimes stored inside for transport.

Place the roof mounting frame on the trimmer beam by first lining up the inlet and then the outlet. (2 - figure 6).

After levelling the frame, fix the surface flaps onto the trimmer.

Figure 5

Figure 6

Figure 7

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INSTALLATION ON A ROOFMOUNTING FRAME

When the frame is correctly positioned, it is essential to secure the assembly with a disconnected welding seam (20 to 30 mm for every 200 mm) along the outside, or by using an alternative method (1 - figure 8).

Assembly joint (1 - figure 9) Insulate the frame before installation. We recommend the

minimum application of 20 mm thick insulation. Check that the covering is continuous and apply a seal (2 figure 9).

CAUTION : To be effective, the upstream must end below the drop edge (3 - figure 9)

Before installing the equipment, make sure that the assembly seal or the puttying is not damaged and check that the unit is fixed to the mounting frame so that it is resting flat on the frame. Once in position, the bottom of the equipment must be horizontal.

The installer must comply to local authority standards and specifications.

Figure 9

Figure 8

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IOM / ROOF-TOP FLEXY™ Series - Page 13

INSTALLATION ON POSTS

The unit can be fitted on corner posts using the frame provided. The minimum height of the posts should be 400mm.

Figure 10

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This work must only be carried out by trained refrigeration engineers

Before connecting to the power :

- Ensure that the power supply between the building and the unit meets local authority standards and that the cable specification satisfies the start-up and operating conditions.

- Ensure that the electrical connections in the control panel and on the motors are secure.

- Ensure that all drive motors are secure.

- Ensure that the adjustable pulley blocks are secure and that the belt is tensioned with the transmission correctly aligned.

- Using the electrical wiring diagram, check the conformity of the electrical safety devices (circuit breaker settings, presence and rating of fuses).

At this point attach the manometers to the refrigerant circuit

Powering up the system with the unit isolating switch

- Check the direction of rotation of the fans by pressing their contactors. Refer to the rotation arrows situated next to the coils or fans (NOTE: unlike a coil, a fan rotating in the wrong direction may fail).

- The fans' direction of rotation is checked during an end of production test. They should therefore all turn in either the right or wrong direction.

- If they turn in the opposite direction, disconnect the power supply to the machine at the building's mains switch, reverse two phases of the incoming supply to the machine and try again.

- If only one of the fans rotates in the wrong direction, disconnect the power supply at the machine's isolating switch and reverse two of the component initial phases on the terminal within the electrical panel.

Using CLIMA TIC™

- Check the voltages recorded against the rated values, in particular on the system supply fans.

- If the readings on the fans are outside the limits, this indicates excessive air flow which will affect the thermodynamic performance. Refer to the "Air Flow Balancing" section.

Thermodynamic readings using manometers and prevailing environmental conditions

- No rated values are given here. These depend on the climatic conditions both outside and inside the building during operation. However, an experienced refrigeration engineer will be able to detect any abnormal machine operation.

COMMISSIONING

Safety Test

- "Clogged filter" detection test : vary the setpoint value (KP02 setpoint 93) in respect to the air pressure value (KP02, variable 16). Observe the response of the CLIMATIC™.

- Same procedure for detecting "Missing Filter" (setpoint

94) or "Air Flow Detection" (setpoint 92).

- Check the smoke detection function.

- Check the Firestat by pressing the test button.

- Disconnect the circuit breakers of the capacitor fans and check the high pressure cut-out points on different refrigerant circuits.

Reverse Cycle Test

On reversible units this test is used to check the switching of the 4-way valves. Start the reverse cycle with reference to the cold or hot temperature threshold data according to the climatic conditions at the time of testing (setpoint 15 + setpoint 16).

Your machine is now operational. You can now proceed to the setting stage. See the "Control" section.

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IOM / ROOF-TOP FLEXY™ Series - Page 15

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

The actual resistance of ductwork systems is not always the same as the calculated theoretical values. To rectify this, it may be necessary to modify the pulley and belt setting. To this effect, the motors are fitted with variable pulleys.

TEST

You should already have measured the + ve pressure experienced on fan discharge, as well as the pressure experienced in the return duct to the fan. Measure the motor absorbed power.

If the absorbed power is greater and the pressure lower than the rated values, your system has a lower pressure drop than anticipated. Reduce the flow. If the system resistence is significantly lower than design, there is a risk that the motor will overheat resulting in an emergency cut out.

If the absorbed power is lower and the pressure greater than the rated values, your system has a higher pressure drop than anticipated. Increase the flow. At the same time you will increase the absorbed power which may result in having to fit a larger motor.

To carry out the adjustment and to avoid a time-consuming re-start, stop the machine and if necessary lock the main switch.

First unscrew the 4 Allen screw(s) on the pulley (see figure

11).

Figure 12

Slacken the belts, then remove then (see § "BELT TENSION"). The flow can now be increased by turning the flange(s) to

move them closer (or alternatively, move them apart to reduce the flow). For two-groove pulleys, turn the flanges the same number of turns.

If necessary, check the pulley diameter by measuring the outer diameter of a belt positioned in the groove (figure 12).

Finally, replace and tension the belts before carrying out a test. Re-check the absorbed power levels. Repeat the operation until a satisfactory result has been achieved.

To minimise the number of operations, refer to the flow / pressure charts on the following pages for the type of fans used. With reference to the following example, you can estimate your flow and thus calculate the necessary adjustment.

ALLEN wrench 4

Figure 11

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UNIT/F AN KIT REFERENCE TABLE

CHART (see following pages)

Size Fan type A B C D E F

50 FCx or FHx 1

FGx or FDx 1

60 FCx or FHx 1

Centrifugal condensor 1 (*) FGx or FDx 2

70 FCx or FHx 1

Centrifugal condensor 1 (*) FGx or FDx 2

85 FCx or standard FHx 1 (*)

FCx or side FHx 2 Centrifugal condensor 2 FGx or FDx 2

100 FCx or standard FHx 1 (*)

FCx or side FHx 2 Centrifugal condensor 2 FGx or FDx 2

120 FCx or standard FHx 2

FCx or side FHx 2 Centrifugal condensor 2 (*) FGx or FDx 2

140 FCx or standard FHx 2

FCx or side FHx 2 Centrifugal condensor 2 (*) FGx or FDx 2

160 FCx or standard FHx 2

Centrifugal condensor 4 FGx or FDx 2

190 FCx or standard FHx 2

Centrifugal condensor 4 FGx or FDx 2

ROOF-TOP type FX*

Size Fan type ABCDEF

25 Supply 1

Extract 1

30 Supply 1

Extract 1

35 Supply 1

Extract 1

40 Supply 1

Extract 1

55 Supply 1

Extract 1

70 Supply 1

Extract 1

85 Supply 1

Extract 1

100 Supply 1

Extract 1 (*)

110 Supply 2

Extract 2

140 Supply 2

Extract 2

170 Supply 2

Extract 2

The number indicated in the table refers to the number of fans. 1(*) : In this case the two fans are coupled to the same shaft. 2(*) : Indicates that there are 2 groups of 2 coupled fans.

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

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IOM / ROOF-TOP FLEXY™ Series - Page 17

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

EXAMPLE :

You may want to adjust a FHK 120 set to 22 000 m3/h with a system resistance of 150Pa: The machine has 2 fans (chart D). For this operating point, the unit supplied is fitted with E kits comprising 112 mm - 131 mm variable pulleys on the motors and 250 mm pulleys on the fans. In this case the pulley motor adjustment is 126 mm for a fan speed of 730 rpm.

On the chart, for 11 000 m3/h (2 fans), indicates 730 rpm (point A).

• Total pressure 500 Pa (150 Pa system pressure + 230 Pa equipment loss + 120 Pa static pressure)

• Absorbed power 2.1 kW, which gives 5.7 A, calculated as follows: In = (P.kw x Ct / Rm ) / ( 3 x U x cos

ϕϕ

ϕ) = ( 2100 * 1.2 / 0.8 ) / ( 3 x 400 x 0.8 ) = 5.7A

Rm = Motor output Ct = Transmission coefficient

On site you measure :

• System static pressure 70 Pa or total pressure 230 Pa (the pressure must be measured after 1 m minimun on the return ductwork)

• Absorbed power 6.8A

The theoretical absorbed power will be : P = (

3 x 400 x 6.8 x 0.8 ) / 0.8(Rm) x 1.2(Ct) = 2,500 W

With reference to the chart data, the operating point B has been highlighted as we note that: the system is exceeding design airflow rates. 12 700 m

/h and 25 400 m3/h can be read for the two fans instead of the 22,000 m3/h specified.

To return to the design flow, consider point C, which now gives a rotation speed of 650 rpm, i.e. a variable pulley adjustment of : Adjustment = fan speed / motor speed * pulley diameter = 650 / 1450 * 250 = 112 mm.

Alternatively, where there is reduced airflow, i.e.caused by a greater system resistance than anticipated (items B’ and C’), follow the same procedure, but in this case ensure that the absorbed power at C' is compatible with the motor fitted.

Pression dynamique

Pression statique demandée

Pression totale mesurée

Pression statique mesurée

730 RPM

650 RPM

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AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART A

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IOM / ROOF-TOP FLEXY™ Series - Page 19

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART B

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AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART C

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IOM / ROOF-TOP FLEXY™ Series - Page 21

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART D

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AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART E

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AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART F

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A. Set the unit to the "recycle air" position (figure 15) B. Measure the static pressure in the areas indicated 1/2/

3/4/5/6

C. Before proceeding further, check that the pressure

difference between zones 1 and 4 satisfies the static pressure required.

If this is not the case, refer to the

"AIR FLOW

BALANCING"

section.

D. If the flow and the pressure are correct :

On grills "b" and "b’", bring the pressure at 5 to the same level as 3 (the grills must be moved simultaneously by the same amount).

E. Check that the power absorbed by the extract fan

motor is less than its rated power. If the values are not the same, refer to the

"AIR FLOW

BALANCING"

section.

F. Switch the unit to "fresh air" (figure 16), and measure

the static pressure at 2/3/4/5/6.

G. Adjust grill "a" so that the value measured at 3 is the

same as the value at point B.

H. Finally check that the pressure at 5 is the same as the

pressure measured at point B. If not, slightly adjust the grill "b" setting of the fresh air by-pass.

2 3 4 5

b, b'

Figure 15

FX in "recycle air" position

Figure 16

FX in "fresh air" position

AIRFLOW BALANCING - FXA/FXKAIRFLOW BALANCING - FXA/FXK

AIRFLOW BALANCING - FXA/FXK

The FX* models are designed to operate with more complex supply and extract ductwork systems. Without balancing there are numerous risks :

- Fan motor overvoltage

- Significant flow variations depending on the position of the dampers, which affects the building concerned, especially when applied to pressure balanced systems.

To rectify this we have fitted an equilizing grill on the fresh air dampers. The grill can be moved after unscrewing the knurled nuts (1 - figure 14) and operates as an adjustable damper.

Before starting to adjust fully open the equilising grills.

To equilise, proceed as follows :

Example :

Zone 1 2 3 4 5 6

Technical specification Pa 200 -180 Recycled air without setting Pa 190 -230 -210 -190 -70 -120 Recycled air after setting b/b’ Pa 190 -230 -210 -190 -210 -240 Fresh air before setting Pa 270 -80 -50 -200 -220 -250 Fresh air after setting grill a Pa 190 -230 -210 -200 -220 -250 Fresh air after setting grill b’ Pa 190 -230 -210 -190 -210 -240

Extracted air

Fresh air

Discharge

Grill b'

fresh air by pass

Figure 14

Supply air

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IOM / ROOF-TOP FLEXY™ Series - Page 25

filfil

fil

tersters

ters

The CLIMATIC™ controls the filters. Two types of problems may occur :

1 - 004 error code (lit LED “filter”) or the following icon (for a

graphics screen - KP07) :

Item 8 on KP 17 indicates that the filters must be changed. The unit has not stopped but the airflow is likely to be reduced due to increased pressure drop acros the filters.

2 - 005 error code or the following icon (for a graphics screen - KP07) :

Item 9 on KP17 indicates that the filters are out of position : either they have been damaged or not been replaced during maintenance. In the latter case, the unit has not stopped but the increased flowrate may result in the motor overheating. It is important to check the filter immediately.

FIL TER REPLACEMENT :

After opening the filter access panel, unscrew the butterfly nuts maintaining the filter support and remove it (figure 18).

Remove the cells that are slide-mounted (figure 19). Use the rod in the lower filter section to remove the cells at the botton of the sliders.

Install new filters inside the sliders.

Figure 17

Figure 18

Figure 19

KP 17 DISPLAY

Page 27

Page 26 - IOM / ROOF-TOP FLEXY™ Series

HOHO

T WT W

T W

TER COILSTER COILS

TER COILS

HYDRAULIC CONNECTIONS

The heating coil is connected to the isolating valves. Two keys must be used to tighten the connections, one of the keys maintains the valve body. Failure to use two keys may damage the pipes and invalidates the warranty.

Proceed as follows :

- Open the stop valves and set the 3-way valve to the intermediate position (manual position and turn the thumbwheel to a mid position).

- Fill the hydraulic system and bleed the battery using the air vent (figure 20).

- Check the connections for possible leaks.

- Reset the 3-way valve to automatic.

PROTECTION AGAINST FREEZING

1) Use glycol water

GLYCOL IS THE ONLY

EFFECTIVE PROTECTION AGAINST FREEZING

The antifreeze must protect the unit and avoid icing under winter conditions. Warning : monoethylene glycol-based antifreeze may produce corrosive agents when mixed with air.

2) Drain the installation You must ensure that the manual or automatic air vents have

been installed on all high points in the system. In order to drain the system check that all the drain cocks have been installed on all low points of the system. To drain, open all the valves and remember to place the unit in air.

A HEATING COIL FROZEN DUE TO LOW AMBIENT CONDITIONS IS NOT COVERED BY THE WARRANTY.

Figure 21

Figure 20

Figure 22

ELECTROLYTIC CORROSION

Attention is drawn to the corrosion problems resulting from electrolytic reaction created from unbalanced earth connections.

ANY COIL DAMAGED BY ELECTRONIC

REACTION IS NOT COVERED BY THE

WARRANTY.

CONDENSA TE DRAINS

The traps are not assembled when delivered and are stored in the electrical panel with their clamping collars. To assemble them, insert them on the condensate tray outlets and use a screwdriver to tighten the collars (Figure 22).

Page 28

IOM / ROOF-TOP FLEXY™ Series - Page 27

GAS BURNERGAS BURNER

GAS BURNER

PRELIMINARY CHECKS ON COMMISSIONING

NOTE : Any work on the gas system must only be carried out by qualified personnel.

CAUTION : Smoking is forbidden during any intervention on the gas components.

Make sure that the gas supply line installation conforms to the latest technology and the local safety regulations. Check that the gas supply line can provide the burners with the pressure and the gas flow rate necessary to provide the heating output duty.

Bleed the air in the gas delivery pipes by loosening the nuts of the copper tubes on the gas solenoid valve inlet by two turns. Tighten properly after bleeding.

Measure the pressure on the gas solenoid valve inlet (5 - figure

24), with the appliance at its rated value. The rated value must be 20 mbar ± 2 for natural gas and 37 mbar ± 3 for propane. If this is not the case, consult the gaz supplier or see the following "Pressure reducing valve" section in the event of the appliance being pwered by natural gas at 300 mbar.

Check that the supply voltage of the ignition control box(es) is between 220 and 240V.

Check that the air inlet combustion vents and the smoke extract vents are not blocked.

Check that the supply air flow is correct.

IGNITION DET AILS

Make sure that the gas line valves are open. With the ROOF TOP working (Setpoint 06 to ON), adjust

settings 59 and 60 to ON to start the priority. Increase setting 1 (threshold temperature) to a temperature greater than the ambient temperature (Var. 1) This in turn produces a heating demand and starts the burner.

The control box supply switch (KM21) closes and the burner fan (VIN1) starts. When the depression in the fan is reached, the pressostat (B21) tips.

After a pre-ventilation period (approx. 30 seconds) the gas valve (YV51) opens and the firing sequence (ignition electrode B6) is initiated.

Once the ionization probe detects the flame, the burners functions normally.

If, when the ignition sequence is over, the ionization sensor (B4) does not detect a flame, the burner disconnects and CLIMATIC™ indicates the fault after a six-minute time delay.

If the flame goes out during normal operating, the control restarts the firing sequence with pre-ventilation until a flame has been detected or there is disconnection.

When a burner has two gas tiers, the procedure for the second tier is similar but the references are as follows :

- KM22 for the supply switch

- VIN2 for the fan

- B22 for the gas exhaust pressure switch

- YV52 for the gas valve

- B7 for the ignition electrode and

- B5 for the ionization sensor.

Page 29

Page 28 - IOM / ROOF-TOP FLEXY™ Series

GAS BURNERGAS BURNER

GAS BURNER

PRESSURE REDUCING VALVE SETTING

- Connect the tube of the manometer to the power pressure inlet of a solenoid valve (5-figure 24) after loosening the screw.

- Remove the safety plug of the expansion valve setting.

- Use a screwdriver to pre-set by placing the screw at a depth of 34 mm.

- Place the burner(s) in operation at maximum power and set the output pressure. Turn (clockwise) to increase the pressure and (anticlockwise) to reduce it.

- When the pressure has been set, replace the safety plug.

- Disconnect the pressure gauge and retighten the screw.

PRESSURE REGULATOR CONTROL OR SETTING

This is located on the burner tiers (1 – figure 24) of the gas control assembly.

- Increase the value of set point 1 (temperature set point) to a temperature higher than room temperature ) (variable 1).

- Wait until the operation of the burner(s) reaches maximum power.

- Connect the tube of the manometer to the injection pressure inlet after having loosened the screw (4-figure

24).

- Wait until a stable pressure is displayed on the pressure gauge.

- Use a 8 mm key to adjust the maximum pressure (3 – figure 24) – clockwise to increase it and anticlockwise to reduce it. The maximum pressure must always be set before setting the minimum pressure.

- The minimum pressure must be measured if the regulator is not supplied. By disconnecting the tracer wire 116 on card EF45 or EF46 for the one-ramp module or the upper ramp of the two-ramp module. It can be adjusted with a 3.5 mm screwdriver on the screw located inside the maximum pressure setting.

- For the setting of the second ramp, disconnect the tracer wire 116 or 126 in order to switch to low speed.

Figure 23

4 5

Pressure taps : (4) : Injection (5) : Supply

Figure 24

- Manipulate the regulator several times by connecting and disconnecting wire 116 or 126 in order to check the low and high speed settings.

Note : The maximum pressure setting affects the minimum pressure setting and may have to be changed.

- When the settings are correct, connect wires 116 and 126, making sure they are properly tightened, remove the pressure gauge and replace the safety cap.

- Restart the unit and watch the burner complete several full cycles to ensure that all the components are working properly.

NOTE : The minimum and maximum pressure settings corresponding to the various gas types are listed in the table at the end of this manual.

Page 30

IOM / ROOF-TOP FLEXY™ Series - Page 29

IGNITION ELECTRODE

The following two checks can be made :

- Ensure that the electrode tip (1 – figure 25) is always sharp and oxide-free. Use some sand paper to clean it, if necessary.

- The space between the tip and the air duct must be 3 mm approx. (2 – figure 26).

IONISA TION SENSOR

- The sensor must be placed in the air duct at approximately 12.5 mm from the burner (3 – figure 27).

Check that the position is correct in the flame (see figure 28). It must be placed just after the flame front. There is no ionisation inside the blue cone. It reduces and reaches the end of the flame afterwards.

GAS BURNERGAS BURNER

GAS BURNER

Figure 25

Figure 26

Figure 27

Figure 28

Cône bleu

Page 31

Page 30 - IOM / ROOF-TOP FLEXY™ Series

GAS BURNERSGAS BURNERS

GAS BURNERS

BURNER DISASSEMBLY FOR SERVICE AND MAINTENANCE PURPOSES

Please refer to the enlarged diagrams at the end of the section (figures 29 to 31) for further help.

- Stop the unit, switch off the main switch and disconnect the gas supply.

- Disconnect the PCB switches (figure 29).

- Remove the flared flange nuts either on the solenoid valves or on the supply float rails. Do not tamper with the joints.

- Remove the nozzle float rail and the control box. Be careful not to damage or change the setting of the ionisation sensors or ignition electrodes.

- Remove the limiters (2) and deflectors (3) (see figures 30 to 32).

-Déconnecter et déposer les ventilateurs d'extraction avec leur conduit d'évacuation des fumées.

- Release the pressure tap pipes from the pressure controllers.

- Loosen the screws on the fume box and remove the assembly with the fans by slightly raising to release the screws before pulling it towards you. Always make sure not to damage the PCB.

- Using a clamp, remove the turbines from the tubes on the fume box side.

- Use a 50 mm diameter nylon brush to sweep inside the upper and lower tubes. Extract the dust with a vacum cleaner.

REASSEMBLY

Use the supplied rod in the compartment to reassemble the turbines. Place the pointed end of the rod inside the hole on the turbine end. Once inside the tube, push until the turbine contact the tube. Pull back the rod and withdraw 2 cm first before giving it ¼ turn. If the rod unhooks during the procedure, pull out the turbine with the hook and repeat all the aforementioned steps.

Figure 29

TROUBLESHOOTING

The fan does not work.

- Check the electrical supply as well as the CLIMATIC™ which should show a heat demand.

- Make sure that B17/18 minigas pressure controller is closed.

- Make sure that B45/46 klixon is neither damaged nor too hot.

- Check whether the fan motor is powered and whether it can turn freely.

- Check the supply and ensure it can rotate freely.

The fan starts without an ignition spark

- Check the operation of the air pressostat (B21/22)

- Check the ignition electrode position (see figures 25 &

26).

- Clean any oxide on the electrode.

- Check that the wire or electrode connections are not earthed.

The fan starts with an ignition spark but without a flame

- Check the gas supply pressure.

- Bleed the gas line.

- Check the injection gas pressure. Adjust the pressure on the solenoid regulator, if necessary.

- YV51/52 solenoid valve does not work : check the supply voltage. Replace it if necessary.

The fan rotates, the flame is lit but goes out without disconnecting

- Gas flow is too low, the pressure drops when the solenoid valve opens.

The fan rotates, the flame is lit but goes out with disconnecting (figure 20)

- Incorrect position of the ionisation sensors.

- Faulty connections of the ionisation electrode.

Page 32

IOM / ROOF-TOP FLEXY™ Series - Page 31

GAS BURNERSGAS BURNERS

GAS BURNERS

60 KW BURNER FOR FGX 60 AND 70 MODELS

Figure 30

Page 33

Page 32 - IOM / ROOF-TOP FLEXY™ Series

GAS BURNERGAS BURNER

GAS BURNER

120 KW BURNER FOR FGX 60, 70 AND 100 MODELS

Figure 31

Page 34

IOM / ROOF-TOP FLEXY™ Series - Page 33

180 KW BURNER FOR FGX 120 AND 140 MODELS

GAS BURNERGAS BURNER

GAS BURNER

2 3

Figure 32

Page 35

Page 34 - IOM / ROOF-TOP FLEXY™ Series

BELBEL

BEL

T TENSIONT TENSION

T TENSION

On delivery, the drive belts are new and correctly tensioned. After the first 50 operating hours check and adjust the tension. 80% of the total elongation of belts is generally produced during the first 15 hours of operation.

Before adjusting the tension, make sure that the pulleys are correctly aligned.

To tension, adjust the play of screw Mx. The recommended deflection is 16 mm per metre from centre to centre. Check that according to the diagram below (figure 34), the following ratio remains

the same.

A (m)

= 16

P (mm)

The belts should always be replaced when :

- the disk is set to maximum,

- the belt rubber is worn or the wire is visible.

Replacement belts must have the same rated size as the ones they are replacing. If a transmission system has several belts, they must all be from the same manufacturing batch (compare serial numbers).

NOTE : An under-tensioned belt will slip, heat and wear prematurely. On the other hand, if a belt is over-tensioned, the pressure on the bearings will cause them to over-heat and wear prematurely. Incorrect alignment will also cause the belts to wear prematurely.

Figure 33

Figure 34

Page 36

IOM / ROOF-TOP FLEXY™ Series - Page 35

PULLEYSPULLEYS

PULLEYS

Remove the 2 screws and put one of them in the extraction threaded screw.

Screw in fully. The hub and the pulley will separate from each other.

Remove the hub and the pulley by hand without damaging the machine.

FAN PULLEY REMOVAL

FAN PULLEY INSTALLATION

Clean and de-grease the shaft, hub and conical bore of the pulley. Lubricate the screws and install the hub and pulley. Position the screws without turning them.

Place the assembly on the shaft and screw in the screws alternatively and evenly. Using a mallet or a hammer with a wooden wedge, tap on the face of the hub to keep the assembly in place. Torque the screws to 30 Nm.

Take the pulley in both hands and shake it vigorously to make sure everything is in place. Fill the holes with grease for protection.

NOTE : During installation, the key should never protrude out of its groove. After 50 operating hours, check that the screws are still in place.

PULLEY MOTOR INSTALLA TION AND REMOVAL

The pulley is held in position by the key and a screw located in the groove. After unlocking, removing this screw by pulling against the shaft spindle (if necessary, use a mallet and tap uniformly on the hub to remove it). To assemble, proceed in the reverse order after having cleaned and de-greased the motor shaft and the pulley bore.

ALIGNMENT

After adjusting one or both of the pulleys, check the transmission alignment using a ruler placed on the inner face of the two pulleys.

NOTE: The warranty may be affected if any major modification is made to the transmission without obtaining our agreement beforehand.

Figure 35

Figure 36

Figure 37

Page 37

Page 36 - IOM / ROOF-TOP FLEXY™ Series

KP17 COMFORT CONTROL DISPLAY WIRING

Failure to install the Comfort control display with the recommended cable may cause the display to malfunction. The KP17 remote must be connected to the CLIMATIC™ using a 4 x 0.5 mm2 braid-screened cable. This connection is provided through a remote interface card which is located within the Control panel section. Refer to the wiring section of this manual.

The CLIMATIC™ 'Comfort' control Display allows an untrained person to easily operate a Lennox Roof-Top. This display connects to a single Rooftop and, through the use of the control keys, LED's and display the user can see how the connected Rooftop is operating, wether there are any faults, modify the comfort setpoint and override the Rooftop operation. If installed correctly the CLIMATIC™ "Comfort" control display can be installed up to 1000 m away from the Rooftop unit.

DISPLAY (1 - figure 39)

In 'Automatic' operation the comfort setpoint is displayed in the event of a fault detected on the unit an error code is automatically displayed.

The + / - keys (2) are used to change the heating/cooling/ operating setpoints.

The LED (3) indicates the current operating mode :

- In 'Automatic' mode, i.e. in the programmed time schedules, the LED flashes,

- In forced occupied mode, the LED is permanently on

- In forced unoccupied mode, the LED is off.

Forced Occupied Key (4) Pressing this key will override the Automatic control and force the unit to run in its "Occupied" mode. Whilst in this mode the LED (3) will remain permanently on. To return to "Automatic" mode press button (6) when the LED (3) will flash again.

Forced Unoccupied Key (5) If, to save energy, the installations are not used within a period programmed for automatic use, it is possible, by pressing this key, to force the unit into its to "unoccupied" mode. The LED (3), which was previously flashing or lit, will now go out.

Automatic Operation Key (6) If the system was previously set to forced occupied mode (LED (3) lit) or forced unoccupied mode (LED (3) off), this key allows you to return to the automatic programmed mode. The LED will flash.

NOTE : 'Forced' modes will automatically be re-set at 00:00h

LED (7) Indicates whether the unit is operating or not. LED (8) Indicates that the filters are dirty.

LED (9) Indicates a general fault has been detected by the CLIMATIC™. Refer to the "Fault codes" section of this manual.

USING THE KP 17 COMFORT CONTROL DISPLAY

Tc Tm Tf

Figure 38

Figure 39

Page 38

IOM / ROOF-TOP FLEXY™ Series - Page 37

USING THE KP02 MAINTENANCE CONTROL DISPLAY

CALLOUT :

1 LIQUID CRYSTAL DISPLAY 2 RAISE/LOWER KEYS 3 "FILTER" LED (flashing red) 4 "ADDRESS" KEY 5 "MODE" KEY 6 "VALUE" KEY 7 "UNIT RUNNING" LED 8 "MODE" LED 9 "GENERAL ALARM" LED.

1 - DISPLA Y FORMATS

Hour

Default display. If the display unit has been inactive for 5 minutes, this screen will automatically be displayed.

<--> 12 hours and 59 minutes

Date

<--> 8 April 1999

Variable or setpoint address

Figure 40

This display unit allows you to read and modify all the values of the variables or setpoints of the rooftop to which it is connected.

NOTE : If your ROOFTOP already has a KP17 Comfort display connected (see previous section) simply disconnect it and connect this panel to the same location, once completed reconnect the KP17. It is not necessary to switch off the power to the CLIMATIC™ whilst the KP02/KP17 is being changed.

The dialogue with the controller is initiated by the CLIMATIC™. If, after 3 attempts, no communication is established, a message will be displayed signalling the problem. The unit will then try to re-connect at regular intervals.

Page 39

Page 38 - IOM / ROOF-TOP FLEXY™ Series

Variable or setpoint value

Digital Values

1 <--> ON 0 <--> OFF

Temperatures Temperatures are displayed in °C, to an accuracy of 0.1 °C

<--> -21.6 °C <--> + 105.8 °C

Pressures Pressure is given in bars, to an accuracy of 0.1 bar.

<--> 18.3 bars

Other analog values

Valeurs displayed Values non

displayed

Specific Displays

Software Version

When the unit is powered up, the KP02 software version number is displayed.

<--> version 1.0 (for example)

Display Test

The display can only be tested for correct operation when the unit is powered up and by pressing on the 3 keys "A", "M" and "-" simultaneously. If the display is working correctly, the following will be displayed :

All digits are properly displayed.

Communication Error

If there is no communication between the KP02 display unit and the CPU card, the following message is displayed :

<--> "Communication problem"

USING THE KP02 MAINTENANCE CONTROL DISPLAY

Page 40

IOM / ROOF-TOP FLEXY™ Series - Page 39

USING THE KP02 MAINTENANCE CONTROL DISPLAY

2 - OPERA TING MODES

The maintenance display allows for 4 modes of operation. Key [M] allows you to move successively and in a loop from one mode to the next. The current mode is indicated by the status of LEDs [V] and

[C] :

Status of LEDs associated with current mode : [V] [C]

A. The variable mode allows you to

read the values of variables lit not lit

B. The setpoint mode allows you to

change the settings not lit lit

C. The read date mode allows you to

view the time and the date not lit not lit

D. The date setting mode allows you to

change the time and the date lit lit

A : VARIABLES MODE

Pressing key [A] displays the address of the variable being read. To go to a higher address, press [A] while simultaneously pressing on [+]. The address will increase slowly by pressing [+] intermittently or more quickly by keeping your finger on the key. To go to a lower address, proceed as above but with the [-] key.

When the required address appears, press [V] to display the variable value. If you do not press any key, the display will automatically return after a minute. The variables are updated every second.

B : SETPOINTS MODE

The setpoint address can be chosen in the same way as for the variable address (see above). When the address of the required setpoint appears, pressing [V] will likewise display the current value. To increase the setpoint press [V] while holding down the [+] key at the same time. The address will increase slowly by pressing [+] intermittently or more quickly by keeping your finger on the key. To go to a lower setpoint, proceed as above but with the [-] key as well as the [V] key.

The new value is applied when [V] is released.

PASSWORD

Access to all the setpoints is password-protected. Enter the password before making changes. To do so, following the above procedure : go to address setting n° 0 and enter the number corresponding to your password.

If the password code is correct, the following message will appear when key [V] is released :

If the keypad has been inactive for 5 minutes, the password is reactivated. You must therefore enter it again to continue making changes to the setpoint values.

C : DATE READING MODE

One of the following modes

- Hour

- or date

can be chosen by pressing [A] and briefly pressing on [+] or [-]. Pressing [V] will display the value of the data selected, otherwise it will automatically be displayed after a minute.

D : DA TE SETTING MODE

This mode allows the 6 date modes to be set :

• Hours and minutes <-->

• Day of the month <-->

• Day of the week <-->

• Month <-->

• Year <-->

In the same way as for the setpoints, the value can be increased by simultaneously pressing on keys [V] and [+] and they can be decreased by simultaneously pressing on [V] and [-].

Page 41

Page 40 - IOM / ROOF-TOP FLEXY™ Series

USING THE KP02 MAINTENANCE CONTROL DISPLAY

Item Minimum value Maximum value

Hours and minutes 00-00H 23-59 H

Day of the month 1 31

Day of the week 1 7

Month 1 12

Year 0 99

For different types of data, the setting ranges are as follows :

Changes are only incorporated when key [A] is pressed.

NOTE : The compatibility of the value for the day of the month is not checked when it is entered. You might therefore enter February 31st but when you try to validate, it will be ignored and the preceding value stored.

3 - POWER SUPPLY (LED 7 - figure 40)

When lit, the LED indicates that the machine is powered up.

4 - MODE (LED 8 - figure 40)

This LED indicates the current operating mode. In normal mode, i.e. within the programmed schedules, the LED flashes. In forced day mode, the LED is permanently on and in forced night mode, the LED is off.

5 - FILTER DIRTY (LED 3 - figure 40)

This LED indicates that the CLIMATIC™ has detected that the filter is blocked.

6 - GENERAL F AULT (LED 9 - figure 40)

This LED indicates a general fault has been detected. Refer to the "Fault codes" section of this manual.

Page 42

IOM / ROOF-TOP FLEXY™ Series - Page 41

USING THE KP02 MAINTENANCE CONTROL DISPLAY

LIST OF SETPOINTS

1st Level

Min. Factory Maxi.

0 Password to access level 2 setpoints and variables 0 # 255 1 Temperature, required setpoint for room, day mode 8.0 21.0 35.0 2 (Used by KP17 only)

KP17 Remote control, overide, occupied mode Off Off On

3 (Used by KP17 only)

KP17 Remote control, overide, automatic mode Off Off On

4 (Used by KP17 only)

KP17 Remote control, overide, unoccupied mode Off Off On

5 Fault reset Off Off On 6 Remote control, On / Off, unit Off Off On 7

(Special software request) Remote control, On / Off, customer output KP12/2

Off Off On

8 (Used for setting up different time zones) 0 0 7

Mode, Selection 0 = Day 1 = Week-end 2 = Night 3 = 4 = Morning 5 = Midday 6 = Evening 7 = BMS

9 Defines end of weekend/Start of week (1 = Sunday, 2 = Monday, etc) 1 # 7

Mode, day of the week, start of mode

10 (Used with setpoint 8 - mode selection - to define the hour of the start time) 0 # 2 3

Mode, hour, start of mode

11 Used with setpoint 8 - mode selection - to define the minute of the start time 0 # 59

Mode, minute, start of mode

12 Defines end of week/Start of weekend (6 = Friday, 7 = Saturday, etc) 1 # 7

Mode, day of the week, end of mode

13 Used with setpoint 8 - mode selection - to define the hour of the stop time 0 # 23

Mode, hour, end of mode

14 Used with setpoint 8 - mode selection - to define the minute of the stop time 0 # 59

Mode, minute, end of mode

15 Defines day mode deadzone, other time zones = cooling setpoint) 8.0 # 35.0

Mode, temperture, room cooling setpoint

16 Defines day mode deadzone (other time zones = heating setpoint) 8.0 # 35.0

Mode, temperature, room heating setpoint

17 (FLEXY™ only)

On = Absolute humidity (g/kg) / Off = Relative humidity (%) Off Off On

18 (FLEXY™ only)

Mode, relative humidity (%), room minimum setpoint required 0 # 100

19 (FLEXY™ only)

Room mode, Relative humidity (%), maximum setpoint required 0 # 100

20 (FLEXY™ only)

Mode, Absolute humidity (g/kg), room minimum setpoint required 0.0 # 30.0

21 (FLEXY™ only)

Mode, Absolute humidity (g/kg), room maximum setpoint required 0.0 # 30.0

22 Mode, Percentage, Minimum fresh air 0 # 100 23 Mode, Fan activity in control zone (cooling mode/heating mode) Off # On 24 Mode, Fan activity in dead zone Off # On 25 (Special application request only)

Mode, Fan automation, dead zone Off # On

26 (FLEXY™ only)

Mode, Fan low speed, control zone Off # On

Page 43

Page 42 - IOM / ROOF-TOP FLEXY™ Series

USING THE KP02 MAINTENANCE CONTROL DISPLAY

Min. Factory Maxi.

27 (FLEXY™ only)

Mode, Fan low speed, dead zone Off # On

28 (FLEXY™ only)

Mode, Fan low speed automation Off # On

29 (on = unit runs at maximum 50% during "night mode")

Mode, Low noise Off # On

30 (J-BUS only)

Remote control, overide, Mode Off Off On

31 (J-BUS only)

Remote control, Overide, Low fan speed Off Off On

32 (J-BUS only)

Remote control, Overide damper with recycled air Off Off On

33 (J-BUS only)

Remote control, Overide damper with minimum fresh air Off Off On

34 (J-BUS only)

Remote control, Overide damper with fresh air Off Off On

35 (J-BUS only)

Remote control, Overide 50% load limit Off Off On

36 (J-BUS only)

Remote control, Overide heating cancellation Off Off On

37 (J-BUS only)

Remote control, Overide cooling cancellation Off Off On

38 (J-BUS only)

Remote control, Overide electrical heaters cancellation Off Off On

39 On = Electrical heaters during defrosting Off On On 40 (Alarm only)

Room temperature, low setpoint 5.0 10.0 20.0

41 (Alarm only)

Room temperature, high setpoint 20.0 40.0 40.0

42 Room relative humidity (%), low setpoint 0 0 50 43 Room relative humidity (%), high setpoint 50 100 100 44 Room absolute humidity (g/kg), low setpoint 0.0 0.0 30.0 45 Room absolute humidity (g/kg), high setpoint 0.0 30.0 30.0 46 Temperature, Curved gradient of anticipated speed 0.0 10.0 20.0 47 (0 = Start at times set in "modes" only, no anticipation start 0 12 100

Value, Gradient of anticipated speed

48 Quantity of CO2, Ppm, minimum fresh air 0 1000 2000 49 Quantity of CO2, Ppm, maximum fresh air 0 1500 2000 50 Percentage, Fresh air damper opening before fan will start 0 10 100

2nd Level

Min. Factory Maxi.

51 Maximum temperature, required setpoint for room, day mode 21.0 27.0 35.0 52 Minimum temperature, required setpoint for room, day mode 8.0 17.0 21.0 53 (Compressor minimum run time in seconds) 25 180 1800 54 Differential temperature, engaged heat setting 0.0 1.0 10.0

Page 44

IOM / ROOF-TOP FLEXY™ Series - Page 43

USING THE KP02 MAINTENANCE CONTROL DISPLAY

Min. Factory Maxi.

55 Differential temperature, heating setting between 2 steps 0.1 1.0 10.0 56 Differential temperature, engaged cooling setting 0.0 1.0 10.0 57 Differential temperature, cold setting between 2 steps 0.1 1.0 10.0 58 (Not used - special option only)

On = Compressors then chilled water coil, room setting Off Off On

On = Heat pump and/or sas then hot water coil or elec. heat, room setting

Off On On

60 On = Gas then heat pump, room setting Off Off On 61 On = Supply setting on Off Off On 62 Time, sampling of supply setting (integration delay) 1 10 120 63 On = Compressors then chilled water coil, supply setting Off Off On 64

On = Heat pump and/or gas then hot water coil or elec. heat, supply setting

Off Off On

65 On = Gas then heat pump, supply setting Off Off On 66 (Not used - Future facility) - Reserved

On = constant supply air temperature via air damper modulation Off Off On

67 (FLEXY™ only)

Time, Sampling of humidity setting 1 10 120

68 (FLEXY™ only)

Humidity range (%), humidity setting 1 5 50

69 (FLEXY™ only)

Differential humidity (%), Engaged dehumidity setting 1 5 50

70 (FLEXY™ only)

Differential humidity (%), Dehumidity setting between 2 steps 1 5 50

71 Supply temperature, low setpoint, 1st level setpoint

+2.0 8.0 19.0

72 Supply temperature, low setpoint, 2nd level setpoint 73

+2.0 6.0 17.0

73 Supply temperature, low setpoint, 3rd level 1.0 2.0 15.0 74 Supply temperature, high setpoint, 1st level 20.0 40.0 70.0 75 Supply temperature, high setpoint, 2nd level setpoint

74 60.0 70.0

76 Temperature, Outside air minimum setpoint,

(Outdoor air <Setpoint 76 = No free cooling, Min % fresh air) 0.0 5.0 30.0

77 Temperature, Outside air maximum setpoint,

(Outdoor air>Setpoint 77 = 50 % compressors OFF in cooling) 0.0 26.0 60.0

78 (Not used - future facility) - Percentage, maximum fresh air,

Damper modulation to provide constant supply air temperature 0 60 100

79 Outside air temperature, setpoint, 50% compressor

(Outdoor air<Setpoint 79 = 50 % compressors stop) 10.0 12.0 30.0

80 Outside air temperature, setpoint, 100% compressor

(Outdoor air<Setpoint 80 = ALL compressors stop) 10.0 12.0 30.0

81 Icing temperature setpoint, evaporator coil -5.0 -1.0 3.0 82 Defrost temperature setpoint, evaporator coil 5.0 10.0 15.0 83 Delay, icing setpoint, evaporator coil 1 360 600 84 Outside air temperature, setpoint, 100% compressor heatpump

(Outdoor air<Setpoint 84 = ALL compressor stop) -50.0 -20.0 20.0

Outside temperature, setpoint, authorised defrosting, condenser coil

8.0 10.0 20.0

(on LINEA™ only)* - (R22 = -3, R407C = 1)

Battery temperature, setpoint, authorised defrosting, condenser coil -10.0 -3.0 6.0

* : LINEA is another range of LENNOX ROOFTOP. For more information, please consult your regional office

Page 45

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USING THE KP02 MAINTENANCE CONTROL DISPLAY

Min. Factory Maxi.

87 Coefficient, icing time, condenser coil 0 3 12 88 Number, condenser restart, condenser coil 1 1 8 89 Low temperature, setpoint,

air/water cooled heat exchanger (non standard) 4.0 5.0 20.0

90 High temperature, setpoint,

air/water cooled heat exchanger (non standard) 20.0 45.0 46.0

91 Outside temperature, setpoint, 100% electrical heater discharge

(Outdoor air > Setpoint 91 = electric heater stop) -20.0 10.0 30.0

92 Sensing setpoint, air flow cutout 0.0 0.2 5.0 93 Sensing setpoint, clogged filters 0.0 2.5 5.0 94 Sensing setpoint, missing filters 0.0 0.5 5.0 95 KP17 = on = On/Off unit Off Off On 96 Delay, closing, KP 12-2 "Day" input 4 60 65535 97 Delay, Opening, KP 12-2 "Day" input 2 300 65535 98 Unit type 0 0 65535 99 On = "LINEA™"* series, Off = "FLEXY™" series Off # On

100 On = Low ambiant Option fitted

(Disable setpoints 79 & 80) (Off = Enable setpoints 79 & 80) Off # On

101

(FLEXY™ only)

On = Advanced Control Pack option fitted Off # On

102 Slave J-Bus, number 1 1 10 103 Link, number 0 0 7 104 All setpoint values overide to factory

default EPROM values (centre column) Off Off On

105 Test stages (for factory test procedures only

reduces all delay timers to 0) 0 0 65535

* : LINEA is another range of LENNOX ROOFTOP. For more information, please consult your regional office

Page 46

IOM / ROOF-TOP FLEXY™ Series - Page 45

USING THE KP02 MAINTENANCE CONTROL DISPLAY

V ARIABLE LIST

(june 2001)

1st Level

0 Error code 1 Temperature, room 2 Relative humidity (%),room 3 Temperature, outside air 4 Relative humidity (%), outside, air 5 Temperature, supply Air 6 Temperature, chilled water battery 7 Temperature, compressor, no. 1 8 Temperature, compressor, no. 2

9 Temperature, compressor, no. 3 10 Temperature, compressor, no. 4 11 Temperature, condenser, no. 1 12 Temperature, condenser, no. 2 13 Temperature, condenser, no. 3 14 Temperature, condenser, no. 4 15 Temperature, air/water cooled heat exchanger, water outlet 16 Pressure, air flow (mb) 17 Air quality sensor, CO² (ppm) 18 Pressure, compressor, no. 1 19 Pressure, compressor, no. 2 20 Pressure, compressor, no. 3 21 Pressure, compressor, no. 4 22 Volt free contact, remote control, unit Off 23 Volt free contact, remote control, forced occupied mode 24 Volt free contact, remote control, forced unoccupied mode 25 Volt free contact, remote control, 50% load limit 26 Volt free contact, remote control, heating disable 27 Volt free contact, remote control, cooling disable 28 Volt free contact, remote control,low ventilation speed 29 Auxiliary contact, blower fan 30 Volt free contact, error, DAD board, detected smoke 31 Auxiliary contact, compressor, no. 1 32 Auxiliary contact, compressor, no. 2 33 Auxiliary contact, compressor, no. 3 34 Auxiliary contact, compressor, no. 4 35 Pressure switch, compressor, no. 1, low pressure 36 Pressure switch, compressor, no. 2, low pressure 37 Pressure switch, compressor, no. 3, low pressure 38 Pressure switch, compressor, no. 4, low pressure 39 Auxiliary contact, condenser fan, no. 1 40 Auxiliary contact, condenser fan, no. 2 41 Auxiliary contact, condenser fan, no. 3 42 Auxiliary contact, condenser fan, no. 4 43 Volt free contact, air/water cooled heat exchanger, water flow regulator 44 Auxiliary contact, pump (hot water coil - frost protection pump) 45 Auxiliary contact, electrical heater, no. 1 46 Auxiliary contact, electrical heater, no. 2 47 Auxiliary contact, gas grade, no. 1 48 Auxiliary contact, gas grade, no. 2 49 Volt free contact, humidifier, error, control & setting board 50 Volt free contact, leak water 51 Volt free contact, information, miscellaneous source 52 Output, supply fan

Page 47

Page 46 - IOM / ROOF-TOP FLEXY™ Series

53 Output, low speed supply fan 54 Output, Extract fan 55 Output, compressor, no. 1 56 Output, compressor, no. 2 57 Output, compressor, no. 3 58 Output, compressor, no. 4 59 Output, compressor, no. 1, hot gas injection valve 60 Output, compressor, no. 1, cycle reversing valve 61 Output, compressor, no. 2, cycle reversing valve 62 Output, compressor, no. 3, cycle reversing valve 63 Output, compressor, no. 4, cycle reversing valve 64 Output, condenser fan, no. 1 65 Output, condenser fan, no. 2 66 Output, condenser fan, no. 3 67 Output, condenser fan, no. 4 68 (FLEXY™ only) - Output, pump 69 Output, electrical heater, no. 1, 1st level 70 Output, electrical heater, no. 1, 2nd level 71 Output, Electrical Heater, no. 2 72 Output gas grade, no. 1, 1st level 73 Output, gas grade, no. 1, 2nd level 74 Output, gas grade, no. 2 75 Output, humidifier 76 Output, miscellaneous 77 Proportional action, economiser 78 Proportional action, chilled water battery 79 Proportional action, hot water battery 80 Proportional action, electrical heaters, static relays 81 Proportional action, humidifier 82 Status, supply fan 83 Status, damper 84 Status, chilled water coil 85 Status, hot water coil 86 Status, compressor, no. 1 87 Status, compressor, no. 2 88 Status, compressor, no. 3 89 Status, compressor, no. 4 90 Status, condenser fans 91 Status, pump 92 Status, electrical heaters 93 Status, gas 94 Status, humidifier 95 Room setpoint, minimum setting, heating 96 Room setpoint, maximum setting, cooling 97 Room setpoint, minimum power point, heating 98 Room setpoint, maximum power point, cooling

99 Setpoint, supply setting 100 Setting, minimum power point, heating, supply 101 Setting, maximum power point, cooling, supply 102 Setting, minimum setpoint, humidification, room 103 Setting, maximum setpoint, dehumidification, room 104 Setting, minimum power point, humidification, room 105 Setting, maximum power point, dehumidification, room 106 Function, operational conditions 107 On = Special software 108 Version number, Software

USING THE KP02 MAINTENANCE CONTROL DISPLAY

Page 48

IOM / ROOF-TOP FLEXY™ Series - Page 47

USING THE KP07 GRAPHIC CONTROL DISPLAY

This display unit allows you to operate 1 to 8 machines. The icon and schematic display provides a vivid and user-friendly interface.It uses a liquid crystal monochrome display, with background lighting, consisting of 240 x 128 pixels. It has 2 LEDs and 12 keys. The remote console must be connected to the unit using a 4 x

0.5 mm² braid-screened cable (maxi length is 1000 m ). Plan the console electric supply in 230V/50Hz (500 mA) On the unit, connection to the KP01 card J18 input will be done with connection items (screws...) delivered with the console.

ITEMS :

1 LCD SCREEN, 240x128 PIXELS, MONOCHROME,

BACKGROUND LIGHTING

2 5 KEYS FOR FIXED FUNCTIONS 3 7 "SCREEN" KEYS FOR VARIOUS FUNCTIONS 4 "ON" LED 5 "GENERAL ALARM" LED.

The main display unit functions are as follows :

- Control of a range of interactive screens allowing access to all information and control data.

- Continual resetting of all dynamic parameters displayed in the various screens.

- Recording of successive status of pre-defined variables to create analog and event histories.

A KP07 unit can be attached to more than 8 LENNOX Rooftops, providing they have the same software.

The link between the controllers and the display is serial and uses the JBUS protocol. After being connected, the unit tries to establish communication with the specified machines. If, after 3 attempts, the unit cannot communicate with the Rooftop(s), the latter will be "disconnected". The connection failure is displayed on the screen and recorded in the event history. The display unit will then try to re-connect at regular intervals.

NOTE : To adjust the screen contrast, please consult the end of this part.

1 - SCREEN KEYS WITH V ARIABLE FUNCTIONS

(figure 41)

There are 7 keys located around the LCD screen :

The function of these keys may vary from one screen to another and is defined on the active screen by an icon. In the case of keys [1], [2], [3] and [4], the icon is displayed above the key. For the 3 other keys [A], [B] and [C], the icon appears to their left.

Each key allows you to :

- Proceed to another screen, or

- Write a value in a given variable.

Figure 41

Page 49

Page 48 - IOM / ROOF-TOP FLEXY™ Series

USING THE KP07 GRAPHIC CONTROL DISPLAY

2 - FIXED KEYS (FIGURE 41)

The functions of these 5 keys are fixed :

PAGE DOWN :

Moves to the next page of the same screen type.

PAGE UP :

Returns to the previous page of the same screen type.

STRUCTURE :

Returns to the first screen (showing the structure).

PREVIOUS SCREEN :

Returns to the screen previously displayed

MODIFICATION :

Pressing on this key activates the "modification" mode (see below).

3 - ON (LED 4 - figure 41)

When lit, it indicates that the machine is powered up.

4 - GENERAL F AULT (voyant 5 - figure 41)

This LED indicates a general fault has been detected.

5 - "MODIFICATION" MODE

This mode allows you to change the values of all the variables displayed on the active screen. It uses the 4 keys "1", "2", "3" and "4" by attributing preset functions to them :

KEY / ASSOCIA TED ICON

Selects the variable to be changed

Selects the number to be changed

(By pressing successively on the key the cursor will move from digit to digit, from right to left, then the cursor remains on the last digit of the value to be changed.)

Increases the number from 0 to 9

Confirms the current change.

Through "MODIFICATION" mode, the user is able to :

- choose the number of the controller he wishes to see the variables of (if several LENNOX Rooftops are attached to the same KP07 display unit),

- control the setpoints.

To exit "MODIFICATION" mode and return to the active screen, press the "MODIFICATION" key.

Note :

- During modification, the screen is no longer updated.

- If a change is not confirmed, the variable will retain its previous value.

CONTRAST SETTING

The display contrast can be set in "MODIFICATION" mode :

- Pressing successively on key [A] increases the contrast.

- Pressing successively on key [B] decreases the contrast.

- Key [C] allows you to find the default contrast.

Page 50

IOM / ROOF-TOP FLEXY™ Series - Page 49

USING THE KP07 GRAPHIC CONTROL DISPLAY

GENERAL SCREEN LA YOUT

Summary

Measurements :

Humidity

Operational status :

Ventilation

Chart :

Ambient temperature

Chart :

Ambient humidity

History :

Safety & Errors

Hourmeters :

Ventilation, customer...

Operational status :

Frost

History :

Safety & Errors

Operational status :

Compressor n° 1

Operational status :

Compressor n° 2

Operational status :

Compressor n° 3

Operational status :

Compressor n° 4

Operational status :

Heaters

History :

Safety & Errors

Hourmeters :

Electrical resistance

History :

Safety & Errors

Hourmeters :

Humidifier

History :

Sécurité & défauts

Hourmeters :

Compressors

Hourmeters :

Fan. Capacitors

Measurements :

Temperatures

perational status :

Humidification

Page 51

Page 50 - IOM / ROOF-TOP FLEXY™ Series

USING THE KP07 GRAPHIC CONTROL DISPLAY

Settings :

Time

Settings :

On/Off

Settings :

On ; Ventilation

Settings :

Condition ; Day

Password :

Level 1

Settings :

Condition ; Weekend

Settings :

On ; Ventilation

Settings :

Condition ; Night

Settings :

On ; Ventilation

Settings:

Time

Settings :

Condition ; Morning

Settings :

On ; Ventilation

Settings :

Time

Settings :

Anticipation

Settings :

Condition ; Noon

Settings :

On ; Ventilation

Settings:

Time

Settings :

Condition ; Evening

Settings :

On ; Ventilation

Settings :

Time

Page 52

IOM / ROOF-TOP FLEXY™ Series - Page 51

USING THE KP07 GRAPHIC CONTROL DISPLAY

Settings :

On ; Ventilation

Settings :

Condition ; BMS

Settings :

Control ; Cold

Settings :

Control ; Hot

Settings :

Control. ; Dehumidification

Settings :

Control ; Humidification

Settings :

Control ; Misc.

Settings :

Limits ; Ambient

Settings :

Remote controls

Settings :

Remote controls

Settings :

Remote controls

Password :

Level 2

Settings :

Limits ; Outside

Settings :

Limits ; Blowing

Settings :

Air flow ; Filters

Settings :

Std. order ; Ambient

Settings :

Std. order ; Blowing

Page 53

Page 52 - IOM / ROOF-TOP FLEXY™ Series

USING THE KP07 GRAPHIC CONTROL DISPLAY

INDEX OF ICONS

Keys

Select variable to change Select digit to change. Increase value

Enter current change. Go to temperature and humidity values and charts. Go to the machine component status. Go to various notices. Go to room temperature chart. Go to room humidity chart (Flexy only) Reset errors and error meters. Go to error history. Go to operation hourmeters. Go to frosting component status. Go to compressor and condenser operational status. Go to heating devices operational status. Go to humidifier operational status (Flexy only) Enter password. Go to operational condition settings. Go to control settings. Go to safety settings.

Go to On/Off and Discharge settings.

Go to fan On/Off settings. Go to anticipation settings.

Logging on

Log on password to go to settings.

Log on date and time.

Page 54

IOM / ROOF-TOP FLEXY™ Series - Page 53

USING THE KP07 GRAPHIC CONTROL DISPLAY

Sensors

Temperature sensor

Humidity sensor Pressure sensor Return or room data

Supply data Outside data

Operating conditions

Operating condition: Day

Operating condition: Weekend

Operating condition: Night

Operating condition: Morning

Operating condition: Noon

Operating condition: Evening

Operating condition: BMS

Operating status

Cooling mode setting operation. Heating mode setting operation.

Device in manual mode (prohibited under control)

/ (On / Off) Customer option

/ (On / Off) blower fan

/ (High / Low) Ventilation speed (Flexy only)

Filters

/ (On / Off) Fresh air damper.

/ (On / Off) Cold proportional valve, cold water battery

/ (On / Off) Compressor

Page 55

Page 54 - IOM / ROOF-TOP FLEXY™ Series

Compressor defrosting. Compressor stopped in anti-short cycle.

/ (On / Off) Condenser

/ (On / Off) Gas grade.

Half flow gas.

/ (On / Off) Hot proportional valve, hot water valve.

/ (On / Off) Electrical heaters.

/ (On / Off) Humidifier

/ (On / Off) Dehumidification

/ (On / Off) Pump

Errors

General alarm

/ (Start / End)

Communication interrupted between unit KP07 and a CPU board.

/ (Start / End) [081][083][085][086][087][113] [123] [133] [143]

Faulty temperature sensors.

/ (Start / End) [082][084]

Faulty humidity sensors (Flexy only)

/ (Start / End) [112] [122] [132] [142]

Faulty pressure transmitters (Flexy only)

/ (Start / End) [013][022][096]

Low temperature limit.

/ (Start / End) [012][023][097]

High temperature limit.

/ (Start / End) [032]

Low humidity limit (Flexy only)

/ (Start / End) [033]

High humidity limit. (Flexy only)

/ (Start / End) [094]

Error : only applicable to customer.

USING THE KP07 GRAPHIC CONTROL DISPLAY

Page 56

IOM / ROOF-TOP FLEXY™ Series - Page 55

/ (Start / End) [091]

Faulty processing fan.

/ (Start / End) [001]

Wrong air flow.

/ (Start / End) [099]

Error smoke.

/ (Start / End) [004]

Dirty filters.

/ (Start / End) [005]

Missing filters.

/ (Start / End) [115][125][135][145]

Faulty high pressure or faulty electrical compressor.

/ (Start / End) [117][127][137][147]

Faulty low pressure compressor.

/ (Start / End) [092][093]

Faulty condensers.

/ (Start / End) [098]

Faulty water flow. (Flexy only)

/ (Start / End) [041]

Faulty pump. (Flexy only)

/ (Start / End) [011]

Faulty electrical batteries.

/ (Start / End) [014][015]

Faulty gas burner.

/ (Start / End) [031]

Faulty humidifier. (Flexy only)

USING THE KP07 GRAPHIC CONTROL DISPLAY

Page 57

Page 56 - IOM / ROOF-TOP FLEXY™ Series

This option is used for making a connection to the BMS only, by a set of hard contacts. It requires the addition of a KP05 card, if this is not already in place, and a KP12 card. Input connection must be by screened cable only.

Limits of relays :

• 10A – 250V with resistive load

• 4A – 250V with inductive load.

Input Function

A Instruction shift :

A 0/20mA signal can be used to add a linear shift of 0 to 10 °C to the setpoint temperature (mid-point between air-conditioning and heating setpoint). If your command signal is a different type, our engineers can advise you on the type of interface to use before input to the CLIMATIC™

B Unit on/off (ROOFTOP on when unit is off). C Contact - force night operation D Contact - force day operation E Contact - force operation at 50%. F Lock heating function G Lock air-conditioning function. H Feedback of information from an external client

component

BMS VOLT FREE CONTACTS KIT

12V 12V

KP 12.2

200mA

1 2 3 4 5 6 7 8

RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8

Com No Com No Com No Com No Com NoCom No Com No Com No

J3 J1

+18V

KP05

1 2 7 8

cd e f g

Output Function a Signal filter fault b Signal fan fault c Signal compressor fault d Signal fault on gas burner or electric coil. e Signal supplying temperature greater than

setpoint (Setpoint 74)

f Signal supplying temperature less than setpoint

(setpoint 71)

g Command from an external client component

Page 58

IOM / ROOF-TOP FLEXY™ Series - Page 57

CLIMATIC™ PARAMETERS

ON - OFF

The unit is declared On if setpoint 6 (C06) is ON. The unit can be stopped by a remote control command by hard contact. On KP12 extension card - see chapter on BMS contact kit.

For certain configurations a CLIMATIC™ system actuator can be used to control an external function (option: Client). The Client option is declared On if setpoint 7 (C07) is ON.

DEFINITION OF TIME SLOT P ARAMETERS

The CLIMATIC™ allows you to programme 5 operating zones per day, in addition to an idle zone for the weekend. Slot activation is :

- automatically controlled by the CLIMATIC™, if you have defined these time parameters for each slot

- forced manually by action on the controller (instructions 02/03 and 04 for KP02).

- forced by the BMS contacts kit ( see this chapter).

- forced by the computer connection.

The five available time slots are :

WEEK-END

NIGHT

MORNING

NOON

EVENING

If none of the time slots listed above is active, the active slot is :

DAY

A particular time slot :

BMS is activated if the unit is connected to a computer network.

0123456789101112131415161718192021222324

With the KP07 :

- Go directly to the screen concerning the time slot to be modified, enter the parameters described below on the screen (see organisation of screens in KP07chapter).

With the KP02 :

- The slot to be set up must first be defined by the 08 instruction. Enter the information below then return to the 08 instruction to go to the next slot.

Friday 22h. Monday 8h.

Page 59

Page 58 - IOM / ROOF-TOP FLEXY™ Series

DESCRIPTION OF P ARAMETERS

Parameters are defined for the time slot. Select by instruction 08 setting. 0 = DAY / 1 = WEEKEND / 2 = NIGHT / 3 = unused / 4 = MORNING / 5 =MIDDAY / 6 = EVENING / 7 = BMS.

Instruction Description 09 Day of the week of start of setting . From 1 to 7, 1 = Sunday. 10 Hour of start of setting 11 Minutes for start of setting 12 Day of the end of setting 13 Hour of end of setting 14 Minutes of end of setting 15 Setpoint in heating 16 Setpoint in air conditioning 17 Defined if the hygrometry values below are taken as absolute (ON) or relative (OFF). 18 Minimum relative humidity of ambient air (%) 19 Maximum relative humidity of ambient air (%) 20 Minimum absolute humidity of ambient air (g/kg of dry air) 21 Maximum absolute humidity of ambient air (g/kg of dry air) 22 Relative value of minimum flow of new air (%) 23 Fan operation in regulation zone *. ON on OFF off 24 Fan operation in neutral zone*. ON on OFF off 25 Automatic fan operation in neutral zone*. In this zone after operation in air-conditioning mode, the fan is off. If after

one hour the ambient air is still in this zone the fan is started up again.

26 On ON, forces low speed fan operation in the regulation zone*. 27 On ON, forces low speed fan operation in the neutral zone*. 28 On ON, forces automatic low speed operation. If the unit is in air-conditioning or dehumidifying mode and less

than 3 compressors are in use the fan then switches to low speed.

29 Low noise 30 Instruction used to force operation in the current setting

CLIMATIC™ PARAMETERS

* The regulation zone is defined for a temperature less than the heating instruction or greater than the air-conditioning instruction. The neutral zone is between these 2 values.

NOTE : The end of the night slot night is defined by the start of the morning slot : this is why there is no need to define the end of the night slot in the table below

Setpoint

value DAY WEEK-END NIGHT MORNING MIDDAY EVENING BMS

for KP02 = 0 = 1 = 2 = 4 = 5 = 6 = 7

9 -7----- 10 - 22 22 6 12 19 11 -00000- 12 -2----- 13 -6-61219- 14 -0-000- 15 23.0 30.0 30.0 23.0 23.0 23.0 23.0 16 19.0 10.0 10.0 19.0 19.0 19.0 19.0 17 Off Off Off Off Off Off Off 18 0000000 19 100 100 100 100 100 100 100 20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 21 30.0 30.0 30.0 30.0 30.0 30.0 30.0 22 20 0 0 0 20 20 20 23 On On On On On On On 24 Off Off Off Off Off Off Off 25 Off Off Off Off Off Off Off 26 Off Off Off Off Off Off Off 27 Off Off Off Off Off Off Off 28 Off Off Off Off Off Off Off 29 Off Off Off Off Off Off Off 30 Off Off Off Off Off Off Off

Page 60

IOM / ROOF-TOP FLEXY™ Series - Page 59

ADV ANCE ACTIVATION OF THE MORNING SLOT

Depending on the thermal inertia of the building or the installation and external climatic conditions, it is possible to advance the switch from the NIGHT slot to the MORNING slot.

The time advanced, in minutes, is calculated using the following formula : Time advanced = (gradient start temperature) x inertia coefficient

For example :

- Outside temperature 0 °C

- Gradient start temperature set to + 10 °C (i.e. below 10°C outside, you want to advance start-up)

- Inertia coefficient set to 12

- Start of Morning slot set to 8h30

In these conditions the switch to the morning slot will be advanced by: (10 - 0) x 12 i.e. 120 min. The installation will therefore start up at 6h30 instead of 8h30.

REGULA TION OF AMBIENT AIR

Two power factors, one for cooling (variable 98), the other for heating (variable 97), are calculated according to the difference in temperature between the Setpoint and the reference temperature. The progression of these cooling or heating power factors is limited by the temperature hysteresis and the activation differentials between 2 stages. If the hysteresis value is 0, the power factor concerned is no longer limited. See below for setting hysteresis and activation differentials.

The power factors are periodically recalculated by the CLIMATIC™. The integration time (setpoint 53) is adjustable. This parameter should depend on the air agitation ratio of the unit and temperature variations in the sector to be air conditioned.

CLIMATIC™ PARAMETERS

ORDER OF COMPONENTS IN REGULATION

Cooling operation

Setpoint 58 =Off

Damper è Water coil è Compressors

Setpoint 58 =On

Damper è Compressors è Water coil

Heating operation

Setpoint 59 =Off

Water coil or electric coil è Compressors è Gas

Setpoint 59 =On

Compressors è Gas è Water coil or electric coil

Setpoint 60 =Off

Water coil or electric coil è Gas è Compressors

Setpoint 60 =On

Water coil or electric coil è Compressors è Gas

Page 61

Page 60 - IOM / ROOF-TOP FLEXY™ Series

CLIMATIC™ PARAMETERS

100%

75%

50%

25%

Cp1

Cp2

Cp3

Cp4

Cp1

Cp2

Cp3

Cp4

Figure 79

Inversion by

setpoint 60

Differential in heating

setpoint 55

Inversion by

setpoint 59

Hysteresis in heating

setpoint 55











: Gas 2 + Gas 1



: Gas 2 + 1/2 Gas 1



: Gas 1



: 1/2 Gas 1

Cp1...Cp4 : Compressor no. 1...4

Inversion by

setpoint 58

Hysteresis in air cond.

setpoint 56

Differential in air cond.

setpoint 57

Inertia

zone

Min. fresh

air

Heating

setpoint 16

Air conditioning setpoint 15

Damper

3-way valve

3-way valve or water coil

Page 62

IOM / ROOF-TOP FLEXY™ Series - Page 61

REGULA TION OF SUPPLY AIR

Supplying air regulation should be activated by setting setpoint 61 to ON.

The main aim of supplying air regulation is to maintain the temperature of supplied air at a value close to the average of the neutral zone, if ambient air regulation is not active.

Two power factors, one for cooling (variable 101), and the other for heating (variable 100), are calculated according to the difference in temperature between the setpoint and the reference temperature.

The power factors are periodically recalculated by the CLIMATIC™. The integration time (setpoint 62) is adjustable

ORDER OF COMPONENTS IN REGULATION

Cooling operation

Setpoint 63 =Off

Damper è Water coil è Compressors

Setpoint 63 =On

Damper è Compressors è Water coil

Heating operation

Setpoint 64 =Off

Water coil or electric coil è Compressors è Gas

Setpoint 64 =On

Compressors è Gas è Water coil or electric coil

Setpoint 65 =Off

Water coil or electric coil è Gas è Compressors

Setpoint 65 =On

Water coil or electric coil è Compressors è Gas

BLOWING REGULA TION BY AIR DAMPER

Regulation of air supplying by the air damper must be activated by setting setpoint 66 to ON.

The aim of air supplying regulation by the air damper is to even out the temperature of supplied air to a value close to the average of the neutral zone. This function is not taken into account if blowing regulation is active.

A power factor (variable 'R_Supply_Damper') is calculated according to difference in temperature between the setpoint and the ambient and outside temperatures. The progression of the power factor is limited by the maximum percentage of fresh air (setpoint 78) if the outside temperature is less than the minimum outside air temperature (setpoint

76). The power factor is recalculated periodically by the

CLIMATIC™. The integration time is adjustable (setpoint 62).

CLIMATIC™ PARAMETERS

REGULA TION IN HUMIDITY

Two power factors, one for dehumidifying (variable 105), the other for humidifying (variable 104), are calculated according to the difference in relative hygrometry between the setpoint and the reference relative hygrometry.

The power factors are recalculated periodically by the CLIMATIC™. The integration time is adjustable (setpoint 67).

Page 63

Page 62 - IOM / ROOF-TOP FLEXY™ Series

REGULA TION IN DEHUMIDIFYING

REGULA TION IN HUMIDIFYING

100%

SETTING THE FRESH AIR MINIMUM

The minimum value for opening the damper to outside air can be set by instruction (see configuration of operating zones). This value is expressed directly as a percentage.

CO² SENSOR

Where a CO² sensor is connected to the unit, the value of the fresh air minimum is calculated according to the CO² ratio. The value measured by the sensor can be read in variable

17.

2000 ppm

CO2

0 ppm

100%

Setpoint 48 defines the number of ppm up to which the fresh air minimum is still achieved. Setpoint 49 defines the number of ppm from which 100% fresh air is used.

CLIMATIC™ PARAMETERS

ENTHALPY FUNCTION

This function is used to control the use of the economiser register according to air enthalpy. If the outside hygrometry is greater than the inside hygrometry, the respective enthalpy values are then calculated. According to the result obtained, input of new air is optimised.

COMPRESSOR-RELA TED FUNCTIONS

Anti-short cycle

The CLIMATIC™ provides protection of the compressors against frequent restarts. This is why the compressors cannot be started, even if requested to do so by regulation, unless the time since they were last put into operation is greater than six minutes.

Equalisation of compressor operating times (F series)

The CLIMATIC™ program is organised to equalise compressor operating times

Defrost function

For heat pump units and air condensation units, cycle inversion phases are programmed for defrosting the outside coil.

Defrosting is activated depending on :

- outside temperature (limit set by setpoint 85),

- coil temperature (limit set by setpoint 86),

- with overall weighting by an icing constant (setpoint 87).

Humidity band %

setpoint 65

Setpoint 48

Setpoint 49

Dehumidification

Hysteresis

(setpoint 69)

Hysteresis

(setpoint 69)

Activation differential (setpoint 70)

Activation differential

(setpoint 70)

Hysteresis

(setpoint 69)

1st stage

2nd stage

3rd stage

Page 64

IOM / ROOF-TOP FLEXY™ Series - Page 63

ELECTRICITYELECTRICITY

ELECTRICITY

The power cable should be connected to the main isolating switch and is fed from the underside of the unit into the electrical panel. Refer to the general arrangement drawings in the documentation to locate the exact entry position.

The power cable sizes must be calculated with reference to the electrical characteristics of your machine. We are unable to state the cross sectional area of the cable as it is directly related to the type of cable you are using, the distance separating the equipment from the source but also various factors relating to the cable fitting.

Items Mark Page

Supply/ Transformers .......................................................................................................................................................... 64

Full fresh air damper activator............................................................................................................. 07 ......................... 68

Economizer damper activator ............................................................................................................. 05 ......................... 67

Exhaust damper activator .................................................................................................................... 06 ......................... 67

Gas burner ............................................................................................................................ 4.1 4.2 4.3 4.4

Supply ........................................................................................................................................................................... 64

Control ......................................................................................................................................................................... 67/69

Internal wiring .............................................................................................................................................................. 70/71

Electrical coil ....................................................................................................................................... 02

Power wiring .................................................................................................................................................................. 64

Control ........................................................................................................................................................................... 67

Thermal safety .............................................................................................................................................................. 68

Water coil............................................................................................................................................ 03

3-way valve ................................................................................................................................................................... 67

Antifreeze thermostat .................................................................................................................................................... 68

Supply fans .......................................................................................................................................................................... 64

Condensing fans/ Exhaust .................................................................................................................................................. 65

Exhaust roofcurb ................................................................................................................................ 06

Supply ........................................................................................................................................................................... 64

Motors safety................................................................................................................................................................. 68

Compressors

Compressors ................................................................................................................................................................. 65

Crankcase heaters ........................................................................................................................................................ 65

Reversing valve .................................................................................................................................. 01 ......................... 68

Air sock ............................................................................................................................................... 14 ......................... 64

FX drain pan electric heater ................................................................................................................................................ 65

Displays

KP02 maintenance........................................................................................................................ 11 .......................... 66

KP17 comfort ................................................................................................................................ 12 .......................... 66

Sensors

Room temperature ...................................................................................................................... BT10........................ 67

Outdoor temperature................................................................................................................... BT11........................ 67

Water coil temperature ............................................................................................................... BT13........................ 67

Room humidity ............................................................................................................................BH10 ....................... 67

Outdoor humidity......................................................................................................................... BH11........................ 67

IAQ sensor ................................................................................................................................... 13 ......................... 67

Compressor pressure sensor .............................................................................................................................................. 67

Firestat ................................................................................................................................................ 08 .......................68/69

Smoke detector .................................................................................................................................. 09

CLIMATIC ™ Connexion.......................................................................................................................................... 67/68/69

Smoke detector wiring .................................................................................................................................................. 72

BMS contacts kit.................................................................................................................................................................. 72

In the following pages you will find references to electrical diagrams which will allow you to select the wiring for your equipment. As the diagrams are valid for the entire range, they will refer to items not included in your scope of supply.

Page 65

Page 64 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

-QG

-T1

TRI : 400V 50Hz + T PA : ... kW IN : ... A ID : ... A

-ZL

-QF1

L3 L2 L1

5 3 1

21 2220

-F2-F1

01 030204 05 06 07 08

S2 S3 S4 S5 S6 S7 S8

-F3 -F4

A1 A2

-Q1

-KM1

PE PE

-V1 -V1

PE PE

-A1 -A1

-KM2

-MS1

FCA/FHA/FXA MS1

7.5 kW

TRIAC 18 KW

TRIAC 36 KW ....................................72 KW

MS2

7.5 kWFCK/FHK/FXK

-B19 -B20

-MS2

T> T>

12 12

4- 3+

-Q2

-KE1

-E1

-QE1

-KE2

-E2

-QE2

-KM5

-Q5

L13 L12 L11

10A

2.5A

0.8A

0.25A

6 4 2

400V

300VA

230V 24V

30VA

12V

10VA

12V

30VA 230V

230V.K 230V.J

12V.H 12V.G

12V.F

12V.E

24V.D 24V.G

-KM1

-A1

-MS1

FCA/FHA 050...100 -MS1 5.5 kW

-MS1

5.5 kW

-MS2

5.5 kW

FXA/FXK 025...100 -MS1

5.5 kW

FCK/FHK 050...100

FCA/FHA 120...190

FXA/FXK 025...100

FCK/FHK 120...190

FCA/FHA 120...190 FCK/FHK 120...190

FCA/FHA 050...100 FCK/FHK 050...100

-B19

-KM1

-A1

-MS1

-B19

-MS2

-B20

-KM1

-X3

-ME1

-B23

-ME2

-B23

FOLIO

04/7

-X3

FOLIO

04/7

FOLIO

3/11

-V2 -V2

12 12

4- 3+

FOLIO

3/11

-ME1

-B23

DIAGRAM OF POWER

Page 66

IOM / ROOF-TOP FLEXY™ Series - Page 65

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

L13 L12 L11

-KM11

-Q11

-MG1

-E51

-KM11

SCROLL

-B81

-MG1

-KM12

-Q12

-MG2

-E52

-KM13

-Q13

-MG3

-E53

FCA/FHA 060 085................FCK/FHK 060 085

FCA/FHA 050 FCK/FHK 050

FCA/FHA 160

190 (*)

FCK/FHK 160

190 (*)

FCA/FHA 120

190 (**)

FCK/FHK 120

190 (**)

FCA/FHA 085

100 (*)

FCK/FHK 085

100 (*)

FCA/FHA 060

070 (*)

FCK/FHK 060

070 (*)

FCA/FHA 120

140 (*)

FCK/FHK 120

140 (*)

FXA/FXK 025

100 (*)

FCA/FHA 050 070 (**) FCK/FHK 050

070 (**)

FX (*)

FCK/FHK 120

140 (*)

FCA/FHA 085

100 (**)

FCK/FHK 085

100 (**)

FXA/FXK 110

170 (*)

FXA 025

085.................................FXK 025 085

FCA/FHA 100........................................................FCK/FHK 100

FCA/FHA 140................................................................................................................FCK/FHK 140

FCA/FHA 190..................................................................................................................................................................FCK/FHK 190

FXA 100.........................................................................FXK 100

FCA/FHA 120..................................................................................FCK/FHK 120

FCA/FHA 160...........................................................................................................................FCK/FHK 160

FXA 110

170...................................................................................................................FXK 110 170

-KM14

-Q14

-MG4

-MP1

-E54

-KM20

-Q20

-Q25

-E7

-E8

-B1

-KM9

-Q9

-MC1

-B71

-KM9

-MC1

-B71

-KM10

-MC2

-B72

-MC2

-B72

-KM9

-MC1

-B71

-MC2

-B72

-KM9

-E9

-E10

-B1

-MC1

-B71

-MC2

-B72

-MC3

-B73

-KM10

-Q10

-MC3

-B73

-MC4

-B74

FOLIO

4/5

-KM11

SCROLL

-B82

-MG2

FOLIO

-KM13

SCROLL

-B83

-MG3 PE

FOLIO

-KM14

SCROLL

-B84

-B28

-MG4

FOLIO

DIAGRAM OF POWER

Page 67

Page 66 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

KP 02

KP 18

KP 17

KP 05.1

KP 01

KP 12.1

KP 12.2

-E30

-E28

-E20

-E29

-E29.2

-E32

-E31

+A0

1234

1122334

12341234

1234

TxD

RxD

TxD

RxD

TxD

RxD

TxD

12V

11 12

10FC 10FH 13 15

221

+18V

12V

+18V

DIALOGUE

200mA200mA

+5V

33445566778

221

Nf C No Nf C No Nf C No Nf C No

Nf C No Nf C

CNoCNoCNoCNoCNoCNoCNoC

No Nf C NoNf C No

33445566778

21 3 45 67 8

SW9

SW1

SW5

SW1

RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8

NoCNoCNoCNoCNoCNoCNoCNoC

RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8

SW2

ALIM. INT

ALIM. EXT

SW3

SW2

SW3

SW1

CTN 0/20 mA

CTN 0/20 mA EXTENS

J19

J13

J11

160mAT.

J4 J5 J6 J7 J8

J17 J21 J26 J24

J18J22

J14

J10

4AT

J15

J25

J22

KP01

KP17

FCA/FHA 120 190..............FCK/FHK 120 190

FXA 110

170...............................FXK 110 170

CLIMATIC™ CONTROLLER

Page 68

IOM / ROOF-TOP FLEXY™ Series - Page 67

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

+18V

142

24V.D 02

24V.C 01

142

KP 05

V0-+

01 01

-BT94-BT93

-BH10-BH11-BG0

137136

136138

143

143138

0/4mA

137

142142

142

-X5 -X5-X5 -X5

-X5

643

10FC 10FH

123

0 10V

24V

24V 24VY

24V

4- 3+ 4- 3+ 4- 3+ 4-

-X7

-X5

-X4

-X1 -X1 -X1

200

48 48

45 45

-X5

-X4

71 02 01

01 72 02

01 72

124

7374

A2A2A1

-X1 -X1 -X1

-X3 -X3 -X3 -X3 -X3 -X3

-KM1

KP01

J13 J17

0/10V

LINK

0/10V

J21 J26 J25 J24

KP02 KP07

+18V

OUT

+IN

GND

+18V

TxD

RxD

+5V

TxD

RxD

+5V

J22 J18

DIAL

+5V

12345678-+ + + ++12345678-- ---

41 42 43

-KM11

2421

-KM12

-KM20

-KE1 -KM9

-BT10 -BT12 -BT11

-BT91 -BT92 -B13

-KA3

-B51

P< P<

-B52

-KT1

-KM5 -KM5

J17

21212

03 02

19 02

SI KP05

-V1

-MR1

24V 24V

-MR4

24V 24V

-MR4

-YV2

-V1 -V2 -V2

05 06 06

46785

COMFORT SETPOINT

(GTC-4-20mA)

CLIMA TIC™ CONTROLLER INPUTS

Page 69

Page 68 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

-KT1

KP 01

KP12.1

J1 J2 J3 J4 J5 J8

J10

J14 J15

J6 J7J11

-X1

-X3

-X324-X4

-X1

-X2

-X1

-X4

-X5

178

-X1

-X5

177

-X5

174

-X5

175

178

-X5

178

-X5

178

-X1

150

-X5

178

-X3

12V

12V12V

12V 12V 12V

Com No Nc Com No Nc Com No

Com

RL1 RL2 RL3 RL4 RL6 RL7 RL8RL5

No Com No Com No Com No Com No Com No Com No Com No

Nc Com No Nc Com No Nc Com No Nc Com No Nc Com No

12V.H

12V.G

12V.H

12V.G

FAILURE

200mA

12V.F

12V.E

24V.D

04 0305

F* F3

06 05

A4A2

A1A2

-MR3

ALARM

ON TRANSFER

ON HU

10FC

10FH

-B15

-B16

-B19

-X1

-B41

-X1

-B81

-X1

-B42

-X1

-B81

-X1

-B71

-X1

-B61

-X1

-B62

-X7

-X2

300

-X2

303

-X2

304

-X2

301

-X2

302

-B25

-KM13

-KM13 -KM10

-KM1

-X1

172 173

-X1

-B28

-X7

-B26

-X1

-B72

-X1

-B20

-B23

-X3

-B24

-KA3

-B14

24V.C

24V.C 01

FIRE

DETECTION

T> P> P> P>

T> T> T> T>

-KM1

-KT1

-KM1 -KM2

-KM13

-KM14

-KM10

-YV13

-YV14

-KM2 -KM11 -KM9 -YV11 -YV12 -KM20 -KE1 -KE2-KM12

-B53

P> P> P>P>

T> T> T>

-B54

-B43

-X1

151

-X1

152

-B83

-X1

160

-X1

154

-B44

-X1

-B63

-X1

-X2

307

-X2

308

-B64

-X1

161

-X1

162

-B84

-X1

155

-X1

155

-X1

155

-B73

-X1

156

-X1

157

-X1

-B74

12345678++ ++

10FC

10FH

A1A2

A2 A4

CLIMA TIC™ CONTROLLER OUTPUTS

Page 70

IOM / ROOF-TOP FLEXY™ Series - Page 69

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

DAD

-X4 196

-X4 197

-X4 24

FOLIO 3/18

FOLIO 4/8

-X4 23

-X4 39

-X4 48

-X4 47

07 08

5x20

500mAT

5x20

500mAT

6.3x23

100mAT

BBG

DIST.Cde

LEED

DETECTION REPORT

NPh

321321654981110

TCR+-+-

230V.J 230V.K

-KA3

195194

-E11 -B2

RS 232

J18

J22

RS232

J22

4 3 2 1

+ 0V RxD TxD

2345

3 2 1

+ 0V RxD TxD

RxD TxD

230V

230V PE

4 3 2 1

+ 0V RxD TxD

4 3 2 1

+ 0V RxD TxD

230V

RESISTANCE 1/4W 3,9 K ou 4,7 K

KP01 Units 2,3,4,5,6,7,8

KP01 Unit 1

DB9

Female

DB9 Male

RS 232/KP01 Interface

DB9 Female

Page 71

Page 70 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

KP07

936 937

QF70

0.5A

230VAC

CPU

CLIJ18

J22 J18

KP07 J22 KP07 J22

J22

RDTD

102

40VA

COM

12Vac

T.KP07

CPU

KP07

103

102

230

102

J10

KP01

TxD

RxD

TxD

RxD

J43

Customer supply 230V-50Hz-0.5A

TRANSFO.

KP07/KP01

INTERFACE

Page 72

IOM / ROOF-TOP FLEXY™ Series - Page 71

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

CL06.2

BMS

GND

RxD

2 3 5

J16

J15

J14

VRF1

0V OPTO

T2 T1

SW3

SW2 SW1

SW5

SW4

LD4

LD1

LD3

12 11 10

9 8

7 6

5 4 3 2 1

12 11 10

9 8

7 6

5 4 3 2 1

LD2

1 1

F1 5x20

TxD

GND

RxD TxD

RELAY SPST

12V 50mA

KP01KP01

J22 J22J18 J18

GND

RxD

TxD

RxD

TxD

RxD

TxD

RxD

TxD

SPEED CONFIGURATION THROUGH SW-SW2 SW1 2.3 2.3 1.2 1.2 SW2 2.3 1.2 2.3 1.2 SPEED 9600 4800 2400 1200

RS232 OR RS485 LINK CONFIGURATION SW3 1.2 2.3 SW4 1.2 2.3 SERIE RS485 RS232

RS232 SERIAL LINK :

RS232 link used for short distances. Only a master device may be connected to this link.

RS485 SERIAL LINK

Used for long distances (1000 meters maxi). Until 31 deviced may be connected (1 of them is the master)

F1 1A fuse J2 Memory size :

8K (position 1.2) 32 K (position 2.3)

J3 SUBD 9 points plug in connector - RS232 link J4 SUBD 9 points plug in connector - RS485 link J7 Phoenix 3 point plug in connector - 230V supply J14 4 point plug in connector - CLIMATIC™ link J15 ON OFF input 12 point plug in connector J16 ON OFF output 12 point plug in connector LD1 link 6V supply monitoring LED LD2 Dialogue monitoring LED LD3 Power fell monitoring LED LD4 5V supply monitoring LED SW1 Configuration vitesse (9600, 4800n 2400 ou 1200

bauds)

SW2 Speed configuration (9600, 4800n 2400 or 1200

bauds)

SW3 TxD Signal (RS232 configuration (position 2-3)/

RS485 (position 1-2)

SW4 RxD Signal (RS232 configuration (position 2-3)/

RS485 (position 1-2)

SW5 +10C converter (position 1-2) U7 CL06 program Eprom U9 Configuration Eprom

GTC

Page 73

Page 72 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

GTC

12V.H 12V.G

200mA

06 05

12V

+18V +18V

12V

RL1

Com No No No No No No No NoCom Com Com Com Com Com Com

RL2 RL3 RL4 RL5 RL6 RL7 RL8

J1J3

KP12.2

KP05

23+45+6 +87

Remote control stop

Remote control night

Remote control day

Load limit 50%

Disable heating

Disable cooling

Customer status

Comfort

setpoint

(4-20mA)

Filter alarm

Blower alarm

Compressor alarm

Gas heat alarm or

electric heat alarm

High temperature alarm

Low temperature alarm

Humidifier alarm

Customer control

Page 74

IOM / ROOF-TOP FLEXY™ Series - Page 73

G43x60 L = 700 mm

G43x60 L = 1010 mm

G43x60 L = 1200 mm

G30x80 L = 1315 mm

G60x80 L = 1160 mm

60x80 L = 895 mm

43x80 L = 680 mm

60x80 L = 895 mm

43x80 L = 330 mm

G60x80 L = 445 mm

43x80 L = 330 mm

G60x80 L = 1040 mm

G60x80 L = 100 mm

G60x80 L = 180 mm

G30x80 L = 150 mm

G43x60 L = 355 mm

G60x80 L = 505 mm

G60x80 L = 475 mm

-X6 -X4

-X1

-X2

-Z3

-Z2

-X3

-X4

-X1 -X2 -X3

KP17.1

FCA/FHA 050 FCK/FHK 050

FCA/FHA 060.......190

FCK/FHK 060.......190

FXA/FXK 035.......170

FXA/FXK 025.030

-QG

QQ QQQ 1

-K -K -K

-Z1

-A1 M11

-K

M1 M12 M9

11 12 9

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMSAMS

AMS

Bornier

Barette terre

Page 75

Page 74 - IOM / ROOF-TOP FLEXY™ Series

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMS lisAMS lis

AMS lis

t of itemSt of itemS

t of itemS

+A0 ......... CLIMATIC™ controller

+A1/+A2.. Condensing unit 1 / Condensing unit 2 +A3/+A4.. Condenser 1 / Condenser 2

-A1 .......... Démarreur progressif

-B1 .......... External air thermostat

-B2 .......... Smoke detection head

-B3 .......... RC circuit

-B4/B5..... Gas manifold ionisation sensor

-B6/-B7.... Gas manifold ignition electrode

-B11 ......... Water flow switch

-B13 ........ Clogged air filter pressure switch/air flow rate

-B14 ........ Hot water battery antifreeze thermostat

-B15 ........ Hot water battery antifreeze thermostat

-B16 ........ Fire thermostat

-B17/18 ... Gas manifold minimum gas pressure switch

-B19/20 ... Blower fan motor -MS1/-MS2 stoptherme

-B21/22 ... Gas manifold smoke extraction air pressure switch

-B23/24 ... Extraction fan motor -ME1/-ME2 stoptherme

-B25/26 ... Electric battery -E1/-E2 safety klixon

-B27 ........ Electric battery -E3 safety klixon

-B28 ........ Circulation pump -MP1 motor stoptherm

-B29/30 ... Gas manifold air flow rate safety klixon

-B31 ........ Water leak detection

-B32/33 ... Gas manifold flashback safety klixon

-B41/42 ... Compressor -MG1/-MG2 high pressure safety switch

-B43/44 ... Compressor -MG3/-MG4 high pressure safety switch

-B45/46 ... Gas manifold 1 / gas manifold 2 regulation klixon

-B51/52 ... Compressor -MG1/-MG2 low pressure safety switch

-B53/54 ... Compressor -MG3/-MG4 low pressure safety switch

-B61/62 ... Compressor -MG1/-MG2 high pressure control switch

-B63/64 ... Compressor -MG3/-MG4 high pressure control switch

-B71/72 ... Condenser -MC1/-MC2 fan motor stoptherme

-B73/74 ... Condenser -MC3/-MC4 fan motor stoptherme

-B81/82 ... Scroll compressor -MG1/-MG2 protection module

-B83/84 ... Scroll compressor -MG3/-MG4 protection module

-B91/92 ... Pressure switch 4 / 20ma compressor -MG1/-MG2

-B93/94 ... Pressure switch 4 / 20ma compressor -MG3/-MG4

BCD ........ Condenser coil

BEC......... Hot water coil

BEG ........ Chilled water

BEV......... Evaporator coil

-BG10 ..... Hygiene sensor

-BH10...... Regulation hygrometry sensor

-BH11 ...... External hygrometry sensor

-BT10 ...... Regulation temperature sensor

-BT11 ...... External temperature sensor

-BT12 ...... Blower temperature sensor

-BT13 ...... Chilled water temperature sensor

-BT14 ...... Condenser 1 speed regulation temperature sensor

-BT15 ...... Condenser 2 speed regulation temperature sensor

-BT16 ...... Water exchanger outlet antifreeze sensor

-BT21/22 . Compressor 1-2 antifrost temperature sensor

-BT23/24 . Compressor 3-4 antifrost temperature sensor

-BT91/92 . Defrost temperature sensor compressor 1-2

-BT93/94 . Defrost temperature sensor compressor 3-7

BTP1/2.... -MG1/-MG2 compressor accumulator

BTP 3/4 ... -MG3/-MG4 compressor accumulator

CL06.2 .... JBUS

DT ........... Thermostatic expansion valve

EEH......... Horizontal water heat exchanger

EEV......... Vertical water heat exhanger

-E1/2 ....... Heater -E1/E2

-E3 .......... Heater -E3

-E4 .......... Humidificateur -E4

-E7/8 ....... Hot water coil antifreeze radiant strip heater

-E9/10 ..... Antifreeze heater

-E11......... Smoke detector printed circuit

-E12 ........ Humidifier -E4 electrodes

-E13 ........ Water leak electrode

-E14 ........ Burner control box

-E15 ........ Steam humidifier -E4 printed circuit

-E16 ........ Steam humidifier -E4 printed circuit 0/10V

-E20 ........ CPU card KP01

-E21 ........ On Off input card KP03

-E22 ........ On Off output card KP08.1

-E23 ........ Analog output card KP04.1

-E24 ........ Analog output card KP04.2

-E25 ........ Analog output card KP04.3

-E26 ........ Analog output card KP04.4

-E27 ........ On Off output card KP08.2

-E28 ........ Input card 4/20mA KP05.1

-E29.1.2 .. Input output card KP12

-E30 ........ Digital console KP02

-E31 ........ Digital console KP17

-E51/52 ... Compressor -MG1/-MG2 crankcase heater

-E53/54 ... Compressor -MG3/-MG4 crankcase heater

FCO ........ Water circuit filter

FD ........... Drier filter

FDB......... Receiver dehumidifier filter

FDW........ Double flow dehumidifier filter

-F1........... Secondary circuit -T1 128VA / 24V protection fuse

-F2........... Secondary circuit -T1 30VA / 12V protection fuse

-F3........... Secondary circuit -T1 6VA / 12V protection fuse

-F4........... Secondary circuit -T1 36VA / 24V protection fuse

-KA31/32. Gas burner fault relay

-KA41/42. Gas burner fault relay

-KA3........ Smoke fault relay

-KA4........ Low speed/high speed relay

-KE1/2..... Heater -E1/-E2 contactor

-KE3........ Heater -E3 contactor

-KE4........ Steam humidifier contactor E4

-KM1/2 .... Blower fan motor -MS1/-MS2 contactor

-KM3 ....... Blower fan motor low speed contactor

-KM4 ....... Star coupling contactor

-KM5/6 .... Extraction fan motor -ME1/-ME2 contactor

-KM7 ....... Extraction fan motor low speed contactor

-KM8 ....... Star coupling contactor

-KM9/10 .. Condenser 1 / condenser 2 fan motor contactor

-KM11/12 . Compressor -MG1/-MG2 contactor

-KM13/14 Compressor -MG3/-MG4 contactor

-KM15 ..... Condenser 2 fan motor contactor

-KM20 ..... -MP1 circulating pump contactor

-KM21/22 Gas manifold 1 - gas manifold 2 contactor

-KT1 ........ Timing replay

-MC1/2 .... Condenser -MC1/-MC2 fan motor

-MC3/4 .... Condenser -MC3/-MC4 fan motor

-ME1/2 .... Extraction fan motor -ME1/-ME2

-ME3/4 .... Extraction fan motor -ME3/-ME4

-MG1/2 .... Compressor -MG1/-MG2

-MG3/4 .... Compressor MG3/MG4

-MP1 ....... Circulating pump motor

-MR1 ....... Economiser damper motor

-MR2 ....... Blower damper motor

-MR3 ....... Fresh air damper motor

-MR4 ....... Extraction damper motor

-MR5 ....... Recycled air damper motor

-MR6 ....... Distribution air damper motor

-MS1/2 .... Blower fan motor -MS1/-MS2

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IOM / ROOF-TOP FLEXY™ Series - Page 75

-Q1/2 ....... Blower fan motor -MS1/-MS2 protection

-Q5 .......... Extraction fan motor -ME1/-ME2 protection

-Q9 .......... Condenser -MC1/-MC2 fan motor protection

-Q10 ........ Condenser -MC3/-MC4 fan motor protection

-Q11/12 ... Compressor -MG1/-MG2 protection

-Q13/14 ... Compressor -MG3/-MG4 protection

-Q15 ........ Condenser -MC2 fan motor protection

-Q20 ........ Circulating pump protection -MP1

-Q25 ........ Crankcase heater protection

QCC ........ Quick release coupling

-QF1........ Primary circuit protection -T1

-QF2........ Primary circuit protection -T3

-QF3........ Secondary circuit protection -T3

-QF4........ Primary circuit protection -T4

-QG ......... Main switch

-QG1/2 .... Condenser 1 / condenser 2 main switch

-QE1/2 .... Heater -E1/-E2 protection

-QE3........ Heater -E3 protection

-QE4........ Steam humidifier protection -E4

-RL .......... Liquid receiver

-SAT ........ Shut-off valve

-SA1 ........ Humidifier -E4 ON/OFF switch

-SA2 ........ Humidifier -E4 drain switch

ELECTRICAL WIRING DIAGRELECTRICAL WIRING DIAGR

ELECTRICAL WIRING DIAGR

AMS lisAMS lis

AMS lis

t of itemSt of itemS

t of itemS

-SB1 ........ Emergency stop

-T1 ........... Control circuit transformer 400V/24V/12V/12V/230V

-T3........... Burner power supply transformer 400V / 230V

-TI4.......... Power supply transformer humidifer -E4

UF ........... Cooling unit

UT ........... Air handling unit

U1 ........... Interface

VAM ........ Manual shut-off valve

VL............ Liquid indicator

VRM ........ Manual control valve

-V1 .......... Electric battery static contactor

-V2 .......... Electric battery static contactor

-V2VP ..... Pressure switched 2-way valve

-V3VP ..... Pressure switched 3-way valve

-Y1 .......... Gas manifold N1 reset electromagnet

-Y2 .......... Gas manofold N2 reset electromagnet

-YR .......... Loading humidifier electrovalve -E4

-YV .......... Draining humidifier electrovalve -E4

-YV1 ........ Chilled water 3-way valve

-YV2 ........ Hot water 3-way valve

-YV11/12 . Compressor -MG1/-MG2 cycle reversal valve

-YV13/14. Compressor -MG3/-MG4 cycle reversal valve

-YV31/32. Burner gas solenoid valve

-YV41/42. Gas manifold safety solenoid valve

-YV51/52. Gas manifold main solenoid valve

-YV61 ...... Compressor -MG1 hot gas injection solenoid valve

-YV71/72. Compressor -MG1/-MG2 liquid solenoid valve

Z* ............ Capacity resistance circuit

Links to be made by installer

-X4

-X5

-X1

-X2

-X3

Screened cable mark

-Fil 0.5 mm²

Smoke detection terminal strip Auxiliary terminal strip

Main terminal strip

Terminal strip/customer connection

CAUTION

All the contacters and coils contacted on site having a CLIMATIC™ input must be fitted with a RC circuit.

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Page 76 - IOM / ROOF-TOP FLEXY™ Series

SAFETY AND ERROR CODES

000 No error

001 Failure air flow 004 Dirty filters 005 Missing filters 011 Faulty electrical heater batteries 012 Supply air overtemperature 013 Temperature too low 014 Faulty gas burner no. 1 015 Faulty gas burner no. 2 022 Supply temperature too low 023 Room overtemperature 031 Faulty humidifier 032 Room humidity too low 033 Room overtemperature 041 Faulty pump 081 Faulty return air or room temperature sensor 082 Faulty return air or room relative humidity sensor 083 Faulty outside temperature sensor 084 Faulty outside relative humidity sensor 085 Faulty supply air temperature sensor 086 Faulty cold water loop temperature sensor 087 Faulty water condenser outlet temperature sensor 091 Faulty blower fan 092 Faulty condenser : system 1 or 2 093 Faulty condenser : system 3 or 4 094 Customer error 095 Water leak 096 Condenser water temperature too low 097 Condenser water overtemperature 098 Faulty water flow 099 Error : smoke 111 Faulty condensation temperature sensor no. 1 112 Faulty pressure transmitter no. 1 113 Faulty frost power temperature sensor no. 1 115 Faulty high pressure or faulty electrical compressor no. 1 117 Faulty low pressure compressor no. 1 121 Faulty condenser temperature sensor no. 2 122 Faulty pressure transmitter no. 2 123 Faulty frost temperature sensor no. 2 125 Faulty high pressure or faulty electrical power compressor no. 2 127 Faulty low pressure compressor no. 2 131 Faulty condenser temperature sensor no. 3 132 Faulty pressure transmitter no. 3 133 Faulty frost temperature sensor no. 3 135 Faulty high pressure or faulty electrical power compressor no. 3 137 Faulty low pressure compressor no. 3 141 Faulty condenser temperature sensor no. 4 142 Faulty pressure transmitter no. 4 143 Faulty frost temperature sensor no. 4 145 Faulty high pressure or faulty electrical power compressor no. 4 147 Faulty low pressure compressor no. 4

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IOM / ROOF-TOP FLEXY™ Series - Page 77

The following text includes references such as [C11] and [V25]. They relate to the threshold or variable numbers used with the KP02 unit.

Wrong Air Flow

If the pressure differential obtained by the analog sensor [V16] is less than the setpoint value [C92] for more than 20 seconds, and if the blower fan has operated for more than 1 minute 30

seconds, the air flow safety system is activated and stops the ventilation. The air flow safety system automatically stops after 1 minute 30 seconds and is automatically locked out after 3 cut-outs in the same day. In this case a manual reset is obligatory. The cutout counter is reset to zero every evening at 20:00 if the value does not exceed 3 failures.

Dirty Filters

If the pressure differential obtained by the analog sensor [V16] is greater than the setpoint value [C93] for more than one minute, the CLIMATIC™ indicates that the filters are dirty. The unit is not stopped.

Missing Filters

If the pressure differential obtained by the analog sensor [V16] is less than the setpoint value [C94] for more than one minute, the CLIMATIC™ indicates that the filters are missing. The unit

is not stopped.

SUPPLY AIR TEMPERA TURE SAFETY SYSTEM

Supply Air Overtemperature Limit

1st Safety Level

If the supply air temperature is greater than or equal to the setpoint [C74], the heat control system starts to reduce progressively. The control cycle will recommence normal operation for a temperature lower than 3°C below this setpoint.

2nd Safety Level

If the supply air temperature is greater than or equal to the setpoint [C75], the safety system is activated. The safety system automatically stops at a temperature lower than 3°C below this setpoint.

Supply Air Temperature Too Low

1st Safety Level

If the supply air temperature is greater than or equal to the setpoint [C71], the cold control system starts to reduce progressively. The control cycle will recommence normal operation for a temperature in excess of 3°C above this setpoint.

2nd Safety Level

If the supply air temperature is less than or equal to the setpoint [C72], the unit automatically positions its fresh air damper to the all air recycled position and cuts out cold production. This safety level automatically stops at a temperature in excess of 3°C above this setpoint.

3rd Safety Level

If the supply air temperature is less than or equal to the setpoint [C73] for more than 15 minutes and for 15 minutes after the fan has started, the "supply air temperature too low" safety system is activated. The unit shuts down completely. This safety system cuts out if the supply air temperature is greater than 3°C above this setpoint. It is automatically maintained after 3 cut-outs in the same day, and in this case a manual reset is obligatory. The cut-out counter is reset to zero every evening at 20:00 if the value does not exceed 3 failures.

NOTE : If a unit has a hot water battery, the temperature setpoint value is fixed at +6°C and the

SAFETY AND ERROR CODES

001

004

005

012

022

Page 79

Page 78 - IOM / ROOF-TOP FLEXY™ Series

041

register time set to 5 seconds. In addition, if the antifreeze thermostat is opened, the 3rd safety level is immediately automatically maintained. In this case, manual resetting of the thermostat followed by the CLIMATIC™ is obligatory

Room Overtemperature Safety System

Upper Room Air Limit

If the room temperature is greater than or equal to the setpoint [C41], the safety system is activated. It automatically cuts out at a temperature lower than 3°C below this setpoint.

Lower Room Air Limit

If the room temperature is less than or equal to the setpoint [C40], the safety system is activate

Faulty Electrical Heater Batteries

The electrical heater battery safety thermostats act directly on the heater stage contactors. This information is fed to the CLIMATIC™ via auxiliary contacts. If the CLIMATIC™ gives the order to the heater to operate and if 5 seconds later the auxiliary contact is still open, the heat safety system is activated and stops the electrical heater assembly. This safety system is automatically locked-out. In this case a manual reset is obligatory. Note: This fault is also displayed in the event of a contact "shunt".

Faulty Gas Burners

If there is a fault with the gas control boxes the heat safety system is activated and stops the respective burner. This safety system automatically cuts out on the CLIMATIC™ and the control unit must be manually reset.

Faulty Humidifier (Flexy Only)

If there is a fault with the gas control unit for more than a minute, the safety system is activated and stops the humidifier. This safety system is automatically locked-out. In this case a manual reset is obligatory.

Room Humidity Safety System

Lower Room Limit

If the room humidity is less than or equal to the setpoint [C42] or [C44], the safety system is activated. It automatically cuts out at a humidity of 3% above this setpoint.

Upper Room Limit

If the room humidity is greater than or equal to the setpoint [C43] or [C45], the safety system is activated. It automatically cuts out at a humidity of 3% below this setpoint.

Faulty Pump

The internal protection of the water pump motor acts directly on the pump contactor. This information is transmitted to the CLIMATIC™ via an auxiliary contact of the contactor. If the CLIMATIC™ gives the pump the order to operate and if 5 seconds later the auxiliary contact remains open, the safety system is activated and stops the pump. The safety system is immediately automatically locked out. In this case, manual resetting is obligatory. Note: This error is also displayed in the event of a "shunt" of the auxiliary contact of the contactor.

SAFETY AND ERROR CODES

023

013

011

031

014 015

032

033

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IOM / ROOF-TOP FLEXY™ Series - Page 79

Sensor Status

Room temperature sensor missing or faulty.

Room relative humidity sensor missing or faulty

Outside air temperature sensor faulty

Outside relative humidity sensor faulty

Supply Air temperature sensor faulty

Temperature sensor on cold water loop faulty

Temperature sensor on condenser water outlet faulty.

NOTE :

Missing or faulty room, supply air or outside air temperature sensors can affect the overall control system. A safety device will be activated and all equipment except for the ventilation will cut out. Failure of the other sensors will only stop the equipment involved.

Faulty inter card link

The inter card link is faulty or missing.

Faulty blower fan

The fan contactor is not connected although the CLIMATIC™ requests it.

- The thermostat fire safety mechanism, or the fire insertion, is open.

- The internal protection of the blower fan motor is open.

The fire detector and the fan motor internal protection act directly on the fan motor contactor. This information is transmitted to the CLIMATIC™ via an auxiliary contact of the contactor. If the CLIMATIC™ gives the order to operate to the fan and if the auxiliary contact is still open 5 seconds later, the fan safety system is activated and stops the unit. The safety system is immediately automatically locked out. In this case, manual resetting is obligatory. If a unit is fitted with an all-or-nothing servomotor-powered damper, the detection time extends to 2 minutes (Flexy™ only). Note : This error is also displayed in the event of a "shunt" of the auxiliary contact of the contactor.

Faulty ventilation, condenser circuit 1 or 2

The fan contactor is not connected although the CLIMATIC™ requests it. The fan motor internal protection acts directly on the fan motor contactor. This information is transmitted to the CLIMATIC™ via an auxiliary contact of the contactor. If the CLIMATIC™ gives the order to operate to the fan and if the auxiliary contact is still open 5 seconds later, the fan safety system is activated and stops the condenser fan and the compressors concerned. The safety system is immediately automatically locked out. In this case, manual resetting is obligatory.

Faulty ventilation, condenser circuit 3 or 4

The fan contactor is not connected although the CLIMATIC™ requests it. The fan motor internal protection acts directly on the fan motor contactor. This information is transmitted to the CLIMATIC™ via an auxiliary contact of the contactor. If the CLIMATIC™ gives the order to operate to the fan and if the auxiliary contact is still open 5 seconds later, the fan safety system is activated and stops the condenser fan and the compressors concerned. The safety system is immediately automatically setpoint. In this case, manual resetting is obligatory.

089

SAFETY AND ERROR CODES

081

082

083

084

085

086

087

091

092

093

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Page 80 - IOM / ROOF-TOP FLEXY™ Series

Customer error

A fault has been detected, external to the unit.

Water leak

If the contact of the water leak detection card is closed for more than 30 seconds, the safety system is activated.

W ATER HEA T EXCHANGER OUTLET TEMPERATURE SAFETY SYSTEM.

Condenser Water Temperature Too Low

If the temperature of the water loop is less than or equal to the preset setpoint [C89] during the operation of one of the compressors, the condenser safety mechanism is applied. The compressors are stopped. This safety mechanism automatically cuts out if the loop temperature exceeds 4°C from this setpoint. It is also automatically locked out after 3 failures within a day. In this case, manual resetting is obligatory. The counter is reset to zero every evening at 20:00 if its value does not exceed 3 failures.

Condenser Water Temperature Too High

The temperature of the water loop is greater than or equal to the preset setpoint [C90] during the operation of one of the compressors, the condenser safety mechanism is applied. The compressors are stopped. This safety mechanism automatically cuts out if the loop temperature is less than 4°C from this setpoint. It is also automatically locked out after 3 failures within a day. In this case, manual resetting is obligatory. The counter is reset to zero every evening at 20:00 if its value does not exceed 3 failures.

Faulty Water Flow

If the contact of the water flow controller is open for more than 20 seconds, the condenser safety mechanism is applied. The compressors are stopped. This safety mechanism automatically cuts out if the loop temperature is less than 4°C from this setpoint. It is also automatically locked out after 3 failures within a day. In this case, manual resetting is obligatory. The meter is reset to zero every evening at 20:00 if its value does not exceed 3 failures.

Error : Smoke

If the contact closes due to the smoke detector card, the smoke safety mechanism is activated. The unit is completely shut down and the fresh air louver is set to the fresh air position. This safety mechanism is automaticallylocked out. In this case, manual resetting is obligatory.

SAFETY AND ERROR CODES

094

095

096

098

099

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IOM / ROOF-TOP FLEXY™ Series - Page 81

Refrigeration system faults

Faulty condenser temperature sensor

Faulty pressure transmitter sensor, refrigeration system

Faulty refrigeration system, frost temperature sensor

High pressure switch safety or compressor electrical safety

The compressor contactor is not connected although the CLIMATIC™ requests it.

- The high pressure pressostat is open.

- The internal protection of the compressor motor is open.

The high pressure pressostat and the compressor motor thermal protection act directly on the compressor contactor. This information is transmitted to the CLIMATIC™ via an auxiliary contact of the contactor. If the CLIMATIC™ gives the order to operate to the compressor and if the auxiliary contact is still open 5 seconds later, the fan safety system is activated and stops the compressor.The safety system automatically cuts out after 4 minutes. It is also automatically locked out after 3 failures within a day. In this case, manual resetting is obligatory. The counter is reset to zero every evening at 20:00 if its value does not exceed 3 failures.

Faulty low pressure compressor

If the low pressure pressostat is open and the compressor has been operating for more than 2 minutes, the low pressure safety system is activated and stops the compressor. This safety system is not taken into account during the defrost cycle for the heat pump units. The compressor is engaged when the pressostat contact closes. It is also automatically locked out after 3 failures within a day. In this case, manual resetting is obligatory. The counter is reset to zero every evening at 20:00 if its value does not exceed 3 failures.

SAFETY AND ERROR CODES

111 121 131 141

112 122 132 142

113 123 133 143

115

125 135 145

117

127

137

147

Page 83

Page 82 - IOM / ROOF-TOP FLEXY™ Series

Before Calling for Assistence

- The network voltage should not vary from + or - 10 % of the supply required for the equipment,

- The supply variation between the phases should never exceed + or - 3 %.

1. Check that there is current in the electrical panel,

2. Check that the filters are not clogged,

3. Make sure the fans are in good working order (belts

tensioned, etc...),

4. Test the operation of the compressor(s),

5. If the equipment is fitted with an electrical reset safety

mechanism, reset it and test to see if the fault reoccurs. If so, have the following checks performed by trained personnel.

MAIN OPERA TING F AULTS

No Air Flow (blower side)

Problem :

- Low performance.

- Danger of one or more compressors cutting out (low pressure switch cutout).

- Danger of evaporator freezing.

- Possible cutout of the electrical heaters safety thermostat.

Cause :

- The blow sleeve assemblies drop their load excessively (sleeves too small, closed valves, obstacle).

- Blocked filters or coils.

- Wrongly tensioned or brocken belts.

Solution :

- Check the sleeve assemblies.

- Check the filters, coils and service them, if necessary.

- Check the belts, re-tension or replace them, if necessary.

No Air Flow (condenser side)

Problem :

- Compressor cutout (high pressure switches).

Cause :

- Dirty coils.

- One or more fans do not work properly.

Solution :

- Clean the coil.

- Change one of more faulty fans.

Fan stops following thermal relay cutout (indicated via an error code)

Problem :

- The fan and the compressors are not working.

Cause :

- Drive absorbed power too high:

• Air flow too high.

• Belts over tensioned.

• Bearing seized.

• Phase Lost

• Supply voltage too low or unbalanced phases (+/-

3%).

Solution :

- Reset the thermal relay. If the error recurs:

• Check the thermal relay setting (it must correspond to

the rated current shown on the drive plate).

• Check the flow, belts and bearings.

• Check the supply voltage.

Stopping compressor (indicated via an error code)

Problem :

- Thermal or freezing process drops or stops,

Causes :

- The compressor absorbs very high current (very hot air on the evaporator and condenser inlet, missing flow, voltage too low or unbalanced phases (+/- 3%).

- The compressor is manually out of action.

- The coil thermal safety is open.

- The compressor is powered by two phases instead of three.

Solution :

- Try to restart when the compressor is cold. If the fault recurs:

• Check the air flows (see lack of air flow).

• Check that the fans are working properly and the

outer heat exchangers are clean.

• Check the supply voltage.

• If the compressor is manually out of action, replace it.

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IOM / ROOF-TOP FLEXY™ Series - Page 83

Before Calling for Assistence

The unit no longer works

Cause :

- No supply voltage.

- Ruptured remote control fuses.

- Wrong connections.

Solution :

- Check the supply voltage.

- Check the fuses.

- Check and tighten the connections.

The fan rotates but the compressor does not work

Problem :

- The air rerun conditions are not followed.

Cause :

- The control does not engage the compressor(s), a pressure switch has tripped.

- The drive of the compressor(s) is out of action.

Solution :

- Check the control supply voltage.

- Check the connections.

- Reset the pressure switches (electrical control only).

- Check the compressor supply voltage.

- See previous sections.

Refrigerant fluid level too low

Problem :

- Evaporator partly frozen.

- Low pressure switch cutout.

Cause:

- Refrigerant liquid leak.

Action:

- Search for leaks, repair if necessary and add some refrigerant liquid.

The electrical heater battery is not powered

Problem :

- Variable temperatures,

Cause :

- One or more fuses are ruptured.

- The safety thermostat is open (temperature is too high due to insufficient air flow),

Solution :

- Check the electrical supply and fuses.

- Check the ohmic values.

- Reset the safety thermostat and check the air flow (first section)

Page 85

Page 84 - IOM / ROOF-TOP FLEXY™ Series

PLANNED MAINTENANCE

Regular maintenance of your Rooftop will extend its operating life and reduce operating faults. We recommend that the unit is serviced by a trained refrigeration engineer. A log book kept near the equipment detailing work carried out, by whom and when, is an excellent diagnostic tool.

The panel opening key is required for this work (see “TRANSPORT”).

MOTOR-F AN ASSEMBL Y

After 50 operating hours check the belt tension and the pulley screws for tightness. Repeat this check every two months. The fans contain bearings that are "lubricated for life", but we recommend replacing them every 10,000 operating hours. During this inspection, check the condition of the anti-vibration mounts, by looking for any cracks or signs of abnormal wear.

FILTERS

The filters fitted as standard are manufactured with a washable and recyclable material. The CLIMATIC™ indicates if they are blocked. The cleaning schedule is directly related to the environment in which the equipment is operated. However, monthly cleaning is recommended. A blocked filter will reduce the performance and reliability of the Rooftop. After removing the filters, remove any dust and wash them in a tepid water solution with a little liquid detergent. After rinsing in fresh water, leave the filters to dry. Take all necessary precautions during operation to avoid damaging or piercing the media, as this would require the damaged cell to be replaced.

NOTE : The equipment must never be operated with the filters removed.

To avoid prolonged shutdown, always keep a spare filter set.

HEA T EXCHANGERS

The performance of your equipment is directly linked to the state of the heat exchangers, and it is therefore important to ensure that they are cleaned regularly.

EV APORA T OR COIL (INTERNAL)

The exchange area must be kept clean at all times. It is protected by the filters. If the filters are well maintained, the coil will only require occasional general cleaning. A brief inspection should be carried out when servicing the filters.

CONDENSER COIL (EXTERNAL)

The condenser coil is not protected by the filters. The cleaning schedule is directly related to the environment in which the equipment is operated. A brief inspection should be carried out when servicing the machine. Cleaning can be performed using compressed air or a soft brush. Maximum caution is needed as the aluminium fins are relatively fragile. However, this type of cleaning is sometimes difficult and relatively ineffective because the clogging is caused by a

mixture of grease vapour and powder. For this reason we would recommend cleaning with PRESTOSOL, a de-greasing agent with very low toxicity, non-flammable and which does not corrode standard metals. As a rule, it is sufficient to apply the product to the fins, moving up and down and from left to right (as if you were painting it). If the coil is very blocked, it may be necessary to wait a few minutes after first applying the product and then continue. This cleaning must be performed when the machine is switched off. In addition, prior to restarting the machine, we recommend waiting until the coil is fully drained and the solvent has totally evaporated.

HOT W ATER COIL

At the start of the heating season, check the following :

- There is sufficient water in the system

- The coil has been correctly drained

- The percentage of antifreeze proportion is sufficient for the degree of protection required.

CONDENSA TE TRAY AND DRAIN TRAP

The trag must be free of sediment and dirt which could block the movement of condensation. Check that the siphon is not obstructed. This inspection must be carried out at least once a year, preferably at the start of the air-conditioning season.

GAS BURNER

Once a year, before the heating season, clean the burners and the exchanger pipes using a nylon brush, the smoke box and the extraction fan. Check that the air inlet pipe to the safety thermostats is not obstructed. Check and adjust if necessary the min./max. pressure settings on the controllers. Check the position of the ionisation sensors and check the ignition electrode. To disassemble the burner, refer to the "GAS BURNER" section.

ELECTRICAL TERMINALS

At least once a year :

- Power down the machine, blow away any dust from inside the unit, and check and tighten if necessary the connections.

- Power up the machine, test the safety mechanisms.

- An analysis of the terminal in operating mode can throw light on any strange noises from the contactors or other units. Foreign bodies can disrupt the operation of the components and causes noisy vibration.

To avoid accidents, remember that this type of maintenance requires electrical expertise.

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IOM / ROOF-TOP FLEXY™ Series - Page 85

PLANNED MAINTENANCE

REFRIGERA TION CIRCUITS

At least once a year, carry out an in-depth inspection of the refrigerant circuits. In addition, before each season (or every 3 months if used permanently) the tasks listed in the maintenance contract must be performed, i.e. check the refrigerant charge, evaporation and condensing temperatures etc...

This work must be carried out by a trained refrigeration engineer. We shall therefore keep the details of the work and the type of checks to be performed to a minimum.

IN ACCORDANCE WITH THE LAW

REFRIGERATION FLUIDS MUST BE COLLECTED.

DEGASSING INTO THE A TMOSPHERE IS

FORBIDDEN.

REFRIGERANT CHARGES valid for R407c and R22

Gamme FC/FH/FG/FD Gamme FX

Size Nbr of circuits kg Size Nbr of circuits kg

50 1925 22 x 4

60 27 + 730 22 x 4 70 2 8,5 + 8,5 35 22 x 5

85 2 13 + 13 40 22 x 6 100 2 13 + 13 55 22 x 6 120 2 + 1 ( 8 + 7,5 ) + 11 70 2 2 x 10 140 2 + 1 (9 + 9) + 11 85 2 2 x 11 160 4 4 x 11 100 2 2 x 12 190 4 4 x 11 110 44 x 7

140 4 4 x 7,5

170 4 4 x 8,5

Page 87

Page 86 - IOM / ROOF-TOP FLEXY™ Series

PLANNED MAINTENANCE

GENERAL

At least once a year after winter the equipment casing must be cleaned, inspected and if necessary treated for corrosion.

The equipment casing is made of aluminium-zinc plate, with a polyester finish and oven-treated powder, and is ultra-violet resistant. The assembly is fixed with stainless steel rivets. Any corrosion can only be caused by scratches incurred on assembly or during maintenance of the Rooftop.

MAINTENANCE SCHEDULE

NOTE :

6 monthly maintenance is performed when changing from the heating season to the air-conditioning season and vice-versa. Annual maintenance is performed just before the start of the air-conditioning season or the heating season, depending on the unit.

After 2 3 6 Annually

50 hours months months months

Fan motor assembly X Gas burner X Terminal unit X

Air-conditioning only

Filters and internal coil X External coil X Hot water coil X Condensate tray X Refrigerant system X

Permanent operation

Filters and internal coil X External coil X Condensate tray X Refrigerant system X

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IOM / ROOF-TOP FLEXY™ Series - Page 87

WARRANTY

TERMS AND CONDITIONS

In the absence of any other written agreement, the guarantee shall only apply to design faults which occur within a 12 month period (warranty period).

The warranty period starts on the date of commissioning and at the latest six months after the delivery of the Rooftop.

ANTI-CORROSION WARRANTY

10 year warranty terms and conditions for corrosion to the Rooftop casing :

Lennox shall guarantee the casing of its Rooftop units manufactured since May 1991 against corrosion for 10 years commencing from the date of delivery of the material.

The warranty shall not apply in the following cases :

1. If the corrosion of the casing is caused by external damage to the protective layer such as scratches, projections, abrasion, impacts etc...

2. If the casing is not kept continually clean in the course of maintenance work or by a specialist company,

3. If the casing is not cleaned and maintained in accordance with regulations,

4. If the Rooftop units are installed on a site or in an environment which is known to be corrosive, unless a special protective coating has been applied by the owner for these applications, which has been recommended by a competent body not linked to the owner and after carrying out a study of the site.

Note : With the exception of the casing, the rest of the machine is covered by the warranty of our general terms of sale.

DO NOT CONFUSE THE W ARRANTY WITH MAINTENANCE

The warranty will only apply if a maintenance contract has been signed, starting from the date of commissioning, and if the maintenance contract has actually been performed.

The maintenance contract must be made with a specialist,

competent company. The sole effect of any repair, modification or replacement of

an item during the warranty period must be to extend the material's warranty period.

Maintenance must be carried out in accordance with regulations.

If a spare part is supplied after the expiry of the warranty period, it shall be guaranteed for a period equal to the initial warranty period and will be subject to the same conditions.

We recommend for a contract four inspections per year (every three months), before the start of each season, in order to check the operation of the equipment in the various operating modes.

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Page 88 - IOM / ROOF-TOP FLEXY™ Series

ISO 9001 CERTIFICAISO 9001 CERTIFICA

ISO 9001 CERTIFICA

TIONTION

TION

Page 90

IOM / ROOF-TOP FLEXY™ Series - Page 89

CE CERTIFICACE CERTIFICA

CE CERTIFICA

TION OF CONFORMITYTION OF CONFORMITY

TION OF CONFORMITY

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Page 90 - IOM / ROOF-TOP FLEXY™ Series

EU4 FILEU4 FIL

EU4 FIL

TER FIRE CLASSTER FIRE CLASS

TER FIRE CLASS

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IOM / ROOF-TOP FLEXY™ Series - Page 91

33 kW GAS BURNER CE CERTIFICA33 kW GAS BURNER CE CERTIFICA

33 kW GAS BURNER CE CERTIFICA

TION OF CONFORMITYTION OF CONFORMITY

TION OF CONFORMITY

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Page 92 - IOM / ROOF-TOP FLEXY™ Series

60 kW GAS BURNER CE CERTIFICA60 kW GAS BURNER CE CERTIFICA

60 kW GAS BURNER CE CERTIFICA

TION OF CONFORMITYTION OF CONFORMITY

TION OF CONFORMITY

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IOM / ROOF-TOP FLEXY™ Series - Page 93

120 kW GAS BURNER CE CERTIFICA120 kW GAS BURNER CE CERTIFICA

120 kW GAS BURNER CE CERTIFICA

TION OF CONFORMITYTION OF CONFORMITY

TION OF CONFORMITY

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Page 94 - IOM / ROOF-TOP FLEXY™ Series

180 kW GAS BURNER CE CERTIFICA180 kW GAS BURNER CE CERTIFICA

180 kW GAS BURNER CE CERTIFICA

TION OF CONFORMITYTION OF CONFORMITY

TION OF CONFORMITY

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IOM / ROOF-TOP FLEXY™ Series - Page 95

INSULAINSULA

INSULA

TION FIRE CLASSTION FIRE CLASS

TION FIRE CLASS

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Page 96 - IOM / ROOF-TOP FLEXY™ Series

INSULAINSULA

INSULA

TION FIRE CLASSTION FIRE CLASS

TION FIRE CLASS

Page 98

IOM / ROOF-TOP FLEXY™ Series - Page 97

INSULAINSULA

INSULA

TION FIRE CLASSTION FIRE CLASS

TION FIRE CLASS

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Page 98 - IOM / ROOF-TOP FLEXY™ Series

INSULAINSULA

INSULA

TION FIRE CLASSTION FIRE CLASS

TION FIRE CLASS

Page 100

www.Lennox.com

LENNOX INDUSTRIES LTD

tél. : + 44 1604 599400 fax : + 44 1604 594200 e-mail : marketing@lennoxind.com

LENNOX BENELUX N.V./S.A.

tel. : + 32 3 633 30 45 fax : + 32 3 633 00 89 e-mail : info.be@lennoxbenelux.com

JANKA RADOTIN AS

tel. : + 420 2 510 88 111 fax : + 420 2 579 10 393 e-mail : janka@janka.cz

LENNOX FRANCE

tel. : + 33 4 72 23 20 20 fax : + 33 4 78 20 07 76 e-mail : accueil@lennoxfrance.com

LENNOX DEUTSCHLAND GmbH

tel. : + 49 69 42 09 79 0 fax : + 49 69 42 09 79 40 e-mail : info.de@lennoxdeutschland.com

LENNOX BENELUX B.V.

tel. : + 31 33 2471 800 fax : + 31 33 2459 220 e-mail : info@lennoxbenelux.com

LENNOX POLSKA Sp. z o. o.

tel. : + 48 22 832 26 61 fax : + 48 22 832 26 62 e-mail : lennoxpolska@inetia.pl

LENNOX CLIMATIZAÇAO LDA.

tel. : +351 22 999 84 60 fax : +351 22 999 84 68 e-mail : info@lennoxportugal.com

LENNOX DISTRIBUTION MOSCOW

tel. : + 7 095 246 07 46 fax : + 7 502 933 29 55 e-mail : lennox.dist.moscow@mtu-net.ru

LENNOX SLOVAKIA

tel. : + 421 7 44 87 19 27 fax : + 421 7 44 88 64 72

LENNOX REFAC S.A.

tel. : + 34 902 400 405 fax : + 34 91 542 84 04 e-mail : marketing@lennox-refac.com

LENNOX DISTRIBUTION KIEV

tel. : + 380 44 213 14 21 fax : + 380 44 213 14 21 e-mail : jankauk@uct.kiev.ua

LENNOX DISTRIBUTION

tel. : + 33 4 72 23 20 14 fax : + 33 4 72 23 20 28 e-mail : marketing@lennoxdist.com

GREAT BRITAIN ,

IRELAND :

BELGIUM :

CZECH REPUBLIC :

FRANCE :

GERMANY :

NETHERLANDS :

POLAND :

PORTUGAL :

RUSSIA :

SLOVAKIA :

SPAIN :

UKRAINE :

OTHER EUROPEAN COUNTRIES,

AFRICA,

MIDDLE-EAST :

IOM_RTF_0901-E

Lennox FCA 50, FCA 60, FCA 85, FCA 70, FCA 100 Installation Operating & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual