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

INSTALLATION
OPERATING &
MAINTENANCE MANUAL

ROOFTOP
FLEXY

English
Sept 2001

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

Page 2 - IOM / ROOF-TOP FLEXY™ Series

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

IOM / ROOF-TOP FLEXY™ Series - Page 3

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.

V

V

A

Hz

FCK 190

2000

215 900-01/01

400 3 50

140 269

24

111111 11

R407C

Page 4 - IOM / ROOF-TOP FLEXY™ Series

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

IOM / ROOF-TOP FLEXY™ Series - Page 5

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

Page 6 - IOM / ROOF-TOP FLEXY™ Series

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

mm

for angle = 45°C

IOM / ROOF-TOP FLEXY™ Series - Page 7

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

Page 8 - IOM / ROOF-TOP FLEXY™ Series

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

IOM / ROOF-TOP FLEXY™ Series - Page 9

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

Page 10 - IOM / ROOF-TOP FLEXY™ Series

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

INSINS

INS

TT

TT

T

ALLAALLA

ALLAALLA

ALLA

TIONTION

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

IOM / ROOF-TOP FLEXY™ Series - Page 11

2

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.

1

Figure 5

Figure 6

Figure 7

Page 12 - IOM / ROOF-TOP FLEXY™ Series

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.

1

2

3

Figure 9

1

Figure 8

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

Page 14 - IOM / ROOF-TOP FLEXY™ Series

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.

IOM / ROOF-TOP FLEXY™ Series - Page 15

AIR FLOW BALANCINGAIR FLOW BALANCING

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

Page 16 - IOM / ROOF-TOP FLEXY™ Series

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 BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

IOM / ROOF-TOP FLEXY™ Series - Page 17

AIR FLOW BALANCINGAIR FLOW BALANCING

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

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

3

/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

Page 18 - IOM / ROOF-TOP FLEXY™ Series

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART A

IOM / ROOF-TOP FLEXY™ Series - Page 19

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART B

Page 20 - IOM / ROOF-TOP FLEXY™ Series

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART C

IOM / ROOF-TOP FLEXY™ Series - Page 21

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART D

Page 22 - IOM / ROOF-TOP FLEXY™ Series

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART E

IOM / ROOF-TOP FLEXY™ Series - Page 23

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCINGAIR FLOW BALANCING

AIR FLOW BALANCING

CHART F

Page 24 - IOM / ROOF-TOP FLEXY™ Series

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.

1

2 3 4 5

6

a

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/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

1

Supply air

IOM / ROOF-TOP FLEXY™ Series - Page 25

filfil

filfil

fil

tersters

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 26 - IOM / ROOF-TOP FLEXY™ Series

HOHO

HOHO

HO

T WT W

T WT W

T W

AA

AA

A

TER COILSTER COILS

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).

IOM / ROOF-TOP FLEXY™ Series - Page 27

GAS BURNERGAS BURNER

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 28 - IOM / ROOF-TOP FLEXY™ Series

GAS BURNERGAS BURNER

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

1

2

3

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.

IOM / ROOF-TOP FLEXY™ Series - Page 29

1

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.

2

3

GAS BURNERGAS BURNER

GAS BURNERGAS BURNER

GAS BURNER

Figure 25

Figure 26

Figure 27

Figure 28

Cône bleu