Lennox FCM 200, FCM 100, FCM 120, FCM 170, FCM 230 Installation, Operating And Maintenance

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Providing indoor climate comfort

FLEXY II

FLEXYII-IOM-0409-E

Installation, operating and maintenance

FLEXYII-IOM-0409-E Page 1

INSTALLATION OPERATION MAINTENANCE MANUAL

Ref. FLEXYII_IOM/0409-E

The present manual applies to the following ROOFTOP versions: FCM 85 - FCM 100 - FCM 120 - FCM 150 - FCM 170 - FCM 200 - FCM 230 FHM 85 - FHM 100 - FHM 120 - FHM 150 - FHM 170 - FHM 200 - FHM 230 FDM 85 - FDM 100 - FDM 120 - FDM 150 - FDM 170 - FDM 200 - FDM 230 FGM 85 - FGM 100 - FGM 120 - FGM 150 - FGM 170 - FGM 200 - FGM 230 FXK 25 - FXK 30 - FXK 35 - FXK 40 - FXK 55 - FXK 70 - FXK 85 - FXK 100 - FXK 110 - FXK 150 - FXK 170

NOTES FOR UNIT FITTED WITH GAS BURNER:

LENNOX have been providing environmental solutions since 1895, our range of Baltic TM rooftop continues to meet the standards that have made LENNOX a household name. Flexible design solutions to meet YOUR needs and uncompromising attention to detail. Engineered to last, simple to maintain and Quality that becomes a standard. Further Information on www.lennoxeurope.com. All the technical and technological information contained in this manual, including any drawing and technical descriptions provided by us, remain the property of Lennox and must not be used (except in operation of this product), reproduced, issued to or made available to third parts without the prior written agreement of Lennox.

The technical informations 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.

CONTENTS

THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL VENTILATED AREA. PLEASE READ CAREFULLY THE MANUFACTURER'S INSTRUCTIONS BEFORE STARTING THIS UNIT.

THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FOLLOWING CODES: GB IR GR DA NO FI IS

In case these symbols are not displayed on the unit, please refer to the technical documentation which will eventually detail any modifications required to the installation of the unit in a particular countr

Switchgear must be installed on each unit in accordance with the Machine Directive and the standard NF EN 60204.

FLEXYII-IOM-0409-E Page 2

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

INSTALLATION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMMISSIONING

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

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

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

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

VENTILATION

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

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

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

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

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

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

HEATING OPTIONS

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

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

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

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

CONTENTS

FLEXYII-IOM-0409-E Page 3

ELECTRICAL DATA: WIRING DIAGRAMS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

REFRIGERATION CIRCUIT

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

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

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

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

MAINTENANCE DIAGNOSTIC

.............................................................................................................................91

MAINTENANCE PLAN

.........................................................................................................................................94

WARRANTY

..........................................................................................................................................................97

CERTIFICATES

....................................................................................................................................................98

CONTENTS

FLEXYII-IOM-0409-E Page 4

All FLEXY II Units are compliant with the PED directive 97-23/CE The following note must be followed carefully

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

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

Work on the unit:

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

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

Work on the electrical system:

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

authorisation.

Work on the refrigerating circuit(s):

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

for this purpose and suitable equipment.

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

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

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

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

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

silver).

Replacing components:

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

parts approved by Lennox.

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

coolants, hydrocarbons, etc.).

CAUTION:

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

TRANSPORT – HANDLING:

- Never lift the unit without forklift protections

- Remove the forklift protection before installation

- An approach ramp must be installed if the unit’s installation requirements tell that it's necessary to reach the main switch. This recommendation is valid for installations in general and in particular for return and curbs. It’s also valid to reach other parts of the unit: filters, refrigerant circuit, etc…

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

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

COMMISSIONING:

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

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

FILTERS:

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

FANSTART:

- Any adjustment has to be done power stopped.

GAS:

- Any work on gas module must be carried out by qualified personnel

- A unit with gas module must be installed in accordance with local safety codes and regulations and can only be used in planed installation conditions for outdoor.

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

IMPORTANT NOTICE – Safety instructions

FLEXYII-IOM-0409-E Page 5

UV LIGHT :

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

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

- Do not enter the machine while UV are switched on

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

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

IMPORTANT NOTICE – Safety instructions

FLEXYII-IOM-0409-E Page 6

Site details

Site Unit Ref Installer

………………………………………

……………………………………....

………………………………………

Controller Model Serial No Refrigerant

…………………………………. ……………….………………… ………………………………… …………………………………

(1) ROOF INSTALLATION

Sufficient Access OK

Yes

Condensate drain fitted

Yes No

Roofcurb OK Not OK

(2) CONNECTIONS CHECK

Phase check

Yes

Voltage between Phases

1 / 2

……………….

2 / 3

……………….

1 / 3

……………….

(3)CLIMATIC CONFIGURATION CHECK

CLIMATIC 50 Configured according to the Options and Specifications: Yes

(4) SUPPLY BLOWER SECTION

Type : Power displayed on plate: Voltage displayed on plate: Current displayed on plate:

KW V A

N°1

…………………… …………………… ……………………

N°2

…………………… …………………… ……………………

Fan Type : Forward

Backward

Forward

Backward Displayed Belt Length : mm …………………… …………………… Tension Checked: Yes No Yes No Alignment Checked : Yes No Yes No Motor Pulley Diameter: DM mm …………………… …………………… Fan Pulley Diameter: DP mm …………………… ……………………

Fan Speed = Motor rpm x DM / DP Averaged Measured Amps :

rpm A

…………………… ……………………

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

Operating point checked : Yes No Yes No

Estimated Airflow

m3/h

…………………… ……………………

(5) AIRFLOW PRESS. SENSOR CHECK

Measured pressure drop…………………………… mbar

Set Points Adjusted: Yes

If Yes enter new values:

3410: ………… 3411: ………… 3412: …………

(6) EXTERNAL SENSOR CHECKS

Check and record temp. in menu 2110

Yes

Non

Check electrical connections : Yes

100% Fresh Air 100% return Air

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

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

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

(7) MIXING AIR DAMPERS CHECKS

Dampers open & close freely

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

Yes No ……………..% Yes No Yes No

COMMISSIONING REPORT

FLEXYII-IOM-0409-E Page 7

(8) REFRIGERATION SECTION

Outdoor Fan Motor Current: Check Rotation

Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Yes No Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Yes No

Compressor Voltage

Motor 3 / Moteur 3 L1 ……..A L2 ……..A L3 ……A Yes No Comp1: …….. V Motor 4 / Moteur 4 L1 ……..A L2 ……..A L3 ……A Yes No Comp2: …….. V Motor 5 / Moteur 5 L1 ……..A L2 ……..A L3 ……A Yes No Comp3: …….. V Motor 6 / Moteur 6 L1 ……..A L2 ……..A L3 ……A Yes No Comp4: …….. V

Compressor Amps COOLING Pressures & Temperatures

Temperatures Pressures

Phase 1 Phase 2 Phase 3

Suction

Discharge

LP/ BP

HP / HP

Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar

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

Check Reversing valves :

Valve1: Yes

Valve2: Yes

Valve3: Yes

Valve4: Yes

Compressor Amps HEATING Pressures & Temperatures

Temperatures Pressures

Phase 1 Phase 2 Phase 3

Suction

Discharge

LP/ BP

HP / HP

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

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

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

(8)ELECTRIC HEATER SECTION

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

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

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

(9) HOT WATER COIL SECTION

Check Three Way Valve Movement : Yes No

(10) GAS HEATING SECTION

Gas Burner N°1 Gas Burner N°2

Size :

……………………….

Valve type :

…………………….

Size :

……………………….

Valve type :

…………………….

Pipe size:

Gas type : G…….

Pipe size

Gas type : G…….

Line pressure :

………………………

Drop test

Yes No

line pressure :

………………………

Drop test

Yes No

Check manifold pressure:

High fire …….…Low fire ………..

Check manifold pressure:

High fire …….…... Low fire ………..

Pressure cut out airflow press switch :

……………………mbar /Pa

Pressure cut out airflow press switch :

……………………mbar /Pa

Motor amps :

……….A

Flue temp.

……… °C

CO2 %:

………%

CO ppm:

………%

Motor Amps:

……….A

Flue temp.

………. °C

CO2 %:

………%

CO ppm:

………%

(11) REMOTE CONTROL BMS CHECK

Type :

…………………………..

Sensor type

………………………………..

KP07 KP/17 checked:

Yes No

Interconnect wiring checked:

Yes No

COMMISSIONING REPORT

FLEXYII-IOM-0409-E Page 8

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

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

Time Zones / Zones Horaires

Hour

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Example

UNO

7h15

11h00

14h00

19h00

UNO

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

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

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

hour (3211) min (3212) hour (3213) min (3214) hour (3215) min (3216) hour (3217) min (3218) Monday Tuesday Wednesday Thursday Friday Saturday Sunday

Description Unit Menu Min

Max

Zone A Zone B Zone C UNOC

Sp Room °C 3311 8 35

Mini.Air % 3312 0 100

Sp Dyna °C 3321 0 99.9

Sp Cool °C 3322 8 35

Sp Heat °C 3323 8 35

Swap Heater On/Off 3324 ~ ~

Activation On/Off 3331 ~ ~

Swap Heater On/Off 3332 ~ ~

Sp.Dehu % 3341 0 100

Sp.Humi % 3342 0 100

Fan On/Off On/Off 3351 ~ ~

Fan Dead On/Off 3352 ~ ~

F.Air On/Off 3353 ~ ~

CO2 On/Off 3354 ~ ~

Comp.Cool. On/Off 3355 ~ ~

Comp.Heat. On/Off 3356 ~ ~

AuxHeat On/Off 3357 ~ ~

Humidif. On/Off 3358 ~ ~

Low Noise On/Off 3359 ~ ~ N/A N/A N/A

COMMISSIONING REPORT

FLEXYII-IOM-0409-E Page 9

COMMENTS:…………………………………………………………………………………………………………………………………… ………………………….……………………………………………………………………………………………………………………… ……...

……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….…………………………………… ………………………………………………………………………………………...…………………… ….………………………………………………………………………………………………………… …………………...……………………….………………………………………………………………… …………………………………………………………...……………………….………………………… …………………………………………………………………………………………………...………… …………….……………………………………………………………………………………………… ……………………………...……………………….……………………………………………………… ……………………………………………………………………...……………………….……………… ……………………………………………………………………………………………………………... ……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….…………………………………… ………………………………………………………………………………………...…………………… ….………………………………………………………………………………………………………… …………………...……………………….………………………………………………………………… …………………………………………………………...……………………….………………………… …………………………………………………………………………………………………...………… …………….……………………………………………………………………………………………… ……………………………...……………………….……………………………………………………… ……………………………………………………………………...……………………….……………… ……………………………………………………………………………………………………………... ……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….…………………………………… ………………………………………………………………………………………...…………………… ….………………………………………………………………………………………………………… …………………...……………………….………………………………………………………………… …………………………………………………………...……………………….………………………… …………………………………………………………………………………………………...………… …………….……………………………………………………………………………………………… ……………………………...……………………….……………………………………………………… ……………………………………………………………………...……………………….……………… ……………………………………………………………………………………………………………... ……………………….…………………………………………………………………………………… …………………………………

COMMISSIONING REPORT

FLEXYII-IOM-0409-E Page 10

DELIVERY CHECKS

On receipt of a new equipment please check the following points. It is the customer’s responsibility to ensure that the products are in good working order:

- 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 here-in.

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

- The equipment supplied corresponds to 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.

RATING PLATE

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 start-up, 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 and the required charge for each compressor circuit.

Fig. 1

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 (AQUILUX 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 accessible place. This allows you to open the panels for maintenance and installation work. The locks are ¼ turn + then tighter (figure 2).

CONDENSATE DRAINS

The condensate drains 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 3).

TRANSPORT – HANDLING – WARNING

Fig. 3

FLEXYII-IOM-0409-E Page 11

TRANSPORT – HANDLING

Handling slings to guide the

unit towards the roofcurb

Vacuum lifting beam to

position the unit

COMPLIAN

NON-COMPLIAN

FLEXYII-IOM-0409-E Page 12

DIMENSIONS AND WEIGHTS

FLEXY2 FCM/FHM/FGM/FDM

85 100 120 150 170 200 230

View (F, G, H box)

F BOX F BOX F BOX G BOX G BOX H BOX H BOX

mm 2200 2200 2200 2200 2200 2200 2200

mm 3350 3350 3350 4380 4380 5533 5533

mm 1510 1510 1510 1834 1834 2134 2134

mm 360 360 360 450 450 615 615

Weight of standard units FCM

Without economiser kg 933.8 1008.8 1085.0 1367.0 1430.0 1650.0 1950.0 With economiser kg 990.3 1065.3 1141.5 1442.0 1505.0 1751.7 2051.7

Weight gas unit FGM

Standard heat Without economiser kg 1040.8 1115.8 1192.0 1608.0 1671.0 1913.9 2213.9 Standard heat With economiser kg 1097.3 1172.3 1248.5 1683.0 1746.0 2015.6 2315.6 High heat without economiser kg 1110.8 1185.8 1262.0 1631.0 1694.0 1954.1 2254.1 High heat With economiser kg 1167.3 1242.3 1318.5 1706.0 1769.0 2055.8 2355.8

TRANSPORT – HANDLING

F & G BOX H BOX

FLEXYII-IOM-0409-E Page 13

DIMENSIONS AND WEIGHTS

LENGTH HEIGHT WIDTH HOOD WEIGHT Side Fan Standard

mm mm mm

mm mm kg FXK025 4070 1635 1055 490 600 950 FXK030 4070 1635 1055 490 600 980 FXK035 4750 2255 1290 490 600 1400 FXK040 4750 2255 1290 490 600 1450 FXK055 4750 2255 1290 490 600 1600 FXK070 5050 2255 1725 890 600 1800 FXK085 5050 2255 1725 890 600 1900 FXK100 5050 2255 1725 890 600 2000 FXK110 5650 2255 2000 860 - 2620 FXK140 5650 2255 2000 860 - 2620 FXK170 5650 2255 2000 860 - 2650

TRANSPORT – HANDLING

FLEXYII-IOM-0409-E Page 14

LIFTING THE UNIT

As shown on the picture below, a lifting frame is necessary.

After lifting, withdraw angle’s feet and lifting lugs.

TRANSPORT – HANDLING

FLEXYII-IOM-0409-E Page 15

FORKLIFT PROTECTIONS

NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS

REMOVE THE FORKLIFT PROTECTIONS BEFORE INSTALLATION

PRELIMINARY CHECKS

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

- Have the forklift protections been removed?

- Is there sufficient space for the equipment?

- Is the surface on which the equipment is to be installed 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?

- 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 local 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.

INSTALLATION REQUIREMENTS

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 of prevailing winds

-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.

CONNECTIONS

-Ensure that all the pipe-work crossing walls or roofs

are secured, sealed and insulated.

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

NOTE: The AQUILUX protection sheets fitted to the finned surfaces must be removed prior to start up.

INSTALLATION

FLEXYII-IOM-0409-E Page 16

MINIMUM CLEARANCE AROUND THE UNIT

Figure 4 shows the required clearances and service access around the unit.

NOTE: Ensure the fresh air inlet does not face prevailing wind direction.

A B C D FCM/FHM/FGM/FDM F BOX

2200

(1)

2000 2000 2000

G BOX

2700

(1)

2000 2000 2000

H BOX

2700

(1)

2000 2000 2000

FX 25 & 30

* 1100 * 1700

35Æ55

* 1300 * 2300

70Æ100

* 1700 * 2300

110Æ170

* 2000 * 2300

(1) Add 1 meter if the units are equipped with gas burner

INSTALLATION

FLEXYII-IOM-0409-E Page 17

CAUTION:

- An approach ramp must be installed if the unit’s installation requirements tell that it's

necessary to reach the main switch. This recommendation is valid for installations in general and in particular for return and curbs. It’s also valid to reach other parts of the unit: filters, refrigerant circuit, etc…

- It’s recommended to fix curbs and roofcurbs to the unit using cables to link the

lifting lugs together.

- It’s recommended to secure curbs to the trimmer or to the floor (horizontal curbs)

As levels are adjustable, observe the following recommendations when installing the equipment

Above all, ensure that all the adjustable returns are facing outward (“1” figure 4). They are usually turned inside-out for transport.

Place the roof mounting frame on the trimmer beam by first lining up the inlet and the outlet opening. (“2”- figure 5)

After levelling the frame, secure the adjustable returns on the trimmer.

It is important to centre the unit on the roof frame

INSTALLATION ON A ROOFMOUNTING FRAME

Fig. 4

Fig. 5

Fig. 6

FLEXYII-IOM-0409-E Page 18

When the frame is correctly positioned, it is essential to secure the assembly with a disconnected stitched welded seam (20 to 30mm every 200mm

) along the outside or by using an alternative method

CURBING AND FLASHING

Outside of frame must be insulated with rigid type insulation; We recommend a minimum of 20 mm thick insulation (2-figure 7).

Check that the insulation is continuous, counter flash and seal around the

frame

as shown in (1-figure 7).

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

7).

Where pipes and electrical conduits extend through the roof, flashing must be conformed to local codes of practice.

Before installing the equipment, make sure that seals are not damaged and check that the unit is secured to the mounting frame. Once in position, the bottom of the equipment must be horizontal. The installer must comply with local authority standards and specifications.

RECOMMENDATIONS FOR DUCTS CONNECTIONS

Some rules must be complied with for the connections between ducts and unit done on site.

INSTALLATION ON A ROOFMOUNTING FRAME

Fig. 7

FLEXYII-IOM-0409-E Page 19

Whatever the supply configuration is, respect a minimal duct’s length (D) of 2m before any elbow or any duct’s diameter change.

These recommendations are imperative in the case of 2 independent turbines (sizes from 150kW to 230kW and all units equipped with gas module)

Horizontal supply

Vertical supply

Here are obvious bad examples of ducts connections noted on site:

D ≥ 2m

DUCT CONNECTIONS

INSTALLATION ON A ROOFMOUNTING FRAME

D ≥ 2m

D ≤ 2m

FLEXYII-IOM-0409-E Page 20

NON ADJUSTABLE NON ASSEMBLIED ROOFCURB INSTALLATION

FRAME PARTS IDENTIFICATION

Figure 8 shows the different parts used in the assembly of this roof mounting frame.

INSTALLATION

The roof mounting frame provides support when the units are installed in down-flow configurations. The non adjustable, non assembled roof mounting frame can be installed directly on decks having adequate structural strength or on roof supports under deck.

NOTE: frame assembly must be installed flat, leveled within 5mm per linear meter in any direction

UNIT FLOOR

IR DUCT

UNIT Support rail

ROOFCURB

Fig. 8

INSTALLATION ON A ROOF MOUNTING FRAME

FLEXYII-IOM-0409-E Page 21

This roof curb will arrive as a packaged on a pallet and need to be built together. The part will be connected by special corrosion free nails. It is not possible to connect with standard nail equipment because there is a lot of power needed. Therefore, you need a pneumatic or electric device.

All parts must be sealed with polyurethan sealant during assembly.

Foam Insulation Installing

• Stick large foam pieces underneath the flat top

Foam Gasket Installing

• Stick gasket all around the curb flange’s top

Spare parts

Fbox Gbox Hbox

GASKET 5840071R Grey foam M1 17 m / 0.85 m² 19 m / 0.95 m² 21 m /1.1 m²

INSULATION 5840071R 760 x 1960 - 1.39 m² 920 x 1960 - 1.79m² tbd

Rivets 5820542X 4.8 x 8 mm 100 130 160

Let it free on 200 mm

long to enable water

drainage

NON ADJUSTABLE ROOF CURB - Installation instructions

FLEXYII-IOM-0409-E Page 22

SIZE A B C D E F G H J K L M N P Q R

F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95

G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95

H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800 80 1133 95

ADJUSTABLE ROOFCURB

All units

RETURN AIR

SUPPLY AIR

MAIN POWER ENTRY

FLEXYII-IOM-0409-E Page 23

SIZE A B C D E F G H J K L M N P Q R

F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95

G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95

H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800 80 1133 95

NON ADJUSTABLE NON ASSEMBLED ROOFCURB

SUPPLY AIR

MAIN POWER ENTRY

All units

FLEXYII-IOM-0409-E Page 24

SIZE A B C D E F G H J K L M N P Q R S

F-BOX 85-100-120 2056 2745 2005 800 100 600 300 1335 88 980 780 600 100 600 100 600 100

G-BOX 150-170 2056 3441 2493 800 100 600 300 1540 88 980 780 900 100 600 100 900 100

H-BOX 200-230 2056 4063 2493 800 100 600 300 1830 88 980 780 1000 100 600 100 1000 100

SUPPLY AIR

MULTIDIRECTIONAL ROOFCURB

RETURN AIR

SUPPLY AIR

All units

FLEXYII-IOM-0409-E Page 25

SIZE A B C D E F G H J K L M N P Q R

F-BOX 85-100-120 2156 2740 2005 1030 2056 2005 1650 180 310 840 140 700 1440 326 593 95

G-BOX 150-170 2156 3437 2494 1030 2056 2494 1650 410 310 840 140 700 1540 434 770 95

H-BOX 200-230 2156 4073 2494 1030 2056 3294 2550 100 310 840 80 800 1830 434 1113 95

RETURN ROOFCURB

CAUTION: An approach ramp must be installed if the

machine installation requirements tell that it's necessary to reach the main switch. This recommendation is valid for installations in general and in particular for return and curbs. It’s also valid to reach other parts of the unit: filters, refrigerant circuit, etc…

It is recommended to tighten Rooftop to Return Roofcurb using cables linking the lifting lugs together. It’s recommended to secure curbs to the trimmer or to the floor (horizontal curbs)

SUPPLY AIR

EXHAUST AIR

All units

RETURN AIR

MAIN POWER ENTRY

FLEXYII-IOM-0409-E Page 26

SIZE A B C D E F G H J K L M N P

F-BOX 85-100-120 2056 2755 2005 1220 1180 100 400 100 1335 200 1605 200 100 700

G-BOX 150-170 2056 3465 2493 1220 1180 100 400 100 1540 200 2000 200 100 700

H-BOX 200-230 2056 4095 2493 1305 1205 200 400 150 1830 150 2293 100 260 700

RETURN HORIZONTAL ROOFCURB

CAUTION: An approach ramp must be installed if the

It is recommended to tighten Rooftop to Return Roofcurb using cables linking the lifting lugs together. It’s recommended to secure curbs to the trimmer or to the floor (horizontal curbs)

EXHAUST AIR

All units

RETURN AIR

SUPPLY AIR MAIN POWER ENTRY

FLEXYII-IOM-0409-E Page 27

SIZE A B C D E F G H J K L M N

F-BOX 85-100-120 2056 2008 2072 366 2783 1880 70 85 530 700 145 1432 342

G-BOX 150-170 2056 2496 2072 366 3480 2377 70 85 530 700 145 1540 440

H-BOX 200-230 2056 2493 2072 366 4106 2377 70 85 530 800 85 1830 440

TRANSITION CURB

SUPPLY AIR

MAIN POWER ENTRY

RETURN AIR

All units

FLEXYII-IOM-0409-E Page 28

SIZE A B C D E F

F-BOX 85-100-120 2279 2212 1447 360 1911 938

G-BOX 150-170 2539 2473 1544 457 2211 938

H-BOX 200-230 2789 2723 1703 616 2461 938

ENERGY RECOVERY

All units

IOM – FLEXY II – 0409 – E Page 29

1) The unit being already erected on the roofcurb, remove the lifting lug shown on [A], and the doors of the Recovery

module

[B].

2) Fit the support part of the Recovery Module on interior level of the rooftop ,

3) Fix the Recovery Module at the roof of the rooftop

and corner structures by using self-driling screws.

4) Apply Mastic on side junctions and on higher junction.

ENERGY RECOVERY

Fig. 25

zoom

IOM – FLEXY II – 0409 – E Page 30

ECONOMISER Free cooling can be provided through the use of fresh air which is more appropriate than excessive cooling amounts of return air. The economiser is factory fitted and tested prior to shipment. It includes two dampers operating from a 24V actuator

RAIN HOOD

It also includes a factory fitted rain hood. Hoods is folded during transportation to limit risks of damage and must be unfolded on site as shown on fig. 9

EXTRACTION

Installed with economiser assembly, the gravity exhaust dampers relieve the pressure when outside air is introduced into the system. When large amount of fresh air is introduced into the system power exhaust fans can be used to equalise the pressures. The extraction fan runs when return air dampers are being closed and supply air blower is in operation. The extraction fan runs when outdoor air dampers are at least 50% open (adjustable value). It is overload protected. NOTE: When horizontal flow configuration is required, the multidirectional roof curb will be installed.

0-25% FRESH AIR MANUAL

It is enough to loosen the mobile grid's screws and to make it slip. 0%: screw into limit stop on the right 25%: screw into limit stop on the left

FRESH AIR

ETURN AIR

XHAUST AIR

SUPPLY AIR

Fig. 9

ECONOMISER AND EXTRACTION

FLEXY II PRINCIPLE SKETCH

MULTIDIRECTIONAL ROOFCURB

PRINCIPLE SKETCH

ENERGY RECOVERY MODULE PRINCIPLE SKETCH RETURN ROOFCURB PRINCIPLE SKETCH

IOM – FLEXY II – 0409 – E Page 31

THIS WORK MUST ONLY BE CARRIED OUT BY TRAINED REFRIGERATION ENGINEERS

FILL THE COMMISSIONNING SHEET AS YOU GO ALONG

Don’t forget to

open the

isolation Valves

on the liquid line

before starting

the unit (see

sticker below)

ISOLATION VALVES MUST BE

OPENED BEFORE RUNNING

ELECTRICAL CONNECTIONS

- 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 POWER SUPPLY

INCLUDES 3 PHASES

- Check the following wire connections for tightness: Main switch connections, mains wires linked to the contactors and circuit breakers and the cables in the 24V control supply circuit.

How to connect roof curbs and energy recovery module

Cables and their connectors corresponding to the roof curb’ motor and actuator and extraction box’ ones are already rolled up in these elements; it is enough to bring them through the openings envisaged and to connect them on the sites.

It’s the same procedure when you have an energy recovery module.

PRELIMINARY CHECKS

- 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. Refer to the next section foe details.

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

- Check the temperature probe connections.

COMMISSIONING

Energy recovery cable fixed on

the grid of the roofcurb

Connector for the

extraction roof curb

Connector for the

energy recovery

module

IOM – FLEXY II – 0409 – E Page 32

STARTING THE UNIT

At this point the unit circuit breakers should be open You will need a DS50 maintenance controller or Adalink with appropriate Interface.

The jumpers are factory set and the configuration switches are adjusted depending on the option the type of unit. Connecting the CLIMATIC displays

Close the 24V Control Circuit breakers.

The CLIMATIC 50 starts after 30s

Reset the DAD photo (If fitted)

Check and adjust the control settings.

Refer to the control section in this manual to adjust the different parameters.

POWERING THE UNIT

- Power up the unit by closing the isolator switch (if fitted). - At this point the blower should start unless the climatic does not energise the contactor. In this particular case the blower can be forced by bridging the port NO7 and C7 on connector J14 on the Climatic. Once the fan is running, check the rotation direction. Refer to the rotation arrow located on the fan.

- The fans and compressors direction of rotation is checked during the end of line test. They should therefore all turn in either the right or wrong direction.

NOTE: A compressor rotating in the wrong direction will fail.

- If the fan turns in the wrong direction (the right direction is shown on figure n° 11), disconnect the main power supply to the machine at the building's mains switch, reverse two phases and repeat the above procedure.

- Close all circuit breakers and power up the unit, remove the bridge on connector J14 if fitted.

- If now only one of the components rotates in the wrong direction, disconnect the power supply at the machine's isolator switch (if fitted) and reverse two of the component’s phases on the terminal within the electrical panel.

- Check the current drawn against the rated values, in particular on the supply fan (ref. page 33).

- If the readings on the fan are outside the specified limits, this usually indicates excessive air flow which will affect the life expectancy and the thermodynamic performances of the unit. This will also increase the risks of water ingress into the unit. Refer to the "Air Flow Balancing" section to correct the problem.

At this point attach the manometers to the refrigerant circuit

Fig. 11

COMMISSIONING

IOM – FLEXY II – 0409 – E Page 33

RUN TEST

Start unit in cooling mode

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.

Safety test

- Check Air pressure switch (if fitted) "Dirty filter" detection test: vary the set-point value (menu page 3413 on DS50) in respect to the air pressure value. Observe the response of the CLIMATIC™.

- Same procedure for detecting "Missing Filter" (page menu 3412) or "Air Flow Detection" (page menu 3411).

- Check the smoke detection function (if fitted).

- Check the Firestart by pressing the test button (if fitted).

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

Reverse cycle test

This test is designed to check the good operation of the 4way reversing valves on heat pump reversible systems. Start the reverse cycle by adjusting the cold or hot temperature threshold data according to the indoor and outdoor conditions at the time of test (menu 3320).

COMMISSIONING

IOM – FLEXY II – 0409 – E Page 34

BELT 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 the belt, set the height of motor support plate by moving the plate adjustment screws.

The recommended deflection is 20 mm per meter from centre to centre.

Check that according to the diagram below (figure 12), the following ratio remains the same.

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

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.

VENTILATION : BELT TENSION

Fig. 12

IOM – FLEXY II – 0409 – E Page 35

MOUNTING AND ADJUSTING PULLEYS

FAN PULLEY REMOVAL

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 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.

OTOR PULLEY INSTALLATION & 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.

ULLEYS 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.

VENTILATION : PULLEYS

FLEXYII-IOM-0409-E Page 36

The actual resistance of ductwork systems is not always identical to 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.

SITE TEST AND MAINTENANCE

Measure the motor absorbed power.

If the absorbed power is greater and the pressure lower than the rated values, the ventilation system has a lower pressure drop than anticipated. Reduce the flow by reducing the rpm. If the system resistance 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 by increasing the rpm. At the same time you will increase the absorbed power which may result in having to increase the motor size.

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 13).

Actual diameter (DM) or distance between faces for a given number of

turns from fully closed with SPA belt in (mm)

Pulley

type

Pulley

External

Diameter

Min

Dia /

Min Dist

Max

Dia /

Max Dist

Nb of turns

from fully closed to

fully open

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

95 116 5 114 112 110 108 106 103 101.3 99.2 97.1 95 -

8450 /

D8450

120

20.2 28 5 21 21.8 22.5 23.3 24.1 24.9 25.7 26.4 27.2 28 -

110 131 5 129 127 125 123 121 118 116 114 112 110 -

8550 /

D8550

136

20.6 31.2 5 21.6 22.7 23.8 24.8 25.9 26.9 28 29.1 30.1 31 -

Table_1

The easiest way to determine the fan rotation speed is to use a Tachometer. If not available the fan rpm can be estimated using the following two methods.

Method with the pulley secured in place:

Measure the distance between the two outside faces of the pulley. Using table (1) the motor pulley actual diameter can be estimated.

VENTILATION : AIRFLOW BALANCING

Fig. 13

FLEXYII-IOM-0409-E Page 37

2nd method when adjusting the pulley :

-Close the pulley fully and count the number of turns from fully closed position. Using table_1 determine the motor pulley actual diameter.

-Record the fix fan pulley diameter.(DF)

-Determine the fan speed using the following formulae:

FMMOTORFAN

/DDrpmrpm ×=

Where: rpm

MOTOR

:from the motor plate or table_2

: from table_1

: from machine

Once the pulleys are adjusted and the belt checked and tensioned, start the fan motor and record the Amps and Voltage between the phases: Using the measured data and table_2

-Theoretical mechanical power at the fan shaft:

meca fan

= P

meca Motor

x η

Transmission

meca fan

= P

elec

x η

meca motor

x η

Transmission

meca fan

= V x I x √3 x cosϕ x η

meca motor

x η

Transmission

This formula can be approximated in this way

meca fan

= V x I x 1.73 x 0.85 x 0.76 x 0.9

With the fan “rpm” and the mechanical power at the fan shaft an operating point and the supplied airflow can be estimated using the fan curves.

CHECKING AIRFLOW AND ESP

Using the fan curves on page 36 to 40, the airflow, the total pressure available (P

TOT

) and the corresponding dynamic pressure (Pd) can now be estimated, for a specific operating point;

The next step consists in estimating the pressure losses across the unit. This can be achieved using the “dirty filter pressure sensor” and the accessories pressure drop table: table_3 Also the pressure drop due to the duct inlet into the rooftop unit can be taken as 20 to 30 Pa.

∆P

INT

= ∆P

filter + coil

+ ∆P

Inlet

+ ∆P

Options

Using the results from above, the external static pressure (ESP) can then be estimated:

ESP = P

TOT

- Pd - ∆P

INT

Table_ 2 Motor information

Motor Size Nom. Speed

Cos ϕ η

meca motor

0.75 kW 1400 rpm 0.77 0.70

1.1kW 1429 rpm 0.84 0.77

1.5kW 1428 rpm 0.82 0.79

2.2kW 1436 rpm 0.81 0.81

3.0kW 1437 rpm 0.81 0.83 4kW 1438 rpm 0.83 0.84

5.5kW 1447 rpm 0.85 0.86

7.5kW 1451 rpm 0.82 0.87

9.0kW 1455 rpm 0.82 0.88

11.0kW 1451 rpm 0.85 0.88

Table_3 Accessories pressure drops

Economiser

Filters

LIGH

Hot

Water

coil S

Hot

Water

coil H

Electric

Heater

Electric

Heater

Electric Heater

Heating

Gaz

fired H

Adjustable

roofcurb

Multidire

ctional

Roofcurb

Heat

Recovery

Modul

Fresh Air

12000 12 1 75 18 9 15 3 5 6 14 17 22 164

15000 19 7 105 30 13 22 6 7 7 23 27 33 204

23000 45 28 199 63 26 44 7 9 11 53 63 73 313 14000 17 5 94 26 11 19 6 7 8 20 23 30 191

18500 29 15 143 44 18 31 8 10 11 34 41 51 252

100

23000 45 28 199 63 26 44 11 14 16 53 63 78 313 15000 19 7 105 30 13 22 7 8 9 23 27 35 204

20500 36 21 167 52 21 37 10 12 13 42 50 62 279

120

23000 45 28 199 63 26 44 12 15 17 53 63 78 313 18000 6 1 75 15 6 10 4 5 7 16 30 35 170

150

26000 12 12 130 33 12 19 9 10 13 33 62 72 245

35000 22 29 204 54 19 33 15 18 23 59 112 131 329

21000 8 5 94 21 8 14 8 9 10 21 40 49 198

30000 16 19 161 42 15 25 10 13 15 44 82 95 282

170

35000 22 29 204 54 19 33 17 19 21 59 112 131 329 24000 12 3 88 18 7 11 16 15 14 21 53 67 173

35000 26 18 154 39 13 22 22 21 20 44 112 133 252

200

43000 39 31 211 54 19 31 24 26 29 66 169 195 310 27000 15 7 105 24 8 14 18 18 17 26 67 84 195

39000 32 24 182 46 16 26 24 24 25 55 139 163 281

230

43000 39 31 211 54 19 31 24 26 29 66 169 195 310

VENTILATION : AIRFLOW BALANCING

FLEXYII-IOM-0409-E Page 38

EXAMPLE

The unit used for this example is a FGM170ND with standard supply and return airflow configuration. It is also fitted with an economiser and an electric heater type H. It is fitted with 2 ADH450 L fans which curve is shown on page 36 and 2x 5.5 kW motors..

- Motor rpm: 1447 rpm

- cosϕ = 0.83

- Voltage = 400V

- Current = 9.00A (per fan)

mech fan

= V x I x √3 x cosϕ x η

mech motor

x η

Transmission

= 400 x 9.00 x √3 x 0.83 x 0.86 x 0.9 = 4.00kW

The unit is also fitted with 2 transmission kits 3.

- Fixed Fan pulley: 200mm

- Motor adjustable pulley type “8550” opened 4 turns from fully closed or measured distance between pulley end plates is

29.1mm: from table_1 it can be determined that each motor pulley has a diameter of 114.2mm

rpm

FAN

= rpm

MOTOR

x DM / DF = 1447 x 114.2 / 200 = 826 rpm

Using the fan curve, the operating point can be located.

In order to facilitate the calculation, you won’t make any mistake by considering that the external static pressure available is the one calculated with one fan providing the half of the nominal flow (here 15000m3/h).

It can be determined that the fan is providing approximately 15000 m3/h

with a total

pressure P

TOT

= 630 Pa

The pressure losses in the unit are the sum of all pressure drops across the different parts of a unit:

- Coil and filter (measured) = 89 Pa

- Inlet into the unit = 50 Pa

- Options = 16 Pa for economiser and 15

Pa for electric heater H

∆P = 89 + 16 + 15 +50 = 170 Pa

The dynamic pressure at 15000m

/h is given at the bottom of the fan curve. Pd = 81 Pa

The external static pressure available is therefore

ESP = P

TOT

- Pd - ∆P

INT

=630 - 91 - 170 =

369 Pa

VENTILATION : AIRFLOW BALANCING

826rpm

630Pa

FLEXYII-IOM-0409-E Page 39

VENTILATION : AIRFLOW BALANCING

AT15-15G2L(*)

(*) The performances of twin fan units can be calculated starting from the corresponding operation point for a single fan (see the figure behind) by applying the formulas below.

- pressure : PTwin = P x 1

- volume flow rate : Qb = Q x 2

- impeller power: Wb = W x 2,15

- fan speed : Nb = N x 1,05

- Lws : Lwsb = Lws + 3 dB

FLEXYII-IOM-0409-E Page 40

VENTILATION : AIRFLOW BALANCING

AT18-18S

FLEXYII-IOM-0409-E Page 41

VENTILATION : AIRFLOW BALANCING

ADH355L

FLEXYII-IOM-0409-E Page 42

VENTILATION : AIRFLOW BALANCING

ADH450L

FLEXYII-IOM-0409-E Page 43

VENTILATION : AIRFLOW BALANCING

ADH500L

FLEXYII-IOM-0409-E Page 44

FILTER REPLACEMENT

After opening the filter access panel, lift the filter retaining log. The filters can then be removed and replaced easily by sliding the dirty filters out and clean ones in.

The CLIMATIC controller can monitor the pressure drop across the filter (If option fitted)

The following set points can be adjusted depeding on the installation. “Airflow” in page 3411 = 25Pa by default “No filter “ in page 3412 = 50Pa by default “Dirty Filter” in page 3413 = 250Pa by default

The actual pressure drop measured accross the coil can be read on the Climatic Display DS50 in menu 2131

The following faults may be identified

-Fault code 0001 AIRFLOW FAILURE, if measured ∆P across the filter and coil is below the value set in page 3411

-Fault code 0004 DIRTY FILTERS, if measured ∆P across the filter and coil is above the value set in page 3413

-Fault code 0005 MISSING FILTERS, if measured ∆P across the filter and coil is below the value set in page 3412

VENTILATION : FILTERS

Be Careful: do the filters' fire classification's choice according to

the local regulations

FLEXYII-IOM-0409-E Page 45

AIR SOCK CONTROL

FANSTART OPERATION

The use of air socks for space conditioning allows high air volumes to be distributed at low velocity and is becoming a common feature in many applications. To accommodate this trend, Air-sock control is offered which allows the air socks to be progressively filled with air on start up. It takes up to 1 minute to go from 0% of air to full air flow.

START-UP

This option requires the economiser to be delivered inside the machine Both return air and fresh air damper are linked with and independent actuator. The return air damper is controlled by a spring return damper driven by the opposite signal delivered to the fresh air damper.

An auxiliary switch allows setting a minimum (few %) of return air opening before the fan is switched on.

Starting steps:

- Both dampers are fully closed and Fan is OFF

- Rooftop is set to RUN (by the schedule or the remote display order)

- Return air damper move to the minimum position manually adjustable

on the auxiliary switch, Fresh air damper is OFF

- Fan motor starts

- Return air damper goes to 100% return air slowly during 1 minute

allowing the duct to be smoothly inflated

- Finally, the fresh air damper and return air damper return to adjusted

fresh air ratio recorded in the climatic50 program

The return air damper with its auxiliary switch

VENTILATION : AIR SOCK CONTROL

FLEXYII-IOM-0409-E Page 46

UV LIGHT

UV light option allows to kill bacteria living on the fin.

The UV lamp emits shortwave UV-C ultraviolet radiation which is harmful to skin and eyes It can cause serious skin burns and eye inflammation within ONE SECOND of exposure Do not enter the machine while UV are switched on Make sure the UV light circuit breaker is OFF when opening the return air section door and the supply air section doors The following logo will appear to inform about the UV-C radiation risk A safety interlock is fitted to switch off the access doors to the lamps

VENTILATION : UV light

Fig. 14

Filters

UV light

COIL

Sight Glass

Door opened

Safety locks

FLEXYII-IOM-0409-E Page 47

HYDRAULIC CONNECTIONS

Hot water coils offer fully modulating control through the use of a 3 way valve. The hot water coil, connections and valves are all tested at pressure of 15 bars. Frost protection is provided by forcing the opening the 3 way valve when supply temperature from hot water coil falls below 8°C and by stopping the outdoor fan when that supply temperature falls below 6°C. In addition to that, the 3 ways is also opened at 10% value if the outdoor temperature falls below an adjustable value. Hot water coils are always factory fitted, wired and fully tested, prior to shipment. Hot water coil includes automatic purge system.

The hot water coil is fitted with a three way proportional valve and two isolating shut off valves. Two spanners must be used to tighten the connections. One spanner must maintain the valve body when connecting the pipe-work to the main. Failure to do so may damage the pipes joints and invalidates the warranty.

Filling up and starting the system

- Adjust the control for Heating by reducing the simulated ambient temperature down to 10°C

- Check that the red indicators located under the valve actuator are moving correctly with the signal.

- Fill the hydraulic system and bleed the coil using the air vents. Check incoming hot water.

- Check the various connections for possible leaks

FREEZE PROTECTION

1) Glycol for freeze protection. Check the hydraulic system contains Glycol for protection against freezing.

GLYCOL IS THE ONLY EFFECTIVE PROTECTION

AGAINST FREEZING

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

2) Drain the installation. You must ensure that the manual or automatic air bleeders 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.

HOT WATER COILS FROZEN DUE TO LOW AMBIENT

CONDITIONS ARE NOT COVERED BY THE

WARRANTY.

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

ANY COIL DAMMAGED BY ELECTROLYTIC

CORROSION IS NOT COVERED BY THE WARRANTY

HEATING : HOT WATER COIL

FLEXYII-IOM-0409-E Page 48

Connection HWC F-G-H box

Pipe Internal Diameters (DN)

AXIMUM WORKING PRESSURE: 8 BARS

AXIMUM WORKING TEMPERATURE: 110°C

F085 F100 F120 F150 F170 F200 F230

S 25 25 25 32 32 32 32

H 32 32 32 40 40 40 40

HEATING : HOT WATER COIL

FLEXYII-IOM-0409-E Page 49

ENERAL INFORMATIONS

The electric heater comprises of shielded resistance heaters, which are smooth stainless steel tubes 6 W/cm2 capacity. High temperature limit control offers overload protection and is set to 90°C and located at less than 150mm after electric heaters. This is provided as a standard feature on the electric heater, with the electric power supply cables made of reticulated silicon rubber, resistant to temperatures up to 200°C. For any rooftop unit size, three sizes of electric heater are available, S (standard), M (Medium) and H (high).

FLEXY 2 85, 100 and 120 have: Standard heat: 30 kW, 2 stages Medium Heat: 54 kW, Fully modulating (Triac) High Heat: 72 kW, Fully modulating (Triac) FLEXY 2 150 and 170 have: Standard heat: 45 kW, 2 stages Medium Heat: 72 kW, Fully modulating (Triac) High Heat: 108 kW, Fully modulating (Triac) FLEXY 2 150 and 170 have: Standard heat: 72 kW, 2 stages Medium Heat: 108 kW, Fully modulating (Triac) High Heat: 162 kW, Fully modulating (Triac)

Capacity of the medium and high heat heater can be limited electronically to an exact value through the CLIMATIC™ 50. To reduce installation time and hence cost, electric heaters are always factory fitted, fully wired and tested, prior to shipment.

380V 400V 415V

Module size (kW) Current (A) Cap (kW) Current (A) Cap (kW) Current (A) Cap (kW)

30 40.7 26.8 42.5 29.5 44.5 32.0

45 61.1 40.5 63.8 44.3 66.8 48

54 73.4 48.4 76.6 52.9 80 57.7

72 55.1 36.2 57.5 39.8 60.0 43.1

108 146.8 96.8 153.2 105.8 160 115.4

162 220.2 145.2 229.8 158.7 240 173.1

HEATING : ELECTRIC HEATER

FLEXYII-IOM-0409-E Page 50

PRELIMINARY CHECKS BEFORE START-UP

NOTE :

ANY WORK ON THE GAS SYSTEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN PLANED INSTALLATION CONDITIONS FOR OUTDOOR. PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING A UNIT. BEFORE COMMISSIONING A UNIT WITH GAS BURNER, IT IS MANDATORY TO ENSURE THAT THE GAS DISTRIBUTION SYSTEM (type of gas, available pressure…) IS COMPATIBLE WITH THE ADJUSTMENT AND SETTINGS OF THE UNIT.

CHECK ACCESS AND CLEARANCE AROUND THE UNIT

- Make sure one can move freely around the unit.

- A minimum one-meter clearance must be left in front of the burnt gas exhaust flue.

- Combustion air inlet and burnt gas exhaust(s) must NOT be obstructed in any way.

UPPLY NETWORK PIPE SYZING

MALE THREADED CONNECTION FOR GAZ BURNER: 3/4” Check that the gas supply line can provide the burners with

the pressure and the gas flow rate necessary to provide the heating nominal output.

Number of male threaded connections (3/4”)

UNIT SIZE 85 100 120 150 170 200 230

S POWER 1 1 1 2 2 2 2

H POWER 2 2 2 2 2 2 2

GAS FLOW (for G20 at 20mbar and 15°C) m

UNIT SIZE 85 100 120 150 170 200 230

S POWER 6.3 6.3 6.3 12.5 12.5 18.8 18.8

H POWER 12.5 12.5 12.5 18.8 18.8 25 25

For modulating gas we have just H power for F, G & H-box

- The gas supply of a Rooftop gas unit must be realized according to Sound Engineering Practice and the local safety codes and rules.

- In any case the diameter of pipe-work connected to each Rooftop must not be smaller than the diameter of the connection on the Rooftop unit.

- Make sure that a shut-off isolation valve has been installed before EACH Rooftop.

- Check the supply voltage to the exit of the power supply's transformer T3 of the burner: it must be between 220 and 240V.

STARTING UP THE GAS BURNER

Purge the pipe-work near the connection on the ignition control Valve for a few seconds.

- Check that the unit's treatment “Fan” blower is running.

- Set the control to “ON” This will priorities the gas burner.

- Increase the set temperature (room set point temperature) to a temperature higher than the actual room temperature.

Table4 - Standard start-up Chronology

Time in seconds

Operations

Control operation sequence

Extraction fan

Smoke extraction fan "ON"

30 to 45 seconds pre-ventilation

Fire-up spark electrode 4s

Opening of the gas valve "High Heat" Flame propagation towards the ionisation

probe

If ionisation within 5s: Normal running Otherwise fault on gas ingnition control

block After 5minutes, fault reported on the

climatic controller

If incorrect sequence refer to the fault analysis table to identify the problem

399

400

401

398

414243

373839

333435

293031

567

123

HEATING : GAS BURNER

FLEXYII-IOM-0409-E Page 51

PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4125 P

Pressure regulator adjustment with 300mbar gas supply:

- The Burner must run in High Heat mode for this check.

- Place the tube of the “accurate” manometer on the Inlet pressure port (Figure 15) of the Gas Regulating Valve after having loosened the screw by one turn

Check and adjust if necessary the valve Inlet pressure to

20.0mbar (G20) or 25.0mbar for Groningen (G25) or

37.0mbar for propane (G31) after gas burner ignition (fig.16)

High Heat Injection Pressure Checks

Check and adjust if necessary the valve OUTLET pressure to 10.4mbar (G 20) / 13.1mbar for Groningen (G25) & 34.3 mbar for propane (G31) (fig.17)

The out pressure must be measured on the pressure tap located on the gas injector support bar to avoid the pressure drop due to the elbow after the valve

Fig. 15

Fig. 17

Fig.16

HEATING : GAS BURNER 60 & 120kW

INLET

PRESSURE

MEASURING

PORT

FLEXYII-IOM-0409-E Page 52

Low Heat Injection Pressure Checks

- Switch the control to Low Heat

- Check and adjust if necessary the Outlet pressure to 3.7 mbar (G20) or 5.1 mbar for Groningue(G25) & 15.3 mbar for propane (G31)(fig.18)

- After the adjustment of the low heat, re-verify the high heat

- re-position the stoppers and close the pressure ports.

Pressure adjustments table for each type of gas (mbar)

Category

Supply pressure

Low Heat Injection min.

High Heat Injection

G20 20.0 +/- 1 3.1 +/- 0.1 8+/- 0.2

G25 (Groningue) 25.0 +/- 1.3 3.9 +/- 0.1 10.4 +/- 0.2

G31 (GPL) 37.0 +/- 1.9

12.6 +/- 0.3 28.3 +/- 0.6

HEATING : GAS BURNER 180 & 240kW

Fig.22

FLEXYII-IOM-0409-E Page 55

BURNER SAFETY CHECKS

Smoke extractor pressure switch Test.

- With the gas burner running, disconnect the flexible tube fitted to the pressure taping on the pressure switch (Fig.

23).

- The Flame must disappear and the extraction fan must carry on running.

- However, NO fault will be displayed (Gas ignition control block or CLIMATIC).

- After reconnecting of the tube, the Burner will restart after a period of 30 to 45 seconds pre-ventilation.

Gas pressure switch test

-With the gas burner running, close the shut off valve located before the rooftop. (fig. 24)

-The burner stops completely.

-However, No fault light will be displayed on the Gas ignition control block. After 6 Minutes, the CLIMATIC will display a fault.

-Reset the CLIMATIC.

Ionisation Probe test

- With the gas burner running, disconnect the terminal plug coming from the ionisation probe to the gas ignition control box.

-The flame disappears

-The fan is still running and attempting to restart the burner (restart cycle 30 to 45 seconds).

-if the ignition probe is not reconnected at the end of the ignition sequence the burner will stop completely.

-The fault light on the gas ignition control block is ON.

-Manually reset the gas ignition control block to eliminate the fault

IN CASE OF PROBLEMS REFER TO THE START UP SEQUENCE FLOWCHART NEXT PAGE

Fig. 23

HEATING : GAS BURNER

Fig. 24

FLEXYII-IOM-0409-E Page 56

GAS BURNER FIRE-UP SEQUENCE

HEATING : GAS BURNER

Operation from control

Thermostat GAZ =Closed

Supply Thermostat Limit?

(Auto Reset)

Fault on CLIMATIC

Extraction Fan ON

AIR Pressure Switch ON

Backfire Thermostat ON?

Gas Control

Valve Closes

BURNER

STOPS

Gas Low Pressure switch?

Gas Ignition Control Block Signal

Normal Operation

6 Minutes Delay

Pre-Ventilation 30 seconds

Fire-up Electrode 4s

Gas Valve Open

Ionisation 1second after

the end of sparking?

Gas Valve remains Open

Gas Control

Valve Closes

BURNER STOPS

Fault on Gas

Control Block

Signal from Ionisation

Air Press Switch ON

YES

FLEXYII-IOM-0409-E Page 57

GAS BURNER TROUBLESHOUTING

If faults reported on CLIMATIC

-Reset the CLIMATIC.

-Check voltage: 230V after circuit breaker.

-Check GAS isolation shut-off valves are open.

-Check GAS pressure at the inlet of the GAS valves. It must be >20 mbar when the Burners shut down.

-Adjust the set points to priorities the burner. Increase the value of the room temperature set point to a temperature higher than actual room temperature.

DIAGNOSTIC TABLE BALTIC GAS BURNER

STAGE

NORMAL

OPERATION

POSSIBLE

FAULT

ACTION POSSIBLE SOLUTION

Fault on the blower thermostat

+ Check connections on the blower thermostat.

+ Replace thermostat

Lack of gas supply

+ Check valve’s opening & supply pressure + Restore gas supply

Heating

Requested

Extraction fans

start

Fault on the superheat thermostat on the gas burner support bar

+ Check superheat thermostat’s operation after manual reset

+ Replace superheat thermostat

After 10 seconds safety shutdown by the ignition control block

+ Check connections of the control block on the gas valve

+ Repositioning of the control block on the valve + Replace valve

Starting of

the

extraction

fans

Extraction Fans

are running

Nothing happens

+ Check the free movement of the fan wheel + Check Electrical connection on the Gas Ignition Control Block and on EF connection Board + Check the Fan supply voltage

+ Replace fan + Replace EF connection board If necessary

Extraction Fan is ON

After 30 to 45 seconds: preventilation the

fire-up

electrode

should spark.

Continuous Ventilation without sparks from fire-up electrode

+ Check the fire-up electrode + Check the pressure drop at the pressure switch: It must be higher than 165 Pa +Check the good operation of the pressure switch using an Ohmmeter and by artificially creating a depression in the tube.

+ Re-position the pressure switch tube. + Change the pressure switch.

After 4 seconds the GAS Burner still not operating and safety shutdown by the Ignition Control Block.

+ Check injection pressure during start-up (Value for High Heat) +Remove the control box from the gas block.

+ Remove the air from the Gas pipe-work + Adjust the injection pressure to high heat value. + Change the Control Box if the Gas valve is OK.

Continuous

ventilation

and sparks

from fire up

electrode.

After a few

seconds the

gas burner

fires-up

Within 4 seconds the gas Burner fires-up BUT safety shutdown from the Ignition Control Block.

+ Check the Position and connection of the Ionisation Probe. It must not be Earthed (230V). + Measure the Ionisation Current: It must be higher than 1.5 microAmps. + Check the Type of GAS.

+Check the whole electrical supply. + Adjust the supply and injection pressure if gas is different from natural gas G20 :( G25 Gas of Groningue for example).

HEATING : GAS BURNER

FLEXYII-IOM-0409-E Page 58

DISASSEMBLING THE GAS BURNER FOR MAINTENANCE PURPOSES

Preliminary Safety Recommendations

- Isolate the unit using the main isolator switch.

- Close off the isolating gas valve located before the unit.

- Disconnect the Pipe-work. Do not discard the seals.

Disassembling the gas «burner support bar»

- Disconnect the Electrical Connector on the electric connection board EF47

- Remove the two screws which hold the gas Bar in Place

-Carefully remove the gas « burner support bar » avoiding any damages to the electrodes.

Disassembling the flue

- Electrically disconnect the fan and remove the screws holding it in place.

-Take care not to loose any cage nuts in the smoke box.

ATTENTION: Check the correct position of the pressure tube used by the extraction pressure switch.

Required Equipment List for maintenance Adjustment and Start-up

- An accurate manometer from 0 to 3500 Pa (0 to 350 mbar): 0.1% full scale.

- A Multimeter with Ohmmeter and Micro-amps scale

- An Adjustable Spanner

- Tube Spanner Set: 5, 7, 8, 9, 10, and 13.

- Flat spanner: 5, 7, 8 & 9

- Flat Screwdrivers diameter 3 and 4, Fillips n°1

- Vacuum cleaner

- Paint brush

GAS BURNER SUPPORT BAR

HEATING : GAS BURNER

FLEXYII-IOM-0409-E Page 59

60kW

120kW

HEATING : GAS BURNER

FLEXYII-IOM-0409-E Page 60

180kW

240kW

HEATING : GAS BURNER

FLEXYII-IOM-0409-E Page 61

MODULATING GAS (UNDER PATENT INPI May 2004)

The actuator

The actuator receives an information 0-10V from the regulation for the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valve.

Check position and operation of the actuator

STARTING UP THE GAS BURNER

Purge the pipe-work near the connection on the ignition control Valve for a few seconds.

- Check that the unit's Treatment Fan Blower is running.

- Set the control to “ON” This will priorities the gas burner.

- Increase the set temperature (room set point temperature) to a temperature higher than the actual room temperature.

The start of the gas burner must be done at high heat

injection.

Manual rotation

of the actuator

Disengaging for

hand drive operation

HEATING : MODULATING GAS BURNER 60 & 120kW

Actuator screw

Bearing surface of

the actuator’s screw

Maximum opening

Minimum opening

FLEXYII-IOM-0409-E Page 62

PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE

REGULATING VALVE

VK4105MB AND ON ELECTRONIC BOARD

W4115D1024

Pressure regulator adjustment with 300mbars gas supply:

- The Burner must run in High Heat mode for this check.

- Place the tube of the “accurate” manometer on the Inlet pressure port (Figure 25) of the Gas Regulating Valve after having loosened the screw by one turn

Check and adjust if necessary the valve Inlet pressure to

20.0mbar (G20) or 25.0mbar for Groningen (G25) after gas burner ignition (fig.26)

High & Low heat injection pressure check:

Electronic board W4115D1024

There is one board for two valves

Regulating valve VK4105MB

Electrical connections

HEATING : MODULATING GAS BURNER 60 & 120kW

230V power supply

Potentiometer

called

« CURRENT »

Switches in

position 3 for an

output intensity

varying until

330m

INPUT

OUTPUT

Actuator 0/10V

Common (wire 01

of the 24V)

Solenoid valve power

supply

Inlet pressure

measuring port

Adjusting nut (5mm) Minimum

Adjusting nut (8mm)

Minimum Pressure

Fig. 25

Fig. 26

FLEXYII-IOM-0409-E Page 63

- Check the 230V supply voltage of electronic board: the phase on terminal 01 and the neutral conductor on terminal 02

- Check the wiring of the signal 0-10V between terminal 64 (polarity 01 of the 24V) and terminal 66 (+ coming from the actuator)

- Check the connection of the modulating solenoid valve between the electronic board’s terminals 61 & 62

- Select the operating mode n°3 “output 0-330mA”:

• Switch n°1 Æ ON

• Switch n°2 Æ OFF

High heat:

- Place the potentiometer called “current” on position Max.

- Apply 9V to the climatic output; the actuator and the gas valve position themselves in full opening and the burner starts.

- Regulate the value of the maximum flow at 10.4mbar (for natural gas and at approximately 13.1mbar for Groningen gas) by operating on the adjusting nut called “maximum pressure”.

Low heat:

- Place the potentiometer called “current” on position Min

- Regulate the value of the minimum flow at 2 mbar (for natural gas and at approximately 2.6 mbar for Groningen gas) by operating on the adjusting nut called “minimum pressure”.

- Bring back the potentiometer towards the position + until obtaining the desired 10.4mbar in high heat for natural gas.

- Check the pressure values for high and low heat using the climatic output and refine the

adjustments thanks to the nuts of the solenoid valve.

- Check that by applying 10V to the climatic output, we do not exceed the maximum pressure (10.4mbar for natural gas).

- Ditto, by disconnecting the power supply of the solenoid valve, check that the pressure is the same one as the minimum pressure regulated previously.

- Check the good reaction of the Honeywell board’s

regulation by applying 7V to its input; it must already act on the position of the actuator and on the gas flow, which must have a value lower than the max flow ones.

HEATING : MODULATING GAS BURNER 60 & 120kW

FLEXYII-IOM-0409-E Page 64

MODULATING GAS (UNDER PATENT INPI May

2004)

The actuator

The actuator receives an information 0-10V from the regulation for the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valve.

Check position and operation of the actuator

STARTING UP THE GAS BURNER

Purge the pipe-work near the connection on the ignition control Valve for a few seconds.

- Check that the unit's Treatment Fan Blower is running.

- Set the control to “ON” This will priorities the gas burner.

- Increase the set temperature (room set point temperature) to a temperature higher than the actual room temperature.

The start of the gas burner must be done at high heat

injection.

Manual rotation

of the actuator

Disengaging for

hand drive operation

HEATING : MODULATING GAS BURNER 180 & 240kW

Actuator screw

Maximum opening

Minimum opening

FLEXYII-IOM-0409-E Page 65

PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE

REGULATING VALVE

VR4605MB AND ON ELECTRONIC BOARD

W4115D1024

Pressure regulator adjustment with 300mbars gas supply:

- The Burner must run in High Heat mode for this check.

- Place the tube of the “accurate” manometer on the Inlet pressure port (Figure 27) of the Gas Regulating Valve after having loosened the screw by one turn

Check and adjust if necessary the valve Inlet pressure to

20.0mbar (G20) or 25.0mbar for Groningen (G25) after gas burner ignition (fig.28)

High & Low heat injection pressure check:

Electronic board W4115D1024

There is one board per valve

Regulating valve VK4605MB

230V power supply

Potentiometer

called

« CURRENT »

Switches in

position 3 for an

output intensity

varying until

330mA

INPUT

OUTPUT

Actuator 0/10V Common (wire 01

of the 24V)

Solenoid valve power

supply

Inlet pressure

measuring port

Adjusting nut (7mm) Maximum Pressure

Adjusting nut (9mm)

Minimum Pressure

Electrical

connections

HEATING : MODULATING GAS BURNER 180 & 240kW

Shaft

Fig. 27

Fig. 28

FLEXYII-IOM-0409-E Page 66

- Check the 230V supply voltage of electronic boards: the phase on terminal 01 and the neutral conductor on terminal 02

- Check the wiring of the signal 0-10V between terminal 64 (polarity 01 of the 24V) and terminal 66 (+ coming from the actuator)

- Check the connection of the modulating solenoid valve between the electronic board’s terminals 61 & 62

- Select the operating mode n°3 “output 0-330mA”:

• Switch n°1 Æ ON

• Switch n°2 Æ OFF

The minimum pressure setting must first be adjusted to ensure that burner will safety light up, then maximum pressure setting can be adjusted. Any adjustment of the minimum pressure influences the maximum pressure setting. Any adjustment must be done with flat

spanners.

Adjustment of the W4115D1024 board’s potentiometer:

- Connect the Multimeter with MicroAmps scale in serial with the MODUREG.

- To prevent hysteresis, place the potentiometer called “current” on position Min.

- Increase the current by

turning this potentiometer, until the desired maximum current is obtained: here, to reach 8.0mbar, we must apply 105mA, according to the curve below.

Adjusting minimum pressure setting:

- Disconnect electrical connection to MODUREG (=modulating solenoid valve)

- Regulate the value of the minimum flow at 2.2mbar (for natural gas and at 3.0 mbar for Groningen gas) by turning the adjusting nut “Maximum pressure”.

Adjusting maximum pressure setting:

- By Pushing the shaft gently

downwards to the maximum adjustment screw, you’ll see an approximate value of the maximum pressure

- Reconnect the electrical connection to MODUREG

- Regulate the value of the maximum flow at 8.0mbar (for natural gas and at 10.4mbar for Groningen gas) by turning the potentiometer called “current”, until the desired maximum pressure.

When maximum and minimum pressures are set wire the valve in the circuit.

- Now, check the good reaction of the assembly, MODUREG + electronic board, by applying 2 V to its input (=climatic 50 output); it must reach the minimum pressure (2.2mbar for natural gas)

HEATING : MODULATING GAS BURNER 180 & 240kW

FLEXYII-IOM-0409-E Page 67

60kW

120kW

HEATING : MODULATING GAS BURNER

FLEXYII-IOM-0409-E Page 68

180kW

240kW

HEATING : MODULATING GAS BURNER

FLEXYII-IOM-0409-E Page 69

FCM* FHM* FGM* FDM*

HEAT PUMP

ELECTRIC HEATER (Standard heat) 2 steps (*)

ELECTRIC HEATER (Medium heat) modulating (*)

ELECTRIC HEATER (High heat) modulating (*)

HOT WATER COIL (Standard / High heat) (*)

GAS BURNER S(*)

GAS BURNER H (*)

MODULATING GAS BURNER (*)

ECONOMISER

CENTRIFUGAL EXHAUST FAN

POWER EXHAUST FAN AXIAL

MAIN DISCONNECT SWITCH

SMOKE DETECTOR

FIRESTAT

AIR SOCK CONTROL

CO2 SENSOR

ANALOG DIRTY FILTER AND FAN PROVEN SWITCH

COMFORT DISPLAY DC50

COMFORT DISPLAY WIRELESS DC50W

SERVICE DISPLAY DS50

MULTIROOFTOP DISPLAY DM50

ADALINK

TCB

ADVANCED CONTROL PACK (ENTHALPY AND HUMIDITY CONTROL)

HEAT RECOVERY MODULE

LOW AMBIENT KIT

LOW NOISE

UV LIGHT

HIGH EFFICIENCY SUPPLY FAN

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 70

DIAGRAM REFERENCE LEGEND

– A1-2-3-4 AIR SOCK CONTROL

– B1 EXTERNAL AIR THERMOSTAT – KE1-2-3 HEATER -E1 - E2 - E3 CONTACTOR

– B2 SMOKE DETECTIO N HEAD

– B3 RC CIRCUIT

– B4 - B5 GAS MANIFOLD IONISATION PROBE – KM1 - KM2 BLOWER FAN MOTOR -MS1 - MS2 CONTACTOR

– B6 - B7 GAS MANIFOLD IGNITION ELECTRODE

– B10 AIR PRESSURE SWITCH – KM5 - KM6 EXTRACTION FAN MOTOR -ME1 - ME2 CONTACTOR

– B11 WATER FLO W RATE CONTROLLER

– B13 CLOGGED AIR FILTER PRESSURE SWITCH / AIR FLOW RATE

– B14 HOT WATER COIL ANTIFREEZE THERMOSTAT – KM9 - KM10 CONDENSER 1 / CONDENSER 2 FAN MOTOR CONTACTOR

– B15 HOT WATER COIL ANTIFREEZE THERMOSTAT – KM11 - KM12 COMPRESSOR -MG11 - MG12 CONTACTOR

– B16 FIRE THERMOSTAT – KM21 - KM22 COMPRESSOR -MG21 - MG22 CONTACTOR

– B17 - B18 GAS MANIFOLD MINIMUM GAS PRESSURE SWITCH

– B19 - B20 BLOWER FAN MOTOR -MS1 - MS2 STOP THERM

– B21 - B22 GAS MANI FOLD SMOKE EXTRACTION AIR PRESSURE SWITCH

– B23 - B24 EXTRACTION FA N MOTOR -ME1 - ME2 STOPTHERM

– B25 - B26 ELECTRIC BATTERY -E1 - E2 SAFETY KLIXON

– B27 ELECTRIC BATTERY -E3 SAFETY KLIXON

– B28 CIRCULATION PUMP -MP1 MOTOR STOPTHERM

– MC1.2 CONDENSER -MC1 - MC2 F AN MOTOR

– MC3.4 CONDENSER -MC3 - MC4 F AN MOTOR

– B29 - B30 GAS MANIFOLD AIR FLOW RATE SAF ETY KLIXON – ME1 - ME2 E XTRACTION FAN MOTOR -ME1 - ME2

– B32 - B33 GAS MANIFOLD FLASHBACK SAFETY KLIXO N – MG11 - MG12 COMPRESSOR -MG11 - MG12

– B41 - B42 COMPRESSOR -MG11 - 12/-MG21 - 22 HIGH PRESSURE SAFETY SWITCH – MG21 - MG22 COMPRESSOR -MG21 - MG22

– B45 - B46 GAS MANIFOLD 1/ GAS MANIFO LD 2 REGULATION KLIXON – MR1 ECONOMISER DAMPER MOTOR

– B51 - B52 COMPRESSOR -MG11 - 12/-MG21 - 22 LOW PRESSURE SAFETY SWITCH – MR2 BLOWER DAMPER MOTOR

– MR3 NEW AIR DAMPER MOTOR

– B61 - B62 COMPRESSOR -MG11 - 12/-MG21 - 22 HIGH PRESSURE CONTROL SWITCH – MR4 EXTRACTION DAMPER MOTOR

– B71 - B72 CONDENSER -MC1 - MC2 FAN MOTOR MOTOR STOPTHERM – MR6 BY-PASS DAMPER MOTOR

– B73 - B74 CONDENSER -MC3 - MC4 FAN MOTOR MOTOR STOPTHERM – MS1 - MS2 BLOWER FAN MOTOR -MS1 - MS2

– B811 - B812 SCROLL COMPRESSOR - MG11 - 12 PROTECTION MODULE – Q1 - Q2 B LO WER FAN MOTOR -MS1 - MS2 PROTECTION

– B821 - B822 SCROLL COMPRESSOR -MG 21 - 22 PROTECTION MODULE – Q5 - Q6 EXT RACTION FAN MOTOR -ME1 - ME2 PROTECTI ON

– Q9 CONDENSER -MC1 - MC2 FAN MOTOR PROTECTION

– B91 - B92 COMPRESSOR -MG11 - 12/-MG21 - 22 PRESSURE SWITCH 4/20mA – Q10 CONDENSER -MC3 - MC4 FAN MOTOR PROTECTION

– Q11 - Q12 COMPRESSOR -MG11 - MG12 PROTECTION

– Q21 - Q22 COMPRESSOR -MG21 - MG22 PROTECTION

BCD CONDENSER COIL

BEC HOT WATER CO IL

BEG CHI LLED WATER COIL

BEV EVAPORATOR COIL

– BG10 HYGIENE PROBE – QF1 PRIM ARY CIRCUIT PROTECTI ON -T1

– BH10 REGULATION HYGROMETRY PROBE – QF2 PRIMARY CIRCUIT PROTECTION -T2

– BH11 EXTERNAL HYGROMETRY PROBE – QF3 PRIMARY CIRCUIT PROTECTI ON -T3

– BT10 REGULATION TEMPERATURE PROBE

– BT11 EXTERNAL TEMPERATURE PROBE – QG MAIN SWITCH

– BT12 BLOWER TEMPERATURE PROBE

– BT13 COLD WATER TEMPERATURE PROBE – QE1-2-3 HEATER -E1 - E2 - E3 PROTECTION

– BT14 CONDENSER 1 SPEED REGULATION TEMPERATURE PROBE

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 71

FCM

= Cooling only unit

FHM

= Heat pump unit

FGM

= Cooling only unit with gas fired heating

FDM

= Heat pump unit with gas fired heating

MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 72

MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 73

CLIMATIC 50 CONTROLER

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 74

CLIMATIC 50 INPUT FCM / FHM / FGM / FDM

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 75

CLIMATIC 50 OUTPUT FCM / FHM / FGM / FDM

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 76

DAD SMOKE DETECTOR

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 77

GENERAL CUSTOMER CONNECTION TCB

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 78

GENERAL CUSTOMER CONNECTION WITH ADVANCED CONTROL PACK (ADC)

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 79

WIRING DIAGRAM GAS BURNER 60 kW and HOT WATER COIL

ELECTRICAL DATA : WIRING DIAGRAMS

HOT WATER COIL

FLEXYII-IOM-0409-E Page 80

WIRING DIAGRAM GAS BURNER 120kW

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 81

WIRING DIAGRAM GAS BURNER 180 / 240kW

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 82

WIRING DIAGRAM ELECTRIC HEATER

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 83

GENERAL CUSTOMER CONNECTION DIAGRAM

ELECTRICAL DATA : WIRING DIAGRAMS

FLEXYII-IOM-0409-E Page 84

STANDARD

Logical Output Board

(2 outputs: 1 assigned, 1 customized)

DO 1 - Alarm, General DO 2 - Customized (choose 1 output between those 7 possibilities)

- Alarm, Filters

- Alarm, Blower

- Alarm, Compressors

- Alarm, Gas

- Alarm, Electric Heater

- Alarm, Hot Water Coil Freezing

- Alarm, Smoke detector

- Heating mode

- Humidifier

- Zone A, Activated

- Zone B, Activated

- Zone C, Activated

- Zone Uno, Activated

- Zone BMS, Activated

- Free, for BMS

Logical Input Board

(4 inputs: 2 assigned, 2 customized)

DI 1 - ON/OFF DI 2 - Reset alarm DI 3 & 4 - Customized (choose, for each input (2) between those 12

possibilities)

- Zone Uno Activate

- Disable, Compressors & Heaters

- Disable, Compressors

- Disable, 50% Compressors

- Disable, Heaters

- Disable, Cooling

- Disable, Heating

- Fault contact, Humidifier

- 0 % Fresh air

- 10 % Fresh air

- 20 % Fresh air

- 30 % Fresh air Those contacts add up

- 40 % Fresh air

- 50 % Fresh air

- 100 % Fresh air

- Free, for BMS

ADVANCED CONTROL PACK OR TCB

Logical Output Board

(4 outputs: 0 assigned, 4 customized)

DO 3 to 6 - Customized (choose, for each input (4) between those 7

possibilities)

- Alarm, Filters

- Alarm, Blower

- Alarm, Compressors

- Alarm, Gas

- Alarm, Electric Heater

- Alarm, Hot Water Coil Freezing

- Alarm, Smoke detector

- Heating mode

- Humidifier

- Zone A, Activated

- Zone B, Activated

- Zone C, Activated

- Zone Uno, Activated

- Zone BMS, Activated

- Free, for BMS

Logical Input Board

(4 outputs: 0 assigned, 4 customized

)

DI 5 to 8 - Customized (choose, for each input (4) between those 12 possibilities)

- Zone Uno Activate

- Disable, Compressors & Heaters

- Disable, Compressors

- Disable, 50% Compressors

- Disable, Heaters

- Disable, Cooling

- Disable, Heating

- Fault contact, Humidifier

- 0 % Fresh air

- 10 % Fresh air

- 20 % Fresh air

- 30 % Fresh air Those contacts add up

- 40 % Fresh air

- 50 % Fresh air

- 100 % Fresh air

- Free, for BMS

Analogue Input Board

(4 outputs: 0 assigned, 2 customized)

AI 1 & 2 - Customized (choose, for each input (4) between

those 4 possibilities)

- Override room temp set point -5 +5°C (4-20mA)

- Override fresh air set point 0-100% (4-20mA)

- Weather Temperature -40°C +80°C (4-20mA)

- Weather Humidity 0% 10% (4-20mA)

- Free temperature (NTC probe)

- Free relative humidity (4-20mA)

ELECTRICAL DATA : CONTROL VARIABLES

FLEXYII-IOM-0409-E Page 85

REFRIGERANT DEFINITION

R-410A is an HFC, or hydro fluorocarbon, and is made of hydrogen, fluorine, and carbon atoms. Because it has no chlorine, it won’t interact with the ozone layer once it breaks down. It’s non-toxic and non-inflammable.

CHEMICAL CHARACTERISTICS OF REFRIGERANT

*1 see table below :

Refrigerant Safety classifications from ASHRAE Standard

Lower toxicity Higher toxicity

Higher

flammability

A3 B3

LFL≤0.10kg/m3 or

heat of

combustion≥19000k

J/kg

Lower

flammability

A2 B2

LFL>0.10kg/m3 and

heat of combustion

>19000kJ/kg

No flame

propagation

A1 B1 No LFL

No indentified

toxicity at

concentration

≤ 400ppm

Evidence of

toxicity below

400ppm

LFL = Lower Flammability Limit

*2 Based on CFC11 *3 Based on CO2

STANDARDS THAT MUST BE MET WITH R410A:

• An ester oil (POE) is used for R410A (as with

R407c)

• It’s important to work with absolute cleanliness

• Brazing must be done with the use of Nitrogen

(OFN)

• The system must be evacuated thoroughly

(0.3mbar or less)

• The system must always be charged in the liquid

phase

SATURATION PRESSURE

Saturation pressure (relative pressure in bars)

Temp. °C R22 R407C Vapor R410A

70 28.97 31.94 46.54

65 26.01 28.55 41.7

60 23.27 25.44 37.29

58 22.24 24.26 35.63

56 21.24 23.13 34.03

54 20.27 22.04 32.49

52 19.33 20.99 31.01

50 18.43 19.98 29.57

48 17.55 19 28.19

46 16.70 18.05 26.86

44 15.89 17.14 25.57

42 15.10 16.26 24.33

40 14.34 15.42 23.14

38 13.60 14.61 21.99

36 12.89 13.82 20.88

34 12.21 13.07 19.81

32 11.55 12.35 18.79

30 10.92 11.65 17.8

28 10.31 10.99 16.85

26 9.72 10.35 15.93

24 9.16 9.73 15.06

22 8.62 9.14 14.21

20 8.10 8.58 13.41

18 7.60 8.04 12.63

16 7.12 7.52 11.89

14 6.67 7.03 11.17

12 6.23 6.55 10.49

10 5.81 6.1 9.84

8 5.41 5.67 9.21

6 5.03 5.26 8.61

4 4.66 4.87 8.04

2 4.31 4.5 7.5

0 3.98 4.14 6.98

-2 3.66 3.81 6.48

-4 3.36 3.49 6.01

-6 3.08 3.19 5.56

-8 2.81 2.9 5.14

-10 2.55 2.63 4.73

-12 2.30 2.37 4.35

-14 2.07 2.13 3.98

-16 1.85 1.9 3.64

-18 1.65 1.68 3.31

-20 1.45 1.48 3

Name R22 R407C R410A

Component HCFC22

HFC32/HFC12

5/HFC134a

HFC32/HFC1

Composition (%) 100 23/25/52 50/50

Type of refrigerant

Single

refrigerant

Non-azeotropic

refrigerant

mixture

Near azeotropic refrigerant

mixture

Chlorine Contained Not contained Not contained

Safety Class *1 A1 A1/A1 A1/A1

Ozone Depletion

Potential (ODP) *2

0.055 0 0

Global Warming

Potential (GWP) *3

1700 1530 1730

Refrigerant charging

method

Gas

change

Refrigerant is

taken out from

the liquid

phase of gas

cylinder

Refrigerant is

taken out from

the liquid

phase of gas

cylinder

Additional charge

due to refrigerant

leakage

Possible

temporarily

Possible

R410A

FLEXYII-IOM-0409-E Page 86

PERATION MODE EXPLANATION

 Protection is activated when Scroll Discharge

Port. Reaches 150°C

(+/- 17K)

 Compressor is protected as « Unloaded » but

continues to run

• Protection mode balances

discharge/suction pressure

- Motor heat builds inside

compressor

- No refrigerant flow to carry

motor heat away

 Motor protector opens (Klyxon)

• Compressor turns off, cools

 Motor protector resets, compressor restarts

• Bi-metal disk resets before motor

protection

• Cycle will continue until cause of

overheat is fixed

SERVICE A COMPRESSOR

 What to do?

• If a protected compressor is identified

- Stop the compressor

- Allow to cool thoroughly

- Restart pump & check for

normal operation

 DO NOT ASSUME A COMPRESSOR RUNNING

UNLOADED (BALANCE PRESSURE) IS A FAILURE

 Likely situations where protection may activate :

• Initial system charging (or recharging after

servicing)

- Compressor is run with too little

system charge

 Very common on split

system

 Will result in very low

suction pressures (<1.7 Bars)

 Do not disable low

pressure cutouts while charging

 Charge high-side with

liquid first

• Field servicing (system problem causes

overheating)

- Technician will observe

« Balanced pressures »

- Risk of misdiagnosis as failed

compressor

- Must stop pump, cool

thoroughly, reset

ADVANCED SCROLL TEMPERATURE PROTECTION (ASTP)

Temperature Behavior with ASTP Protection

120

150

180

0 20 40 60 80 100 120 140 160

Time (Minutes)

Temperature (°C)

DISC OPENS,

SCROLLS UNLOAD

Compressor Runs

Balanced

Pressures

PROTECTOR RESETS,

PUMP RESTARTS FULLY

LOADED

MOTOR PROTECTOR

OPENS, PUMP TURNS

OFF

Discharge

Port

Klyxon

ASTP

Compressor

off

FLEXYII-IOM-0409-E Page 87

BCD1.2

CONDENSER COIL

BEC HOT WATER COIL

BEV EVAPORATOR COIL

CA1.2 CHECK VALVE

DT1.2 THERMOSTATIC EXPANSION VALVE

FD1.2 FILTER DRIER

- B14 - B15 HOT WATER COIL ANTIFREEZE THERMOSTAT

- BT12 BLOWER TEMPERATURE PROBE

- BT17 RETURN REGULATION TEMPERATURE SENSOR

- B41 - B42 COMPRESSOR -MG1 - MG2 HIGH PRESSURE SAFETY SWITCH

- B51 - B52 COMPRESSOR -MG1 - MG2 LOW PRESSURE SAFETY SWITCH

- B61 - B62 COMPRESSOR -MG1 - MG2 HIGH PRESSURE CONTROL SWITCH

- MC1 - MC2 CONDENSER -MC1 - MC2 FAN MOTOR

- MC3 - MC4 CONDENSER -MC3 - MC4 FAN MOTOR

- MG11 - MG12 COMPRESSOR -MG1 - MG2

- MG21 - MG22 COMPRESSOR -MG3 - MG4

- MS1 - 2 BLOWER FAN MOTOR -MS1

VAM1.2 MANUAL CHECK VALVE

VRM MANUAL REGULATION VALVE

- YV2 HOT WATER 3-WAY VALVE

- YV11 - YV12 COMPRESSOR -MG1 - MG2 REVERSAL CYCLE VALVE

FCM 085 to 120

FHM 085 to 120

PRINCIPLE SKETCHES

FLEXYII-IOM-0409-E Page 88

FCM 150

FHM 150

PRINCIPLE SKETCHES

FLEXYII-IOM-0409-E Page 89

FCM 170

FHM 170

PRINCIPLE SKETCHES

FLEXYII-IOM-0409-E Page 90

FCM 200 & 230

FHM 200 & 230

PRINCIPLE SKETCHES

FLEXYII-IOM-0409-E Page 91

HOT WATER COIL DIAGRAM

PIPE DIAMETERS

1 ROW 2 ROWS 085 25 32 100 25 32 120 25 32

150 32 40 170 32 40

200 32 40 230 32 40

HOT WATER

FLEXYII-IOM-0409-E Page 92

REFRIGERATION

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

Measure the superheat and sub-cooling:

Good if 5°C<SC<10°C and 5°C<SH<10°C

Bad if SC>10°C and SH too Low

Refrigerant charge too low

Check superheat adjustment and charge unit (a

leak check must be carried out)

In Heat Pump Mode the temperature difference

between T outdoor and Tevap. (Dew) is too high

5°C < Delta T < 10°C excellent

10°C < Delta T < 15°C acceptable

15°C < Delta T < 25°C too high

If too high check the coils are clean or check coil

internal pressure drop between the liquid line and

the suction line

Good if < 3bar

Too high if > 3bar (coil blocked)

Refrigeration circuit blocked in distribution

Stop the fan and create icing of the coil.

Check all circuits freeze evenly across the whole

surface of the coil

If some parts of the coil do not freeze this could

indicate a problem with the distribution

Liquid line drier blocked. High temperature

difference between inlet and outlet of the drier

Change filter drier

Contaminant in the expansion valve

Attempt to free the valve adjusting element by

freezing the valve and then heating the

thermostatic element. Replace the valve if

necessary

Expansion valve not adjusted properly Adjust the expansion Valve

Ice plug in the expansion valve.

Heat the main body of the valve. If the LP

increases and then decreases gradually, empty

the circuit and replace the drier.

Incorrect insulation of the thermostatic bulb of

the expansion valve

Superheat too low: adjust superheat Move the thermostatic element along the pipe Insulate the Thermostatic element of the valve

Low Pressure Switch cut out point too high

Check the cut out pressure of the Low Pressure

switch: It must be 0.7+/- 0.2bar and must closes

at 2.24 +/- 0.2 bar

LP PROBLEMS and

LP CUT OUTS

LP cut out due to not enough defrost on heat

pumps

Adjust the CLIMATIC settings to extend the

defrost cycles or shorten the time between

defrosts

Incorrect Airflow rates

Heat pump mode:

Check the filter before the indoor coil

measure and estimate the airflow rate

increase the speed of the fan

Cooling mode:

Check the condenser fan (Amps)

HP PROBLEMS AND HP CUT OUTS

Moisture or contaminants in the system

Summer operation

Several hours after the unit has stopped, check

the correspondence between the measured

pressure and the outdoor temperature

MAINTENANCE DIAGNOSTIC

FLEXYII-IOM-0409-E Page 93

Moisture or contaminants in the system

If the circuit pressure is higher (<1bar) than the

saturated pressure corresponding to the measured outdoor temperature, there is

possibility that some contaminants are present in

the system.

Reclaim the refrigerant, and vacuum the circuit

(Ensure very low and slow vacuum for R407c)

Recharge the unit

Condenser coil is obstructed Check the condenser coil and clean is necessary

HP PROBLEMS AND HP CUT OUTS

Recycled Hot Air Check clearance around the condenser

Incorrect adjustment of the expansion valve

Low refrigerant charge

Strong variations of

pressure ( 2 to 3 bar)

Thermostatic

Expansion Valve

"hunting"

Filter drier obstructed with gas bubbles at the

expansion valve inlet

Moisture in the system

Refer to LP problems and LP cut out section

Very high superheat, very hot compressor

Open the superheat adjustment on the expansion

valve.

Check the pressure drop on the filter drier in the

suction line

Very high discharge

temperature,

High amps measured

at compressor

Four Way reversing valve possibly blocked,

abnormal noise from the valve, low LP and

increasing HP

Check operation of the valve by going through

cycle inversions. Change if necessary.

Refer to LP problems

INDOOR FAN BLOWER

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

High amps on action

Fan motor

Pressure drop in the ducting installation too low.

Reduce the rotation speed of the fan

Measure and estimate the airflow and pressure

and compare with the specification from

customer.

High amps on reaction

Fan motor

Pressure drop in the ducting installation too high.

Reduce the rotation speed of the fan

Measure and estimate the airflow and pressure

and compare with the specification from

customer.

Unstable running and

high vibration

Fan jumping from one operating point to the

other

Change rotation speed of the fan.

OUTDOOR AXIAL FAN

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

High Amps due to a low voltage from the main

supply

Check the voltage drop when all components are

running.

Change the circuit breaker for one with a higher

rating.

High amps due to freezing of the coil

Check the adjustable amps on the motor starter.

Adjust the defrost cycle set points.

Heat Pump mode:

Circuit breaker open

Flexy: Water ingress in the motor connection

box.

Change the component

MAINTENANCE DIAGNOSTIC

FLEXYII-IOM-0409-E Page 94

ELECTRICAL HEATER

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

Low airflow rate

Measure and estimate the airflow and pressure

and compare with the specification from

customer.

High Temperature trip

out on electric heater

Incorrect position of the Klixon

Check that the Klixon, is positioned in the airflow,

relocate Klixon if necessary

Check that there is no heat transfer from the

Klixon support.

WATER LEAKS

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

Cooling mode:

Water carried away from the coil because of

excessive airflow and speed on the coil.

Estimate the airflow rate and check the speed is

lower than 2.8 m/s

Low air pressure in the compartment due to a

high airflow rate or a high pressure drop before

the fan

Check filter

Reduce airflow rate

Water found in the

ventilation section

Check seals around the ventilation section.

Check the door seal

Check for the presence of silicone seals in the

corners of the door and at the bottom of the

refrigeration section bulkhead.

Water ingress in the

filter compartment

Water ingress through a leaking fresh air hood or

when running 100% fresh air

Check the seals and flanges in the fresh air hood

Reduce the airflow rate if necessary

DC50 & DS50

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

DC50: Nothing is

written on the screen

but it’s enlightened

Problem of addressing pLAN on the DC50

Press on the three right-hand side’s buttons at

the same time during a few seconds then

reconfigure the terminal address

(Confer DC addressing procedure)

DS50: Nothing is

written on the screen

but it’s enlightened

Idem

Press on the three right-hand side’s buttons at

the same time during a few seconds then reconfigure display address setting at 32.

Nothing occurs on the

unit or an option

disappeared

Possible problem of units' configuration

Check the instructions from 3811 to 3833 and

reconfigure options if necessary.

DS50 & DC50: the message “No Link”

appears

Problem of addresses’ recognition

Disconnect the DS50 from the unit and then

reconnect it.

All the units are extinct Problem BM50 pLAN addressing

Disconnect then re-plug; disconnect each unit

from the others then change all the pLAN

addresses

MAINTENANCE DIAGNOSTIC

FLEXYII-IOM-0409-E Page 95

Rooftops are generally placed on the roof but can also be installed in technical rooms. These units are very robust but minimum regular maintenance is required. Some moving parts in the units can suffer from wear and tear and must be checked regularly (belts). Other parts can get clogged by dirt carried in the air (filters) and must be cleaned or replaced.

These units are designed to produce cooled or heated air through the use of a refrigeration vapour compression system, it is therefore imperative to monitor the refrigeration circuit operating pressures and check the pipe-work for leaks.

The table below, details a possible maintenance plan, including the operations to be carried out and the periodicity at which they must be accomplished. It is recommended to follow such a plan to keep a rooftop unit in good working order. Regular maintenance of your rooftop will extend its operating life and reduce operating faults

Symbols and Legend:

o Operation which can be carried out by on-site maintenance technicians.

[] Operation which must be carried out by qualified refrigeration personnel, trained to operate on this type of equipment.

NOTE :

• Times are given for information purpose only and may vary depending on the unit size and type of installation.

• Coil cleaning must be carried out by qualified personnel using appropriate methods that won’t damage the fins or the tubes.

• It is recommended to keep a minimum stock of common replacement parts in order to be able to carry out regular

maintenance operations (i.e. filters). You can contact your local Lennox representative which can assist you in establishing a parts list for each type of equipment.

• The access ports to the refrigeration circuits MUST be leak checked every time gauges are connected to the service ports

MAINTENANCE PLAN

FLEXYII-IOM-0409-E Page 96

Task Operating mode

Monthly

Quarterly

6 monthly

Yearly B4

winter

Estimated

Time

(min)

Clean or replace filters: Disposable, or

metal frame.

Replace filters with new ones if disposable. Vacuum clean

or blow the dirt. Wash and dry carefully. Replace media

if necessary

Blocked filter will reduce the performance of the unit.

THE UNIT MUST NOT OPERATE WITHOUT FILTERS

o 20

Visual check of the oil level

Visually check the oil level through the sight glass on the

side of the compressor casing

o 2

Position check of the compressor

crankcase heater.

Check the heating resistance is fitted properly and tight

around the compressor body.

o 2

Belt tension check. Check belt tension (Info in IOM) Replace belt if necessary. o 10

Centrifugal fan bearings check

Isolate unit from the main power supply; Push the fan

wheel manually and check for abnormal noises. Bearings

are lubricated for life but may need replacement after

10000 hours

o 10

Check absorbed Amps

Check absorbed Amps on all three phases; compare with

the nominal value given in the electrical wiring diagram.

[] 15

Check Smoke detector

Start the unit. Trigger the smoke detector by moving a

magnet around the detector head. Reset unit and control.

[] 5

Check Climatic control, set-points and

variables

Refer to the commissioning sheet; Check all set points are

set according to this document.

[] 15

Check clock settings Check the time and date of the control o 5

Check the position and tightness of

refrigeration components

Check systematically all connections and fixings on the

refrigeration circuit. Check for oil traces, eventually a leak

test should be conducted. Check operating pressures

correspond to the ones indicated on the commissioning

sheet

[] 30

Check Airflow rate safety switch (if

fitted).

Shut down supply fan. The fault must be detected within 5

seconds.

Check freeze protection on HWC [] 5

Check three way valve on HWC

Increase room set-point 10°C above the actual room

temperature. Check operation of the piston. It must move

away from the valve head. Reset the control.

[] 5

Check economiser actuator operation

Check all fixings and transmission. Stop the unit using the

control. The fresh air damper must close. Start the unit the

fresh air damper should open

[] 5

Check refrigeration 4way valve

With the unit running in cooling mode increase the room

set-point temperature by 10°C. The unit should switch to

heat pump mode. Reset the control.

[] 5

Check tightness of all electrical

connections

Power down the unit and check and tighten all screws,

terminal and electric connections, taking a particular

attention to the power lines and low voltage control wires

O 30

MAINTENANCE PLAN

FLEXYII-IOM-0409-E Page 97

Check HP / LP safety switches

Install manifold gauges on the circuit to be checked. Shut

down the axial fans and wait for the HP switch to shut

down the compressor: 29bar (+1 / -0) auto-reset 22bar (+

- 0.7) Reconnect fans. Switch off the centrifugal supply fan and wait for the LP switch to cut out: 0.5bar (+ - 0.5) reset

1.5bar (+-0.5).

[] 15

Check outdoor fans and fan guards

Check the fan blades conditions and all fan guards and

protections

o 5

Check position of all sensors

Check the good positioning and operation of all sensors of

all sensors. Check the values given in the control system.

Replace sensor if necessary

o 5

Check and clean if necessary all fresh

air grilles

Check the fresh air grilles (if fitted). If dirty or damaged,

remove them from unit and clean with high pressure water

cleaner. Refit on unit once clean and dry.

o 5

Clean condensate drain, indoor and

outdoor coils (following local

regulations)

Visually check the coils for dirt. If not too dirty, cleaning

with a light brush may be enough (WARNING: Fins and

copper tubes are very fragile! Any damage WILL reduce

the performances of the unit). If very dirty, deep industrial

cleaning is required using de-greasing agents.(External

contractors must be called).

o / []

1h if

cleaning

Check electric heater element for

excessive corrosion

Isolate the unit; Pull the electric heater out of the heater

module box and check the resistances of traces of

corrosion; Replace resistance as required;

1h if

replacement

Check anti-vibration mountings, for

wear and tear.

Visually check anti-vibration mountings on compressors

and centrifugal fan. Replace if damaged.

1h if

replacement

Check refrigeration circuit for traces of

acid in the oil

Take a sample of oil from the refrigeration circuit. []

Check Glycol concentration in the HWC

circuit

Check the glycol concentration in the pressurised water

circuit. ( a concentration of 30% gives a protection down to

aprox. -15°C) check the circuit pressure

[] 30

Check defrost cycle with 4-way valve

inversion.

Switch the unit to heat pump mode. Change the set point

to obtain the standard defrost mode and reduce the cycle

time to the min value. Check the operation of the defrost

cycle.

[] 30

Gas burner module check for corrosion

Pull out the burner to access the tubes (refer to Gas burner

section in the IOM)

[] 30

Sweeping and cleaning the gas burner

Clean the in-shot burners and the blower wheel lightly with

a brush. Sweep the flue and flue box. Wipe-off the dust

from the housing of the motor. Clean combustion air inlet

louvers Pull-out baffles from the tubes, sweep the tubes

CHECK FLUE BOX GASKET

[] 30

Gas supply pressures / connections

checks

refer to Gas burner section in the IOM for details [] 15

Gas regulation valve settings refer to Gas burner section in the IOM for details [] 30

Check gas burner safety switches refer to Gas burner section in the IOM for details [] 30

MAINTENANCE PLAN

FLEXYII-IOM-0409-E Page 98

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.

5. Nevertheless the LENNOX coating is highly resistant to corrosion, the warranty will not be applied for rooftop installed at less than 1000m away from the sea

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 WARRANTY 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.

WARRANTY

FLEXYII-IOM-0409-E Page 99

LONGVIC SITE - ISO 9001 (2000) CERTIFICATE

Lennox FCM 200, FCM 100, FCM 120, FCM 170, FCM 230 Installation, Operating And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual