Lennox FCM 200, FCM 100, FCM 150, FCM 170, FCM 230 Installation, Operating And Maintenance Manual

lennoxemeia.com

FLEXY

FCM/FHM/FGM/FDM

FWH/FWM

Installation, operating and maintenance

Air cooled and water cooled rooftop packaged units

85 > 234 kW

FLEXYII WSHP-IOM-1307-E

TABLE OF CONTENTS

FLEXYII_WSHP-IOM-1307-E - 1 -

INSTALLATION OPERATION MAINTENANCE MANUAL

Ref. FLEXYII_WSHP-IOM-1307-E

IMPORTANT NOTICE - Safety Instructions ....................................................................................................... 2

TRANSPORT - HANDLING - WARNING .............................................................................................................. 5

Delivery checks .............................................................................................................................................. 5

Rating plate .................................................................................................................................................... 5

Storage ........................................................................................................................................................... 5

Maintenance key ............................................................................................................................................ 5

Condensate drain ........................................................................................................................................... 5

Mandatory handling devices ........................................................................................................................... 6

Dimensions and weights ................................................................................................................................. 7

Lifting the units ............................................................................................................................................... 9

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

Forklift protections .......................................................................................................................................... 10

Minimum clearance around the unit ................................................................................................................ 11

Duct connections ............................................................................................................................................ 12

WATER CONDENSING (water source heat pump only) ....................................................................................... 13

Water connection............................................................................................................................................ 13

Antifreeze ....................................................................................................................................................... 14

Water loop configuration ................................................................................................................................. 16

Pressure loss .................................................................................................................................................. 17

INSTALLATION OF A ROOF MOUNTING FRAME ............................................................................................. 18

Curbing and flashing ...................................................................................................................................... 19

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

Energy recovery installation ........................................................................................................................... 22

SERVICE MANUAL .............................................................................................................................................. 31

IMPORTANT NOTICE – Safety instructions

FLEXYII_WSHP-IOM-1307-E - 2 -

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 FWH 85 - FWH 100 - FWH 120 – FWH150 – FWH170 FW M 85 - FWM 100 - FWM 120 – FWM150 – FWM170 FXM 25 - FXM 30 - FXM 35 - FXM 40 - FXK 55 – FXM 70 - FXM 85 - FXM 100 - FXM 110 - FXM 150 - FXM 170

NOTES FOR UNIT FITTED WITH GAS BURNER:

THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL VENTILATED AREA.

IF MACHINE IS INCLUDING GAZ BURNER, MINIMUM CLEARANCE AROUND THE UNIT MUST BE AT LEAST 8 M TO ALLOW A PROPER GAZ FLUE DILUTION. IF NOT POSSIBLE, THE FRESH AIR INTAKE MUST BE DUCTED AT LEAST 8 M AWAY FROM THE GAS BURNER EXHAUST.

PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING THIS UNIT.

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

THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FO L LOWI NG CODES: GB IR GR DA NO FI IS

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

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), repr oduced, 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.

IMPORTANT NOTICE – Safety instructions

FLEXYII_WSHP-IOM-1307-E - 3 -

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 us ing 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 installat ion

- 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_WSHP-IOM-1307-E - 4 -

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

TRANSPORT – HANDLING – WARNING

FLEXYII_WSHP-IOM-1307-E - 5 -

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

Fig. 3

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-1307-E - 6 -

Handling slings to guide the

unit towards the roofcurb

Vacuum lifting beam to

position the unit

COMPLIANT

NON-COMPLIANT

MANDATORY HANDLING DE V ICES

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-1307-E - 7 -

DIMENSIONS AND WEIGHTS

FLEXY2

FCM/FHM/FGM/FDM

85

100

120

150

170

200

230

View (F, G, H box)

F BOX

G BOX

H BOX

A

mm

2200

B

mm

3350

4380

5533

C

mm

1510

1834

2134

D

mm

360

450

615

Weight of standard units FCM

kg

990

1065

1141

1442

1505

1752

2052

Weight gas unit FGM

Standard heat

kg

1097

1172

1248

1683

1746

2016

2316

High heat

kg

1167

1242

1318

1706

1769

2056

2356

WSHP

FWH/FWM

85

100

120

150

170

View (F & G box)

F BOX

G BOX

A

mm

2200

B

mm

3350

4380

C

mm

1510

1834

D

mm

360

450

Weight of standard units FWH

kg

867.7

874.7

1045.4

1225.8

1314.8

Weight gas unit FWM

Standard heat

kg

999.1

989

1174.4

1461.2

1571.6

High heat

kg

1060

1049.9

1235.3

1500.5

1610.9

F & G BOX

H BOX

A

D B C D A B C

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-1307-E - 8 -

DIMENSIONS AND WEIGHTS

LENGTH

HEIGHT

WIDTH

HOOD

WEIGHT

mm mm mm

Side

Fan

Standard

mm

kg

FXM025

4070

1635

1055

490

600

950

FXM030

4070

1635

1055

490

600

980

FXM035

4750

2255

1290

490

600

1400

FXM040

4750

2255

1290

490

600

1450

FXM055

4750

2255

1290

490

600

1600

FXM070

5050

2255

1725

890

600

1800

FXM085

5050

2255

1725

890

600

1900

FXM100

5050

2255

1725

890

600

2000

FXM110

5650

2255

2000

860

-

2620

FXM140

5650

2255

2000

860

-

2620

FXM170

5650

2255

2000

860

-

2650

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-1307-E - 9 -

LIFTING THE UNIT

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

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

INSTALLATION

FLEXYII_WSHP-IOM-1307-E - 10 -

FORKLIFT PROTECTIONS

NEVER LIFT THE UNIT WITHOUT FORKLI FT 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 struct ure?

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

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

- 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 pr i or to start up.

INSTALLATION

FLEXYII_WSHP-IOM-1307-E - 11 -

MINIMUM CLEARANCE AROUND THE UNI T

Figure 4 shows the required clearances and service access around the unit. NOTE: Ensure the fresh air i nlet does not face prevailing wind direction.

A B C

D

FCM/FHM/FGM/FDM/FWH/FWM

F BOX

2200

(1)

2000

G BOX

2700

(1)

2000

H BOX

2700

(1)

2000

FX 25 & 30

*

1100

*

1700

35à55

*

1300

*

2300

70à100

*

1700

*

2300

110à170

*

2000

*

2300

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

A

B

C

D

DUCT CONNECTIONS

FLEXYII_WSHP-IOM-1307-E - 12 -

RECOMMENDATIONS FOR DUCTS CONNECTI ONS

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

D ≤ 2m

WATER CONDENSING

FLEXYII_WSHP-IOM-1307-E - 13 -

WATER SOURCE HEAT PUMP ONLY

Water connections

The water circulating pump will be preferably installed upstream so that the evaporator/condenser will be subjected to positive pressure. Inlet and Outlet water connections are indicated on the certified drawing sent with the unit or shown in the sales brochure. The water pipes connected to the unit must not transmit any radial or axial force or any vibration to the heat exchangers.

It is important to follow non exhaustive recommendations hereunder:

• Comply with the water inlet and outlet connections shown on the unit.

• Install manual or automatic air purge valves at all high points in the ci rcuit.

• Install a safety valve as well as an expansion tank to maintain the circuit pressure.

• Install thermometers in both the inlet and outlet water connections.

• Install drain connections at all low points to all ow the whole circuit to be drained.

• Install stop valves, close to the inlet and outlet water connections.

• Use flexible connections to reduce vibrations transmission.

• After testing for leaks, insulate all pipe work, to reduce thermal leaks and to prevent condensation.

• If the external water pipes are in an area, where the ambient temperature is likely to fall below 0°C, insulate the piping and

add an electric heater.

• Ensure full earthling continuity

A drainage plug is located at the base of the evaporator. A drainage pipe may be connected to this to enable drainage of evaporator water for service operations or for seasonal shut down.

Connections at the inlet and outlet are Victaulic type.

Water analysis

The water must be analysed; the water circuit installed must include all items necessary for water treatment: filters, additives, intermediate exchangers, bleed valves, vents, isolating valves etc... depending on the results of the water analysis.

We do not advise operation of the units with open loops which can cause troubles with oxygenation, or operation with untreated ground water.

Use of untreated or improperly treated water can cause deposits of scale, algae and sludge or cause corrosion and erosion. It is advisable to call in a qualified water treatment specialist to determine what kind of treatment will be necessary. The manufacturer cannot accept liabilit y for damage caused by the use of untreated or improperly treated water, salt water or brine.

Here are our non exhaustive recommendations given as an indication:

• No NH4+ ammonium ions in the water, they are very detrimental for copper. <10mg/l

• Cl- Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture. < 10 mg/l.

• SO42- sulphate ions can cause perforating corrosion.< 30 mg/l.

• No fluoride ions (<0.1 mg/l).

• No Fe2+ and Fe3+ ions with dissolved oxygen. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l. Over

those values, it means a corrosion of steel which may generate a corrosion of c opper parts under deposite of Fe – this is

mainly the case with shell and tube heat exchangers.

• Dissolved silicon: silicon is an acid element of water and can also lead to corrosion risks. Content < 1mg/l.

• Water hardness: TH >2.8 K. Values between 10 and 25 can be recommended. This will facilitate scale deposit that can limit

corrosion of copper. TH values that are too high can cause piping blockage over time.

• TAC< 100.

• Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to

deoxygenate the water by mixing it with inert gas as it is to over-oxygenate it by mixing it with pure oxygen. The disturbance of the oxygenation conditions encourag es dest abi lis ation of copper hydroxides and enlargemen t of parti cl es.

• Specific resistance – electric conductivity: the higher the specific resistance, the slower the corrosion tendency. Values

above 3000 Ohm/cm are desirable. A neutral environment favours maximum specific resistance values. For electric conductivity values in the order of 200-6000 S/cm can be recommended.

• pH: pH neutral at 20°C (7 < pH < 8)

WATER CONDENSING

FLEXYII_WSHP-IOM-1307-E - 14 -

Antifreeze protection

Use glycol/water solution

ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZING

The glycol/water solution must be sufficiently c oncentrated to ensure proper protection and prevent formation of ice at the lowest outdoor air temperatures expected on an installation. Take precautions when using non passivated MEG antifreeze solutions (Mono Ethylene Glycol or MPG Mono Propylene Glycol). Corrosion can occur with these antifreeze solutions with oxygen.

Drain the installation

To enable drainage of the circuit, make sure that drain cocks are installed at all the low points of the circuit. To drain the circuit, the drain cocks must be opened and an air inlet ensured. Note : air bleeders are not designed to admit air.

EVAPORATOR FREEZING DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX WARRANTY.

Minimum water content

The minim um volume of the rooftop water circuit must be determined. If necessary, install a buffer tank. Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient.

The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formulas hereafter:

WATER COOLED FLEXYII RANGE

Vt à Minimum water content of the installation Q à Water capacity in kW N à Number of control steps available in the unit Dt à Maximum acceptable temperature rise (Dt = 6°c for an air conditioning application)

Vmini = 86 x Q / (N x Dt)

Unit Size

Number of

stages

Mini Water

Volume (L)

FWH/FWM 085

FWH/FWM 100 FWH/FWM 120 FWH/FWM 150

FWH/FWM 170

2

2 2 3

4

631

781 867 702

627

Victaulic connection assembly instruction Be careful not to roll or pinch the seal when installing the half-shells. This would cause a leak. 1-Install the bolts and tighten the nuts by hand on them. 2- tighten bolts uniformly passing from one side to the other, until the pads for the bolts are in metal-metal contact. Make sure the shoulders are well engaged in the grooves.

WATER CONDENSING

FLEXYII_WSHP-IOM-1307-E - 15 -

It is imperative to tighten the nuts evenly to avoid pinching the gasket.

WATER CONDENSING

FLEXYII_WSHP-IOM-1307-E - 16 -

WATER LOOP CONFIGURATION (FOR WATER SOURCE HEAT PUMP)

Figures below show the 2 water configurations. Figure 1 indicates all components used as standard :

• the electronic water flow switch,

• the water filter,

• the pressure taps and drain valves,

• the automatic airvent,

The second figure shows rooftop water loop with Low Water Loop Temperature option.

LOW WATER LOOP TEMPERATURE (OPTION)

In order to operate with low water inlet temperature in cooling mode (ie: ground source water loops) it is necessary to control the water flow rate in the heat exchanger to maintain a minimum condensing pressure in the refrigeration circuit. In cooling mode the CLIMATIC 60 will control the water flow rate in the condenser by monitoring the condensing pressure and by closing the water flow valve accordingly by a 0-10 Volts signal.

This option offers a second opportunity: give the possibility to close the rooftop water loop when compressors are stopped. Warning: the valve does not allow to do the balance on customer circuit

Several checks have been to do to avoid creating perturbations on customer circuit :

- check valve pressure drop at water flow

-use variable speed pump.

- adjust water flow switch set up at small water flow acceptable by the unit

WATER FILTER REPLACEMENT (ONLY FOR WATER SOURCE HEAT PUMP) It is important that units are serviced regularly by a qualified technician, at least once

every year or every 1000 hours of operation.

1

All Victaulic Connections

5

Pressure Taps and drain Valve

2

Inlet Water Filter

6

Stainless steel Exchanger

3

Automatic Air Vent

7

ElectroValve (HP control option)

4

Electronic Flow Switch

2 1

3 4 5 6 1 2 3

4 5 6

7

Low Water Loop Temperature Option

Hydraulic Data

Standard

Access for cartridge cleani ng

Figure 1

Figure 2

WATER CONDENSING

FLEXYII_WSHP-IOM-1307-E - 17 -

CAUTION: The water circuit may be pressurised. Observe the usual precautions when depressurising the circuit before opening it. Failure to observe these rules could lead to accidents and cause injury to service personal.

FWH/FWM

Exchanger Curve Filter Curve

85 C B

100 D B

120 D B

150 E C

170 E C

Pressure Loss - Heat plat e Exch anger

ABC

D

E

10

100

1 10 100

Water flow (m3/h)

Pressure Loss (kPa)

Pressure Loss - WATER FILTER

A

B

C

1.0

10.0

1 10 100

Water flow (m3 /h)

Pressure Loss (kPa)

INSTALLATION ON A ROOFMOUNTING FRAME

FLEXYII_WSHP-IOM-1307-E - 18 -

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 advised to fix curbs and roofcurbs to the unit.

As levels are adjustable, obs erve 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

•

Fig. 4 Fig. 5

Fig. 6

INSTALLATION ON A ROOFMOUNTING FRAME

FLEXYII_WSHP-IOM-1307-E - 19 -

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

conform to local codes of practice

Before installing the equipment, make sure that seals are not damaged and chec k that the unit is se cured 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.

Fig. 7

INSTALLATION ON A ROOF MOUNTING FRAME

FLEXYII_WSHP-IOM-1307-E - 20 -

NON ADJUSTABLE NON ASSEMBLIED ROOFCURB INSTALLATION

FRAME PARTS IDENTIFICATION

Figure 8 shows the different parts used in the assembly of this roof mounti ng 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

UNIT FLOOR AIR DUCT

UNIT Support rail ROOFCURB

Fig. 8

TRANSITION CURB

FLEXYII_WSHP-IOM-1307-E - 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 pneum at ic or electr ic dev ice.

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

ENERGY RECOVERY INSTALLATION

FLEXYII_WSHP-IOM-1307-E - 22 -

..

STEP 1 : Rooftop configuration

SIZE

Dimensions

Weight

A B C D E

F

F-box 85-100-120 2146* 2063 1422 367 1796 900 525 kg G-box 150-170 2330* 2247 1518 463 2170 900 635 kg

H-box 200-230 2516 2497 1676 623 2418 900 730 kg

All units

* F & G

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 23 -

STEP 1 : Rooftop configuration

STEP 2 : Lifting

Remove lifting lug

Remove corner sheet metal

No Hood

No panel

4 x

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 24 -

STEP 3 : Fitting

STEP 4 : Check

SAME LEVEL

10-15 mm

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 25 -

STEP 5 : Fixing

§ H-box : for each side :

§ F & G-box : for each side :

F : 8

x Ø4.8x25mm

G : 8

H : 10

x Ø4.8x32mm

5-10 mm

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 26 -

§ On top :

STEP 6: Masticate

Apply mastic on side junctions and higher junction.

F : 13

G : 15

x Ø4.8x25mm

H : 15

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 27 -

STEP 7: Electrical wiring

The Recovery module is sent with a power cable and a T-lan cable :

Separate these 2 cables

(communication and power ones) using the two holes.

Power cable

Modbus cable

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 28 -

Then fix the 2 cables on the grid of the extraction roofcurb and insert them in

rooftop electrical panel :

Communication and power

cables

from the module should

be separated.

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 29 -

To check the wiring, please refer to Rooftop and Recovery Module electrical diagram.

Then connect the power cable from the module to the rooftop, and

the Modbus cable according to the bus connection wiring diagram (it could be connected to the BE60 (A1) connector in elect r ic al rooftop panel or other options with bus communication).

Recovery module connection

Extraction roofcurb connection

Be careful: Check connections and connect male connections to good

female one. Roofcurb and recovery module connectors are the same.

Actuator roofcurb connection

COMMISSIONNING

FLEXYII_WSHP-IOM-1307-E - 30 -

STEP 8: Roof curb economiser Adjustment

With Heat Recovery module option the extract air goes through the wheel, that’s why the economiser of the roofcurb has to be permanently fully closed.

If roofcurb economiser is not fully closed, close it

manually.

And don’t connect the actuator to the rooftop.

Actuator roofcurb not

connected

TABLE OF CONTENTS

FLEXYII_WSHP-IOM-1307-E - 31 -

SERVICE MANUAL

COMMISSIONING

Commissioning report ..................................................................................................................................... 32

Refrigerant transaction logbook ...................................................................................................................... 35

Economiser and extraction ............................................................................................................................. 38

Before starting the unit ................................................................................................................................... 39

Starting the unit .............................................................................................................................................. 40

Run test .......................................................................................................................................................... 41

VENTILATION

Belt tension.......................................................................................................................... ............................ 42

Mounting and adjusting pulleys........................................................................................ ............................... 43

Airflow balancing............................................................................................................... .............................. 44

Filters...................................................................................................................................... ......................... 52

Air sock control ............................................................................................................................................... 53

UV Light .......................................................................................................................................................... 54

REFRIGERATION CIRCUIT

Electronic expansion valve ............................................................................................................................. 55

Advanced scroll temperature protection (ASTP)............................................................................................. 56

HEATING OPTIONS

Hot water coils ............................................................................................................................................... 57

Electric heater................................................................................................................................................. 59

Gas burners .................................................................................................................................................... 60

CONTROL VARIABLES ....................................................................................................................................... 71

MAINTENANCE DIAGNOSTIC ............................................................................................................................. 73

Refrigeration .................................................................................................................................................. 73

Indoor fan blower ............................................................................................................................................ 75

Outdoor axial fan ............................................................................................................................................ 75

Electrical heater .............................................................................................................................................. 75

Water leaks .................................................................................................................................................... 76

Climatic displays ............................................................................................................................................. 76

MAINTENANCE PLAN ......................................................................................................................................... 77

SPARE PART LIST ............................................................................................................................................... 80

WARRANTY .......................................................................................................................................................... 82

CONTROL MANUAL ............................................................................................................................................ 83

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-1307-E - 32 -

Site details

Controller Model Serial No Refrigerant

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

Site

Unit Ref Installer

………………………………………

……………………………………....

………………………………………

(1) ROOF INSTALLATION

Sufficient Access OK

Yes No

Condensate drain fitted

Yes No

Roofcurb OK Not OK

(2) CONNECTIONS CHECK

Phase check

Yes No

Voltage between Phases

1 / 2

……………….

2 / 3

……………….

1 / 3

……………….

(3) CLIMATIC CONFIGURATION CHECK

CLIMATIC 60 Configured according to the Options and Specifications: Yes No

(4) SUPPLY BLOWER SECTION

Type :

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

KW V A

N°1

…………………… …………………… ……………………

N°2

…………………… …………………… ……………………

Fan Type :

Forward

Backward

Forward

Backward

Displayed Belt Length :

mm

……………………

Tension Checked:

Yes No

Alignment Checked :

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

Estimated Airflow

m3/h

……………………

(5) AIRFLOW PRESS. SENSOR CHECK

Measured pressure drop (2332)……………………… mbar

Set Points Adjusted: Yes No If Yes enter new values:

2333: ………… 2334: ………… 2335: …………

(6) EXTERNAL SENSOR CHECKS

Check electrical connections : Yes No

Check and record temp. in menu 2211

Yes Non

100% Fresh Air

100% return Air

Supply Temperature

………………………..°C

Return Temperature

………………………..°C

Outdoor Temperature

………………………..°C

Inlet Water Temp. (for Water Condensing) ………………………..°C ………………………..°C Outlet Water Temp. (for Water Condensing) ………………………..°C ………………………..°C

(7) MIXING AIR DAMPERS CHECKS

Dampers open & close freely

OK

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

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-1307-E - 33 -

Yes No ……………..% Yes No Yes No

(8) REFRIGERATION SECTION

Outdoor Fan Motor Current: Check Rotation Compressor Voltage

Motor 1 / Moteur 1

L1 ……..A

L2 ……..A

L3 ……A

Yes No

Comp1: …….. V

Motor 2 / Moteur 2

L1 ……..A

L2 ……..A

L3 ……A

Yes No

Comp2: …….. V

Motor 3 / Moteur 3

L1 ……..A

L2 ……..A

L3 ……A

Yes No

Comp3: …….. V

Motor 4 / Moteur 4

L1 ……..A

L2 ……..A

L3 ……A

Yes No

Comp4: …….. V

Compressor Amps COOLING

Pressures & Temperatures

Phase 1 Phase 2 Phase 3

Temperatures

Pressures

Suction

Discharge

LP/ BP

HP / HP

Comp 1

…..… A

……… °C

……… Bar

Comp 2

…..… A

……… °C

……… Bar

Comp 3

…..… A

……… °C

……… Bar

Comp 4

…..… A

……… °C

……… Bar

Check Reversing valves :

Valve1: Yes No Valve2: Yes No

Valve3: Yes No Valve4: Yes No

Compressor Amps HEATING

Pressures & Temperatures

Phase 1 Phase 2 Phase 3

Temperatures

Pressures

Suction

Discharge

LP/ BP

HP / HP

Comp 1

…..… A

……… °C

……… Bar

Comp 2

…..… A

……… °C

……… Bar

Comp 3

…..… A

……… °C

……… Bar

Comp 4

…..… A

……… °C

……… Bar

HP cut out

……Bar

LP cut out

………..…... Bar

Refrigerant charge

C1 : ………..kg

C2 : ………..kg

C3 : ………..kg

C4 : ………..kg

(9) ELECTRIC HEATER SECTION

Type : ………………………………………………….

Serial No.:………………………..

AMPS 1st stage

AMPS 2nd stage

1 ……………….

2 ……………….

3 ……………….

1 ……………….

2 ……………….

3 ……………….

(10) HOT WATER COIL SECTION

Check Three Way Valve Movement : Yes No

(11) 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: ………%

(12) SETTINGS

Using Wizard software, edit the com plete list of settings by 'Print' function.

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-1307-E - 34 -

COMMENTS:

.......................................................................................................................................................................................................

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

.......................................................................................................................................................................................................

REFRIGERANT TRANSACTION LOGBOOK

FLEXYII_WSHP-IOM-1307-E - 35 -

General information

Site name:

Serial Number:

Site address:

Site operator:

Cooling load :

Refrigerant type:

Refrigerant quantity (kg)

Unit manufacturer

Year of installation

Refrigerant additions

Date Engineer

Quantity (kg)

Reason for addition

Refrigerant removal

Date Engineer

Quantity (kg)

Reason for removal

REFRIGERANT TRANSACTION LOGBOOK

FLEXYII_WSHP-IOM-1307-E - 36 -

Leak tests (part 1)

Date Engineer

Test Result

Follow up action required

Follow up actions

Date Engineer

Related to test dated

Action taken

REFRIGERANT TRANSACTION LOGBOOK

FLEXYII_WSHP-IOM-1307-E - 37 -

Testing of automatic leak detection system (if fitted)

Date Engineer

Test result

Comments

Refrigerant load according to model size

Refrigerant Box Model

Number of

circuit

Cooling only units

Load (kg)

Heat pump units

Load kg

R410A

C

24 1 6,1

6,1

30 1 6,1

6,1

38 1 8,1

8,1

42 1 8,1

8,1

D

45

1

6,5

6,5 2 6,5

6,5

52

1

6,5

6,5 2 6,5

6,5

57

1

8,0

8,0 2 8,0

8,0

65

1

8,0

8,0 2 8,0

8,0

E

75

1

10,5

10,5 2 10,5

10,5

85

1

10,5

10,5 2 10,5

10,5

ECONOMISER AND EXTRACTION

FLEXYII_WSHP-IOM-1307-E - 38 -

ECONOMISER Free cooling is 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 ship me nt. 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.

FRESH AIR

RETURN AIR

EXHAUST AIR

SUPPLY AIR

Fig. 9

FLEXY II PRINCIPLE SKETCH

MULTIDIRECTIONAL ROOFCURB

PRINCIPLE SKETCH

ENERGY RECOVERY MODULE PRINCIPLE SKETCH

RETURN ROOFCURB PRINCIPLE SKETCH

COMMISSIONING

FLEXYII_WSHP-IOM-1307-E - 39 -

BEFORE STARTING THE UNIT

THIS WORK MUST ONLY BE CARRIED OUT BY TRAINED REFRIGERATION ENGINEERS

FILL THE COMMISSIONNING SHEET AS YOU GO ALONG

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.

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

FLEXYII_WSHP-IOM-1307-E - 40 -

STARTING THE UNIT

At this point the unit circuit breakers should be open You will need a DS60 maintenance controller.

Connecting the CLIMATIC displays (RJ12 connector on the main board) :

Close the 24V Control Circuit breakers.

The CLIMATIC 60 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. - 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 NO11 and C4 on connector J15 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 J15 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.

- 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

FLEXYII_WSHP-IOM-1307-E - 41 -

RUN TEST

Start unit in cooling mode

Thermodynamic readings are possible on Climatic 60 or using manometers. 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 "Dirty filter" detection test: vary

the set-point value (menu page 2335 on DS60) in respect to the air pressure value. Observe the response of the CLIMATIC™ (menu 2332).

- Same procedure for detecting "Missing Filter" (page menu

2334) or "Air Flow Detection" (page menu 2333).

- Check the smoke detection function (if fitted).

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

- Disconnect the circuit breakers of the condensor 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 2222).

VENTILATION : BELT TENSION

FLEXYII_WSHP-IOM-1307-E - 42 -

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 s upport 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.

Fig. 12

VENTILATION : PULLEYS

FLEXYII_WSHP-IOM-1307-E - 43 -

MOUNTING AND ADJUSTING PULLEYS F

AN PULLEY REMOVAL

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

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

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

F

AN 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.

M

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.

P

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 : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 44 -

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 wil l 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 necess ary lock the main switch. First unscrew the 4 Allen screw(s) on the pulley (see figure 13).

Pulley

type

Pulley

External

Diameter

Min

Dia /

Min

Dist

Max

Dia /

Max

Dist

Nb of turns

from fully closed to

fully open

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

turns from fully closed with SPA belt in (mm)

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

8450 / D8450

120

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

20.2

28 5 21

21.8

22.5

23.3

24.1

24.9

25.7

26.4

27.2

28

-

8550 / D8550

136

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

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.

1st 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.

L

Fig. 13

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 45 -

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

D

M

: from table_1

DF: from mac hine 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:

P

meca fan

= P

meca Motor

x η

Transmission

P

meca fan

= P

elec

x η

meca motor

x η

Transmission

P

meca fan

= V x I x √3 x cosϕ x η

meca motor

x η

Transmission

This formula can be approximated in this way

P

meca fan

= V x I x 1.73 x 0.78 x 0.87 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 roof-top 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

1415 rpm

0,75

79,9

1.1kW

1435 rpm

0,78

83,7

1.5kW

1435 rpm

0,76

84,2

2.2kW

1450 rpm

0,78

87,1

3.0kW

1445 rpm

0,79

85,7

4kW

1445 rpm

0,75

86,7

5.5kW

1465 rpm

0,79

89,0

7.5kW

1460 rpm

0,79

89,1

9.0kW

1467 rpm

0,77

90,9

11.0kW

1460 rpm

0,79

90,4

Table_3 Accessories pressure drops

G4

Filters

F7

Filters

UV

LIGH

T

Hot

Water

coil S

Hot Water coil H

Electric Heater

S

Electric

Heater

M

Electric

Heater

H

Heating

Gaz

fired H

Adjustable

roofcurb

Multidire

ctional

Roofcurb

Heat

Recovery

Modul

Fresh Air

85

12000 1 75

18 9 15 3 5 6 14

17

22

164

15000

7

105

30

13

22 6 7 7 23

27

33

204

23000

28

199

63

26

44 7 9

11

53

63

73

313

100

14000 5 94

26

11

19 6 7 8 20

23

30

191

18500

15

143

44

18

31 8 10

11

34

41

51

252

23000

28

199

63

26

44

11

14

16

53

63

78

313

120

15000 7 105

30

13

22 7 8 9 23

27

35

204

20500

21

167

52

21

37

10

12

13

42

50

62

279

23000

28

199

63

26

44

12

15

17

53

63

78

313

150

18000 1 75

15 6 10 4 5 7 16

30

35

170

26000

12

130

33

12

19 9 10

13

33

62

72

245

35000

29

204

54

19

33

15

18

23

59

112

131

329

170

21000 5 94

21 8 14 8 9

10

21

40

49

198

30000

19

161

42

15

25

10

13

15

44

82

95

282

35000

29

204

54

19

33

17

19

21

59

112

131

329

200

24000 3 88

18 7 11

16

15

14

21

53

67

173

35000

18

154

39

13

22

21

20

44

112

133

252

43000

31

211

54

19

31

24

26

29

66

169

195

310

230

27000 7 105

24 8 14

18

17

26

67

84

195

39000

24

182

46

16

26

24

25

55

139

163

281

43000

31

211

54

19

31

24

26

29

66

169

195

310

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 46 -

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 previous page and 2x 5.5 kW motors..

- Motor rpm: 1465 rpm

- cosϕ = 0.79

- Voltage = 400V

- Current = 9.00A (per fan)

P

mech fan

= V x I x √3 x cosϕ x η

mech motor

x η

Transmission

= 400 x 9.1 x √3 x 0.79 x 0.89 x 0.9 = 4.0 kW

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 = 1465 x 114.2 / 200 = 836 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 ( her e 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 P a

The dynamic pressure at 15000m

3

/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

836rpm

630Pa

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 47 -

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

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 48 -

AT18-18S

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 49 -

ADH355L

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 50 -

ADH450L

VENTILATION : AIRFLOW BALANCING

FLEXYII_WSHP-IOM-1307-E - 51 -

ADH500L

FILTERS

FLEXYII_WSHP-IOM-1307-E - 52 -

F

ILTER 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 monitors the pressure drop across the filter. The following set points can be adjusted depeding on the installation.

“Airflow” in page 2333 = 25Pa by default “No filter “ in page 2334 = 50Pa by default “Dirty Filter” in page 2335 = 250Pa by default

The actual pressure drop measured accross the coil can be read on the Climatic Display DS60 in menu 2332

.

The following faults may be identified

-Fault code 0001 AIRFLOW FAILURE, if measured ΔP across the filter and coil is below the value set in page 233 3

-Fault code 0004 DIRTY FILTERS, if measured ΔP across the filter and coil is above the value set in page 2335

-Fault code 0005 MISSING FILTERS, if measured ΔP across the filter and coil is below the value set in page 2334

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

the local regulations

VENTILATION : AIR SOCK CONTROL

FLEXYII_WSHP-IOM-1307-E - 53 -

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 climatic60 program

The return air damper with its auxiliary switch

VENTILATION : UV lights

FLEXYII_WSHP-IOM-1307-E - 54 -

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 ac cess doors to the lamps

Fig. 14

Filters

UV light

COIL

Sight Glass

Door opened

Safety locks

REFRIGERATION CIRCUIT

FLEXYII_WSHP-IOM-1307-E - 55 -

Electronic expansion valve

2 electronic valves types can be fitted on FlexyII (ASHP only if the option is selected or in Flexy EC)

F box G box Hbox

Model designation

085 100 120 150 170 200 230

Reference

E3V45 E3V45 E3V45 E3V45 E3V45 E3V55 E3V55

EEV adjustments

EEV allows to control superheat in biflow operation (see climatic 60 sections).

E3V Welding instructions

Electronic expansion valves are sensitive to dust – strainers must be used in case of replacing.

ADVANCED SCROLL TEMPERATURE PROTECT I ON (ASTP )

FLEXYII_WSHP-IOM-1307-E - 56 -

OPERATION MODE EXPLANATION v Protection is activated when Scroll Discharge Port.

Reaches 150°C (+/- 17K)

v 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

v Motor protector opens (Klyxon)

• Compressor turns off, cools

v Motor protector resets, compressor restarts

• Bi-metal disk resets before motor protection

• Cycle will continue until cause of overheat is fixed

SERVICE A COMPRESSOR

v What to do?

• If a protected compressor is identified

- Stop the compressor

- Allow to cool thoroughly

- Restart pump & check for normal operation

v DO NOT ASSUME A COMPRESSOR RUNNING

UNLOADED (BALANCE PRESSURE) IS A FAILURE

v 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

Temperature Behavior with ASTP Protection

40

65

90

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

HEATING : HOT WATER COIL

FLEXYII_WSHP-IOM-1307-E - 57 -

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.

- F ill the hyd raulic sys tem and bl eed the co il using t he 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 Glyco l for prote cti on 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_WSHP-IOM-1307-E - 58 -

Hot water coil connection

F-G-H box

Pipe Internal Diameters (DN)

M

AXIMUM WORKING PRESSURE: 8 BARS

M

AXIMUM WORKING TEMPERATURE: 110°C

F085

F100

F120

F150

F170

F200

F230 S 25

25

32

H

32

40

HEATING : ELECTRIC HEATER

FLEXYII_WSHP-IOM-1307-E - 59 -

G

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™ 60. 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 : GAS BURNER

FLEXYII_WSHP-IOM-1307-E - 60 -

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 f reely around the unit.

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

- Com bustion air inl et and burnt gas exhaus t(s) must NOT be obstructed in any way.

S

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 out put.

Number of male thread ed 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 20m bar and 15°C) m3/h 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 mus t be realized according to Sound Engineering Practice and the local safety codes and rul es.

- In any c ase the di ameter of pipe-work c onnected t o 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 EAC H Rooftop.

- Check the suppl y v olt age to t h e exit of t he pow er s uppl y's transformer T3 of the burner: it m ust be between 220 a nd 240V.

STARTING UP THE GAS BURNER

Purge the pipe-work near the connection on the i gnition 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 ionisat i on probe

If ionisation within 5s: Normal running

Otherwise fault on gas ingnition cont rol block

After 5minutes, f aul t reported on the climatic cont rol l er

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

399

400

401

45

46

398

414243443738394033343536293031

32910

11

5678123

4

HEATING : GAS BURNER 60 & 120 kW

FLEXYII_WSHP-IOM-1307-E - 61 -

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 s upport bar to avoid the pressure drop due to the el bow after the valve

Fig. 15

Fig. 17

Fig.16

INLET

PRESSURE

MEASURING

PORT

HEATING : GAS BURNER 60 & 120 kW

FLEXYII_WSHP-IOM-1307-E - 62 -

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

Fig.22

HEATING : GAS BURNER

FLEXYII_WSHP-IOM-1307-E - 65 -

BURNER SAFETY CHECKS Smoke extractor pressure switch Test.

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

23).

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

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

- After reconnecting of the tube, the Burner wi ll 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 termina l 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 complete ly.

-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

Fig. 24

HEATING : GAS BURNER

FLEXYII_WSHP-IOM-1307-E - 66 -

GAS BURNER FIRE-UP SEQUENCE

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

Gas Ignition Control Block Signal

Normal Operation

6 Minutes Delay

Pre-Ventilation 30 seconds

Fire-up Electrode 4s

Gas Valve Open

Ionisation 1second

Gas Valve remains Open

Gas Control Valve

Closes

BURNER STOPS

Fault on Gas

Control Block

Signal from Ionisation

Air Press Switch ON or

NO

YES

HEATING : GAS BURNER

FLEXYII_WSHP-IOM-1307-E - 67 -

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

Heating

Requested

Extraction fans

start

Fault on the

blower

thermostat

+ Check connections on the blower thermostat.

+ Replace thermostat

Lack of gas supply

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

Fault on the

superheat thermostat on the gas burner

support bar

+ Check superheat thermostat’s operation after manual reset

+ Replace superheat thermostat

Starting of

the

extraction

fans

Extraction Fans

are running

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

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: pre-

ventilation 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.

Continuous

ventilation

and sparks

from fire up

electrode.

After a few

seconds the

gas burner

fires-up

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.

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_WSHP-IOM-1307-E - 68 -

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_WSHP-IOM-1307-E - 69 -

60kW

120kW

HEATING : GAS BURNER

FLEXYII_WSHP-IOM-1307-E - 70 -

180kW

240kW

CONTROL VARIABLES

FLEXYII_WSHP-IOM-1307-E - 71 -

Function

The Climatic

TM

60 has free inputs / outputs on the main board BM60 and the expansion board BE60 to

offer different possibilities to customize input / output for remote control of the unit.

Description

Free customized inoputs / outputs number depends on added option. Without any option, expansion board BE60 is available with DCBO option. Below, "not always available" means that some inputs/outputs could be used by options. Refer to the electrical wiring diagram or to the CL60_IOM.

Digital outputs (dry contacts NO)

Maximum 2 free output contacts on BM60 :

BM_J14-NO7

Not always available

BM_J15-NO12

Not always available

Maximum 4 free output contacts on BE60

BE-J5-NO1

Not always available

BE-J6-NO2

always available

BE-J7-NO3

always available

BE-J8-NO4

always available

Functions can be set among followings:

Alarm

Alarm, General

Minor A

Alarm, Minor

Major A

Alarm, Major

Filter A

Alarm, Dirty filters or missing

Blower A

Alarm, Blower

Comp. A

Alarm, Circuit (Compressor)

Gas A

Alarm, Gas burner

Elec. A

Alarm, Electrical heaters

Frost. A

Alarm, Supply to low (Freeze protection)

Smoke A

Alarm, Smoke detect ion

Defrost

Circuit, Defrosting cycle reque sted or

activated (Compressor)

Heating

Control, Heating mode activated

Dead Z.

Control, Dead zone mode activated

Cooling

Control, Cooling mode activated

by BMS

BMS, Activated by BMS

Sched. A

Schedule, Mode A activated

Sched. B

Schedule, Mode B activated

Sched. C

Schedule, Mode C activated

Sched. D

Schedule, Mode D activated

Sched.BMS

Schedule, Mode BMS activated

Sched.Z0

Schedule, Zone 0 activated

Sched.Z1

Schedule, Zone 1 activated

Sched.Z2

Schedule, Zone 2 activated

Sched.Z3

Schedule, Zone 3 activated

Sched.Z4

Schedule, Zone 4 activated

Sched.Z5

Schedule, Zone 5 activated

Sched.Z6

Schedule, Zone 6 activated

Analog inputs (NTC probe or 4/20mA signal)

No analog input on BM60 : Maximum 4 free analog inputs on BE60

BE_J9-B1

Not always available

BE_J9-B2

Not always available

BE_J10-B3

Not always available

BE_J10-B4

Not always available

Functions can be set among followings:

Power

Power of the unit (ON/OFF)

Ntc BMS

BMS, temperature (NTC) reading for BMS

Hr. BMS

BMS, relative humidity (4-20mA) reading for

BMS

Sp Temp.

Control set point, swift of the value (4mA=-5K,

20mA=+5K)

Sp F.Air

Fresh air set point, value (4mA=0%,

20mA=100%)

Sp Speed

Speed blower set point, value (4mA=low level,

20mA=nominal level)

T. Out.

Control, outside temperature by 4-20mA

sensor

T. Room

Control, room temperature by 4-20mA sensor

Hr. Out.

Control, outside relative humidity by 4-20mA

sensor

Hr. Room

Control, room relative humidity by 4-20mA

sensor

CONTROL VARIABLES

FLEXYII_WSHP-IOM-1307-E - 72 -

Digital inputs (dry contacts)

Maximum 2 free input contacts on BM60 :

BM-J4-ID4

Not always available

BM-J4-ID7

Not always available

Maximum 4 free input contacts on BE60

BE-J4-ID1

always available

BE-J4-ID2

always available

BE-J4-ID3

always available

BE-J4-ID4

always available

Functions can be set among followings:

Power

Power of the unit (ON/OFF)

Reset Al

Reset, Alarm

Summer

Control, Unloaded heating mode

Winter

Control, Unloaded cooling mode

Low Fan

Blower, Force reduced flow (low speed)

High Fan

Blower Force nominal flow (high speed)

No F.A

Fresh Air, Force the damper to close (0%)

10% F.A

Fresh Air, Force the damper to minimum opening (10%)

20% F.A

Fresh Air, Force the damper to minimum opening (20%)

30% F.A

Fresh Air, Force the damper to minimum opening (30%)

40% F.A

Fresh Air, Force the damper to minimum opening (40%)

50% F.A

Fresh Air, Force the damper to minimum opening (50%)

All F.A

Fresh Air, Force the damper to full opening (100%)

No FreeC

Fresh Air, Unloaded Free-C oo l ing mode

No FreeH

Fresh Air, Unloaded Free-H ea ting mod e

No Air.Q

Air Quality, Unloaded control

Defrost

Circuit, Defrosting cycle delayed (Com pres sor)

50% Cp.

Circuit, Unloaded immediately 50% of compressors

running

No Comp.

Circuit, Unloaded all compressor

No HPump

Circuit, Unloaded all compressor in heat-pump mode

No Cp&Ht

Circuit and Heaters, Unloaded all

50% Ht.

Heaters, Unloaded immediately 50% of heaters running

No Heat.

Heaters, Unloaded all heaters

Prio.Ht.

Control, Force the Priority of the heaters vs Compressors

Tcb G

TCB, G

Tcb B

TCB, B

Tcb Y1

TCB, W1

Tcb Y2

TCB, W2

Tcb W1

TCB, Y1

Tcb W2

TCB, Y2

for BMS

BMS, input reading for BMS

Sched. A

Schedule, Force the Mode A

Sched. B

Schedule, Force the Mode B

Sched. C

Schedule, Force the Mode C

Sched. D

Schedule, Force the Mode D

Sched.BMS

Schedule, Force the Mode BMS

MAINTENANCE DIAGNOSTIC

FLEXYII_WSHP-IOM-1307-E - 73 -

REFRIGERATION

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

LP PROBLEMS AND LP CUT OUTS

Refrigerant charge too low

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 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 > 3 bar (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 temperatur e 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 replac e 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 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

MAINTENANCE DIAGNOSTIC

FLEXYII_WSHP-IOM-1307-E - 74 -

REFRIGERATION

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

HP PROBLEMS AND HP CU T OUTS

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)

Incorrect water flow rate (Water cooled rooftop only)

Check water flow value

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

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

Water Filter is obstructed (only for Water Cooled Rooftop)

Check the water filter and clean if necessary

Recycled Hot Air

Check clearance around the condenser

Strong variations of pressure ( 2 to 3 bar) Thermostatic Expansion Valve "hunting"

Incorrect adjustment of the expansion valve

Refer to LP problems and LP cut out section

Low refrigerant charge

Filter drier obstructed with gas bubbles

at the expansion valve inlet

Moisture in the system

Very high discharge temperature, High amps measured at compressor

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

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

MAINTENANCE DIAGNOSTIC

FLEXYII_WSHP-IOM-1307-E - 75 -

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 ai rflow 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

Heat Pump mode: Circuit breaker open

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

Water ingress in the motor connection box.

Change the component

ELECTRICAL HEATER

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

High Temperature trip out on electric heater

Low airflow rate

Measure and estimate the ai rflow and pressure and compare with the specification from customer.

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.

MAINTENANCE DIAGNOSTIC

FLEXYII_WSHP-IOM-1307-E - 76 -

WATER LEAKS

FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION

Water found in the ventilation section

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

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

CLIMATIC DISPLAYS

FAULT

POSSIBLE CAUSE AND SYMPTOMS

SOLUTION

Nothing is written on the screen but it’s enlightened

Possible problem of display addressing’

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.

The message “no link” appears Problem of addresses’ recognition

Disconnect the DS from the unit and then reconnect it.

All the units are extinct Problem main board plan addressing

Disconnect then re-plug; disconnect each unit from the others then change all the plan addresses

MAINTENANCE PLAN

FLEXYII_WSHP-IOM-1307-E - 77 -

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 maintenan ce techn ic ian s.

[] 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_WSHP-IOM-1307-E - 78 -

Task Operating mode

Monthly

Quarterly

6 monthly

Yearly before

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 (inform ation on installation manual). 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 the 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, setpoints 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.

O

Check freeze protection on hot water coil

[] 5

Check three way valve on hot water coil

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

temperature. Check operation of the piston . It must mov e away from the valve head.

Reset the control

[] 5

Check economizer 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 4 way 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 electrical connections, taking a particular

attention to the power lines and low voltage control wires.

O 30

MAINTENANCE PLAN

FLEXYII_WSHP-IOM-1307-E - 79 -

Task Operating mode

Monthly

Quarterly

6 monthly

Yearly before

winter

Estimated time

(min)

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 : 29 bar (+1/-0) auto reset 22 bar (+/- 0,7). Reconnect fans. Switch off the centrifugal supply fan and wait for the LP

switch to cut out : 0,5 bar (+/- 0,5) reset 1,5 bar (+/- 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.

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 from the 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/[]

1 h if

cleaning.

Check electrical heater element for excessive corrosion

Isolate the unit. Pull the electrical heater out of the heater

module box and check the resistances of traces of corrosion.

Replace resistance as required.

O

1 h if

replace

ment

Check anti-vibration mountin g s, for wear and tear

Visuall y check anti-vibration mountings on compressors

and centrifugal fan.

Replace if damaged.

O

1h if

replace

ment

Check refrigeration circuit for traces of acid in the oil

Take a sample of oil from the refrigeration circuit.

[]

Check glycol concentration in the

hot water coil circuit

Check the glycol concentration in the pressurised water

circuit (a concentration of 30% gives a protection down to approx. -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 minimum 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 installation manual)

[] 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 louver. 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 installation manual for details

[] 15

Gas regulation valve settings

Refer to gas burner section in the installation manual for details

[] 30

Check gas burner safety switch

Refer to gas burner section in the installation manual for details

[] 30

Check and clean water filter (only

for water cooled rooftop)

CAUTION : the water circuit may be pressurized.

Observe the usual precautions when depressurizing the circuit before opening it. Failure to observe thes e rules could lead to accidents and cause injury to servi c e

personal.

[] 20

SPARE PART LIST

FLEXYII_WSHP-IOM-1307-E - 80 -

Refrigeration components

Designation Familly Code

Compressor

ZP154KCE

Compressor

4220431T

ZP182 KCE

4220432V

ZP235 KCE

4220433W

INDOOR coil

ID Fbox

Coil

4310442L

ID Gbox

4310443M

ID Hbox

4310472H

OUTDOOR coil

OD Fbox

Coil

4310445P

OD Fbox

4310446R

OD Gbox

4310447T

OD Gbox

4310448V

OD Hbox

4310449W

OD Hbox

4310450X

Expansion valve

Thermostatic expansion valve TGEL20-19

Refrigeration circuit

4720918E

Thermostatic expansion valve TGEL20-23

4720912V

Thermostatic expansion valve TGEL40-31

4720924M

Electronic expansion valve E3V45

4720928T

Electronic expansion valve E3V55

4720155H

cable EEV 3M

4720931X

cable EEV 6M

4720156J

Driver EEV

4770717M

Filter Drier

DMB165S

Refrigeration circuit

4720905K

DML165S

4720907M

DML167S

4720908N

Non return valve

NRV16S

Refrigeration circuit

4720002H

4 way valve

STF0715

Refrigeration circuit

4740101N

STF1511

4740104T

STF2506

4740105V

STF3006

4740107X

4 way valve coil

24V 50

4740103R

Pressure switch

HP sensor 4/20mA 45 bar Quick-On

Control

4770212V

BP sensor 0/5V 20 bar Quick On

4770214X

Inox flexible tube

Inox flexible tube 7/8 DN20 600mm

Hoses

4681043P

Inox flexible tube 1 3/8 DN32 800mm

4681044P

Inox flexible tube 1 5/8 DN40 850mm

4681025M

Tigthening ring

D28 428 Pa

Piping

5680573L

D35 535 Pa

5680574M

D40 542 Pa

5680575N

Casing

Designation

Familly

Code

Economiser

Fresh air hood grille Ebox

Sheetmetal

4921086T

Fresh air hood grille Fbox

4921087V

Fresh air hood grille Gbox

4921088W

Lock1/4T

1000-U188-N2+51+990

Fixings

5880163Z

Handle dorr

1091-103-02

5880109W

Handle Outdoor coil

M443/140N

5880160W

Charnieres clips

8576178 SNAP LINE

5880187L

SPARE PART LIST

FLEXYII_WSHP-IOM-1307-E - 81 -

Outdoor fans

Designation

Familly

Code

Axial fan

FE071

Fan

4921080K

A6D800-AU0101 F-G box

4921099M

A6D800-AU0101 Hbox

4921098L

Electrical & control components

Designation Familly Code

CLIMATIC

Main control board BM60 medium

Control

4770702P

Main control board BM60 medium

4770708Y

Sensors

Ntc -50+105 7 meters

4770721T

Ntc -50+105 3 meters

4770720R

Pressure sensor

Analog filter sensor

4730097A

Ambient sensors

4770613K

Soft starter

ATS 01N222QN

4780414X

Miscillaneous

Designation

Familly

Code

Siphon

Black rubber pipe - Thickness 5 mm

Fixings

4680360K

Key

Maintenance key

5880158T

Ventilation & Filtration components

Designation Familly Code

Filter EU3

625x500x50

Filters

4960118T

Filter EU4 metal frame

625x500x50

4960031P

Filter EU4 rechargeable

625x500x50

4960099P

Filter EU7

625x500x50 GP10

4960066R

Filter EU3

800x500x50

4960124A

Filter EU4 metal frame

800x500x50

4960027K

Filter EU4 rechargeable

800x500x50

4960095K

Filter EU7

800x500x50 GP10

4960068V

Actuator

SM 24A + 5m cable

Damper

4781281l

Indoor fan

AT15-15 G2L

Supply fan

4910040Y

ADHE 355

4910090X

AT18-18

4910023Y

ADHE 450

4910092Z

ADHE 500

4910093A

Motor

1.5 kW IE2

Motor

4521802L

2.2 kW IE2

4521806R

3 kW IE2

4521807T

4 kW IE2

4521808V

5.5 kW IE2

4521809W

7.5 kW IE2

4521811Y

9 kW IE2

4521813A

11 kW IE2

4521815F

WARRANTY

FLEXYII_WSHP-IOM-1307-E - 82 -

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 c asing of its Rooftop units manufactured since May 1991 against corrosi on 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 MAINTEN ANCE

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.

CERTIFICATES

FLEXYII_WSHP-IOM-1307-E - 83 -

CONTROL MANUAL

DISPLAY DC60

INSTALLATION ....................................................................................................................................... 84

CONNECTION ......................................................................................................................................... 84

IMPORTANT WARNING

...................................................................................................................................... 85

ONE 'DC60' FOR ONE, AND ONLY ONE, ROOFTOP ........................................................................... 86

TEMPERATURE MEASUREMENT ........................................................................................................ 86

RELATIVE HUMIDITY MEASUREMENT ................................................................................................ 86

CONFIGURATION ................................................................................................................................... 87

INITIALIZATION ...................................................................................................................................... 88

PRESENTATION ..................................................................................................................................... 88

USE .......................................................................................................................................................... 90

LEVEL 2 ACTIVATION ............................................................................................................................ 92

DISPLAY DM60

INSTALLATION ....................................................................................................................................... 93

DM60 AND COMMUNICATION MASTER/SLAVES ............................................................................... 95

CONFIGURATION ................................................................................................................................... 96

FUNCTIONALITY OF THE DM60 ........................................................................................................... 96

• 84 • DC60-DM60_ROOFTOP-IOM-1307-E

The display DC60 is personalized for the user. It allows an overview of operation of the unit and allows access to certain parameters.

The 'DC60 is designed to be remote connected of the rooftop.

The 'DC60 is equipped with a temperature sensor. The temperature sensor allows the acquisition of room temperature to control.

WARNING: Separate as much as possible probes, displays, logical input cables from power cables with strong inductive load, in order to avoid possible electromagnetic perturbations.

DISPLAY DC60

INSTALLATION

The DC60 has been designed for ﬂ ush mount assembly, on distribution boxes compliant with the standards in force.

CONNECTION

• 85 •

DC60-DM60_ROOFTOP-IOM-1307-E

Power supply

The power of the DC60 can be 24Vac (+10…-15%) 50/60Hz or 24Vdc (22…35Vdc), maximum current of 2VA.

LENNOX recommends a 24Vac supply (provided by rooftop) for installation of the display less within 30 meters of rooftop. For connection of the display of over 30 meters, a power supply, close to the display, 24Vac must be provided by the installer.

For an external connection to the rooftop (24V) using a transformer class 2 under 0,1A.

Communication

The DC60 is controlled by a communication bus: RS485.

Cable features

The connection of power and communication must be made by the following cable:

• LiYCY-P (0.34 mm ²), 2 pairs with general shield The cable length, with power, should not exceed 30m. The cable length without power (24V external) must not exceed 150m. For a better electromagnetic protection, Lennox recommends the use of LiYCY-P cable

For extended networks ﬁ t a 120 Ohm resistor between RX/TX+ and RX/TX- on the ﬁ rst and last device, to avoid possible communication problems.

IMPORTANT WARNING: Any wiring modiﬁ cation on the CLIMATIC™ 60

must be done by LENNOX technician or employees having valid electrical qualiﬁ cation and authorization.

For any modiﬁ cation of wiring on the 24V supply or on 4-20mA sensor, check the polarity prior to apply the power. Wrong polarity may cause serious damage and destroy the Plan network. LENNOX will not accept liability for damage caused by wrong power connection or any wiring modiﬁ cation done by people without valid training and qualiﬁ cations.

DISPLAY DC60

• 86 • DC60-DM60_ROOFTOP-IOM-1307-E

ONE 'DC60' FOR ONE, AND ONLY ONE, ROOFTOP

The DC60 displays only the values and information of the 'Roof-Top' on which the DC60 is connected.

TEMPERATURE MEASUREMENT

All LENNOX rooftop comes with a temperature sensor; it must be placed in the conditioned area. But if the DC60 is placed in the area conditioned by the rooftop, that display is connected, it is possible, in this case, to use the temperature measurement of the DC60.

To indicate the CLIMATIC™ 60 your choice, set the point 3213:

• ‘128' to use the measure of the 'DC60'

• ‘1 BM-B12' or '2 BM-B1' to use the remote probe

Note :

• for rooftop with a 'medium' CLIMATIC™ 60: connect the remote sensor between points B12 and GND, terminal block J18.

• for rooftop with a 'small' CLIMATIC™ 60: by default the CLIMATIC™ 60 control the return temperature measurement. If you want to control on a room temperature measure, disconnect the return probe between points B1 and GND, terminal block J13. Connect the remote sensor in place.

RELATIVE HUMIDITY MEASUREMENT

If the rooftop is designed to manage humidity, a box of combined sensors (temperature and humidity), supplied with the rooftop, it must be placed in the conditioned area. It's possible to use the temperature measurement DC60.

DISPLAY DC60

• 87 •



• :

• :

• :

• :

• :

• :

•  :

• :

• :

• :

• :

• :

• :

• :

• :

• : 31

• : 2

• : 22

DC60-DM60_ROOFTOP-IOM-1307-E

CONFIGURATION

Setup menu

To do this, when the 'DC60 is powered; Simultaneously press the keys and q. After some seconds, the text  appears and the value '000' ﬂ ashes. Turn the knob

to change the value to select the number 022. Then validate the code by pressing the knob. If the code is wrong access the setup menu is not possible and the DC60 returns to the previous display. If the code is correct the display shows .

Parameter's choice

Changing the parameters value

To activate the modiﬁ ed mode value:

• After selecting the desired parameter by rotating the knob

.

• Press the knob

.

• The

 symbol appears on the right side of the value.

• Turn the knob

to adjust the desired value.

• Press again on the knob

to conﬁ rm your choice.

• The

 symbol is no longer displayed on the right side of the value.

• The rotation of the knob

is for select a new setting.

Mandatory values

To communicate with the CLIMATIC™ 60 this basic parameters of internal DC60 must to be settled.

(2 buttons on the right

simultaneously)

By rotating of the knob

, you can view and modify the following parameters:

Address DC60 on the communication bus (Always set to value 31)

Communication speed (always set to value 2)

Backlight mode

Backilght iIntensity

Probe calibration

Screen contrast

Disabling 'Bip' keys

Password (always set to value 22)

Real time clock DC60; year

Real time clock DC60; month

Real time clock DC60; day

Real time clock DC60; weekday (1 = Monday)

Real time clock DC60; hour

Real time clock DC60; minute

Exits the settings mode

DISPLAY DC60

• 88 • DC60-DM60_ROOFTOP-IOM-1307-E

INITIALIZATION

If the connection between the CLIMATIC™ 60 and the 'DC60 is not correct (Ofﬂ ine) screen displays only the symbol .

In this case, check: :

• the connection between CLIMATIC™ 60 and DC60

• the setting of the DC60

• the power of CLIMATIC™ 60

If the connection between the CLIMATIC™ 60 and the 'DC60 is correct (Online) to power up the screen displays only the symbol . This phase allows the CLIMATIC™ 60 to set up the DC60 with options of rooftop.

After some seconds, DC60 is operational.

PRESENTATION

Showing

Control operating mode

Value

Fan operating mode

Label or clock

Staus

Schedule mode

BMS

Alarm

Pump

Compressor(s)

Defrost

Condenser(s)

Heaters

Hidden : to stop Visible : running

Blinking : in fault

DISPLAY DC60

Day

Day II

Day I

Night

• 89 •

DC60-DM60_ROOFTOP-IOM-1307-E

USE

PRESENTATION

q On/Off unit

By supporting a few seconds the button q, you can activate or not (On/Off) the rooftop connected.

If the symbol

 completed by the time is displayed, the rooftop is stopped and the DC60 in sleep mode.

To restart the unit, press the button

q a few seconds.

Setting time

At initialization of the DC60, the CLIMATIC™ 60 are synchronized time and day of week with the clock DC60.

To view the time, brieﬂ y, press the button

.

To set the time press the button

a few seconds.

The hour value ﬂ ashes. Turn the knob

to adjust the desired value.

Press the knob

to select your choice.

Then the minute value ﬂ ashes. Turn the knob

to adjust the desired value.

Press the knob

to select your choice.

Then the weekday value ﬂ ashes. Turn the knob

to adjust the desired value.

Press the knob

to select your choice.

After a few seconds DC60 communicates the new time to the CLIMATIC™ 60.

Buttons

Control

Not used

Ventilation

Not used

Clock

Viewing or setting the time

Knob

Select or set of values

Standby

DISPLAY DC60

• 90 •





*:

:

:

- :

• 

• 

 :

• 

:

• 

:

• :

• :

• *:

• *:

• *:

• *:

DC60-DM60_ROOFTOP-IOM-1307-E

USE

Number of rooftop connected to the DC60

Predetermined temperature set point current mode (°C)

Volatile temperature set point current mode (°C)

Alarms code

Outdoor temperature (°C)

Supply temperature (°C)

Indoor (Room) temperature (°C)

Indoor (Room) humidity (%hr)

Indoor (Room) Air quality (ppm)

Opening of fresh air damper (%)

Available if the option is enabled.

Available if the level 2 is activated.

Adjustable with ‘DC60.

Volatile temperature set point current mode (°C)

Indoor (Room) temperature (°C)

Information available

By rotating the knob , you can view or modify the following values:

This item can know the number of rooftop connected to the DC60.

This item allows you to view and/or modify the control temperature required for the Roof-Top selected. If this point is changed, this value is used until the scheduling changes mode (A, B, C, D, BMS). At each change of the mode, the CLIMATIC™ 60 sets the value of this set point on the preset value in the mode concerned.

Unit connected

DC60 set in light mode

DC60 set in full mode

Volatile Temperature set point

Indoor (room) temperature

This item indicates the measured air temperature in the room conditioning. The room temperature isn't available if the CLIMATIC™ 60 is conﬁ gured to supply control.

DISPLAY DC60

• 91 •



















DC60-DM60_ROOFTOP-IOM-1307-E

USE

If the value of the selected item is modiﬁ ed :

• To activate the modiﬁ ed value, press the knob

.

• The

 symbol appears on the right side of the value.

• Turn the knob

to adjust the desired value.

• Press again on the knob

to conﬁ rm your choice.

• The

 symbol is no longer displayed on the right side of the value.

• The rotation of the knob

allows to select a new item.

Setting value

This item allows you to view and/or modify the control temperature required for the rooftop selected. If this point is changed, this value is used until the scheduling changes mode (A, B, C, D, BMS). At each change of the mode, the CLIMATIC™ 60 sets the value of this set point on the preset value in the mode concerned.

If level 2 is active, this item allows you to view and/or change the preset temperature control for the active mode.

This item can see the code of different active alarms on the rooftop. If the rooftop isn't in alarm, this item is to 0.

By this item it's possible to reset the alarm activated. To do this set the value of the item to the value 0.

This item indicates the measure temperature of the air outside.

This item indicates the measured air temperature in the room conditioning. The room temperature isn't available if the CLIMATIC™ 60 is conﬁ gured to supply control.

This item indicates the measured rate of CO² in conditioning room, in ppm. The measurement of CO² isn't available if the option isn't set.

This item indicates the measure of outlet air temperature of the rooftop.

This item shows the measured relative humidity of the air in the room conditioning. The room humidity isn't available if the option of humidity management isn't set.

This item indicates the measured value of the opening rate of the fresh air damper, in%, (mixture of outside air and return air) This value is only available if the rooftop is equipped with this option.

Volatile temperature set point

Predetermined temperature set point

Alarms code

Outdoor temperature

Indoor (Room) temperature

CO

2

measurement

Supply temperature

Indoor (Room) relative humidity

Opening of fresh air damper

DISPLAY DC60

• 92 • DC60-DM60_ROOFTOP-IOM-1307-E

LEVEL 2 ACTIVATION

(2 buttons on the right simultaneously)

Simultaneously press the keys

and q.

After some seconds the text  appears and the value '000' ﬂ ashes. Turn the knob

to change the value to select the number 066. Then validate the code by pressing the knob. If the code is wrong access the setup menu is not possible and the DC60 returns to the previous display. If the code is correct the level 2 is actif, and symbol

is displayed to the right of the value.

The level 2 is turned off automatically every hour.

DISPLAY DC60

• 93 •

DC60-DM60_ROOFTOP-IOM-1307-E

DISPLAY DM60

The 'DM60' display is personalized for the user. It allows an overview of unit operation and allows access to certain parameters.

The 'DM60' is designed for connection of remote roof-top.

The optional delivered DM60 is designed to be wall mounted:

• position the cable through the rear

• fasten the rear wall using button head screws provided in the package

• connect the cable from the main board on the jack on the back of the DM60 screen

• attach the front panel on the back using provided countersunk screws

• snap frame.

The display is connected to CLIMATIC™ DM60 on the screw terminals of the card DT50. The connection must be wired as follows:

• for a length of 0 to 300 m: AWG22 (0.34 mm ²), two crossed pairs with screen.

• for a length of 0 to 500 m: LiYCY-P (0.34 mm ²), two pairs shielded general. The cable length should not exceed 500 m. For a better protection of electromagnetic disturbances LENNOX recommends the icable LiYCY-P installation.

INSTALLATION

WARNING : An error connecting to the display immediately causes the deterioration of this one or BM60.

• 94 •

0

1 +VRL (≈30 Vdc)

2 GND

3 Rx/Tx-

4 RX/Tx+

5 GND

6 +VRL (≈30 Vdc)

DC60-DM60_ROOFTOP-IOM-1307-E

Jumpers:

The "displays" are directly supplied by the Climatic™ board with a 30 VDC power supply. Pay attention to the value of this voltage when multiple cards are used.

J14 and J15 closed or cut the power supply:

• J14 and J15 set between 1-2: connectors A, B, C and SC are in parallel. Power is available on all connectors.

• J14 and J15 set between 2-3: B and C connectors are supplied in parallel but the connectors A and SC are not. Displays connected

to these ports are not powered.

If J14 and J15 are set differently, the DT50 dispatcher DOESN'T WORK and therefore connected displays don't work.

Terminal Wire function Connections

Earth Shield

1st pair A

2nd pair A

3rd pair A

3rd pair B

2nd pair B

1st pair B

CONNECTION ON THE DT50 SPLITTER

DT50 dispatcher installation guide

The board is equipped with three RJ12 phone jacks and a screw connector (SC).

Display's ferrites protection

To avoid appearance of RF interference that may cause destruction of components in the displays, you need to equip the cable of a ferrite, during its installation (provided by LENNOX).

DISPLAY DM60

• 95 •

DC60-DM60_ROOFTOP-IOM-1307-E

DM60 AND COMMUNICATION MASTER/SLAVES

If the master/slaves communication bus is connected between several rooftop (maximum 8). The 'DM60', connected on this bus, allows viewing, alternatively, information of all connected units.

The inter-bus boards (pLan) CLIMATIC™ connects to connector J8 on the BM60 cards. Connection with 'star' is not recommended for optimum performance it is advisable to connect a maximum of two cables per unit. The connection must be wired as follows:

• For a length of 0 to 300 m: AWG22 (0.34 mm ²), a twisted pair shielded.

• For a length of 0 to 500 m: LiYCY-P (0.34 mm ²), a pair overall shield. cable length should not exceed 500 m. For better protection of electromagnetic disturbances Lennox recommends the installation of cable LiYCY-P.

MASTER / SLAVES / DM60

WARNING : The BM60 24Vac cards should not be connected to the 'earth'.

DISPLAY DM60

• 96 • DC60-DM60_ROOFTOP-IOM-1307-E

CONFIGURATION

Brightness / Contrast

The display is equipped with a contrast, but it can be adjusted manually. For manual adjustment of contrast, simultaneously press the 'alarm' and 'prg' keys and press 'arrow' or 'down arrow' buttons to increase or decrease the contrast.

Conﬁ guring the terminal's address

The termminal's address (DC60 or DM60) must be checked after putting the card to 'On':

• access the setup mode by pressing the 'arrow', 'enter' and 'down arrow' keys for at least 5 seconds.

• press 'enter' to place the cursor on 'setting'

• with 'arrow' or 'down arrow' set the address of the display 31 of DM60, then conﬁ rm by pressing 'enter'

The screen 'display address changed' is displayed.

If after 5 seconds the display is not correct:

• access, a second time, the setup mode by pressing the 'arrow', 'enter' and 'down arrow' keys for at least 5 seconds, up to the next screen.

• press 'enter' to place the cursor on 'setting'

• press 'enter' a second time to place the cursor on the I / O board address line

• with 'arrow' or 'down arrow' replace '-' by the address of the BM60 connected and conﬁ rm by pressing 'enter'

FUNCTIONALITY OF THE DM60

Rooftop selection

A DM60 can be connected to 8 units per the pLan bus. DM60 screens connected, alternatively, to one of BM60. The next screen allows selection of the unit to display:

Each of the 8 rooftops is represented by a number. The selected rooftop is indicated by its number which is framed. Each time you press the 'down arrow' button, it connects the display to the next rooftop. Pressing 'enter' key returns to the main screen.

DISPLAY DM60

• 97 •

DC60-DM60_ROOFTOP-IOM-1307-E

Main

Top left :

Bottom right:

State mode based on the schedule, hour, minute, of CLIMATIC™ :

• Pressing the 'alarm' button directs you to the alarm list display.

• Pressing the 'prg' button directs you to rooftop setup menus display.

• Pressing the 'esc' button takes you to the selected rooftop choice display.

• Pressing the 'arrow' button increases the set point value.

• Pressing the 'enter' button takes you to the rooftop operation display.

• Pressing the 'down arrow' button decreases the set point value.

Bottom left:

Top right:

Night mode

Day mode

Day I mode

Day II mode

If the unit is in alarm, this symbol is displayed

• Small, numerical value: volatile set point temperature: View and/or modify the offset, or set point, of the desired temperature control for the selected rooftop. Pressing the 'arrow' button increases the set point value. Pressing the 'down arrow' button decreases the set point value. If the setpoint is changed, this value is maintained as long as the rooftop scheduling doesn't change modes (night, day, day I, day II, BMS). At each change of the mode the CLIMATIC™ 60 sets the value of this setpoint on the preset value in the mode concerned.

• Big, numerical value: measured air temperature value in the conditioned space.

Control in heating mode or control in cooling mode

Ventilation state

DISPLAY DM60

• 98 • DC60-DM60_ROOFTOP-IOM-1307-E

DISPLAY DM60

Rooftop off

Rooftop operation

• pressing the 'alarm' button directs you to the alarm list display.

• pressing the 'esc' button takes you to the main display.

• pressing the 'arrow' button directs you to the previous screen.

• pressing the 'down arrow' button directs you to the next screen.

If the rooftop is Off, this screen is activated.

• pressing the 'alarm' button directs you to the alarm list display.

• pressing the 'prg' button directs you to the rooftop setup menus display.

• pressing the 'esc' button takes you to the selected rooftop choice display.

View/edit, status of the unit (On/Off).

Pressing the 'prg' button reverses the On/Off state of the unit.

On the left of the house:

• outdoor humidity value visualization (if enabled).

• outdoor temperature value visualization.

In the house:

• indoor humidity value visualization(if enabled).

• indoor temperature value visualization.

• indoor air quality rate visualization(if enabled).

Lennox FCM 200, FCM 100, FCM 150, FCM 170, FCM 230 Installation, Operating And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual