Providing indoor climate comfort
FLEXY II
FLEXYII-IOM-0308-E
Installation, operating
and maintenance
IOM – FLEXY II – 0308 – E Page 1
INSTALLATION
OPERATION
MAINTENANCE MANUAL
Ref. FLEXYII_IOM/0308-E
The present manual applies to the following ROOFTOP versions:
FCM 85 - FCM 100 - FCM 120 - FCM 150 - FCM 170 - FCM 200 - FCM 230
FHM 85 - FHM 100 - FHM 120 - FHM 150 - FHM 170 - FHM 200 - FHM 230
FDM 85 - FDM 100 - FDM 120 - FDM 150 - FDM 170 - FDM 200 - FDM 230
FGM 85 - FGM 100 - FGM 120 - FGM 150 - FGM 170 - FGM 200 - FGM 230
FXK 25 - FXK 30 - FXK 35 - FXK 40 - FXK 55 - FXK 70 - FXK 85 - FXK 100 - FXK 110 - FXK 150 - FXK 170
NOTES FOR UNIT FITTED WITH GAS BURNER:
LENNOX have been providing environmental solutions since 1895, our range of Baltic TM rooftop continues to meet the
standards that have made LENNOX a household name. Flexible design solutions to meet YOUR needs and uncompromising
attention to detail. Engineered to last, simple to maintain and Quality that becomes a standard. Further Information on
www.lennoxeurope.com.
All the technical and technological information contained in this manual, including any drawing and technical descriptions
provided by us, remain the property of Lennox and must not be used (except in operation of this product), reproduced,
issued to or made available to third parts without the prior written agreement of Lennox.
The technical informations and specifications contained in this manual are for reference only. The manufacturer reserves the right to modify
these without warning and without obligation to modify equipment already sold.
CONTENTS
THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL
SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL
VENTILATED AREA.
PLEASE READ CAREFULLY THE MANUFACTURER'S INSTRUCTIONS
BEFORE STARTING THIS UNIT.
THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FOLLOWING
CODES: GB IR GR DA NO FI IS
In case these sy mbols are not displayed on the unit, please refer to the technical
documentation which will eventually detail any modifications required to the
installation of the unit in a particular country.
Switchgear must be installed on each unit in accordance with the Machine
Directive and the standard NF EN 60204.
IOM – FLEXY II – 0308 – E Page 2
COMMISSIONING SHEET................................................................................................ .............................. 6
INSTALLATION
Transport - Handling.................................................................................................................................10
Dimensions and weights...........................................................................................................................12
Lifting the units................................ ................................ ................................ ................................ .........14
Preliminary checks ...................................................................................................................................15
Minimum clearance around the unit...........................................................................................................16
Installation on roof mounting frame ..........................................................................................................17
Curbing and flashing ................................................................................................................................18
Duct connections......................................................................................................................................19
Non-adjustable non-assembled roof curb installation.................................................................................20
Non-adjustable non-assembled roof curb installation instructions................................ ............................... 21
Adjustable roof curb ................................................................................................ ................................ .22
Non-adjustable Non-assembled roof curb ................................................................................................ .23
Multidirectional roof curb ..........................................................................................................................24
Return roof curb ................................................................................................................................ ......25
Return horizontal roof curb .......................................................................................................................26
Transition roof curb ..................................................................................................................................27
Energy Recovery......................................................................................................................................28
Economiser and extraction .......................................................................................................................29
COMMISSIONING
Before connecting the power ................................ ................................ ................................ .................... 30
CLIMATIC................................................................................................................................................31
Powering the unit .....................................................................................................................................31
Run test ...................................................................................................................................................32
VENTILATION
Belt tension ....................................................................................................................................................33
Mounting ans adjusting pulleys......................................................................................................................34
Airflow balancing............................................................................................................................................35
Filters .............................................................................................................................................................43
Air sock control......................................................................................................................................... 44
UV Light................................................................ ................................ ................................ ................... 45
HEATING OPTIONS
Hot water coils .........................................................................................................................................46
Electric heater................................................................................................................................ .......... 48
Gas burners.............................................................................................................................................49
Modulating gas burners............................................................................................................................60
CONTENTS
IOM – FLEXY II – 0308 – E Page 3
ELECTRICAL DATA: WIRING DIAGRAMS
Diagram reference legend ........................................................................................................................69
Main current diagram TRI/400V/50Hz + T……………………………………………………. ............................70
CLIMATIC 50 controller………………………………………………………………………….............................72
CLIMATIC 50 input……………………………………………………………………………………. .....................73
CLIMATIC 50 output………………………………………………………………………………….......................74
DAD smoke detector……………………………………………………………………………… ..........................75
General customer connection (TCB..........................................................................................................76
General customer connection with Advanced Control Pack (ADC)............................................................. 77
Gas burner 60 kW and hot water coil.........................................................................................................78
Gas burner 120 kW .................................................................................................................................79
Gas burner 180/240 kW................................ ................................ ................................ ............................ 80
Electric heater................................................................ ................................ ................................ .......... 81
General customer connection diagram................................................................ ................................ ......82
Electrical data cont rol variables.................................................................................................................83
REFRIGERATION C IRCUIT
R410A ................................................................................................ ................................ .....................84
Advanced scroll temperature protection (ASTP)........................................................................................ 85
Principle sketches ................................................................................................ ................................ ....86
HOT WATER COIL................................................................................................................................ .........90
MAINTENANCE DIAGNOSTIC
.......................................................................................................................91
MAINTENANCE PLAN...................................................................................................................................94
WARRANTY................................................................................................................................................... 97
CERTIFICATES..............................................................................................................................................98
CONTENTS
IOM – FLEXY II – 0308 – E Page 4
All FLEXY II Units are compliant with the PED directive 97-23/CE
The following note must be followed carefully
All work on the unit must be carried out by a qualified and authorised employee.
Non-compliance with the following instructions may result in injury or serious accidents.
Work on the unit:
The unit shall be isolated from the electrical supply by disconnection and locking using the main isola ting sw itch.
Workers shall wear the appropriate personal protective equipment (helmet, gloves, glasses, etc.).
Work on the electrical system:
Work on electric components shall be performed with the power off by employees having valid electrical qualification and
authorisation.
Work on the refrigerating circuit(s):
Monitoring of the pressures, draining and filling of the system under pressure shall be carried out using connections provided
for this purpose and suitable equipment.
To prevent the risk of explosion due to spraying of coolant and oil, the relevant circuit shall be drained and at zero
pressure before any disassembly or unbrazing of the refrigerating parts takes place.
There is a residual risk of pressure build-up by degassing the oil or by heating the exchangers after the circuit has been
drained. Zero pressure shall be maintained by venting the drain connection to the atmosphere on the low pressure side.
The brazing shall be carried out by a qualified brazier. The brazing shall comply with standard NF EN1044 (minimum 30%
silver).
Replacing components:
In order to maintain CE marking compliance, replacement of components shall be carried out using spare parts, or using
parts approved by Lennox.
Only the coolant shown on the manufacturer’s nameplate shall be used, to the exclusion of all other products (mix of
coolants, hydrocarbons, etc.).
CAUTION:
In the event of fire, refrigerating circuits can cause an explosion and spray coolant gas and oil.
TRANSPORT – HANDLING:
- Never lift the unit without forklift protections
- Remove the forklift protection before installation
- An approach ramp must be installed if the unit’s installation requirements tell that it's necessary to reach the main switch.
This recommendation is valid for installations in general and in particular for return and curbs. It’s also valid to reach other
parts of the unit: filters, refrigerant circuit, etc…
- It’s advised to fix curbs and roofcurbs to the unit
- Whatever the supply configuration is, respect a minimal duct’s length of 2m before any elbow or any duct’s section change.
COMMISSION ING:
- 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 i n accordance with local safety codes and regulations and can only be used in
planed installation conditions for outdoor.
- Before commissioning this type of unit, it’s mandatory to ensure that the gas distribution system is compatible with the
adjustment and settings of the unit.
IMPORTANT NOTICE – Safety instructions
IOM – FLEXY II – 0308 – E Page 5
UV LIGHT :
- The UV lamp emits shortwave UV-C ultraviolet radiation which is harmful to skin and eyes
- It can cause serious skin burns and eye inflammation within ONE SECOND of exposure
- Do not enter the machine while UV are switched on
- Make sure the UV light circuit breaker is OFF when opening the return air section door and the supply air section doors
- The following logo will appear to inform about the UV-C radiation risk
IMPORTANT NOTICE – Safety instructions
IOM – FLEXY II – 0308 – E Page 6
Site details
Site
Unit Ref
Installer
………………………………………
……………………………………....
………………………………………
Controller
Model
Serial No
Refrigerant
………………………………….
……………….…………………
…………………………………
…………………………………
(1) ROOF IN STALLATION
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 50 Configured according to the Options and Specifications:
Yes No
(4) SUPPLY BLOWER SECTION
Type :
Power displayed on plate:
Voltage displayed on plate :
Current displayed on plate:
KW
V
A
N°1
……………………
……………………
……………………
N°2
……………………
……………………
……………………
Fan Type : Forward
Backward
Forward
Backward
Displayed Belt Length : mm …………………… ……………………
Tension Checked: Yes No Yes No
Alignment Checked : Yes No Yes No
Motor Pulley Diameter: DM mm …………………… ……………………
Fan Pulley Diameter: DP mm …………………… ……………………
Fan Speed = Motor rpm x DM / DP
Averaged Measured Amps :
rpm
A
……………………
……………………
……………………
……………………
Shaft Mechanical Power (Refer to airflow balancing) W …………………… ……………………
Operating point checked : Yes No Yes No
Estimated Airflow m
3
/h …………………… ……………………
(5) AIRFLOW PRESS. SENSOR CHECK
Measured pressure drop…………………………… mbar
Set Points Adjuste d: Yes No
If Yes enter new values:
3410: ………… 3411: ………… 3412: …………
(6) EXTERNAL SENSOR CHECKS
Check and record temp. in menu 2110
Yes Non
Check electrical connections :
Yes No
100% Fresh Air 100% return Air
Supply Temperature ………………………..°C ………………………..°C
Return Temperature ………………………..°C ………………………..°C
Outdoor Temperature ………………………..°C ………………………..°C
(7) MIXING AI R DAMPERS CHECKS
Dampers open & close freely
OK
% Minimum FA: Power exhaust checked Enthalpy sensor(s) checked
Yes No ……………..% Yes No Yes No
COMMISSIONING REPORT
IOM – FLEXY II – 0308 – E Page 7
(8) REFRIGERATION SECTION
Outdoor Fan Motor Current: Check Rotation
Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Yes No
Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Yes No
Compressor Voltage
Motor 3 / Moteur 3 L1 ……..A L2 ……..A L3 ……A Yes No Comp1: …….. V
Motor 4 / Moteur 4 L1 ……..A L2 ……..A L3 ……A Yes No Comp2: …….. V
Motor 5 / Moteur 5 L1 ……..A L2 ……..A L3 ……A Yes No Comp3: …….. V
Motor 6 / Moteur 6 L1 ……..A L2 ……..A L3 ……A Yes No Comp4: …….. V
Compressor Amps COOLING Pressures & Temperatures
Temperatures Pressures
Phase 1 Phase 2 Phase 3
Suction
Discharge
LP/ BP
HP / HP
Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Check Reversing valves :
Valve1: Yes No
Valve2: Yes No
Valve3: Yes No
Valve4: Yes No
Compressor Amps HEATING Pressures & Temperatures
Temperatures Pressures
Phase 1 Phase 2 Phase 3
Suction
Discharge
LP/ BP
HP / HP
Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
HP cut out ……Bar LP cut out ………..…... Bar
Refrigerant charge C1 : ………..kg C2 : ………..kg C3 : ………..kg C4 : ………..kg
(8)ELECTRIC HEATER SECTION
Type : …………………………………………………. Serial No.:………………………..
AMPS 1st stage (Baltic) AMPS 2nd stage (Baltic)
1 ………………. 2 ………………. 3 ………………. 1 ………………. 2 ………………. 3 ……………….
(9) HOT WATER COIL SECTION
Check Three Way Valve Movement : Ye s No
(10) GAS HEATING SECTION
Gas Burner N°1 Gas Burner N°2
Size :
……………………….
Valve type :
…………………….
Size :
……………………….
Valve type :
…………………….
Pipe size: Gas type : G……. Pipe size Gas type : G…….
Line pressure :
………………………
Drop test
Yes No
line pressure :
………………………
Drop test
Yes No
Check manifold pressure:
High fire …….…Low fire ………..
Check manifold pressure:
High fire …….…... Low fire ………..
Pressure cut out airflow press switch :
……………………mbar /Pa
Pressure cut out airflow press switch :
……………………mbar /Pa
Motor amps :
……….A
Flue temp.
……… °C
CO2 %:
………%
CO ppm:
………%
Motor Amps:
……….A
Flue temp.
………. °C
CO2 %:
………%
CO ppm:
………%
(11) REMOTE CONTROL BMS CHECK
Type :
…………………………..
Sensor type
………………………………..
KP07 KP/17 checked:
Yes No
Interconnect wiring checked:
Yes No
COMMISSIONING REPORT
IOM – FLEXY II – 0308 – E Page 8
It is recommended that you fill the two tables below before transferring the zone settings to the Climatic 50 controller.
Refer to control section page 55 / Se référer à la section régulation page 55
Time Zones / Zones Horaires
Hour
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Example
UNO
7h15
ZA
11h00
ZB
14h00
ZC
19h00
UNO
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Variables to adjust for each time zone / Consignes à renseigner pour chaque zone horaire
Start z.A Start z.B Start z.C Start UNO
hour (3211) min (3212) hour (3213) min (3214) hour (3215) min (3216) hour (3217) min (3218)
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Description Unit Menu Min
Max
Zone A Zone B Zone C UNOC
Sp Room °C 3311 8 35
Mini.Air % 3312 0 100
Sp Dyna °C 3321 0 99.9
Sp Cool °C 3322 8 35
Sp Heat °C 3323 8 35
Swap Heater On/Off 3324 ~ ~
Activation On/Off 3331 ~ ~
Swap Heater On/Off 3332 ~ ~
Sp.Dehu % 3341 0 100
Sp.Humi % 3342 0 100
Fan On/Off On/Off 3351 ~ ~
Fan Dead On/Off 3352 ~ ~
F.Air On/Off 3353 ~ ~
CO2 On/Off 3354 ~ ~
Comp.Cool. On/Off 3355 ~ ~
Comp.Heat. On/Off 3356 ~ ~
AuxHeat On/Off 3357 ~ ~
Humidif. On/Off 3358 ~ ~
Low Noise On/Off 3359 ~ ~ N/A N/A N/A
COMMISSIONING REPORT
IOM – FLEXY II – 0308 – E Page 9
COMMENTS:……………………………………………………………………………………………………………………………………
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COMMISSIONING REPORT
IOM – FLEXY II – 0308 – E Page 10
DELIVERY CHECKS
On receipt of a new equipment please check the following
points. It is the customer’s responsibility to ensure that the
products are in good working order:
- The exterior has not been damaged in any way.
- The lifting and handling equipment are suitable for the
equipment and comply with the specifications of the
handling instructions enclosed here-in.
- Accessories ordered for on site installation have been
delivered and are in good working order.
- The equipment supplied corresponds to the order and
matches the delivery note.
If the product is damaged, exact details must be confirmed
in writing by registered post to the shipping company
within 48 hours of delivery (working days). A copy of the
letter must be addressed to Lennox and the supplier or
distributor for information purposes. Failure to comply will
invalidate any claim against the shipping company.
RATING PLATE
The rating plate provides a complete reference for the
model and ensures that the unit corresponds to the model
ordered. It states the electrical powe r 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 m ains electrical
supply. The rating plate also states the year of
manufact ure 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 cove rs in posi tion (AQUILUX
cover).
- Keep protective plastic film in position.
- Ensure the electrical panels are closed.
- Keep all items and options supplied in a dry and clean
place for future assembly before using the equipment.
MAINTENANCE KEY
On delivery we recommend that you keep the key which is
attached to an eyebolt in a safe and accessible place. This
allows you to open the panels for maintenance and
installation work.
The locks are ¼ turn + then tighter (figure 2).
CONDENSATE DRAINS
The condensate drains are not assembled when delivered
and are stored
in the electrical panel with their clamping collars.
To assemble them, insert them on the condensate tray outlets
and use a screwdriver to tighten the collars (Figure 3).
TRANSPORT – HANDLING – WARNING
Fig. 3
IOM – FLEXY II – 0308 – E Page 11
TRANSPORT – HANDLING
Handling slings to guide the
unit towards the roofcurb
Vacuum lifting beam to
position the unit
COMPLIANT
NON
-
COMPLIANT
MANDATORY HANDLING DEVICES
IOM – FLEXY II – 0308 – E Page 12
DIMENSIONS AND WEIGHTS
FLEXY2 FCM/FHM/FGM/FDM
85 100 120 150 170 200 230
View (F, G, H box)
F BOX F BOX F BOX G BOX G BOX H BOX H BOX
A
mm 2200 2200 2200 2200 2200 2200 2200
B
mm 3350 3350 3350 4380 4380 5533 5533
C
mm 1510 1510 1510 1834 1834 2134 2134
D
mm 360 360 360 450 450 615 615
Weight of standard units FCM
Without economiser kg 933.8 1008.8 1085.0 1367.0 1430.0 1650.0 1950.0
With economiser kg 990.3 1065.3 1141.5 1442.0 1505.0 1751.7 2051.7
Weight gas unit FGM
Standard heat Without economiser kg 1040.8 1115.8 1192.0 1608.0 1671.0 1913.9 2213.9
Standard heat With economiser kg 1097.3 1172.3 1248.5 1683.0 1746.0 2015.6 2315.6
High heat w ithout economiser kg 1110.8 1185.8 1262.0 1631.0 1694.0 1954.1 2254.1
High heat With economiser kg 1167.3 1242.3 1318.5 1706.0 1769.0 2055.8 2355.8
TRANSPORT – HANDLING
F & G BOX H BOX
A
D
B
C
D
A B
C
IOM – FLEXY II – 0308 – E Page 13
DIMENSIONS AND WEIGHTS
LENGTH HEIGHT WIDTH HOOD WEIGHT
Side Fan Standard
mm mm mm
mm mm kg
FXK025 4070 1635 1055 490 600 950
FXK030 4070 1635 1055 490 600 980
FXK035 4750 2255 1290 490 600 1400
FXK040 4750 2255 1290 490 600 1450
FXK055 4750 2255 1290 490 600 1600
FXK070 5050 2255 1725 890 600 1800
FXK085 5050 2255 1725 890 600 1900
FXK100 5050 2255 1725 890 600 2000
FXK110 5650 2255 2000 860 - 2620
FXK140 5650 2255 2000 860 - 2620
FXK170 5650 2255 2000 860 - 2650
TRANSPORT – HANDLING
IOM – FLEXY II – 0308 – E Page 14
LIFTING THE UNIT
As shown on the picture below, a lifting frame is necessary.
After lifting, withdraw angle’s feet and lifting lugs.
TRANSPORT – HANDLING
IOM – FLEXY II – 0308 – E Page 15
FORKLIFT PROTECTIONS
NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS
REMOVE THE FORKLIFT PROTECTIONS
BEFORE INSTALLATION
PRELIMINARY CHECKS
Before installing the equipment, the following points MUST
be checked:
- Have the forklift protections been removed?
- Is there sufficient space for the equipment?
- Is the surface on which the equipment is to be
installed sufficiently solid to withstand its weight? A
detailed study of the frame must be made beforehand.
- Do the supply and return ductwork openings
excessively weaken the structure?
- Are there any obstructing items which could hinder
the operation of the equipm ent?
- Does the electrical power available correspond to the
equipment's electrical specifications?
- Is drainage provided for the condensate?
- Is there sufficient access for maintenance?
- Installation of the equipment could require different
lifting methods which may vary with each installation
(helicopter or crane). Have these been evaluated?
- Ensure that the unit is installed in accordance with the
installation instructions and local applicable codes.
- Check to ensure that the refrigerant lines do not rub
against the cabinet or against other refrigerant lines.
In general, make sure no obstacles (walls, trees or roof
ledges) are obstructing the duct connections or hindering
assembly and maintenance access.
INSTALLATION REQUIREMENTS
The surface on which the equipment is to be installed must
be clean and free of any obstacles which could hinder the
flow of air to the condensers:
-Avoid uneven surfaces
-Avoid installing two units side by side or close to each
other as this may restrict the airflow to the condensers.
Before installing a packaged Rooftop unit it is important to
understand:
- The direction of prevailing winds
-The direction and position of air flows.
-The external dimensions of the unit and the
dimensions of the supply and return air connections.
-The arrangement of the doors and the spa ce required
to open them to access the various components.
CONNECTIONS
-Ensure that all the pipe-work crossing walls or roofs
are secured, sealed and insulate d.
-To avoid condensation problems, make sure that all
pipes are insulated according to the temperatures of
fluids and type of rooms.
NOTE: The AQUILUX protection sheets fitted to the finned
surfaces must be removed prior to start up.
INSTALLATION
IOM – FLEXY II – 0308 – E Page 16
MINIMUM CLEARANCE AROUND THE UNIT
Figure 4 shows the required clearances and service access around the unit.
NOTE: Ensure the fresh air inlet does not face prevailing wind direction.
A B C D
FCM/FHM/FGM/FDM
F BOX 2200
(1)
2000 2000 2000
G BOX 2700
(1)
2000 2000 2000
H BOX 2700
(1)
2000 2000 2000
FX
25 & 30 * 1100 * 1700
3555 * 1300 * 2300
70100 * 1700 * 2300
110170 * 2000 * 2300
(1) Add 1 meter if the units are equipped with gas burner
A
B
C
D
INSTALLATION
IOM – FLEXY II – 0308 – E Page 17
CAUTION:
- An approach ramp must be installed if the unit’s installation requirements tell that it's
necessary to reach the main switch. This recommendation is valid for installations in
general and in particular for return and curbs. It’s also valid to reach other parts of
the unit: filters, refrigerant circuit, etc…
- It’s advised to fix curbs and roofcurbs to the unit.
As levels are adjustable, observe the following
recommendations when installing the equipment
Above all, ensure that all the adjustable returns are facing
outward (“1” figure 4). They are usual ly turned inside-out
for transport.
Place the roof mounting frame on the trimmer beam by
first lining up the inlet and the outlet opening. (“2”- figure 5)
After levelling the frame, secure the adjustable returns on
the trimmer.
It is important to centre the unit on the roof frame
INSTALLATION ON A ROOFMOUNTING FRAME
Fig. 4
Fig. 5
Fig. 6
IOM – FLEXY II – 0308 – E Page 18
When the frame is correctly positioned, it is essential to secure the assembly with a disconnected stitched welded seam (20 to
30mm every 200mm
) along the outside or by using an alternative method
CURBING AND FLASHING
Outside of frame must be insulated with rigid type insulation;
We recommend a minimum of 20 mm thick insulation (2-figure 7).
Check that the insulation is continuous, counter flash and seal around the
frame
as shown in (1-figure 7).
CAUTION: To be effective, the upstream must end below the drop edge (3 - figure
7).
Where pipes and electrical conduits extend through the roof, flashing must be
conformed to local codes of practice.
Before installing the equipment, make sure that seals are not damaged and check that the unit is secured to the mounting
frame. Once in position, the bottom of the equipment must be horizontal.
The installer must comply with local authority standards and specifications.
RECOMMENDATIONS FOR DUCTS CONNECTIONS
Some rules must be complied with for the connections between ducts and unit done on site.
INSTALLATION ON A ROOFMOUNTING FRAME
Fig. 7
IOM – FLEXY II – 0308 – E Page 19
Whatever the supply configuration is, respect a minimal duct’s length (D) of 2m before any elbow or any duct’s diameter
change.
These recommendations are imperative in the case of 2 independent turbines (sizes from 150kW to 230kW and all units
equipped with gas module)
Horizontal supply
Vertical supply
Here are obvious bad examples of ducts connections noted on site:
D ≥ 2m
DUCT CONNECTIONS
INSTALLATION ON A ROOFMOUNTING FRAME
D ≥ 2m
D ≤ 2m
D ≤ 2m
IOM – FLEXY II – 0308 – E Page 20
NON ADJUSTABLE NON ASSEMBLIED ROOFCURB INSTALLATION
FRAME PARTS IDENTIFICATION
Figure 8 shows the different parts used in the assembly of this roof mounting frame.
INSTALLATION
The roof mounting frame provides support when the units are installed in down-flow configurations.
The non adjustable, non assembled roof mounting frame can be installed directly on decks having adequate structural strength
or on roof supports under deck.
NOTE: frame assembly must be installed flat, leveled within 5mm per linear meter in any direction
UNIT FLOOR
UNIT FLOOR
AIR DUCT
UNIT Support rail
ROOFCURB
Fig. 8
INSTALLATION ON A ROOF MOUNTING FRAME
IOM – FLEXY II – 0308 – E Page 21
This roof curb will arrive as a packaged on a pallet and need to be built together.
The part will be conne cte d by special corrosion free nails. It is not possible to connect with standard nail equipment because
there is a lot of power needed. Therefore, you need a pneumatic or electric device.
Foam Insulation Installing
St ick large foam pieces underneath the flat top
Foam Gasket Installing
Stick gasket all around the curb flange’s top
Spare parts
Fbox Gbox Hbox
GASKET 5840071R Grey foam M1 17 m / 0.85 m² 19 m / 0.95 m² 21 m /1.1 m²
INSULATION 5840071R 760 x 1960 - 1.39 m² 920 x 1960 - 1.79m² tbd
Rivets 5820542X 4.8 x 8 mm 100 130 160
Let it free on 200 mm
long to enable water
drainage
NON ADJUSTABLE ROOF CURB - Installation instructions
IOM – FLEXY II – 0308 – E Page 22
SIZE A B C D E F G H J K L M N P Q R
F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95
G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95
H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800 80 1133 95
ADJUSTABLE ROOFCURB
All units
RETURN AIR
SUPPLY AIR
MAIN POWER ENTRY
IOM – FLEXY II – 0308 – E Page 23
SIZE A B C D E F G H J K L M N P Q R
F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95
G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95
H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800 80 1133 95
NON ADJUSTABLE NON ASSEMBLED ROOFCURB
SUPPLY AIR
MAIN POWER ENTRY
All units
IOM – FLEXY II – 0308 – E Page 24
SIZE A B C D E F G H J K L M N P Q R S
F-BOX 85-100-120 2056 2745 2005 800 100 600 300 1335 88 980 780 600 100 600 100 600 100
G-BOX 150-170 2056 3441 2493 800 100 600 300 1540 88 980 780 900 100 600 100 900 100
H-BOX 200-230 2056 4063 2493 800 100 600 300 1830 88 980 780 1000 100 600 100 1000 100
SUPPLY AIR
MULTIDIRECTIONAL ROOFCURB
RETURN AIR
RETURN AIR
SUPPLY AIR
All units
IOM – FLEXY II – 0308 – E Page 25
SIZE A B C D E F G H J K L M N P Q R
F-BOX 85-100-120 2156 2740 2005 1030 2056 2005 1650 180 310 840 140 700 1440 326 593 95
G-BOX 150-170 2156 3437 2494 1030 2056 2494 1650 410 310 840 140 700 1540 434 770 95
H-BOX 200-230 2156 4073 2494 1030 2056 3294 2550 100 310 840 80 800 1830 434 1113 95
RETURN ROOFCURB
CAUTION
: An approach ramp must be installed if the
machine installation requirements tell that it's necessary
to reach the main switch. This recommendation is valid
for installations in general and in particular for return
and curbs. It’s also valid to reach other parts of the unit:
filters, refrigerant circuit, etc…
SUPPLY AIR
EXHAUST AIR
All units
RETURN
AIR
MAIN POWER ENTRY
IOM – FLEXY II – 0308 – E Page 26
SIZE A B C D E F G H J K L M N P
F-BOX 85-100-120 2056 2755 2005 1220 1180 100 400 100 1335 200 1605 200 100 700
G-BOX 150-170 2056 3465 2493 1220 1180 100 400 100 1540 200 2000 200 100 700
H-BOX 200-230 2056 4095 2493 1305 1205 200 400 150 1830 150 2293 100 260 700
RETURN HORIZONTAL ROOFCURB
CAUTION
: An approach ramp must be installed if the
machine installation requirements tell that it's necessary to
reach the main switch. This recommendation is valid for
installations in general and in particular for return and
curbs. It’s also valid to reach other parts of the unit: filters,
refrigerant circuit, etc…
EXHAUST AIR
All units
RETURN AIR
SUPPLY AIR
MAIN POWER ENTRY
IOM – FLEXY II – 0308 – E Page 27
SIZE A B C D E F G H J K L M N
F-BOX 85-100-120 2056 2008 2072 366 2783 1880 70 85 530 700 145 1432 342
G-BOX 150-170 2056 2496 2072 366 3480 2377 70 85 530 700 145 1540 440
H-BOX 200-230 2056 2493 2072 366 4106 2377 70 85 530 800 85 1830 440
TRANSITION CURB
SUPPLY AIR
MAIN POWER ENTRY
RETURN AIR
All units
IOM – FLEXY II – 0308 – E Page 28
..
SIZE A B C D E F
F-BOX 85-100-120 2279 2212 1447 360 1911 938
G-BOX 150-170 2539 2473 1544 457 2211 938
H-BOX 200-230 2789 2723 1703 616 2461 938
ENERGY RECOVERY
All units
A
C
B
E
F
IOM – FLEXY II – 0308 – E Page 29
1) The unit being already erected on the roofcurb, remove the lifting lug shown on [A], and the doors of the Recovery
module [B].
2) Fit the support part of the Recovery Module on interior level of the rooftop ,
3) Fix the Recovery Module at the roof of the rooftop and corner structures by using self-driling screws.
4) Apply Mastic on side junctions and on higher junction.
ENERGY RECOVERY
Fig. 25
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3
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