Lennox FCM 100, FCM 170, FCM 120, FCM 150, FCM 200 Installation, Operating And Maintenance

Providing indoor climate comfort

FLEXY & FLEXY WSHP

Installation, operating and maintenance

FLEXYII-WSHP-IOM-0909-E

CONTENTS

FLEXYII_WSHP-IOM-0909-E Page 1

INSTALLATION OPERATION MAINTENANCE MANUAL

Ref. FLEXYII_WSHP-IOM-0909-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 FWH 85 - FWH 100 - FWH 120 – FWH150 – FWH170 FWM 85 - FWM 100 - FWM 120 – FWM150 – FWM170 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:

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.

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

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

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

y

.

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

CONTENTS

FLEXYII_WSHP-IOM-0909-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

Duct connections ............................................................................................................................................17

Water connection (water source heat pump)..................................................................................................18

Water loop configuration (water source heat pump) ......................................................................................20

Installation on roof mounting frame ...............................................................................................................22

Curbing and flashing ......................................................................................................................................23

Non-adjustable non-assembled roof curb installation .....................................................................................24

Non-adjustable roof curb - Installation instructions.........................................................................................25

Adjustable roof curb .......................................................................................................................................26

Non-adjustable Non-assembled roof curb .....................................................................................................27

Multidirectional roof curb ...............................................................................................................................28

Return roof curb .............................................................................................................................................29

Return horizontal roof curb .............................................................................................................................30

Transition roof curb.........................................................................................................................................31

Energy Recovery............................................................................................................................................32

Economiser and extraction .............................................................................................................................44

COMMISSIONING

Before connecting the power..........................................................................................................................45

CLIMATIC.......................................................................................................................................................46

Powering the unit............................................................................................................................................46

Run test ..........................................................................................................................................................47

VENTILATION

Belt tension......................................................................................................................................................48

Mounting and adjusting pulleys.......................................................................................................................49

Airflow balancing............................................................................................................... ..............................50

Filters...............................................................................................................................................................58

Air sock control...............................................................................................................................................59

UV Light..........................................................................................................................................................60

HEATING OPTIONS

Hot water coils ...............................................................................................................................................61

Electric heater.................................................................................................................................................63

Gas burners....................................................................................................................................................64

Modulating gas burners ..................................................................................................................................75

CONTENTS

FLEXYII_WSHP-IOM-0909-E Page 3

ELECTRICAL DATA: WIRING DIAGRAMS

Diagram reference legend ..............................................................................................................................84

Main current diagram TRI/400V/50Hz + T……………………………………………………...............................85

CLIMATIC 50 controller………………………………………………………………………….. ............................87

CLIMATIC 50 input…………………………………………………………………………………….......................88

CLIMATIC 50 output…………………………………………………………………………………. .......................89

DAD smoke detector……………………………………………………………………………… ...........................90

General customer connection (TCB) ..............................................................................................................91

General customer connection with Advanced Control Pack (ADC) ................................................................92

Gas burner 60 kW and hot water coil .............................................................................................................93

Gas burner 120 kW ........................................................................................................................................94

Gas burner 180/240 kW..................................................................................................................................95

Electric heater.................................................................................................................................................96

General customer connection diagram...........................................................................................................97

Electrical data control variables ......................................................................................................................98

REFRIGERATION CIRCUIT

R410A ............................................................................................................................................................99

Advanced scroll temperature protection (ASTP).............................................................................................100

Principle sketches...........................................................................................................................................101

HOT WATER COIL DIAGRAM .............................................................................................................................107

MAINTENANCE DIAGNOSTIC

.............................................................................................................................108

MAINTENANCE PLAN

.........................................................................................................................................112

WARRANTY

..........................................................................................................................................................115

CERTIFICATES

....................................................................................................................................................116

IMPORTANT NOTICE – Safety instructions

FLEXYII_WSHP-IOM-0909-E Page 4

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

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

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

Work on the unit:

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

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

Work on the electrical system:

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

authorisation.

Work on the refrigerating circuit(s):

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

for this purpose and suitable equipment.

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

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

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

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

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

silver).

Replacing components:

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

parts approved by Lennox.

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

coolants, hydrocarbons, etc.).

CAUTION:

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

TRANSPORT – HANDLING:

- Never lift the unit without forklift protections

- Remove the forklift protection before installation

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

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

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

COMMISSIONING:

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

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

FILTERS:

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

FANSTART:

- Any adjustment has to be done power stopped.

GAS:

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

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

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

IMPORTANT NOTICE – Safety instructions

FLEXYII_WSHP-IOM-0909-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

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-0909-E Page 6

Site details

Site Unit Ref Installer

………………………………………

……………………………………....

………………………………………

Controller Model Serial No Refrigerant

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

(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 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

m3/h

…………………… ……………………

(5) AIRFLOW PRESS. SENSOR CHECK

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

Set Points Adjusted: 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

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

Yes No ……………..% Yes No Yes No

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-0909-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 : Yes No

(10) GAS HEATING SECTION

Gas Burner N°1 Gas Burner N°2

Size :

……………………….

Valve type :

…………………….

Size :

……………………….

Valve type :

…………………….

Pipe size:

Gas type : G…….

Pipe size

Gas type : G…….

Line pressure :

………………………

Drop test

Yes No

line pressure :

………………………

Drop test

Yes No

Check manifold pressure:

High fire …….…Low fire ………..

Check manifold pressure:

High fire …….…... Low fire ………..

Pressure cut out airflow press switch :

……………………mbar /Pa

Pressure cut out airflow press switch :

……………………mbar /Pa

Motor amps :

……….A

Flue temp.

……… °C

CO2 %:

………%

CO ppm:

………%

Motor Amps:

……….A

Flue temp.

………. °C

CO2 %:

………%

CO ppm:

………%

(11) REMOTE CONTROL BMS CHECK

Type :

…………………………..

Sensor type

………………………………..

KP07 KP/17 checked:

Yes No

Interconnect wiring checked:

Yes No

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-0909-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

COMMISSIONNING REPORT

FLEXYII_WSHP-IOM-0909-E Page 9

COMMENTS:

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

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

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

TRANSPORT – HANDLING – WARNING

FLEXYII_WSHP-IOM-0909-E Page 10

DELIVERY CHECKS

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

- The exterior has not been damaged in any way.

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

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

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

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

RATING PLATE

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

Fig. 1

STORAGE

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

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

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

- Keep protective plastic film in position.

- Ensure the electrical panels are closed.

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

MAINTENANCE KEY

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

CONDENSATE DRAINS

The condensate drains are not assembled when delivered and are stored in the electrical panel with their clamping collars. To assemble them, insert them on the condensate tray outlets and use a screwdriver to tighten the collars (Figure 3).

Fig. 3

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-0909-E Page 11

Handling slings to guide the

unit towards the roofcurb

Vacuum lifting beam to

position the unit

COMPLIAN

T

NON-COMPLIAN

T

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-0909-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 934 1009 1085 1367 1430 1650 1950 With economiser kg 990 1065 1141 1442 1505 1752 2052

Weight gas unit FGM

Standard heat Without economiser kg 1041 1116 1192 1608 1671 1914 2214 Standard heat With economiser kg 1097 1172 1248 1683 1746 2016 2316 High heat without economiser kg 1111 1186 1262 1631 1694 1954 2254 High heat With economiser kg 1167 1242 1318 1706 1769 2056 2356

WSHP FWH/FWM

85 100 120 150 170

View (F & G box)

F BOX F BOX F BOX G BOX G BOX

A

mm 2200 2200 2200 2200 2200

B

mm 3350 3350 3350 4380 4380

C

mm 1510 1510 1510 1834 1834

D

mm 360 360 360 450 450

Weight of standard units FWH

Without economizer kg 797 883 969 1250 1313 With economizer kg 853 939 1026 1325 1388

Weight gas unit FWM

Standard heat Without economiser kg 904 990 1076 1491 1554 Standard heat With economiser kg 960 1046 1133 1566 1629 High heat without economiser kg 974 1060 1146 1514 1577 High heat With economiser kg 1030 1116 1203 1589 1652

F & G BOX H BOX

A

D

B

C

D

A

B

C

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-0909-E Page 13

DIMENSIONS AND WEIGHTS

LENGTH HEIGHT WIDTH HOOD WEIGHT Side Fan Standard

mm mm mm

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

TRANSPORT – HANDLING

FLEXYII_WSHP-IOM-0909-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.

INSTALLATION

FLEXYII_WSHP-IOM-0909-E Page 15

FORKLIFT PROTECTIONS

NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS

REMOVE THE FORKLIFT PROTECTIONS BEFORE INSTALLATION

PRELIMINARY CHECKS

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

- Have the forklift protections been removed?

- Is there sufficient space for the equipment?

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

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

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

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

- Is drainage provided for the condensate?

- Is there sufficient access for maintenance?

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

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

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

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

INSTALLATION REQUIREMENTS

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

-Avoid uneven surfaces

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

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

- The direction of prevailing winds

-The direction and position of air flows.

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

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

CONNECTIONS

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

are secured, sealed and insulated.

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

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

INSTALLATION

FLEXYII_WSHP-IOM-0909-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/FWH/FWM F BOX

2200

(1)

2000 2000 2000

G BOX

2700

(1)

2000 2000 2000

H BOX

2700

(1)

2000 2000 2000

FX 25 & 30

* 1100 * 1700

35Æ55

* 1300 * 2300

70Æ100

* 1700 * 2300

110Æ170

* 2000 * 2300

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

A

B

C

D

DUCT CONNECTIONS

FLEXYII_WSHP-IOM-0909-E Page 17

RECOMMENDATIONS FOR DUCTS CONNECTIONS

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 CONNECTIONS

FLEXYII_WSHP-IOM-0909-E Page 18

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 circuit.

• 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 allow 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 liability 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 copper 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 encourages destabilisation of copper hydroxides and enlargement of particles.

• 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 CONNECTIONS

FLEXYII_WSHP-IOM-0909-E Page 19

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 concentrated 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 minimum 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 Æ Minimum water content of the installation Q Æ Water capacity in kW N Æ Number of control steps available in the unit Dt Æ 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

WATER CONDENSING

FLEXYII_WSHP-IOM-0909-E Page 20

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 50 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.

WATER FILTER REPLACEMENT (ONLY FOR WAT ER 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.

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.

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 cleaning

Figure 1 Figure 2

WATER CONDENSING

FLEXYII_WSHP-IOM-0909-E Page 21

Pressure Loss - Heat plate Exchanger

A

B

CD

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)

FWH/FWM

Exchanger Curve Filter Curve

85 C B

100 D B

120 D B

150 E C

170 E C

INSTALLATION ON A ROOFMOUNTING FRAME

FLEXYII_WSHP-IOM-0909-E Page 22

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 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

c

Fig. 4

Fig. 5

Fig. 6

INSTALLATION ON A ROOFMOUNTING FRAME

FLEXYII_WSHP-IOM-0909-E Page 23

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 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.

Fig. 7

INSTALLATION ON A ROOF MOUNTING FRAME

FLEXYII_WSHP-IOM-0909-E Page 24

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

A

IR DUCT

UNIT Support rail

ROOFCURB

Fig. 8

NON ADJUSTABLE ROOFCURB – Installation instructions

FLEXYII_WSHP-IOM-0909-E Page 25

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

All parts must be sealed with polyurethan sealant during assembly.

Foam Insulation Installing

• Stick large foam pieces underneath the flat top

Foam Gasket Installing

• Stick gasket all around the curb flange’s top

Spare parts

Fbox Gbox Hbox

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

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

Rivets 5820542X 4.8 x 8 mm 100 130 160

Let it free on 200 mm

long to enable water

drainage

ADJUSTABLE ROOFCURB

FLEXYII_WSHP-IOM-0909-E Page 26

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

All units

RETURN AIR

SUPPLY AIR

MAIN POWER ENTRY

NON ADJUSTABLE NON ASSEMBLED ROOFCURB

FLEXYII_WSHP-IOM-0909-E Page 27

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

SUPPLY AIR

MAIN POWER ENTRY

All units

MULTIDIRECTIONAL ROOFCURB

FLEXYII_WSHP-IOM-0909-E Page 28

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 RETURN AIR

RETURN AIR

SUPPLY AIR

All units

Lennox FCM 100, FCM 170, FCM 120, FCM 150, FCM 200 Installation, Operating And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual