Lennox FCM 85 Installation, Operating And Maintenance
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Lennox FCM 85 Installation, Operating And Maintenance

Flexy & flexy wshp series
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Installation, operating
and maintenance
FLEXY & FLEXY WSHP
Providing indoor climate comfort
FLEXYII-WSHP-IOM-0909-E

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Summary of Contents for Lennox FCM 85

  • Page 1 Installation, operating and maintenance FLEXY & FLEXY WSHP Providing indoor climate comfort FLEXYII-WSHP-IOM-0909-E...
  • Page 3 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...

  • Page 4: Table Of Contents

    CONTENTS 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...

  • Page 5: Flexyii_Wshp-Iom-0909-E Page

    CONTENTS 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...
  • Page 6 • 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.).
  • Page 7 IMPORTANT NOTICE – Safety instructions 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 FLEXYII_WSHP-IOM-0909-E...
  • Page 8 COMMISSIONNING REPORT Site details Controller …………………………………. Site ……………………………………… Model ……………….………………… Unit Ref ……………………………………..Serial No ………………………………… Installer ……………………………………… Refrigerant ………………………………… (1) ROOF INSTALLATION Sufficient Access OK Condensate drain fitted Roofcurb Not OK (2) CONNECTIONS CHECK Phase check 1 / 2 2 / 3 1 / 3 Voltage between Phases...
  • Page 9 COMMISSIONNING REPORT (8) REFRIGERATION SECTION Outdoor Fan Motor Current: Check Rotation Compressor Voltage Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Motor 3 / Moteur 3 L1 ……..A L2 ……..A L3 ……A...
  • Page 10 COMMISSIONNING REPORT 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 0 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Hour...
  • Page 11 COMMISSIONNING REPORT COMMENTS: ..................................................................................................................................................................................................................................................………….……………………………………………………………………………………………………………………………............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................FLEXYII_WSHP-IOM-0909-E Page 9...

  • Page 12: Transport - Handling

    This 48 hours of delivery (working days). A copy of the letter allows you to open the panels for maintenance and must be addressed to Lennox and the supplier or installation work. distributor for information purposes. Failure to comply will The locks are ¼...
  • Page 13 TRANSPORT – HANDLING MANDATORY HANDLING DEVICES Handling slings to guide the unit towards the roofcurb Vacuum lifting beam to position the unit NON-COMPLIANT COMPLIANT FLEXYII_WSHP-IOM-0909-E Page 11...

  • Page 14: Dimensions And Weights

    TRANSPORT – HANDLING DIMENSIONS AND WEIGHTS F & G BOX H BOX FLEXY2 FCM/FHM/FGM/FDM View (F, G, H box) F BOX F BOX F BOX G BOX G BOX H BOX H BOX 2200 2200 2200 2200 2200 2200 2200 3350 3350 3350...
  • Page 15 TRANSPORT – HANDLING DIMENSIONS AND WEIGHTS LENGTH HEIGHT WIDTH HOOD WEIGHT Side Standard FXK025 4070 1635 1055 FXK030 4070 1635 1055 FXK035 4750 2255 1290 1400 FXK040 4750 2255 1290 1450 FXK055 4750 2255 1290 1600 FXK070 5050 2255 1725 1800 FXK085 5050...

  • Page 16: Lifting The Units

    TRANSPORT – HANDLING LIFTING THE UNIT As shown on the picture below, a lifting frame is necessary. After lifting, withdraw angle’s feet and lifting lugs. FLEXYII_WSHP-IOM-0909-E Page 14...

  • Page 17: Preliminary Checks

    INSTALLATION FORKLIFT PROTECTIONS NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS REMOVE THE FORKLIFT PROTECTIONS INSTALLATION REQUIREMENTS BEFORE INSTALLATION The surface on which the equipment is to be installed must be clean and free of any obstacles which could hinder the PRELIMINARY CHECKS flow of air to the condensers: -Avoid uneven surfaces...

  • Page 18: Minimum Clearance Around The Unit

    INSTALLATION 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. FCM/FHM/FGM/FDM/FWH/FWM 2200 2000 2000 2000 F BOX G BOX 2700 2000 2000 2000...

  • Page 19: Duct Connections

    DUCT CONNECTIONS 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.

  • Page 20: Water Connection (Water Source Heat Pump)

    WATER CONNECTIONS 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.

  • Page 21: Minimum Water Content

    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.

  • Page 22: Water Loop Configuration (Water Source Heat Pump)

    WATER CONDENSING 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, •...
  • Page 23 WATER CONDENSING Pressure Loss - Heat plate Exchanger Water flow (m3/h) Pressure Loss - WATER FILTER 10.0 Water flow (m3/h) Exchanger Curve Filter Curve FWH/FWM FLEXYII_WSHP-IOM-0909-E Page 21...

  • Page 24: Installation On Roof Mounting Frame

    INSTALLATION ON A ROOFMOUNTING FRAME 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…...

  • Page 25: Curbing And Flashing

    INSTALLATION ON A ROOFMOUNTING FRAME 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;...

  • Page 26: Non-Adjustable Non-Assembled Roof Curb Installation

    INSTALLATION ON A ROOF MOUNTING FRAME 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.

  • Page 27: Non Adjustable Roofcurb - Installation Instructions

    NON ADJUSTABLE ROOFCURB – Installation instructions 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.

  • Page 28: Adjustable Roofcurb

    ADJUSTABLE ROOFCURB All units RETURN AIR SUPPLY AIR MAIN POWER ENTRY SIZE F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800...

  • Page 29: Non Adjustable Non Assembled Roofcurb

    NON ADJUSTABLE NON ASSEMBLED ROOFCURB All units SUPPLY AIR MAIN POWER ENTRY SIZE F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 G-BOX 150-170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 H-BOX 200-230 2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800...

  • Page 30: Multidirectional Roofcurb

    MULTIDIRECTIONAL ROOFCURB All units RETURN AIR SUPPLY AIR RETURN AIR SUPPLY AIR SIZE F-BOX 85-100-120 2056 2745 2005 800 100 600 300 1335 88 980 780 100 600 100 G-BOX 150-170 2056 3441 2493 800 100 600 300 1540 88 980 780 100 600 100 H-BOX 200-230...

  • Page 31: Return Roofcurb

    RETURN ROOFCURB CAUTION: An approach ramp must be installed if the All units 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…...

  • Page 32: Return Horizontal Roofcurb

    RETURN HORIZONTAL ROOFCURB CAUTION: An approach ramp must be installed if the All units 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.

  • Page 33: Transition Roof Curb

    TRANSITION CURB All units RETURN AIR SUPPLY AIR MAIN POWER ENTRY SIZE 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...

  • Page 34: Energy Recovery

    ENERGY RECOVERY All units SIZE F-BOX 85-100-120 2279 2212 1447 1911 G-BOX 150-170 2539 2473 1544 2211 H-BOX 200-230 2789 2723 1703 2461 FLEXYII_WSHP-IOM-0909-E Page 32...
  • Page 35 ENERGY RECOVERY INSTALLATION zoom Fig. 25 zoom zoom The unit being already erected on the roofcurb, remove the lifting lug shown on , and the doors of the Recovery module Fit the support part of the Recovery Module on interior level of the rooftop Fix the Recovery Module at the roof of the rooftop and corner structures by using self-driling screws.
  • Page 36 ENERGY RECOVERY INSTALLATION STEP 1: Rooftop configuration This picture shows how the rooftop configuration has to be before recovery module assembling No Hood No panel The lifting lug and the corner sheet metal The head guard on the left corner of the have to be removed.
  • Page 37 ENERGY RECOVERY INSTALLATION STEP 2: Lifting For Recovery module lift, use lifting lugs localised at the top of each corner structures FLEXYII_WSHP-IOM-0909-E Page 35...
  • Page 38 ENERGY RECOVERY INSTALLATION STEP 3: Fitting During installation phase, fit the support part on the interior level of the rooftop SUPPORT PART INTERIOR LEVEL FLEXYII_WSHP-IOM-0909-E Page 36...
  • Page 39 ENERGY RECOVERY INSTALLATION STEP 4: Check A good fit can be controled by looking at the junction between the rooftop and the recovery module: The junction has to be at the same level. SAME LEVEL For 150 and 170 sizes, a deviation of 70mm Size 150 &...
  • Page 40 ENERGY RECOVERY INSTALLATION STEP 5 : Fixing When the module is well fitted, fix the corner structures to the rooftop by using self- Self-drilling screws 32mm D4.8 drilling screws 32mm And fix the top of the module to the rooftop by using self-driling screws 19mm Self-drilling screws 19mm D6.3 FLEXYII_WSHP-IOM-0909-E Page 38...
  • Page 41 ENERGY RECOVERY INSTALLATION STEP 6: Masticate Apply mastic on side junctions and higher junction FLEXYII_WSHP-IOM-0909-E Page 39...
  • Page 42 ENERGY RECOVERY INSTALLATION STEP 7: Electrical wiring The Recovery module is sent with a power cable and a T-lan cable T-lan cable Power cable These 2 cables have to be inserted through this hole FLEXYII_WSHP-IOM-0909-E Page 40...
  • Page 43 ENERGY RECOVERY INSTALLATION Then fix the 2 cables on the grid of the extraction roofcurb and insert them in rooftop electrical panel as shown Cables from the module, through the hole, to rooftop electrical panel FLEXYII_WSHP-IOM-0909-E Page 41...
  • Page 44 ENERGY RECOVERY INSTALLATION Then connect the power cable from the module to the rooftop, and the t-lan to the Climatic50 (or the BE50 if presents in electrical rooftop panel) Exctraction Roofcurb Connection Recovery Module Connection Actuator Roofcurb Connection Be careful: Check connections and connect male connections to good female one.
  • Page 45 ENERGY RECOVERY INSTALLATION 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.

  • Page 46: Economiser And Extraction

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

  • Page 47: Commissioning

    COMMISSIONING THIS WORK MUST ONLY BE CARRIED OUT BY TRAINED REFRIGERATION ENGINEERS FILL THE COMMISSIONNING SHEET AS YOU GO ALONG Don’t forget to open the isolation Valves on the liquid line before starting the unit (see sticker below) ISOLATION VALVES MUST BE OPENED BEFORE RUNNING ELECTRICAL CONNECTIONS - Ensure that the power supply between the building and the unit meets local authority standards and that the cable specification...

  • Page 48: Climatic

    COMMISSIONING STARTING THE UNIT Check and adjust the control settings. At this point the unit circuit breakers should be open Refer to the control section in this manual to adjust the You will need a DS50 maintenance controller or Adalink with different parameters.

  • Page 49: Run Test

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

  • Page 50: Ventilation Belt Tension

    VENTILATION : BELT TENSION 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.

  • Page 51: Mounting And Adjusting Pulleys

    VENTILATION : PULLEYS MOUNTING AND ADJUSTING PULLEYS 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 will separate from each other. Remove the hub and the pulley by hand without damaging the machine.

  • Page 52: Airflow Balancing

    VENTILATION : AIRFLOW BALANCING 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.
  • Page 53 VENTILATION : AIRFLOW BALANCING CHECKING AIRFLOW AND ESP method when adjusting the pulley : -Close the pulley fully and count the number of turns from fully closed position. Using table_1 determine the Using the fan curves on page 36 to 40, the airflow, the total motor pulley actual diameter.
  • Page 54 VENTILATION : AIRFLOW BALANCING EXAMPLE The unit used for this example is a FGM170ND with standard supply and return airflow configuration. It is also fitted with an economiser and an electric heater type H. It is fitted with 2 ADH450 L fans which curve is shown on page 36 and 2x 5.5 kW motors.. Motor rpm: 1447 rpm - cosϕ...
  • Page 55 VENTILATION : AIRFLOW BALANCING AT15-15G2L(*) (*) The performances of twin fan units can be calculated starting from the corresponding operation point for a single fan (see the figure behind) by applying the formulas below. - pressure : PTwin = P x 1 - volume flow rate : Qb = Q x 2 - impeller power: Wb = W x 2,15 - fan speed : Nb = N x 1,05...
  • Page 56 VENTILATION : AIRFLOW BALANCING AT18-18S FLEXYII_WSHP-IOM-0909-E Page 54...
  • Page 57 VENTILATION : AIRFLOW BALANCING ADH355L FLEXYII_WSHP-IOM-0909-E Page 55...
  • Page 58 VENTILATION : AIRFLOW BALANCING ADH450L FLEXYII_WSHP-IOM-0909-E Page 56...
  • Page 59 VENTILATION : AIRFLOW BALANCING ADH500L FLEXYII_WSHP-IOM-0909-E Page 57...

  • Page 60: Filters

    FILTERS 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 can monitor the pressure drop across the filter (If option fitted) The following set points can be adjusted depeding on the installation.

  • Page 61: Air Sock Control

    VENTILATION : AIR SOCK CONTROL AIR SOCK CONTROL ANSTART 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.

  • Page 62: Uv Light

    VENTILATION : UV lights 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...

  • Page 63: Hot Water Coils

    HEATING : HOT WATER COIL FREEZE PROTECTION HYDRAULIC CONNECTIONS 1) Glycol for freeze protection. Check the hydraulic system contains Glycol for protection Hot water coils offer fully modulating control through the against freezing. use of a 3 way valve. The hot water coil, connections and valves are all tested at pressure of 15 bars.
  • Page 64 HEATING : HOT WATER COIL Hot water coil connection F-G-H box Pipe Internal Diameters (DN) F085 F100 F120 F150 F170 F200 F230 AXIMUM ORKING RESSURE BARS : 110°C AXIMUM WORKING TEMPERATURE FLEXYII_WSHP-IOM-0909-E Page 62...

  • Page 65: Electric Heater

    HEATING : ELECTRIC HEATER ENERAL NFORMATIONS 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.

  • Page 66: Gas Burners

    HEATING : GAS BURNER PRELIMINARY CHECKS BEFORE START-UP GAS FLOW (for G20 at 20mbar and 15°C) m UNIT SIZE NOTE : S POWER 12.5 12.5 18.8 18.8 H POWER 12.5 12.5 12.5 18.8 18.8 ANY WORK ON THE GAS SYSTEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.
  • Page 67 HEATING : GAS BURNER 60 & 120 kW PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4125 P Pressure regulator adjustment with 300mbar gas supply: 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) &...
  • Page 68 HEATING : GAS BURNER 60 & 120 kW Low Heat Injection Pressure Checks - After the adjustment of the low heat, re-verify the high - Switch the control to Low Heat heat - Check and adjust if necessary the Outlet pressure to 3.7 - re-position the stoppers and close the pressure ports.
  • Page 69 HEATING : GAS BURNER 180 & 240kW PRESSURE ADJUSTMENTS HONEYWELL PRESSURE REGULATING VALVE TYPE VR 4605P Pressure regulator adjustment with 300mbar gas supply: Fig.20 High Heat Injection Pressure Checks Check and adjust if necessary the valve OUTLET pressure to 8.0mbar (G 20) / 10.4mbar for Groningen (G25) & 28.3 mbar for propane (G31) (fig.21) - The Burner must run in High Heat mode for this check.
  • Page 70 HEATING : GAS BURNER 180 & 240kW Low Heat Injection Pressure Checks - After the adjustment of the low heat, re-verify the high - Switch the control to Low Heat heat - Check and adjust if necessary the Outlet pressure to 3.1 - re-position the stoppers and close the pressure ports.
  • Page 71 HEATING : GAS BURNER Ionisation Probe test BURNER SAFETY CHECKS - With the gas burner running, disconnect the terminal plug Smoke extractor pressure switch Test. coming from the ionisation probe to the gas ignition control box. - With the gas burner running, disconnect the flexible tube fitted to the pressure taping on the pressure switch (Fig.
  • Page 72 HEATING : GAS BURNER GAS BURNER FIRE-UP SEQUENCE Operation from control thermostat GAZ =Closed Supply Thermostat Limit? (Auto Reset) Gas Low Pressure switch? Gas Ignition Control Block Signal Extraction Fan ON AIR Pressure Switch ON Backfire Thermostat ON? Pre-Ventilation 30 seconds Gas Control Fire-up Electrode 4s Valve Closes...
  • Page 73 HEATING : GAS BURNER 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.
  • Page 74 HEATING : GAS BURNER DISASSEMBLING THE GAS BURNER FOR Disassembling the flue MAINTENANCE PURPOSES - Electrically disconnect the fan and remove the screws holding it in place. Preliminary Safety Recommendations -Take care not to loose any cage nuts in the smoke box. - Isolate the unit using the main isolator switch.
  • Page 75 HEATING : GAS BURNER 60kW 120kW FLEXYII_WSHP-IOM-0909-E Page 73...
  • Page 76 HEATING : GAS BURNER 180kW 240kW FLEXYII_WSHP-IOM-0909-E Page 74...

  • Page 77: Modulating Gas Burners

    HEATING : MODULATING GAS BURNER 60 & 120 kW Maximum opening Actuator screw MODULATING GAS (UNDER PATENT INPI May 2004) The actuator Bearing surface of the Minimum opening actuator’s screw The actuator receives an information 0-10V from the regulation for the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valve.
  • Page 78 HEATING : MODULATING GAS BURNER 60 & 120 kW High & Low heat injection pressure check: RESSURE ADJUSTMENTS ON ONEYWELL PRESSURE VK4105MB REGULATING VALVE AND ON ELECTRONIC BOARD W4115D1024 Electronic board W4115D1024 Pressure regulator adjustment with 300mbars gas There is one board for two valves supply: 230V power supply Potentiometer...
  • Page 79 HEATING : MODULATING GAS BURNER 60 & 120 kW - Check the 230V supply voltage of electronic board: the phase on terminal 01 and the neutral conductor on terminal - Bring back the potentiometer towards the position + until obtaining the - Check the wiring of the signal 0-10V between terminal 64 desired 10.4mbar in high heat for (polarity 01 of the 24V) and terminal 66 (+ coming from the...
  • Page 80 HEATING : MODULATING GAS BURNER 180 & 240 kW Actuator screw Maximum opening MODULATING GAS (UNDER PATENT INPI May 2004) The actuator Minimum opening The actuator receives an information 0-10V from the regulation for the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valve.
  • Page 81 HEATING : MODULATING GAS BURNER 180 & 240 kW High & Low heat injection pressure check: RESSURE ADJUSTMENTS ON ONEYWELL PRESSURE VR4605MB REGULATING VALVE AND ON ELECTRONIC BOARD W4115D1024 Electronic board W4115D1024 Pressure regulator adjustment with 300mbars gas There is one board per valve supply: 230V power supply Potentiometer...
  • Page 82 HEATING : MODULATING GAS BURNER 180 & 240 kW Adjusting minimum pressure setting: - Check the 230V supply voltage of electronic boards: the phase on terminal 01 and the neutral conductor on terminal - Disconnect electrical connection to MODUREG (=modulating solenoid valve) - Check the wiring of the signal 0-10V between terminal 64 (polarity 01 of the 24V) and terminal 66 (+ coming from the - Regulate the value of the minimum flow at 2.2mbar (for...
  • Page 83 HEATING : MODULATING GAS BURNER 60kW 120kW FLEXYII_WSHP-IOM-0909-E Page 81...
  • Page 84 HEATING : MODULATING GAS BURNER 180kW 240kW FLEXYII_WSHP-IOM-0909-E Page 82...
  • Page 85 ELECTRICAL DATA : WIRING DIAGRAMS FCM* FHM* FGM* FDM* HEAT PUMP HEAT PUMP ELECTRIC HEATER (Standard heat) 2 ELECTRIC HEATER (Standard heat) 2 steps (*) steps (*) ELECTRIC HEATER (Medium heat) ELECTRIC HEATER (Medium heat) modulating (*) modulating (*) ELECTRIC HEATER (High heat) ELECTRIC HEATER (High heat) modulating (*) modulating (*)

  • Page 86: Electrical Data: Wiring Diagrams

    ELECTRICAL DATA : WIRING DIAGRAMS DIAGRAM REFERENCE LEGEND A1-2-3-4 AIR SOCK CONTROL BT10 REGULATION TEMPERATURE PROBE MG11/MG12 COMPRESSOR -MG11/MG12 EXTERNAL AIR THERMOSTAT BT11 EXTERNAL TEMPERATURE PROBE MG21/MG22 COMPRESSOR -MG21/MG22 SMOKE DETECTION HEAD BT12 BLOWER TEMPERATURE PROBE ECONOMISER DAMPER MOTOR RC CIRCUIT BT13 COLD WATER TEMPERATURE PROBE MR2 BLOWER DAMPER MOTOR...

  • Page 87: Main Current Diagram Tri/400V/50Hz + T

    ELECTRICAL DATA : WIRING DIAGRAMS = Cooling only unit = Heat pump unit = Cooling only unit with gas fired heating = Heat pump unit with gas fired heating = Heat pump unit with water condensing = Heat pump unit with water condensing and gas fired heating MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T FLEXYII_WSHP-IOM-0909-E Page 85...
  • Page 88 ELECTRICAL DATA : WIRING DIAGRAMS MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T FLEXYII_WSHP-IOM-0909-E Page 86...

  • Page 89: Climatic 50 Controller

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 CONTROLER FLEXYII_WSHP-IOM-0909-E Page 87...

  • Page 90: Climatic 50 Input

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 INPUT FCM / FHM / FGM / FDM / FWH / FWM FLEXYII_WSHP-IOM-0909-E Page 88...

  • Page 91: Climatic 50 Output

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 OUTPUT FCM / FHM / FGM / FDM / FWH / FWM FLEXYII_WSHP-IOM-0909-E Page 89...

  • Page 92: Dad Smoke Detector

    ELECTRICAL DATA : WIRING DIAGRAMS DAD SMOKE DETECTOR FLEXYII_WSHP-IOM-0909-E Page 90...

  • Page 93: General Customer Connection Tcb

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION TCB FLEXYII_WSHP-IOM-0909-E Page 91...

  • Page 94: General Customer Connection With Advanced Control Pack (Adc)

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION WITH ADVANCED CONTROL PACK (ADC) FLEXYII_WSHP-IOM-0909-E Page 92...

  • Page 95: Gas Burner 60 Kw And Hot Water Coil

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 60 kW and HOT WATER COIL HOT WATER COIL FLEXYII_WSHP-IOM-0909-E Page 93...

  • Page 96: Gas Burner 120 Kw

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 120kW FLEXYII_WSHP-IOM-0909-E Page 94...

  • Page 97: Gas Burner 180/240 Kw

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 180 / 240kW FLEXYII_WSHP-IOM-0909-E Page 95...

  • Page 98: Electric Heater

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM ELECTRIC HEATER FLEXYII_WSHP-IOM-0909-E Page 96...

  • Page 99: General Customer Connection Diagram

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION DIAGRAM FLEXYII_WSHP-IOM-0909-E Page 97...

  • Page 100: Electrical Data Control Variables

    ELECTRICAL DATA : CONTROL VARIABLES STANDARD ADVANCED CONTROL PACK OR TCB Logical Output Board Logical Output Board (2 outputs: 1 assigned, 1 customized) (4 outputs: 0 assigned, 4 customized) DO 3 to 6 - Customized (choose, for each input (4) between those DO 1 - Alarm, General 7 possibilities) DO 2 - Customized (choose 1 output between those 7 possibilities)

  • Page 101: R410A

    R410A REFRIGERANT DEFINITION SATURATION PRESSURE Saturation pressure (relative pressure in bars) R-410A is an HFC, or hydro fluorocarbon, and is made of hydrogen, fluorine, and carbon atoms. Because it has no Temp. °C R407C Vapor R410A chlorine, it won’t interact with the ozone layer once it 28.97 31.94 46.54...

  • Page 102: Advanced Scroll Temperature Protection (Astp)

    ADVANCED SCROLL TEMPERATURE PROTECTION (ASTP) ERVICE A OMPRESSOR PERATION XPLANATION What to do? Protection is activated when Scroll Discharge Port. • If a protected compressor is identified Reaches 150°C (+/- 17K) - Stop the compressor - Allow to cool thoroughly Compressor is protected as «...

  • Page 103: Principle Sketches

    PRINCIPLE SKETCHES BCD1.2 CONDENSER COIL HOT WATER COIL EVAPORATOR COIL CA1.2 CHECK VALVE DT1.2 THERMOSTATIC EXPANSION VALVE FD1.2 FILTER DRIER - B14 - B15 HOT WATER COIL ANTIFREEZE THERMOSTAT - BT12 BLOWER TEMPERATURE PROBE - BT17 RETURN REGULATION TEMPERATURE SENSOR - B41 - B42 COMPRESSOR -MG1 - MG2 HIGH PRESSURE SAFETY SWITCH - B51 - B52...
  • Page 104 PRINCIPLE SKETCHES FCM 150 FHM 150 FLEXYII_WSHP-IOM-0909-E Page 102...
  • Page 105 PRINCIPLE SKETCHES FCM 170 FHM 170 FLEXYII_WSHP-IOM-0909-E Page 103...
  • Page 106 PRINCIPLE SKETCHES FCM 200 & 230 FHM 200 & 230 FLEXYII_WSHP-IOM-0909-E Page 104...
  • Page 107 PRINCIPLE SKETCHES EVAPORATOR COIL CA1.1 CA1.2 CA2.1 CA2.2 CHECK VALVE DT1.1 DT1.2 DT2.1 DT2.2 THERMOSTATIC EXPANSION VALVE FD1 FD2 FILTER DRIER BT16 BT19 WATER LOOP TEMPERATURE PROBE - BT12 BLOWER TEMPERATURE PROBE - BT17 RETURN REGULATION TEMPERATURE SENSOR - B41 - B42 COMPRESSOR -MG1 - MG2 HIGH PRESSURE SAFETY SWITCH - B51 - B52 COMPRESSOR -MG1 - MG2 LOW PRESSURE SAFETY SWITCH...
  • Page 108 PRINCIPLE SKETCHES FWH - FWM 150 FWH - FWM 170 FLEXYII_WSHP-IOM-0909-E Page 106...

  • Page 109: Hot Water Coil Diagram

    HOT WATER COIL DIAGRAM HOT WATER PIPE DIAMETERS 1 ROW 2 ROWS FLEXYII_WSHP-IOM-0909-E Page 107...

  • Page 110: Maintenance Diagnostic

    MAINTENANCE DIAGNOSTIC REFRIGERATION FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Measure the superheat and sub-cooling Good if 5°C<SC<10°C and 5°C<SH<10°C Refrigerant charge too low 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.
  • Page 111 MAINTENANCE DIAGNOSTIC REFRIGERATION FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Heat pump mode: Check the filter before the indoor coil measure and estimate the airflow rate Incorrect airflow rates increase the speed of the fan Cooling mode: Check the condenser fan (Amps) Incorrect water flow rate (Water cooled Check water flow value rooftop only)
  • Page 112 MAINTENANCE DIAGNOSTIC INDOOR FAN BLOWER FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Reduce the rotation speed of the fan Pressure drop in the ducting installation Measure and estimate the airflow and High amps on action Fan motor too low. pressure and compare with the specification from customer.
  • Page 113 MAINTENANCE DIAGNOSTIC WATER LEAKS FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Cooling mode: Water carried away from the coil because Estimate the airflow rate and check of excessive airflow and speed on the the speed is lower than 2.8 m/s coil. Low air pressure in the compartment due Water found in the ventilation Check filter...

  • Page 114: Maintenance Plan

    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.

  • Page 115: Commissioning Sheet

    MAINTENANCE PLAN Task Operating mode Replace filters with new ones if disposable. Vacuum clean or blow the dirt. Wash and dry carefully. Clean or replace filters : Replace media if necessary. disposable or metal frame Blocked filter will reduce the performance of the unit. THE UNIT MUST NOT OPERATE WITHOUT FILTERS.
  • Page 116 MAINTENANCE PLAN Task Operating mode 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 Check HP/LP safety switches bar (+/- 0,7).

  • Page 117: Warranty

    ANTI-CORROSION WARRANTY 10 year warranty terms and conditions for corrosion to the Rooftop casing: Lennox shall guarantee the casing of its Rooftop units manufactured since May 1991 against corrosion for 10 years commencing from the date of delivery of the material.

  • Page 118: Certificates

    LONGVIC SITE – ISO 9001 (2008) CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 116...
  • Page 119 EC CONFORMITY DECLARATION FLEXYII_WSHP-IOM-0909-E Page 117...
  • Page 120 SMOKE DETECTOR – NF CONFORMITY CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 118...
  • Page 121 SMOKE DETECTOR - CE CONFORMITY CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 119...
  • Page 122 G4 FILTER INSULATION CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 120...
  • Page 123 F7 FILTER INSULATION CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 121...
  • Page 124 GLASSWOOL INSULATION CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 122...
  • Page 125 GLASSWOOL INSULATION CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 123...
  • Page 126 FLEXY 60-120-180-240 KW GAS BURNER CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 124...
  • Page 127 ROOFTOP PED CONFORMITY CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 125...
  • Page 128 ROOFTOP PED CONFORMITY CERTIFICATE FLEXYII_WSHP-IOM-0909-E Page 126...
  • Page 130 LENNOX DISTRIBUTION +33.4.72.23.20.00 info.dist@lennoxeurope.com Due to Lennox’s ongoing commitment to quality, the Specifications, Ratings and Dimensions are subject to change without notice and without incurring liability. Improper installation, adjustment, alteration, service or maintenance can cause property damage or personal injury.

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