Page 1 INSTALLATION OPERATING & MAINTENANCE MANUAL ROOFTOP FLEXY™ English August 2003...
Page 3: Iom / Roof-Top Flexy™ Series
The present manual applies to the following ROOFTOP versions : FCA 60 - FCA 70 - FCA 85 - FCA 100 - FCA 120 - FCA 140 - FCA 160 - FCA 190 FCK 60 - FCK 70 - FCK 85 - FCK 100 - FCK 120 - FCK 140 - FCK 160 - FCK 190...
Page 4: Table Of Contents
CONTENTS CONTENTS IMPORTANT NOTICE ..................3 INSTALLATION TRANSPORT - HANDLING ....................4 INSTALLATION ....................... 12 INSTALLATION ON A ROOF MOUNTING FRAME ............13 INSTALLATION ON POSTS .................... 15 COMMISSIONING ......................16 OPERATION VENTILATION ......................... 21 AIR FLOW BALANCING ....................23 FILTERS .........................
Page 5: Important Notice
• 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 6: Transport - Handling
48 hours of delivery (working days). A copy of the letter must attached to an eyebolt in a safe and accessible place. This be addressed to Lennox and the supplier or distributor for allows you to open the panels for maintenance and information purposes.
Page 7 TRANSPORT - HANDLING DIMENSIONS AND WEIGHTS WEIGHT (kg) SLING Condensation Airflow configuration high Standard Centrifugal FC/FH 060 - Cooling only and heat pump 2825 2255 1470 1060 2210 2825 2255 1470 1090 2210 2825 2285 1470 1090 2210 2875 2255 2070 1230 2590...
Page 8 TRANSPORT - HANDLING DIMENSIONS AND WEIGHTS WEIGHT (kg) SLING Condensation Airflow configuration high Standard Centrifugal FC/FH 120 - Cooling only and heat pump 3585 2255 1470 1530 2700 2080 3585 2255 1470 1580 2700 2080 3585 2285 1470 1600 2700 2080 3635 2255...
Page 9 TRANSPORT - HANDLING DIMENSIONS AND WEIGHTS LENGTH HEIGHT WIDTH AUVENT WEIGHT (kg) lateral ventil standard MODELS FX 025 4070 1635 1055 FX 030 4070 1635 1055 FX 035 4750 2255 1290 1400 FX 040 4750 2255 1290 1450 FX 055 4750 2255 1290...
Page 10 TRANSPORT - HANDLING Figure 3 for all handling drawings - pages 7 to11 FC.../FH.../FD.../FG... 060 & 070 with centrifugal fans Sling length = 2590 mm for angle = 45°C FC.../FH.../FD.../FG... 085 & 100 Sling length = 2830 mm for angle = 45°C Sling length = 2330 mm for angle = 64,5°C FC.../FH.../FD.../FG...
Page 11 TRANSPORT - HANDLING Figure 3 for all handling drawings - pages 7 to11 FC.../FH.../FD... 120 & 140 Sling length = 2080 mm Sling length = 2700 mm for angle = 45°C for angle = 45°C FC.../FH.../FD... 120 & 140 with centrifugal fans Sling length = 2410 mm for angle = 45°C Sling length = 3000 mm...
Page 12 TRANSPORT - HANDLING Figure 3 for all handling drawings - pages 7 to11 FG... 120 & 140 with gas burner and centrifugal fans Sling length = 3300 mm Sling length = 2700 mm for angle = 45°C for angle = 45°C Sling length = 2080 mm for angle = 45°C FC.../FH.../FD...
Page 13 TRANSPORT - HANDLING FX 25 & 30 Sling length 1 = 3000 mm Sling length 2 = 2350 mm FX 35 - 40 - 55 Sling length 1 = 3700 mm Sling length 2 = 2850 mm FX 70 - 85 - 100 Sling length 1 = 3900 mm Sling length 2 = 3000 mm FX 110 - 140 - 170...
Page 14: Installation
INSTALLATION PRELIMINARY CHECK INSTALLATION REQUIREMENTS Before installing the equipment, the following items MUST be The surface on which the equipment is to be installed must checked : be clean and free of any obstacles which could hinder the flow of air to the condensers: - Is there sufficient space for the equipment? - Avoid uneven surfaces - Is the surface on which the equipment is to be installed...
Page 15: Installation On A Roofmounting Frame
INSTALLATION ON A ROOFMOUNTING FRAME levels are adjustable, observe the following recommendations for correct installation of the equipment. Above all, ensure that all the adjustable returns are facing outward (1 - figure 6). They are usually turned inside-out for transport. Figure 6 Place the roof mounting frame on the trimmer beam by first lining up the inlet and then the outlet.
Page 16 INSTALLATION ON A ROOFMOUNTING FRAME When the frame is correctly positioned, it is essential to secure the assembly with welding seam (20 to 30 mm for every 200 mm) along the outside, or by using an alternative method (1 - figure 9). Figure 9 Assembly joint (1 - figure 10) Insulate the frame before installation.
Page 17: Installation On Posts
INSTALLATION ON POSTS The unit can be fitted on corner posts using the frame provided. The minimum height of the posts should be 400mm. Figure 12 IOM / ROOF-TOP FLEXY™ Series - Page 15...
Page 18: Commissioning
COMMISSIONING THIS WORK MUST ONLY BE CARRIED OUT 1. Check the configuration BY TRAINED REFRIGERATION ENGINEERS - You will need a KP02 maintenance controller or CLIMALOOK with KP 14 interface. Before connecting the power : - Ensure that the power supply between the building and the unit meets local authority standards and that the cable specification satisfies the start-up and operating conditions.
Page 19 COMMISSIONING Check the setpoints on CLIMATIC™ (LF 20). Password technician Level Type of Unit Refer to configuration table LF20 Type of Unit [off] Flexy [on] Linea On or OFF [off] LINEA C103 Humidity and enthalpy management Option [on] only Flexy with Advanced Pack (Linea) Authorisation of defrost.
Page 20 COMMISSIONING Configuration table LF20 F.A050 FXA025 F.K050 FXK025 F.A060 FXA030 F.K060 FXK030 F.A070 FXA035 F.K070 FXK035 F.A085 FXA040 F.K085 FXK040 F.A100 FXA055 F.K100 FXK055 F.A120 FXA070 F.K120 FXK070 F.A140 FXA085 F.K140 FXK085 F.A160 FXA100 F.K160 FXK100 F.A190 FXA110 F.K190 FXK110 FXA140 FXK140 FXA170...
Page 21 COMMISSIONING report Site details / Informations site Controller/ Contrôleur …………………………………. Site / Site ……………………………………… Model/Modele ……………….………………… Unit Ref/ N° Affaire Serial No/ No Série ………………………………… ……………………………………..Installer/ Installateur Refrigerant / Réfrigérant ………………………………… ……………………………………… (1) ROOF INSTALLATION / INSTALLATION SUR LE TOIT Sufficient Access OK / Accès Suffisants Condensate drain fitted / Drainage condensats Roofcurb / Costière...
Page 22 COMMISSIONING report (8) REFRIGERATION SECTION / SECTION REFRIGERATION Outdoor Fan Motor Current / Intensité Moteurs Batterie externe: Check Rotation Compressor Voltage/ Tension Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Yes/Oui No/ Non Compresseur. Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A...
Page 23: Ventilation
VENTILATION 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 24 VENTILaTION : PULLEYS MOUNTING AND ADJUSTING PULLEYS Fan pulley removal Remove the 2 screws and put one of them in the extraction threaded screw. Screw in fully. The hub and the pulley will separate from each other. Figure 19 Remove the hub and the pulley by hand without damaging the machine.
Page 25: Airflow Balancing
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. Measure the absorbed amps If the absorbed amps are greater than the rated values, the ventilation system has a lower pressure drop than anticipated.
Page 26 AIRFLOW BALANCING 2nd method when adjusting the pulley : CHECKING AIRFLOW AND ESP - Close the pulley fully and count the number of turns Using the fan curves on page 25, 26, 27, the airflow, the total from fully closed position. Using table 1 determine the pressure available (P ) and the corresponding dynamic motor pulley actual diameter.
Page 27 AIRFLOW BALANCING EXAMPLE The unit used for this example is a FHK 060N with standard supply and return airflow configuration. It is also fitted with an economiser and an electric heater type H. It is fitted with a AT 18-18 fan which curve is shown on page xxx and a 2.2 kW motor. - Motor rpm : 1430 rpm - cos ϕ...
Page 28 AIRFLOW BALANCING FAN TYPE CURVE FAN TYPE CURVE PICTURE PICTURE SINGLE TWIN ON PAGE SINGLE TWIN ON PAGE FC/FH/FD... 060 - Standard FC/FH/FD... 120 - Standard AT 18-18 S AT 18-18 S AT 18-18 S AT 18-18 S AT 18-18 S AT 18-18 S AT 18-18 S AT 18-18 S...
Page 29 AIRFLOW BALANCING FAN TYPE CURVE PICTURE SINGLE TWIN ON PAGE FC/FH/FD... 085 - Side discharge AT 15-15 S AT 15-15 S AT 15-15 S AT 15-15 S AT 15-15 S AT 15-15 S AT 15-15 S AT 15-15 S FC/FH/FD... 100 - Side discharge AT 15-15 S AT 15-15 S AT 15-15 S...
Page 30 AIRFLOW BALANCING FAN TYPE CURVE FAN TYPE CURVE PICTURE PICTURE SINGLE TWIN ON PAGE SINGLE TWIN ON PAGE FG... 060 - Gas FG... 120 - Gas AT 15-15 S ADN 370L AT 15-15 S ADN 370L AT 15-15 S ADN 370L AT 15-15 S ADN 370L AT 15-15 S...
Page 31 AIR FLOW BALANCING FAN TYPE CURVE FAN TYPE CURVE PICTURE PICTURE SINGLE TWIN ON PAGE SINGLE TWIN ON PAGE FX... 025 Indoor FX... 070 Indoor AT 12-12 S AT 18-18 S AT 18-18 S AT 12-12 S AT 18-18 S AT 12-12 S AT 18-18 S AT 12-12 S...
Page 32 AIR FLOW BALANCING FAN TYPE CURVE FAN TYPE CURVE PICTURE PICTURE SINGLE TWIN ON PAGE SINGLE TWIN ON PAGE FX... 025 Outdoor FX... 085 Outdoor AT 12-12 S AT 18-18 S AT 12-12 S AT 18-18 S AT 12-12 S AT 18-18 S AT 12-12 S AT 18-18 S...
Page 33 AIR FLOW BALANCING AT 12-12 FAN IOM / ROOF-TOP FLEXY™ Series - Page 31...
Page 34 AIR FLOW BALANCING AT 15-15 FAN Page 32 - IOM / ROOF-TOP FLEXY™ Series...
Page 35 AIR FLOW BALANCING AT 18-13 IOM / ROOF-TOP FLEXY™ Series - Page 33...
Page 36 AIR FLOW BALANCING AT 18-18 FAN Page 34 - IOM / ROOF-TOP FLEXY™ Series...
Page 37 AIR FLOW BALANCING RDN 450 FAN IOM / ROOF-TOP FLEXY™ Series - Page 35...
Page 38 AIR FLOW BALANCING ADN 355 FAN Page 36 - IOM / ROOF-TOP FLEXY™ Series...
Page 39 AIR FLOW BALANCING ADN 400 FAN IOM / ROOF-TOP FLEXY™ Series - Page 37...
Page 40 AIR FLOW BALANCING ADN 450 FAN Page 38 - IOM / ROOF-TOP FLEXY™ Series...
Page 41: Filters
filters The CLIMATIC™ controls the filters. Two types of problems may occur : KP 17 DISPLAY 1 - 004 error code (lit LED “filter”) or the following icon (for a graphics screen - KP07) : Item 8 on KP 17 indicates that the filters must be changed. The unit has not stopped but the airflow is likely to be reduced due to increased pressure drop acros the filters.
Page 42: Fanstart Operation
VENTILaTION : FANSTART OPERATION AIR SOCK CONTROL Current protection of the Thyristor The use of air socks for space conditioning allows high air volumes to be distributed at low velocity and is becoming a The FANSTART will display a fault (red LED) if the current common feature in many applications.
Page 43: Fx Air Flow Balancing
FX AIR FLOW BALANCING 1. Operation of the grids - Balancing grids are installed on fresh air side in order to compensate for the higher pressure drop on the ducted return air side. - The aim is to avoid the pressure variations in the area to air conditioned (risk of doors opening in cinemas for example) but also to avoid a current surge on the motor when running 100% fresh air.
Page 44 FX AIR FLOW BALANCING Example of pressure tapping point available on each box : Figure 26 "Treatment" side damper Extraction side damper + fresh air bypass (25% damper). Figure 27 Figure 28 Page 42 - IOM / ROOF-TOP FLEXY™ Series...
Page 45 FX AIR FLOW BALANCING PRINCIPLE SKETCHES 0% FRESH AIR TREATMENT Fresh air hood Treatment By pass grid 10 000 m3/h 2 500 m3/h 12 500 m3/h 10 000 m3/h 10 000 m3/h SUPPLY EXTRACTION air duct Extraction fan air duct Grid on damper RETURN air duct...
Page 46: Hot Water Coils
HOT WATER COILS HYDRAULIC CONNECTIONS ELECTROLYTIC CORROSION The heating coil is connected to the isolating valves. Two Attention is drawn to the corrosion problems resulting from keys must be used to tighten the connections, one of the electrolytic reaction created from unbalanced earth keys maintains the valve body.
Page 47: Gas Burners
GAS BURNER GN 300 mbar option with pressure regulator : 1. PRELIMINARY CHECKS AND VERIFI- Check the pressure at the regulator inlet. CATIONS BEFORE START-UP Propane 37 mbar option : NOTE : Check the pressure at the inlet of the HONEYWELL valve. ANY WORK ON THE GAS SYSTEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.
Page 48 GAS BURNER GAS BURNER RESET - Press the "reset" button" on the gas control block to reset the unit after a fault RESET button Figure 44 3. START UP AND SET UP OF THE GAS UNIT 3.1 General operation check of the system - Check that the centrifugal fan blower in the unit is running.
Page 49 GAS BURNER - Standard start-up chronology - If incorrect sequence, refer to the fault table to identify the problem. 3.4 Pressure regulator adjustment (in case of 300 mbar) - The burner must be run in high heat mode for this check. - Fit the tube of the "accurate"...
Page 50 GAS BURNER GAS BURNER GAS BURNER GAS BURNER GAS BURNER Then re-tighten all pressure adjustment screws. 3.8 Rating table for type of gas and corresponding adjusmtent pressure Type of Gas Category Supply pressure Low heat injection High heat injection adjustment pressure pressure Honeywell Valve...
Page 51 GAS BURNER 5. DISASSEMBLING THE GAS BURNER FOR MAINTE- NANCE PURPOSE 5.1 Preliminary safety recommendations - Isolate the unit using the main isolator - Close off the isolating gas valve located before the unit 5.2 Disconnect the pipework. Do not discard the seals Figure 55 5.3 Disassembling the gas "rail"...
Page 52 HEATING : gas burner GAS BURNER FIRE-UP SEQUENCE Operation from control Thermostat GAS = Closed Supply thermostat timit ? (Auto reset) Gaz low pressure switch? Gaz ignition control block signal Extraction Fan ON Air pressure switch ON Backfire thermostat ON ? Pre-ventilation 30 to 45 seconds Gas control Fire-up Electrode 4s...
Page 53 GAS BURNERS 6.1 Fault codes 14 and 15 - Reset the CLIMATIC™ 2 - Check voltage 230V after circuit breaker QF3 - Check gas isolation shut-off valves are open - Check gas pressure at the inlet of the gas valve. It must be > 20 mbar when the burners shut down - Adjust the setpoints 59 and 60 to ON to priorities the burner.
Page 54 GAS BURNERS DIAGNOSTIC TABLE GAS BURNER NORMAL STAGES FAULT ACTIONS SOLUTIONS OPERATION • Check safety thermostats B29- • Replace component Heating Contactors Contactors do requested KM21-22 not engage 30 in the air duct before the gas engaged heat exchanger • Check the free movement of the Contactors Extraction fans Nothing...
Page 55 GAS BURNERS 7. REQUIRE EQUIPMENT LIST 9.3 Sweeping 6.1 Adjustment ans - Disassemble the gas burner (refer to previous start-up paragraph) - An accurate manometer - Disassemble the exhaust extraction fan. from 0 to 3500 Pa (0 to 350 mbar) : 0.1% full - Disassemble the exhaust box scale.
Page 56 GAS BURNERS 60 KW BURNER FOR FGX 60 AND 70 MODELS Figure 63 Page 54 - IOM / ROOF-TOP FLEXY™ Series...
Page 57 GAS BURNER 120 KW BURNER FOR FGX 60, 70 AND 100 MODELS Figure 64 IOM / ROOF-TOP FLEXY™ Series - Page 55...
Page 58 GAS BURNER 180 KW BURNER FOR FGX 120 AND 140 MODELS Figure 65 Page 56 - IOM / ROOF-TOP FLEXY™ Series...
Page 59: Using The Kp 17 Comfort Display
USING THE KP 17 COMFORT CONTROL DISPLAY The CLIMATIC™ 'Comfort' control Display allows an untrained KP17 COMFORT CONTROL DISPLAY person to easily operate a Lennox Roof-Top. WIRING This display connects to a single Rooftop and, through the use of the control keys, LED's and display the user can see...
Page 60: Using The Kp02 Maintenance Display
USING THE KP02 MAINTENANCE CONTROL DISPLAY This display unit allows you to read and modify all the values The dialogue with the controller is initiated by the CLIMATIC™. of the variables or setpoints of the rooftop to which it is If, after 3 attempts, no communication is established, a connected.
Page 61 USING THE KP02 MAINTENANCE CONTROL DISPLAY Variable or setpoint value Digital Values 1 <--> ON 0 <--> OFF Temperatures Temperatures are displayed in °C, to an accuracy of 0.1 °C <--> -21.6 °C <--> + 105.8 °C Pressures Pressure is given in bars, to an accuracy of 0.1 bar. <-->...
Page 62: Operating Modes
USING THE KP02 MAINTENANCE CONTROL DISPLAY If the password code is correct, the following message will 2 - OPERATING MODES appear when key [V] is released : The maintenance display allows for 4 modes of operation. Key [M] allows you to move successively and in a loop from one mode to the next.
Page 63 USING THE KP02 MAINTENANCE CONTROL DISPLAY For different types of data, the setting ranges are as follows : Item Minimum value Maximum value Hours and minutes 00-00H 23-59 H Day of the month Day of the week Month Year Changes are only incorporated when key [A] is pressed. NOTE : The compatibility of the value for the day of the month is not checked when it is entered.
Page 64 USING THE KP02 MAINTENANCE CONTROL DISPLAY LIST OF SETPOINTS (LF 20 - APRIL 2002) 1st Level Mini. Factory Maxi. C 000 [Kp02] Password, technician level [Kp17] [Mode] Required room temperature (in °c). C 001 This value corresponds to the middle of the dead zone - (active for C 051 21.0°C C 050...
Page 65 USING THE KP02 MAINTENANCE CONTROL DISPLAY LIST OF SETPOINTS (LF 20 - APRIL 2002) - cont'd 1st Level Mini. Factory Maxi. [Mode] Required minimum room absolute humidity (in g/kg) – C 021 0.0 g/kg # g/kg 30.0 g/kg Humidification set point C 022 [Mode] Required minimum percentage for fresh air 100 %...
Page 66 USING THE KP02 MAINTENANCE CONTROL DISPLAY LIST OF SETPOINTS (LF 20 - APRIL 2002) - cont'd 1st Level Mini. Factory Maxi. [Safety limits] Room relative humidity low limit (in %) - Threshold of C 041 50 % activation of the safety cut-out [Limit safety] Room absolute humidity low limit (in g/kg) - Threshold of C 042 0.0 g/kg...
Page 67 USING THE KP02 MAINTENANCE CONTROL DISPLAY LIST OF SETPOINTS (LF 20 - APRIL 2002) - cont'd 2nd Level Mini. Factory Maxi. [Humidity control] Relative humidity difference between the beginning C 061 50 % and the end of a stage of control in dehumidification (in %) [Humidity control] Relative humidity difference between two stages of C 062 50 %...
Page 68 USING THE KP02 MAINTENANCE CONTROL DISPLAY LIST OF SETPOINTS (LF 20 - APRIL 2002) - cont'd 2nd Level Mini. Factory Maxi. [Defrost function] Authorization of defrost - Threshold of outdoor 10.0 c / C 076 8.0 c 20.0 c 20.0 c temperature (in °c) [Defrost function] Authorization of defrost - Threshold of temperature 2.0 c /...
Page 69 [Configuration] Activation of the optimised defrost option [Configuration] Activation of the humidity and the enthalpy C 103 management option C 104 [Various] Override all set points to factory settings C 105 [Various] reserved Lennox 65535 IOM / ROOF-TOP FLEXY™ Series - Page 67...
Page 70 USING THE KP02 MAINTENANCE CONTROL DISPLAY VARIABLE LIST (LF 20 - April 2002) 1st Level V 000 [Defects] error codes V 001 [Value] Temperature (in °c), Room, Reference value V 002 [Value] Relative humidity (in %), Room, Reference value V 003 [Value] Absolute humidity (in g/kg), Room, Reference value V 004 [Value] Temperature (in °c), Outdoor, Reference value...
Page 71 USING THE KP02 MAINTENANCE CONTROL DISPLAY V 051 [Output] Gas grade, Reset V 052 [Output] Economiser, Proportional action (0-255) V 053 [Output] Chilled water coil, Proportional action (0-255) V 054 [Output] Hot water coil, Proportional action (0-255) V 055 [Output] Electrical heater, Static relays, Proportional action (0-255) V 056 [Output] Humidifier, Proportionnel action (0-255) V 057...
Page 72 USING THE KP02 MAINTENANCE CONTROL DISPLAY V 068 [Statute] Gas grade not configured 1, 2 or 3 = number of stages activation of a defect ventilation no ready V 069 [Statute] Humidifier not configured activation of a defect ventilation no ready V 070 [Regulation] Real set point, Cooling, Room V 071...
Page 73 USING THE KP02 MAINTENANCE CONTROL DISPLAY Configuration table LF20 F.A050 FXA025 F.K050 FXK025 F.A060 FXA030 F.K060 FXK030 F.A070 FXA035 F.K070 FXK035 F.A085 FXA040 F.K085 FXK040 F.A100 FXA055 F.K100 FXK055 F.A120 FXA070 F.K120 FXK070 F.A140 FXA085 F.K140 FXK085 F.A160 FXA100 F.K160 FXK100 F.A190 FXA110...
Page 74: Using The Kp07 Remote Graphical Display
- Recording of successive status of pre-defined variables to create analog and event histories. A KP07 unit can be attached to more than 8 LENNOX Rooftops, providing they have the same software. The function of these keys may vary from one screen to The link between the controllers and the display is serial and another and is defined on the active screen by an icon.
Page 75 Through "MODIFICATION" mode, the user is able to : - choose the number of the controller he wishes to see Pressing on this key activates the "modification" mode the variables of (if several LENNOX Rooftops are (see below). attached to the same KP07 display unit), - control the setpoints.
Page 76 USING THE KP07 GRAPHIC CONTROL DISPLAY GENERAL SCREEN LAYOUT Summary Measurements : Chart : Temperatures Ambient temperature Measurements : Chart : Humidity Ambient humidity Operational status : History : Ventilation Safety & Errors Hourmeters : Ventilation, customer... Operational status : History : Frost Safety &...
Page 77 USING THE KP07 GRAPHIC CONTROL DISPLAY Password : Level 1 Settings : On/Off Settings : Settings : On ; Ventilation Condition ; Day Settings : Settings : Condition ; Weekend On ; Ventilation Settings : Time Settings : Settings : On ;...
Page 78 USING THE KP07 GRAPHIC CONTROL DISPLAY Settings : Settings : Condition ; BMS On ; Ventilation Settings : Control ; Cold Settings : Control ; Hot Settings : Control. ; Dehumidification Settings : Control ; Humidification Settings : Control ; Misc. Settings : Limits ;...
Page 79 USING THE KP07 GRAPHIC CONTROL DISPLAY INDEX OF ICONS Keys Select variable to change Select digit to change. Increase value Enter current change. Go to temperature and humidity values and charts. Go to the machine component status. Go to various notices. Go to room temperature chart.
Page 80 USING THE KP07 GRAPHIC CONTROL DISPLAY Sensors Temperature sensor Humidity sensor Pressure sensor Return or room data Supply data Outside data Operating conditions Operating condition: Day Operating condition: Weekend Operating condition: Night Operating condition: Morning Operating condition: Noon Operating condition: Evening Operating condition: BMS Operating status Cooling mode setting operation.
Page 81 USING THE KP07 GRAPHIC CONTROL DISPLAY Compressor defrosting. Compressor stopped in anti-short cycle. (On / Off) Condenser (On / Off) Gas grade. Half flow gas. (On / Off) Hot proportional valve, hot water valve. (On / Off) Electrical heaters. (On / Off) Humidifier (On / Off) Dehumidification (On / Off) Pump Errors...
Page 82 USING THE KP07 GRAPHIC CONTROL DISPLAY (Start / End) [091] Faulty processing fan. (Start / End) [001] Wrong air flow. (Start / End) [099] Error smoke. (Start / End) [004] Dirty filters. (Start / End) [005] Missing filters. (Start / End) [115][125][135][145] Faulty high pressure or faulty electrical compressor.
Page 83: Bms Contacts Kit
BMS VOLT FREE CONTACTS KIT This option is used for making a connection to the BMS only, by a set of hard contacts. It requires the addition of a KP05 card, if this is not already in place, and a KP12 card. Input connection must be by screened cable only.
Page 84: Climatic™ Parameters
CLIMATIC™ PARAMETERS The five available time slots are : ON - OFF The unit is declared On if setpoint 6 (C06) is ON. WEEK-END The unit can be stopped by a remote control command by hard contact. On KP12 extension card - see chapter on BMS contact kit. NIGHT MORNING DEFINITION OF TIME SLOT PARAMETERS...
Page 85 CLIMATIC™ PARAMETERS DESCRIPTION OF PARAMETERS Parameters are defined for the time slot. Select by instruction 08 setting. 0 = DAY / 1 = WEEKEND / 2 = NIGHT / 3 = unused / 4 = MORNING / 5 =MIDDAY / 6 = EVENING / 7 = BMS. Instruction Description Day of the week of start of setting .
Page 86 CLIMATIC™ PARAMETERS ORDER OF COMPONENTS IN ADVANCE ACTIVATION OF THE MORNING REGULATION SLOT Depending on the thermal inertia of the building or the installation and external climatic conditions, it is possible to Heating operation advance the switch from the NIGHT slot to the MORNING Setpoint 57 = slot.
Page 87 Inversion by setpoint 57 Inversion by setpoint 57 Inertia 100% zone 3-way valve or " water coil Damper Min. fresh Heating Air conditioning setpoint 16 setpoint 15 Differential in heating Hysteresis in air cond. Hysteresis in heating Differential in air cond. setpoint 56 setpoint 56 setpoint 53...
Page 88 CLIMATIC™ PARAMETERS REGULATION OF SUPPLY AIR BLOWING REGULATION BY AIR DAMPER Supplying air regulation should be activated by setting setpoint 58 to ON. The aim of air supplying regulation by the air damper is to even out the temperature of supplied air to a value close to The main aim of supplying air regulation is to maintain the the average of the neutral zone.
Page 89 CLIMATIC™ PARAMETERS REGULATION IN HUMIDIFYING COMPRESSOR-RELATED FUNCTIONS Anti-short cycle 100% The CLIMATIC™ provides protection of the compressors against frequent restarts. This is why the compressors cannot be started, even if requested to do so by regulation, unless the time since they were last put into operation is greater than six minutes.
Page 90: Control Interface Climalink/Climalook
ON/OFF button. Climalook uses the internet explorer interface for local To avoid this Lennox recommend to connect the central unit operation. The local operating mode is completely automatic to a pulsating current power outlet or "UPS". Lennox cannot and does not require any configuration.
Page 91 The connections between the units and the Climalink/ Climalook must be done using a double shielded pair of wire (not supplied by Lennox) This cable must have external metal braiding, and its cross-section must be at least 0.5mm2 with After the starting procedure of the Climalook 3 central unit,...
Page 92 control interface CLIMALINK / CLIMALOOK SETTINGS FOR THE CONNECTIONS Depending on the version of Windows you are running, access the « Make new connection» function. Click Enter the telephone number to which your ClimaLook’s modem is con- nected. Click on next Click Click on next Click...
Page 93 CLIMALINK / CLIMALOOK Type “http:// Lennox” in the Address field The first time you log in, Windows asks you to confirm your login identifiers: - for User enter Administrateur - for password enter VISION - leave the workgroup field empty.
Page 94: The Main Page
control interface CLIMALINK / CLIMALOOK Unit’s day and time THE MAIN PAGE The colour outline around the roof-top unit and the operating temperatures indicate the unit’s status: Green : Operating mode, White : Stop mode, Orange Night mode, Red: Fault mode, This page gives you the basic information about how your installation functions.
Page 95 control interface CLIMALINK / CLIMALOOK For some settings, a small icon is Use the refresh function to update the values read displayed at the end of the line Click on it to get a history of this setting. The empty fields correspond to occasions when the CLIMALOOK / CLIMALINK unit has stopped - To access the Service page for another unit, simply click on this unit.
Page 96 control interface CLIMALINK / CLIMALOOK THE MACRO PAGE THE ACCESS PAGE This page enables you to modify all the units on your site in one action. This page enables users who have a third level access code You can choose to perform one or more actions. to attribute access codes to other users.
Page 97 The only way to examine the problem in more detail is to obtain the pages you must use the Refresh function to be sure you a monitor and a mouse and contact the Lennox services. are reading the latest values.
Page 98: Electrical Wiring Diagrams List Of Items
ELECTRICAL DATA The power cable should be connected to the main isolating as it is directly related to the type of cable you are using, the switch and is fed from the underside of the unit into the distance separating the equipment from the source but also electrical panel.
Page 99 ELECTRICAL DATA FHA / FHK = Heat pump rooftop FDA / FDK = Cooling only unit Heat pump Heat pump Electric heater TRIAC Hot water coil Gas burner 33/60 kW Economiser Gas burner 120 kW Extraction fan Gas burner 180 kW All fresh air Economiser Firestat...
Page 100 ELECTRICAL DATA FXA / FXK = Heat pump rooftop -B13 Clogged air filter pressure switch / air flow rate -B14 Hot water battery antifreeze thermostat Heat pump -B15 Hot water battery antifreeze thermostat -B16 Fire thermostat Electric heater TRIAC -B17-B18 Gas manifold smoke minimum gas pressure switch -B19-B20 Blower fan motor -MS1-MS2 stoptherme...
Page 101 ELECTRICAL DATA -E16 Printed circuit 0/10V vapour humidifier -E4 -Q1-Q2 Blower fan motor -MS1-MS2 protection -E20 CPU card KP01 -Q5-Q6 Extraction fan motor -ME1-ME2 protection -E21 ON-OFF input card KP03 Condenser -MC1-MC2 fan motor protection -E22 ON-OFF input card KP08,1 -Q10 Condenser -MC3-MC4 fan motor protection -E23...
Page 102 ELECTRICAL DATA FCA / FCK = Cooling only unit FHA / FHK = Heat pump rooftop FXA/FXK = Heat recovery unit MAIN CURRENT DIAGRAM 1112 12V.H 12V.G 12V.F 12V.E 5.5 kW -E51 -E53 -E54 Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid...
Page 103: Electrical Wiring Diagrams
ELECTRICAL WIRING DIAGRAMS FGA / FGK = Cooling only unit with gas firesd heating FDA / FDK = Heat pump rooftopwith gas firesd heating MAIN CURRENT DIAGRAM Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Helicoid Centrifugal Helicoid Helicoid Centrifugal Centrifugal Centrifugal...
Page 104 ELECTRICAL WIRING DIAGRAMS MAIN CURRENT DIAGRAM Page 102 - IOM / ROOF-TOP FLEXY™ Series...
Page 105 ELECTRICAL WIRING DIAGRAMS MAIN CURRENT DIAGRAM Centrifugal Centrifugal Helicoid Helicoid Helicoid Helicoid IOM / ROOF-TOP FLEXY™ Series - Page 103...
Page 106 ELECTRICAL WIRING DIAGRAMS CLIMATIC CONTROLLER Page 104 - IOM / ROOF-TOP FLEXY™ Series...
Page 107 ELECTRICAL WIRING DIAGRAMS CLIMATIC INPUT FC / FH / FX IOM / ROOF-TOP FLEXY™ Series - Page 105...
Page 108 ELECTRICAL WIRING DIAGRAMS CLIMATIC INPUT FG / FD Page 106 - IOM / ROOF-TOP FLEXY™ Series...
Page 109 ELECTRICAL WIRING DIAGRAMS CLIMATIC OUTPUT FC / FH / FX FAILURE IOM / ROOF-TOP FLEXY™ Series - Page 107...
Page 110 ELECTRICAL WIRING DIAGRAMS CLIMATIC OUTPUT FG / FD FAILURE Page 108 - IOM / ROOF-TOP FLEXY™ Series...
Page 111 ELECTRICAL WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 33 / 60 / 120 Kw IOM / ROOF-TOP FLEXY™ Series - Page 109...
Page 112 ELECTRICAL WIRING DIAGRAMS GAS BURNER 180 Kw Page 110 - IOM / ROOF-TOP FLEXY™ Series...
Page 113 ELECTRICAL WIRING DIAGRAMS DAD SMOKE DETECTOR / KP7 GRAPHIC DISPLAY RESISTANCE FEMELLE UNITES UNITE 1 2,3,4,5,6,7,8 CUSTOMER ELECTRICAL GRAPHIC CONTROL DISPLAY TRANSFO IOM / ROOF-TOP FLEXY™ Series - Page 111...
Page 114 ELECTRICAL WIRING DIAGRAMS DRY CONTACT KIT FOR BMS / REMOTE SET POINT TCB THERMOSTAT CONTROL BOARD Page 112 - IOM / ROOF-TOP FLEXY™ Series...
Page 115 ELECTRICAL WIRING DIAGRAMS KP 06 (J-BUS INTERFACE) Relais SPST Liaison Hard Contacts Liaison Fuse 1A Serial link RS232 Unit size 8k (position 1-2) 32k (position 2-3) The link is used for short distances Only a master control can be connected to this link SUBD 9-point connector RS232 link Serial link RS485 This link is used for long distances (maximum 100 metres)
Page 116 ELECTRICAL WIRING DIAGRAMS LAYOUT ELECTRICAL PANEL REPARTITEUR DE PHASES REPARTITEUR DE PHASES REPARTITEUR DE PHASES Page 114 - IOM / ROOF-TOP FLEXY™ Series...
Page 117 ELECTRICAL WIRING DIAGRAMS LAYOUT ELECTRICAL PANEL FGA / FDA 60 at 190 FGK / FDK 60 at 190 IOM / ROOF-TOP FLEXY™ Series - Page 115...
Page 118 SITE ELECTRICAL CONNECTIONS KP02 KP18 KP18 -E32 -E30 -E31 REGULATION TEMPERATURE PROBE HYGIENE PROBE REGULATION HYGROMETRY PROBE Page 116 - IOM / ROOF-TOP FLEXY™ Series...
Page 119: Safety And Error Codes
SAFETY AND ERROR CODES No fault Failure air flow Dirty filters Missing filters Faulty electrical heater Supply air overtemperature Temperature room too low Faulty gas burner no. 1 Faulty gas burner no. 2 Supply temperature too low Room overtemperature Faulty humidifier Room humidity too low Room over humidity Faulty pump...
Page 120 SAFETY AND ERROR CODES The following text includes references such as [C11] and [V25]. They relate to the setpoint or variable numbers used with the KP02 unit. Wrong Air Flow If the pressure differential obtained by the analog sensor [V21] is less than the setpoint value [C88] for more than 20 seconds, and if the blower fan has operated for more than 1 minute 30 seconds, the air flow safety system is activated and stops the ventilation.
Page 121 SAFETY AND ERROR CODES register time set to 5 seconds. In addition, if the antifreeze thermostat is opened, the 3rd safety level is immediately automatically maintained. In this case, manual resetting of the thermostat followed by the CLIMATIC™ is obligatory Room Overtemperature Safety System Upper Room Air Limit If the room temperature is greater than or equal to the setpoint [C40], the safety system is...
Page 122 SAFETY AND ERROR CODES Sensor Status Room temperature sensor missing or faulty. Room relative humidity sensor missing or faulty Outside air temperature sensor faulty Outside relative humidity sensor faulty Supply Air temperature sensor faulty Temperature sensor on cold water loop faulty Temperature sensor on condenser water outlet faulty.
Page 123 SAFETY AND ERROR CODES Customer error A fault has been detected, external to the unit. Water leak If the contact of the water leak detection card is closed for more than 30 seconds, the safety system is activated. WATER HEAT EXCHANGER OUTLET TEMPERATURE SAFETY SYSTEM. Condenser Water Temperature Too Low If the temperature of the water loop is less than or equal to the preset setpoint [C80] during the operation of one of the compressors, the condenser safety mechanism is applied.
Page 124 SAFETY AND ERROR CODES Refrigeration system faults Faulty condenser temperature sensor Faulty pressure transmitter sensor, refrigeration system Faulty refrigeration system, frost temperature sensor High pressure switch safety or compressor electrical safety The compressor contactor is not connected although the CLIMATIC™ requests it. - The high pressure pressostat is open.
Page 125: Maintenance Diagnostic
maintenance diagnostic REFRIGERATION Table 15 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 If too high check the coils are clean or check between T outdoor and Tevap.
Page 126 maintenance diagnostic REFRIGERATION FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION If the circuit pressure is higher (<1bar) than the saturated pressure corresponding to the measured outdoor temperature, there is Moisture or contaminants in the system possibility that some contaminants are present in the system.
Page 127 maintenance diagnostic OUTDOOR AXIAL FAN FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Check the voltage drop when all components High Amps due to a low voltage from the main are running. supply Change the circuit breaker for one with a higher rating.
Page 128: 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 129 Table 16 TASK OPERATING MODE YEARLY ESTIMATED MONTHLY QUARTERLY MONTHLY TIME WINTER (mn) Replace filters with new ones if disposable. Vacuum clean or blow the dirt. Wash and dry carefully. +Replace media if necessary Clean or replace filters: Disposable, or metal frame.
Page 130 TASK OPERATING MODE YEARLY ESTIMATED MONTHLY QUARTERLY MONTHLY TIME WINTER (mn) Install manifold gauges on the circuit to be checked. Shut down Check HP / LP safety switches the axial fans and wait for the HP switch to shut down the ∆...
Page 131: Warranty
Lennox shall guarantee the casing of its Rooftop units modes. manufactured since May 1991 against corrosion for 10 years commencing from the date of delivery of the material.
Page 132: Iso 9001 Certification
ISO 9001 CERTIFICATION Page 130 - IOM / ROOF-TOP FLEXY™ Series...
Page 133: Ped Certification Of Conformity
PED CERTIFICATION OF CONFORMITY IOM / ROOF-TOP FLEXY™ Series - Page 131...
Page 134: Glas Wool Fire Class
GLASS WOOL FIRE CLASS Page 132 - IOM / ROOF-TOP FLEXY™ Series...
Page 135: 33 Kw Gas Burner Ce Certification Of Conformity
33 kW GAS BURNER CE CERTIFICATION OF CONFORMITY IOM / ROOF-TOP FLEXY™ Series - Page 133...
Page 136: Kw Gas Burner Ce Certification Of Conformity
60 kW GAS BURNER CE CERTIFICATION OF CONFORMITY Page 134 - IOM / ROOF-TOP FLEXY™ Series...
Page 137: 120 Kw Gas Burner Ce Certification Of Conformity
120 kW GAS BURNER CE CERTIFICATION OF CONFORMITY IOM / ROOF-TOP FLEXY™ Series - Page 135...
Page 138: 180 Kw Gas Burner Ce Certification Of Conformity
180 kW GAS BURNER CE CERTIFICATION OF CONFORMITY Page 136 - IOM / ROOF-TOP FLEXY™ Series...
Page 139: Insulation Fire Class
INSULATION FIRE CLASS IOM / ROOF-TOP FLEXY™ Series - Page 137...
Page 140 INSULATION FIRE CLASS Page 138 - IOM / ROOF-TOP FLEXY™ Series...
Page 142 : + 33 4 72 23 20 28 e-mail : marketing@lennoxdist.com www.lennoxeurope.com Due to Lennox's ongoing commitment to quality, Specifications, Ratings and Dimensions subject to change without notice and without incurring liability. FLEXY_IOM/0803-E Improper installation, adjustment, alteration, service or maintenance can cause property damage or personal injury.

Lennox FCA 60 Installation, Operation And Maintenance Manual

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