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

Lennox FCM 85 Installation, Operating And Maintenance

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Installation, operating
and maintenance
FLEXY II
Providing indoor climate comfort
FLEXYII-IOM-0308-E

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Summary of Contents for Lennox FCM 85

  • Page 1 Installation, operating and maintenance FLEXY II Providing indoor climate comfort FLEXYII-IOM-0308-E...
  • Page 2 The present manual applies to the following ROOFTOP versions: FCM 85 - FCM 100 - FCM 120 - FCM 150 - FCM 170 - FCM 200 - FCM 230 FHM 85 - FHM 100 - FHM 120 - FHM 150 - FHM 170 - FHM 200 - FHM 230...

  • Page 3: 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 Installation on roof mounting frame ......................17 Curbing and flashing ..........................18 Duct connections............................19 Non-adjustable non-assembled roof curb installation .................20 Non-adjustable non-assembled roof curb installation instructions ...............21 Adjustable roof curb ..........................22 Non-adjustable Non-assembled roof curb ....................23 Multidirectional roof curb ..........................24...
  • Page 4 CONTENTS ELECTRICAL DATA: WIRING DIAGRAMS Diagram reference legend ........................69 Main current diagram TRI/400V/50Hz + T……………………………………………………......70 CLIMATIC 50 controller…………………………………………………………………………......72 CLIMATIC 50 input……………………………………………………………………………………......73 CLIMATIC 50 output………………………………………………………………………………….......74 DAD smoke detector……………………………………………………………………………… ......75 General customer connection (TCB ......................76 General customer connection with Advanced Control Pack (ADC) .............77 Gas burner 60 kW and hot water coil......................78 Gas burner 120 kW ..........................79 Gas burner 180/240 kW..........................80...
  • Page 5  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 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 IOM –...

  • Page 7: Commissioning Report

    COMMISSIONING 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 Voltage between 1 / 2 2 / 3 1 / 3 ……………….
  • Page 8 COMMISSIONING REPORT (8) REFRIGERATION SECTION Outdoor Fan Motor Current: Check Rotation L1 ……..A L2 ……..A L3 ……A Compressor Voltage Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Comp1: ……..
  • Page 9 COMMISSIONING 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 10 COMMISSIONING REPORT COMMENTS:…………………………………………………………………………………………………………………………………… ………………………….……………………………………………………………………………………………………………………… ……... ……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….…………………………………… ………………………………………………………………………………………...…………………… ….………………………………………………………………………………………………………… …………………...……………………….………………………………………………………………… …………………………………………………………...……………………….………………………… …………………………………………………………………………………………………...………… …………….……………………………………………………………………………………………… ……………………………...……………………….……………………………………………………… ……………………………………………………………………...……………………….……………… ……………………………………………………………………………………………………………... ……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….…………………………………… ………………………………………………………………………………………...…………………… ….………………………………………………………………………………………………………… …………………...……………………….………………………………………………………………… …………………………………………………………...……………………….………………………… …………………………………………………………………………………………………...………… …………….……………………………………………………………………………………………… ……………………………...……………………….……………………………………………………… ……………………………………………………………………...……………………….……………… ……………………………………………………………………………………………………………... ……………………….…………………………………………………………………………………… ………………………………………...……………………….…………………………………………… ………………………………………………………………………………...……………………….…… ……………………………………………………………………………………………………………… ………...……………………….…………………………………………………………………………… ………………………………………………...……………………….……………………………………...
  • Page 11 48 hours of delivery (working days). A copy of the attached to an eyebolt in a safe and accessible place. This letter must be addressed to Lennox and the supplier or allows you to open the panels for maintenance and distributor for information purposes.

  • Page 12: Transport - Handling

    TRANSPORT – HANDLING MANDATORY HANDLING DEVICES Handling slings to guide the unit towards the roofcurb Vacuum lifting beam to position the unit NON-COMPLIANT COMPLIANT IOM – FLEXY II – 0308 – E Page 11...

  • Page 13: 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 14 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 15: 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. IOM – FLEXY II – 0308 – E Page 14...

  • Page 16: 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 17: 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 F BOX 2200 2000 2000 2000 G BOX 2700 2000 2000 2000...

  • Page 18: 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 19: 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 20: Duct Connections

    DUCT CONNECTIONS 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 D ≥...

  • Page 21: 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 22 NON ADJUSTABLE ROOF CURB - 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 IOM – FLEXY II – 0308 – E Page 28...

  • Page 30: Energy Recovery

    ENERGY RECOVERY 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 31: 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 32: 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 Connector for the Connector for the energy recovery...

  • Page 33: Powering The Unit

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

  • Page 34: 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 unit in cooling mode Start the reverse cycle by adjusting the cold or hot temperature threshold data according to the indoor and outdoor conditions at the time of test (menu 3320).

  • Page 35: 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 36: Mounting Ans 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 37: 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 38: Filters

    VENTILATION : AIRFLOW BALANCING method when adjusting the pulley : CHECKING AIRFLOW AND ESP -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 motor pulley actual diameter.
  • Page 39 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 - cos...
  • Page 40 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 41 VENTILATION : AIRFLOW BALANCING AT18-18S IOM – FLEXY II – 0308 – E Page 40...
  • Page 42 VENTILATION : AIRFLOW BALANCING ADH355L IOM – FLEXY II – 0308 – E Page 41...
  • Page 43 VENTILATION : AIRFLOW BALANCING ADH450L IOM – FLEXY II – 0308 – E Page 42...
  • Page 44 VENTILATION : AIRFLOW BALANCING ADH500L IOM – FLEXY II – 0308 – E Page 43...
  • Page 45 VENTILATION : 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 46: 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 47: Uv Light

    VENTILATION : UV light 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 48 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 49 HEATING : HOT WATER COIL Connection HWC F-G-H box Pipe Internal Diameters (DN) F085 F100 F120 F150 F170 F200 F230 AXIMUM ORKING RESSURE BARS : 110°C AXIMUM WORKING TEMPERATURE IOM – FLEXY II – 0308 – E Page 48...

  • Page 50: 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 51 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 52 HEATING : GAS BURNER 60 & 120kW 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 53 HEATING : GAS BURNER 60 & 120kW Low Heat Injection Pressure Checks - Switch the control to Low Heat - After the adjustment of the low heat, re-verify the high - Check and adjust if necessary the Outlet pressure to 3.7 heat mbar (G20) or 5.1 mbar for Groningue(G25) &...
  • Page 54 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 55 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 56 HEATING : GAS BURNER BURNER SAFETY CHECKS Ionisation Probe test Smoke extractor pressure switch Test. - With the gas burner running, disconnect the terminal plug coming from the ionisation probe to the gas ignition control - With the gas burner running, disconnect the flexible tube box.
  • Page 57 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 58 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 59 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 60 HEATING : GAS BURNER 60kW 120kW IOM – FLEXY II – 0308 – E Page 59...
  • Page 61 HEATING : GAS BURNER 180kW 240kW IOM – FLEXY II – 0308 – E Page 60...
  • Page 62 HEATING : MODULATING GAS BURNER 60 & 120kW Actuator screw MODULATING GAS (UNDER PATENT INPI May 2004) Maximum opening The actuator Bearing surface of Minimum opening the actuator’s screw STARTING UP THE GAS BURNER The actuator receives an information 0-10V from the Purge the pipe-work near the connection on the ignition regulation for the positioning of the air shutter;...
  • Page 63 HEATING : MODULATING GAS BURNER 60 & 120kW 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 64 HEATING : MODULATING GAS BURNER 60 & 120kW - Check the 230V supply voltage of electronic board: the phase on terminal 01 and the neutral conductor on terminal 02 - Bring back the potentiometer towards the position + until obtaining - Check the wiring of the signal 0-10V between terminal 64 the desired 10.4mbar in high heat for (polarity 01 of the 24V) and terminal 66 (+ coming from the...
  • Page 65 HEATING : MODULATING GAS BURNER 180 & 240kW Maximum opening Actuator screw MODULATING GAS (UNDER PATENT INPI May 2004) The actuator Minimum opening STARTING UP THE GAS BURNER Purge the pipe-work near the connection on the ignition The actuator receives an information 0-10V from the control Valve for a few seconds.
  • Page 66 HEATING : MODULATING GAS BURNER 180 & 240kW 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 67 HEATING : MODULATING GAS BURNER 180 & 240kW - Check the 230V supply voltage of electronic boards: the Adjusting minimum pressure setting: phase on terminal 01 and the neutral conductor on terminal 02 - 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 68 HEATING : MODULATING GAS BURNER 60kW 120kW IOM – FLEXY II – 0308 – E Page 67...
  • Page 69 HEATING : MODULATING GAS BURNER 180kW 240kW IOM – FLEXY II – 0308 – E Page 68...

  • Page 70: Hot Water Coils

    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 71: Electrical Data: Wiring Diagrams

    ELECTRICAL DATA : WIRING DIAGRAMS DIAGRAM REFERENCE LEGEND – A1-2-3-4 AIR SOCK CONTROL – B1 – KE1-2-3 EXTERNAL AIR THERMOSTAT HEATER -E1 - E2 - E3 CONTACTOR – B2 SMOKE DETECTION HEAD – B3 RC CIRCUIT – B4 - B5 –...

  • Page 72: Main Current Diagram Tri/400V/50Hz + T

    ELECTRICAL DATA : WIRING DIAGRAMS FCM = Cooling only unit FHM = Heat pump unit FGM = Cooling only unit with gas fired heating FDM = Heat pump unit with gas fired heating MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T IOM –...
  • Page 73 ELECTRICAL DATA : WIRING DIAGRAMS MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T IOM – FLEXY II – 0308 – E Page 72...

  • Page 74: Climatic 50 Controller

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 CONTROLER IOM – FLEXY II – 0308 – E Page 73...

  • Page 75: Climatic 50 Input

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 INPUT FCM / FHM / FGM / FDM IOM – FLEXY II – 0308 – E Page 74...

  • Page 76: Climatic 50 Output

    ELECTRICAL DATA : WIRING DIAGRAMS CLIMATIC 50 OUTPUT FCM / FHM / FGM / FDM IOM – FLEXY II – 0308 – E Page 75...

  • Page 77: Dad Smoke Detector

    ELECTRICAL DATA : WIRING DIAGRAMS DAD SMOKE DETECTOR IOM – FLEXY II – 0308 – E Page 76...

  • Page 78: General Customer Connection

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION TCB IOM – FLEXY II – 0308 – E Page 77...

  • Page 79: General Customer Connection With Advanced Control Pack (Adc)

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION WITH ADVANCED CONTROL PACK (ADC) IOM – FLEXY II – 0308 – E Page 78...

  • Page 80: 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 IOM – FLEXY II – 0308 – E Page 79...

  • Page 81: Gas Burner 120 Kw

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 120kW IOM – FLEXY II – 0308 – E Page 80...

  • Page 82: Gas Burner 180/240 Kw

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM GAS BURNER 180 / 240kW IOM – FLEXY II – 0308 – E Page 81...

  • Page 83: Electric Heater

    ELECTRICAL DATA : WIRING DIAGRAMS WIRING DIAGRAM ELECTRIC HEATER IOM – FLEXY II – 0308 – E Page 82...

  • Page 84: General Customer Connection Diagram

    ELECTRICAL DATA : WIRING DIAGRAMS GENERAL CUSTOMER CONNECTION DIAGRAM IOM – FLEXY II – 0308 – E Page 83...

  • Page 85: 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 DO 2 - Customized (choose 1 output between those 7 possibilities)

  • Page 86: 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 87: Advanced Scroll Temperature Protection (Astp)

    (ASTP) DVANCED CROLL EMPERATURE ROTECTION ERVICE A OMPRESSOR PERATION XPLANATION  What to do?   Protection is activated when Scroll Discharge If a protected compressor is identified Port. Reaches 150°C (+/- 17K) Stop the compressor Allow to cool thoroughly ...

  • Page 88: 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 89 PRINCIPLE SKETCHES FCM 150 FHM 150 IOM – FLEXY II – 0308 – E Page 88...
  • Page 90 PRINCIPLE SKETCHES FCM 170 FHM 170 IOM – FLEXY II – 0308 – E Page 89...
  • Page 91 PRINCIPLE SKETCHES FCM 200 & 230 FHM 200 & 230 IOM – FLEXY II – 0308 – E Page 90...
  • Page 92 HOT WATER COIL DIAGRAM HOT WATER PIPE DIAMETERS 1 ROW 2 ROWS IOM – FLEXY II – 0308 – E Page 91...

  • Page 93: 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 If too high check the coils are clean or check coil between T outdoor and Tevap.
  • Page 94 MAINTENANCE DIAGNOSTIC HP PROBLEMS AND If the circuit pressure is higher (<1bar) than the HP CUT OUTS saturated pressure corresponding to the measured outdoor temperature, there is possibility that some contaminants are present in Moisture or contaminants in the system the system.
  • Page 95 MAINTENANCE DIAGNOSTIC ELECTRICAL HEATER FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Measure and estimate the airflow and pressure Low airflow rate and compare with the specification from customer. High Temperature trip out on electric heater Check that the Klixon, is positioned in the airflow, relocate Klixon if necessary Incorrect position of the Klixon Check that there is no heat transfer from the...

  • Page 96: 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 97: Commissioning Sheet

    MAINTENANCE PLAN Estimated Task Operating mode Time (min) Replace filters with new ones if disposable. Vacuum clean or blow the dirt. Wash and dry carefully. Replace media Clean or replace filters: Disposable, or if necessary metal frame. Blocked filter will reduce the performance of the unit. THE UNIT MUST NOT OPERATE WITHOUT FILTERS Visually check the oil level through the sight glass on the Visual check of the oil level...
  • Page 98 MAINTENANCE PLAN 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: 29bar (+1 / -0) auto-reset 22bar Check HP / LP safety switches - 0.7) Reconnect fans. Switch off the centrifugal supply fan and wait for the LP switch to cut out: 0.5bar (+ - 0.5) reset 1.5bar (+-0.5).

  • Page 99: 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 100 9001 (2000) ONGVIC SITE CERTIFICATE IOM – FLEXY II – 0308 – E Page 99...
  • Page 101 EC C ONFORMITY ECLARATION IOM – FLEXY II – 0308 – E Page 100...
  • Page 102 DAD L OTUS ERTIFICATE IOM – FLEXY II – 0308 – E Page 101...
  • Page 103 GLASS WOOL INSULATION CERTIFICATE IOM – FLEXY II – 0308 – E Page 102...
  • Page 104 LASS NSULATION ERTIFICATE IOM – FLEXY II – 0308 – E Page 103...
  • Page 105 F7 F ILTER NSULATION ERTIFICATE IOM – FLEXY II – 0308 – E Page 104...
  • Page 106 G4 F ILTER NSULATION ERTIFICATE IOM – FLEXY II – 0308 – E Page 105...
  • Page 107 60-120-180-240 LEXY GAS BURNER CERTIFICATE IOM – FLEXY II – 0308 – E Page 106...
  • Page 108 PED C OOFTOP ONFORMITY ERTIFICATE IOM – FLEXY II – 0308 – E Page 107...
  • Page 109 PED C OOFTOP ONFORMITY ERTIFICATE IOM – FLEXY II – 0308 – E Page 108...
  • Page 110 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. Installation and service must be performed by a qualified installer and servicing agency.

This manual is also suitable for:

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