Инструкция на Rooftops (крышные кондиционеры) Lennox серии FLEXY, FLEXY II бренда Lennox

Installation, operating

and maintenance FLEXY II Providing indoor climate comfort FLEXYII-IOM-1007-E

OPERATION

MAINTENANCE MANUAL Ref. FLEXYII_IOM/1007-E The present manual applies to the following ROOFTOP v ersions: FCM 85 - FCM 100 - FCM 120 - FCM 150 - FCM 170 - FCM 200 - FCM 230 FHM 85 - FHM 100 - FHM 120 - FHM 150 - FHM 170 - FHM 200 - FHM 230 FDM 85 - FDM 100 - FDM 120 - FDM 150 - FDM 170 - FDM 200…

IMPORTANT NOTICE – Safety instructions

All FLEXY II Units are compliant with the PED directive 97-23/CE The following note must be followed carefully All work on the unit must be carried out by a qualified and authorised employee. Non-compliance with the f ollowing instructions may result in injury or serious accidents. Work on the unit…

IMPORTANT NOTICE – Safety instructions

UV LIGHT : - The UV lam p em its shortw ave UV-C ultraviolet radiation which is harmful to skin and eyes It can cause serious skin burns and eye inflamm ation w ithin 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…

Site details

It is recommended that y ou f ill the two tables below bef ore transf erring the zone settings to the Climatic 50 controller. Refer to control section page 55 / Se référer à la section régulation page 55 Time Zones / Zones Horaires Hour Example 7h15 ZA 11h00 ZB 14h00 ZC 19h00 UNO UNO Monday Tuesday…

COMMENTS:……………………………………………………………………………………………………………………………………

IOM – FLEXY II – 1007 – E Page 9

TRANSPORT – HANDLING – WARNING

STOR AGE DELIVERY CHECKS On receipt of a new equipment please check the following points. It is the customer’s responsibility to ensure that the products are in good working order: - The exterior has not been damaged in any way. - The lif ting and handling equipment are suitable for the equipment…

MANDATORY HANDLING DEVICES

Handling slings to guide the unit towards the roofcurb Vacuum lifting beam to position the unit COMPLIANT IOM – FLEXY II – 1007 – E NON-COMPLIANT Page 11

DIMENSIONS AND WEIGHTS

LENGTH FXK025 FXK030 FXK035 FXK040 FXK055 FXK070 FXK085 FXK100 FXK110 FXK140 FXK170 IOM – FLEXY II – 1007 – E HEIGHT WIDTH mm mm mm 4070 4070 4750 4750 4750 5050 5050 5050 5650 5650 5650 1635 1635 2255 2255 2255 2255 2255 2255 2255 2255 2255 1055 1055 1290 1290 1290 1725 1725 1725 2000 2000 2000…

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 – 1007 – E Page 14

FORKLIFT PROTECTIONS

NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS REMOVE THE FORKLIFT PROTECTIONS BEFORE INSTALLATION PRELIMINARY CHECKS Bef ore installing the equipment, the following points MUST be checked: - Hav e the f orklift protections been remov ed? - Is there sufficient space for the equipment? - Is the…

MINIMUM CLEARANCE AROUND THE UNIT

Figure 4 shows the required clearances and serv ice access around the unit. NOTE: Ensure the f resh air inlet does not f ace prevailing wind direction. C B D A A FCM/FHM/FGM/FDM F BOX G BOX H BOX FX 25 & 30 3555 70100 110170 B C D 2200 (1) 2700 (1) 2700 2000 2000 2000 2000 2000 2000 2000 2000…

INSTALLATION ON A ROOFMOUNTING FRAME

CAUT ION: - - 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…

INSTALLATION ON A ROOFMOUNTING FRAME

When the f rame 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 alternativ e method CURBING AND FLASHING Outside of frame must be insulated with rigid type insulation; We recommend a…

DUCT CONNECTIONS

Whatev er the supply conf iguration is, respect a minimal duct’s length (D) of 2m bef ore any elbow or any duct’s diameter change. These recommendations are imperativ e in the case of 2 independent turbines (sizes f rom 150kW to 230kW and all units equipped with gas module) Horizontal supply D ≥ 2m…

INSTALLATION ON A ROOF MOUNTING FRAME

NON ADJ USTABLE NON ASSEMBLIED ROOFCURB INSTALLATION FRAME P ARTS IDENTIFICATION Figure 8 shows the different parts used in the assembly of this roof mounting f rame. INSTALLATION The roof mounting frame prov ides support when the units are installed in down-f low configurations. The non adjustable…

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 f ree nails. It is not possible to connect with standard nail equipment because there is a lot of power needed. Theref ore, you need a pneumatic or electric dev ice.…

ADJUSTABLE ROOFCURB

NON ADJUSTABLE NON ASSEMBLED ROOFCURB

MULTIDIRECTIONAL ROOFCURB

RETURN ROOFCURB

CAUTION: An approach ramp must be installed if the machine installation requirements tell that it's necessary to reach the main sw itch. 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…

RETURN HORIZONTAL ROOFCURB

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

TRANSITION CURB

ENERGY RECOVERY

ECONOMISER AND EXTRACTION

ECONOMISER Free cooling can be provided through the use of fresh air which is more appropriate than excessiv e cooling amounts of return air. The economiser is f actory fitted and tested prior to shipment. It includes two dampers operating f rom a 24V actuator RAIN HOOD It also includes a factory f…

THIS WORK MUST ONLY BE CARRIED OUT

BY T RAINED REFRIGERATION ENGINEERS FILL THE COMMISSIONNING SHEET AS Y OU GO ALONG Connector for the energy recovery module + Fres h air sensor Don’t forget to open the isolation Valves on the liquid line before starting the unit (see sticker below ) Fig. 10 ISOLATION VALVES M UST BE OPENED BEFORE…

STARTING THE UNIT

At this point the unit circuit breakers should be open Y ou will need a DS50 maintenance controller or Adalink with appropriate Interface. Check and adjust the control settings. Ref er to the control section in this manual to adjust the different parameters. POWERING THE UNIT The jumpers are factory…

RUN TEST

Start unit in cooling mode Reverse cycle test This test is designed to check the good operation of the 4way reversing v alves on heat pump reversible systems. Start the reverse cycle by adjusting the cold or hot temperature threshold data according to the indoor and outdoor conditions at the time of…

VENTILATION : BELT TENSION

BELT TENSION On deliv ery, the driv e 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. Bef ore adjusting the tension, make sure that the pulleys…

VENTILATION : PULLEYS

MOUNTING AND ADJUSTING PULLEYS F AN PULLEY REMOVAL Remov e the 2 screws and put one of them in the extraction threaded screw. Screw in f ully. The hub and the pulley will separate from each other. Remov e the hub and the pulley by hand without damaging the machine. F AN PULLEY INSTALLA TION Clean…

The actual resistance of ductwork systems is not alway s identical to the calculated theoretical v alues. To rectify this, it may be necessary to modify the pulley and belt setting. To this effect, the motors are fitted with v ariable pulleys. SITE TEST AND MAINTEN ANCE Measure the motor absorbed…

nd

2 method when adjusting the pulley : -Close the pulley fully and count the number of turns from f ully closed position. Using table_1 determine the motor pulley actual diameter. -Record the fix f an pulley diameter.(DF) -Determine the f an speed using the f ollowing formulae: CHECKING AIRFLOW AND…

EX AMPLE

The unit used f or this example is a FGM170ND with standard supply and return airf low conf iguration. It is also f itted with an economiser and an electric heater type H. It is fitted with 2 ADH450 L fans which curv e is shown on page 36 and 2x 5.5 kW motors.. - Motor rpm: 1447 rpm - cos = 0.83…

AT15-15G2L(*)

(*) The performanc es of twin fan units can be calc ulated starting from the c orresponding oper ation point for a si ngle fan (see the figure behind) by appl ying the formulas below. - pressure : PT win = P x 1 - vol ume flow rate : Qb = Q x 2 - impeller power: Wb = W x 2,15 - fan s peed : Nb = N x…

AT18-18S

IOM – FLEXY II – 1007 – E Page 39

ADH355L

IOM – FLEXY II – 1007 – E Page 40

ADH450L

IOM – FLEXY II – 1007 – E Page 41

ADH500L

IOM – FLEXY II – 1007 – E Page 42

VENTILATION : FILTERS

F ILTER REPLACEMEN T After opening the f ilter access panel, lift the filter retaining log. The f ilters can then be remov ed 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 f…

VENTILATION : AIR SOCK CONTROL

AIR SOCK CONTROL F ANSTAR T OPERA TION The use of air socks f or space conditioning allows high air v olumes to be distributed at low v elocity and is becoming a common f eature in many applications. To accommodate this trend, Air-sock control is offered which allows the air socks to be progressiv…

VENTILATION : UV light

UV LIGHT UV light option allows to kill bacteria liv ing on the fin. The UV lamp emits shortwav e UV-C ultraviolet radiation which is harmf ul to skin and ey es 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…

HEATING : HOT WATER COIL

FREEZE PROTECTION HYDRAULIC CONNECTIONS Hot water coils offer f ully modulating control through the use of a 3 way v alv e. The hot water coil, connections and v alves are all tested at pressure of 15 bars. Frost protection is prov ided by f orcing the opening the 3 way v alve when supply…

таблицы и схемы — в просмотре

HEATING : ELECTRIC HEATER

GENERAL I NFORMA TI ONS The electric heater comprises of shielded resistance heaters, which are smooth stainless steel tubes 6 W/cm2 capacity. High temperature limit control offers ov erload protection and is set to 90°C and located at less than 150mm after electric heaters. This is provided as a…

PRELIMINARY CHECKS BEFORE START-UP

NOTE : ANY WORK ON THE GAS SY STEM MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN PLANED INSTALLATION CONDITIONS FOR OUTDOOR. PLEASE READ CAREFULLY THE MANUFACTURER’S INSTRUCTIONS BEFORE STARTING A…

HEATING : GAS BURNER 60 & 120kW

PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4125 P Pressure regulator adjustment with 300mbar gas supply: High Heat Injection Pressure Checks Fig.16 Check and adjust if necessary the valv e OUTLET pressure to 10.4mbar (G 20) / 13.1mbar f or Groningen (G25) & 34.3 mbar f or…

HEATING : GAS BURNER 60 & 120kW

Low Heat Injection Pressure Checks - Switch the control to Low Heat - Check and adjust if necessary the Outlet pressure to 3.7 mbar (G20) or 5.1 mbar f or Groningue(G25) & 15.3 mbar f or propane (G31)(fig.18) - Af ter the adjustment of the low heat, re-v erify the high heat - re-position the…

HEATING : GAS BURNER 180 & 240kW

PRESSURE ADJUSTMENTS ON 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 valv e OUTLET pressure to 8.0mbar (G 20) / 10.4mbar f or Groningen (G25) & 28.3 mbar f or…

HEATING : GAS BURNER 180 & 240kW

Low Heat Injection Pressure Checks - Switch the control to Low Heat - Check and adjust if necessary the Outlet pressure to 3.1 mbar (G20) or 3.9 mbar f or Groningen (G25) & 12.6 mbar f or propane (G31) (f ig.22) - Af ter the adjustment of the low heat, re-v erify the high heat - re-position the…

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 box. - With the gas burner running, disconnect the f lexible tube f itted to the pressure taping on the pressure switch…

GAS BURNER FIRE-UP SEQUENCE

Operation f rom control Thermostat GAZ =Closed Supply Thermostat Limit? (Auto Reset) NO YES NO Gas Low Pressure switch? YES Gas Ignition Control Block Signal Extraction Fan ON AIR Pressure Switch ON Backfire Thermostat ON? NO YES Pre-Ventilation 30 seconds Gas Control Valv e Closes BURNER STOPS…

GAS BURNER TROUBLESHOUTING

If faults reported on CLIMATIC -Reset the CLIMATIC. -Check v oltage: 230V after circuit breaker. -Check GAS isolation shut-off valv es are open. -Check GAS pressure at the inlet of the GAS valv es. It must be >20 mbar when the Burners shut down. -Adjust the set points to priorities the burner.…

DISASSEMBLING THE GAS BURNER FOR

MAINTENANCE PURPOSES Preliminary Safety Recommendations - Isolate the unit using the main isolator switch. - Close off the isolating gas v alve located bef ore the unit. - Disconnect the Pipe-work. Do not discard the seals. Disassembling the gas «burner support bar» - Disconnect the Electrical…

60kW

180kW

Actuator screw

MODULATING GAS (UNDER PATENT INPI May 2004) Maximum opening The actuator Minimum opening Bearing surf ace of the actuator’s screw STARTING UP THE GAS BURNER The actuator receives an information 0-10V f rom the regulation f or the positioning of the air shutter; then the actuator transmits its…

REGULA TING VALVE VK4105MB AND ON ELECTRONIC BOARD W4115D1024 High & Low heat injection pressure check: Pressure regulator adjustment with 300mbars gas supply: There is one board f or two valv es Electronic board W4115D1024 230V po wer supply Potentiometer called « CURRENT » Switches in position 3…

- 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 the desired 10.4mbar in high heat for natural gas. - Check the wiring of the signal 0-10V between terminal 64 (polarity 01 of the 24V) and terminal 66 (+ coming from…

MODULATING GAS (UNDER PATENT INPI May

2004) Maximum opening Actuator screw The actuator Minimum opening STARTING UP THE GAS BURNER The actuator receives an information 0-10V f rom the regulation f or the positioning of the air shutter; then the actuator transmits its position to the printed-board which will order the valv e. Purge the…

REGULA TING VALVE VR4605MB AND ON ELECTRONIC BOARD W4115D1024 Pressure regulator adjustment with 300mbars gas supply: High & Low heat injection pressure check: Electronic board W4115D1024 There is one board per valv e 230V po wer supply Potentiometer called « CURRENT » Switches in position 3 for an…

- Check the 230V supply v oltage of electronic boards: the

phase on terminal 01 and the neutral conductor on terminal 02 - Check the wiring of the signal 0-10V between terminal 64 (polarity 01 of the 24V) and terminal 66 (+ coming from the actuator) Adjusting minimum pressure setting: - Disconnect electrical connection to MODUREG (=modulating solenoid valv…

HEATING : MODULATING GAS BURNER

таблицы и схемы — в просмотре

AIR SOCK CONTROL 15 AIR SOCK CONTROL CO2 SENSOR 16 CO2 SENSOR ANALOG DIRTY FILTER AND FAN PROVEN SWITCH 17 ANALOG DIRTY FILTER AND FAN PROVEN SWITCH COMFORT DISPLAY DC50 18 COMFORT DISPLAY DC50 COMFORT DISPLAY WIRELESS DC50W 19 COMFORT DISPLAY WIRELESS DC50W SERVICE DISPLAY DS50 20 SERVICE DISPLAY…

DIAGRAM REFERENCE LEGEND

FCM = Cooling only unit

FHM = Heat pump unit FGM = Cooling only unit with gas f ired heating FDM = Heat pump unit with gas f ired heating MAIN CURRENT DIAGRAM TRI / 400V / 50Hz + T IOM – FLEXY II – 1007 – E Page 70

IOM – FLEXY II – 1007 – E Page 71

CLIMATIC 50 CONTROLER

IOM – FLEXY II – 1007 – E Page 72

CLIMATIC 50 INPUT FCM / FHM / FGM / FDM

IOM – FLEXY II – 1007 – E Page 73

CLIMATIC 50 OUTPUT FCM / FHM / FGM / FDM

IOM – FLEXY II – 1007 – E Page 74

DAD SMOKE DETECTOR

IOM – FLEXY II – 1007 – E Page 75

GENERAL CUSTOMER CONNECTION TCB

IOM – FLEXY II – 1007 – E Page 76

GENERAL CUSTOMER CONNECTION WITH ADVANCED CONTROL PACK (ADC)

IOM – FLEXY II – 1007 – E Page 77

WIRING DIAGRAM G AS BURNER 60 kW and HOT WATER COIL

HOT WATER COIL IOM – FLEXY II – 1007 – E Page 78

IOM – FLEXY II – 1007 – E Page 79

IOM – FLEXY II – 1007 – E Page 80

WIRING DIAGRAM ELECTRIC HEATER

IOM – FLEXY II – 1007 – E Page 81

GENERAL CUSTOMER CONNECTION DIAGRAM

IOM – FLEXY II – 1007 – E Page 82

ELECTRICAL DATA : CONTROL VARIABLES

STANDARD ADVANCED CONT ROL PACK OR TCB Logical Output Board (2 outputs: 1 assigned, 1 customized) Logical Output Board (4 outputs: 0 assigned, 4 customized) DO 1 - Alar m, General DO 2 - Customiz ed (choos e 1 output between those 7 possibilities) DO 3 to 6 - C ustomized (choose, for eac h input (…

R410A

REFRIGERANT DEFINITION S ATURATION PRESSURE R-410A is an HFC, or hydro fluorocarbon, and is made of hy drogen, fluorine, and carbon atoms. Because it has no chlorine, it won’t interact with the ozone layer once it breaks down. It’s non-toxic and non-inflammable. Temp. °C R22 R407C Vapor R410A 70…

ADVANCED SCROLL TEMPERATURE PROTECTION (ASTP)

SERVICE A C OMPRESSOR OPERATION MODE EXPLANA TION  Protection is activ ated when Scroll Discharge Port. Reaches 150°C (+/- 17K)  Compressor is protected as « Unloaded » but continues to run   Protection mode balances discharge/suction pressure Motor heat builds inside compressor No ref rigerant…

BCD1.2

BEC CONDENSER COIL HOT WATER COIL BEV CA1.2 EVAPORATOR COIL CHECK VALVE DT1.2 FD1.2 THERMOSTATIC EXPANSION VALVE FILTER DRIER - B14 - B15 - BT12 HOT WATER COIL ANTIFREEZE THERMOSTAT BLOWER TEMPERATURE PROBE - BT17 RETURN REGULATION TEMPERATURE SENSOR - B41 - B42 COMPRESSOR -MG1 - MG2 HIGH PRESSURE…

FCM 150

FHM 150 IOM – FLEXY II – 1007 – E Page 87

FCM 170

FHM 170 IOM – FLEXY II – 1007 – E Page 88

FCM 200 & 230

FHM 200 & 230 IOM – FLEXY II – 1007 – E Page 89

HOT WATER COIL DIAGRAM

HOT WATER IOM – FLEXY II – 1007 – E PIPE DIAMETERS 1 ROW 2 ROWS Page 90

REFRIGERATION

FAULT POSSIBLE CAUSE AND SYMPTO MS Ref rigerant charge too low SOLUTION Measure the superheat and sub-cooling: Good if 5°C<SC<10°C and 5°C<SH<10°C 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…

HP PROBLEMS AND

HP CUT OUTS Moisture or contaminants in the system If the circuit pressure is higher (<1bar) than the saturated pressure corresponding to the measured outdoor temperature, there is possibility that some contaminants are present in the system. Reclaim the ref rigerant, and vacuum the circuit (Ensure…

ELECTRICAL HEATER

FAULT POSSIBLE CAUSE AND SYMPTO MS SOLUTION Low airf low rate Measure and estimate the airflow and pressure and compare with the specification from customer. Incorrect position of the Klixon Check that the Klixon, is positioned in the airf low, relocate Klixon if necessary Check that there is no…

MAINTENANCE PLAN

Roof tops are generally placed on the roof but can also be installed in technical rooms. These units are v ery robust but minimum regular maintenance is required. Some moving parts in the units can suffer from wear and tear and must be checked regularly (belts). Other parts can get clogged by dirt…

Yearly B4

winter 6 monthly Estimated Time (min) Task Operati ng mode Monthly Quarterly MAINTENANCE PLAN Clean or replac e filters: Disposable, or metal frame. Replace filters with new ones if dispos able. Vacuum cl ean or blow the dirt. Wash and dry c arefully. Replace media if nec essar y Bloc ked filter…

MAINTENANCE PLAN

Install manifold gauges on the circuit to be chec ked. Shut down the axial fans and wait for the HP s witch to s hut down the compress or: 29bar (+1 / -0) auto-reset 22bar (+ Chec k HP / LP safety s witches - 0.7) Rec onnect fans . Switch off the c entrifugal s upply fan and wait for the LP s witch…

WARRANTY

TERMS AND CONDITIONS In the absence of any other written agreement, the guarantee shall only apply to design faults which occur within a 12 month period (warranty period). The warranty period starts on the date of commissioning and at the latest six months after the deliv ery of the Rooftop.…

LONGVIC SITE - ISO 9001 (2000) CERTIFICATE

IOM – FLEXY II – 1007 – E Page 98

EC CONFORMITY DECLARATION

IOM – FLEXY II – 1007 – E Page 99

DAD LOTUS CERTIFICATE

IOM – FLEXY II – 1007 – E Page 100

GLASS WOOL INSULATION CERTIFICATE

IOM – FLEXY II – 1007 – E Page 101

GLASS WOOL INSULATION CERTIFICATE

IOM – FLEXY II – 1007 – E Page 102

F7 FILTER INSULATION CERTIFICATE

IOM – FLEXY II – 1007 – E Page 103

G4 FILTER INSULATION CERTIFICATE

IOM – FLEXY II – 1007 – E Page 104

FLEXY 60-120-180-240 KW GAS BURNER CERTIFICATE

IOM – FLEXY II – 1007 – E Page 105

ROOFTOP PED CONFORMITY CERTIFICATE

IOM – FLEXY II – 1007 – E Page 106

ROOFTOP PED CONFORMITY CERTIFICATE

IOM – FLEXY II – 1007 – E Page 107

www.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. Installation and service…

Инструкция на Rooftops (крышные кондиционеры) Lennox серии FLEXY, FLEXY II

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