Lennox ROOFTOP FLEXY FXK 100 Page 24 Installation, Operating And Maintenance Download

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IOM – FLEXY II – 1007 – E

Page 22

SIZE

F-BOX 85-100-120 2056 2770 2005 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95

G-BOX

150-170

2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95

H-BOX

200-230

2056 4100 2493 400 4003 1959 234 1997 145 420 430 1830 800 80 1133 95

ADJUSTABLE ROOFCURB

All units

RETURN AIR

SUPPLY AIR

MAIN POW ER ENTRY

Summary of Contents for ROOFTOP FLEXY FXK 100

Page 1: ...Providing indoor climate comfort FLEXY II FLEXYII IOM 1007 E Installation operating and maintenance...

Page 2: ......

Page 3: ...ed in this manual including any drawing and technical descriptions provided by us remain the property of Lennox and must notbe used except in operation of this product reproduced issued to or made ava...

Page 4: ...nstallation instructions 21 Adjustable roof curb 22 Non adjustable Non assembled roof curb 23 Multidirectional roof curb 24 Return roof curb 25 Return horizontal roof curb 26 Transition roof curb 27 E...

Page 5: ...B 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 Electric heater 81 General customer connection d...

Page 6: ...ntain 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 manuf acturer s nameplate shall be used to...

Page 7: ...us 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 doo...

Page 8: ...Tension Checked Yes No Yes No Alignment Checked Yes No Yes No Motor Pulley Diameter DM mm Fan Pulley Diameter DP mm Fan Speed Motor rpm x DM DP Av eraged Measured Amps rpm A Shaft Mechanical Power Re...

Page 9: ...1 Phase 2 Phase 3 Suction Discharge LP BP HP HP Comp 1 A A A C C Bar Bar Comp 2 A A A C C Bar Bar Comp 3 A A A C C Bar Bar Comp 4 A A A C C Bar Bar HP cut out Bar LP cut out Bar Ref rigerant charge C1...

Page 10: ...pour chaque zone horaire Start z A Start z B Start z C Start UNO hour 3211 min 3212 hour 3213 min 3214 hour 3215 min 3216 hour 3217 min 3218 Monday Tuesday Wednesday Thursday Friday Saturday Sunday De...

Page 11: ...IOM FLEXY II 1007 E Page 9 COMMENTS COMMISSIONING REPORT...

Page 12: ...e achiev ed f or the specif ied operational v oltage The customer must hav e a suitable electrical supply It is theref ore important to check whether the supply v oltage stated on the unit s rating pl...

Page 13: ...IOM FLEXY II 1007 E Page 11 TRANSPORT HANDLING Handling slings to guide the unit towards the roofcurb Vacuum lifting beam to position the unit COMPLIANT NON COMPLIANT MANDATORY HANDLING DEVICES...

Page 14: ...FCM Without economiser kg 933 8 1008 8 1085 0 1367 0 1430 0 1650 0 1950 0 With economiser kg 990 3 1065 3 1141 5 1442 0 1505 0 1751 7 2051 7 Weight gas unit FGM Standard heat Without economiser kg 104...

Page 15: ...XK030 4070 1635 1055 490 600 980 FXK035 4750 2255 1290 490 600 1400 FXK040 4750 2255 1290 490 600 1450 FXK055 4750 2255 1290 490 600 1600 FXK070 5050 2255 1725 890 600 1800 FXK085 5050 2255 1725 890 6...

Page 16: ...IOM FLEXY II 1007 E Page 14 LIFTING THE UNIT As shown on the picture below a lifting frame is necessary After lifting withdraw angle s feet and lifting lugs TRANSPORT HANDLING...

Page 17: ...pplicable codes Check to ensure that the ref rigerant lines do not rub against the cabinet or against other ref rigerant lines In general make sure no obstacles walls trees or roof ledges are obstruct...

Page 18: ...unit NOTE Ensure thef resh air inlet does not f ace prevailing wind direction A B C D FCM FHM FGM FDM F BOX 2200 1 2000 2000 2000 G BOX 2700 1 2000 2000 2000 H BOX 2700 1 2000 2000 2000 FX 25 30 1100...

Page 19: ...ix curbs and roofcurbs to the unit As lev els are adjustable observe the following recommendations when installing the equipment Abov e all ensure that all the adjustable returns are facing outward 1...

Page 20: ...shown in 1 f igure 7 CAUTION To be effective the upstream must end below the drop edge 3 figure 7 Where pipes and electrical conduits extend through the roof flashing must be conf ormed to local codes...

Page 21: ...t 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 Vertical supply Here...

Page 22: ...des support when the units are installed in down f low configurations The non adjustable non assembled roof mountingf rame can be installed directly on decks having adequate structural strength or on...

Page 23: ...e you need a pneumatic or electric dev ice Foam Insulation Installing Stick large foam pieces underneath the flat top Foam Gasket Installing Stick gasket all around the curb flange s top Spare parts F...

Page 24: ...5 400 2672 1959 130 1747 145 420 336 1432 700 140 620 95 G BOX 150 170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95 H BOX 200 230 2056 4100 2493 400 4003 1959 234 1997 145 420...

Page 25: ...00 2672 1959 130 1747 145 420 336 1432 700 140 620 95 G BOX 150 170 2056 3466 2493 400 3367 1959 234 1997 145 420 430 1540 700 140 800 95 H BOX 200 230 2056 4100 2493 400 4003 1959 234 1997 145 420 43...

Page 26: ...100 600 300 1335 88 980 780 600 100 600 100 600 100 G BOX 150 170 2056 3441 2493 800 100 600 300 1540 88 980 780 900 100 600 100 900 100 H BOX 200 230 2056 4063 2493 800 100 600 300 1830 88 980 780 10...

Page 27: ...4165 2493 1030 2056 4065 2550 100 310 800 80 800 1830 430 1113 95 RETURN ROOFCURB CAUTION An approach ramp must be installed if the machine installation requirements tell that it s necessary to reach...

Page 28: ...180 100 400 1830 430 150 2500 100 700 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 T...

Page 29: ...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 85 1830 4...

Page 30: ...700 1250 550 2200 220 460 30000 m3 h 2640 2100 1850 2010 315 200 700 1250 550 2200 220 460 35000 m3 h 3440 2100 1850 3000 220 200 700 1250 550 2200 620 460 ENERGY RECOVERY MAIN POWER ENTRY FRESH AIR...

Page 31: ...amount of f resh air is introduced into the system power exhaust fans can be used to equalise the pressures The extraction fan runs when return air dampers are being closed and supply air blower is i...

Page 32: ...energy recov ery module Cables and their connectors corresponding to the roof curb motor and actuator and extraction box ones are already rolled up in these elements it is enough to bring them throug...

Page 33: ...during the end of line test They should theref ore all turn in either the right or wrong direction NOTE A compressor rotating in the wrong direction will f ail If the fan turns in the wrong direction...

Page 34: ...respect to the air pressure value Observe the response of the CLIMATIC Same procedure for detecting Missing Filter page menu 3412 or Air Flow Detection page menu 3411 Check the smoke detection functio...

Page 35: ...meter from centre to centre Check that according to the diagram below f igure 12 the f ollowing ratio remains the same The belts should alway s be replaced when The disk is set to maximum The belt ru...

Page 36: ...d shake it v igorously to make sure everything is in place Fill the holes with grease for protection NOTE During installation the key should nev er protrude out of its groove After 50 operating hours...

Page 37: ...ing to increase the motor size To carry out the adjustment and to avoid a time consuming re start stop the machine and if necessary lock the main switch First unscrew the 4 Allen screw s on the pulley...

Page 38: ...tic pressure ESP can then be estimated ESP PTOT Pd PINT Table_ 2 Motor inf ormation Motor Size Nom Speed Cos meca motor 0 75 kW 1400 rpm 0 77 0 70 1 1kW 1429 rpm 0 84 0 77 1 5kW 1428 rpm 0 82 0 79 2 2...

Page 39: ...s a diameter of 114 2mm rpm FAN rpm MOTOR x DM DF 1447 x 114 2 200 826 rpm Using the fan curv e the operating point can be located In order to facilitate the calculation you won t make any mistake by...

Page 40: ...rmances of twin fan units can be calculated starting from the corresponding oper ation point for a si ngle fan see the figure behind byappl ying the formulas below pressure PTwin P x1 vol ume flow rat...

Page 41: ...IOM FLEXY II 1007 E Page 39 VENTILATION AIRFLOW BALANCING AT18 18S...

Page 42: ...IOM FLEXY II 1007 E Page 40 VENTILATION AIRFLOW BALANCING ADH355L...

Page 43: ...IOM FLEXY II 1007 E Page 41 VENTILATION AIRFLOW BALANCING ADH450L...

Page 44: ...IOM FLEXY II 1007 E Page 42 VENTILATION AIRFLOW BALANCING ADH500L...

Page 45: ...50Pa by default Dirty Filter in page 3413 250Pa by default The actual pressure drop measured accross the coil can be read on the Climatic Display DS50 in menu 2131 The f ollowing faults may be identi...

Page 46: ...air damper is controlled by a spring return damper driven by the opposite signal deliv ered to thef resh air damper An auxiliary switch allows setting a minimum f ew of return air opening bef ore thef...

Page 47: ...ion 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 do...

Page 48: ...for Heating by reducing the simulated ambient temperature down to 10 C Check that the red indicators located under the valv e actuator are mov ing correctly with the signal Fill the hy draulic system...

Page 49: ...47 Connection HWC F G H box Pipe Internal Diameters DN MAXIMUM WORKING PRESSURE 8 BARS MAXIMUM WORKING TE MPERATURE 110 C F085 F100 F120 F150 F170 F200 F230 S 25 25 25 32 32 32 32 H 32 32 32 40 40 40...

Page 50: ...riac High Heat 72 kW Fully modulating Triac FLEXY 2 150 and 170 have Standard heat 45 kW 2 stages Medium Heat 72 kW Fully modulating Triac High Heat 108 kW Fully modulating Triac FLEXY 2 150 and 170 h...

Page 51: ...18 8 18 8 25 25 Formodulating gas we have just H power forF G H box The gas supply of a Rooftop gas unit must be realized according to Sound Engineering Practice and the local safety codes and rules...

Page 52: ...k and adjust if necessary the valv e Inlet pressure to 20 0mbar G20 or 25 0mbarf or Groningen G25 or 37 0mbar for propane G31 after gas burner ignition f ig 16 High Heat Injection Pressure Checks Chec...

Page 53: ...f or propane G31 fig 18 Af ter the adjustment of the low heat re v erify the high heat re position the stoppers and close the pressure ports Pressure adjustments table for each ty pe of gas mbar Categ...

Page 54: ...k and adjust if necessary the valv e Inlet pressure to 20 0mbar G20 or 25 0mbarf or Groningen G25 or 37 0mbar for propane G31 after gas burner ignition f ig 20 High Heat Injection Pressure Checks Chec...

Page 55: ...f or propane G31 f ig 22 Af ter the adjustment of the low heat re v erify the high heat re position the stoppers and close the pressure ports Pressure adjustments table for each ty pe of gas mbar Cate...

Page 56: ...e burner stops completely Howev er No fault light will be display ed on the Gas ignition control block After 6 Minutes the CLIMATIC will display af ault Reset the CLIMATIC Ionisation Probe test With t...

Page 57: ...trol Valv e Closes BURNER STOPS Gas Low Pressure switch Gas Ignition Control Block Signal Normal Operation 6 Minutes Delay Pre Ventilation 30 seconds Fire up Electrode 4s Gas Valv e Open Ionisation 1s...

Page 58: ...trol Block and on EF connection Board Check the Fan supply v oltage Replacef an Replace EF connection board If necessary Extraction Fan is ON After 30 to 45 seconds pre v entilation the f ire up elect...

Page 59: ...support bar av oiding any damages to the electrodes Disassembling the flue Electrically disconnect the fan and remove the screws holding it in place Take care not to loose any cage nuts in the smoke...

Page 60: ...IOM FLEXY II 1007 E Page 58 60kW 120kW HEATING GAS BURNER...

Page 61: ...IOM FLEXY II 1007 E Page 59 180kW 240kW HEATING GAS BURNER...

Page 62: ...e work near the connection on the ignition control Valve for af ew seconds Check that the unit s Treatment Fan Blower is running Set the control to ON This will priorities the gas burner Increase the...

Page 63: ...cessary the valv e Inlet pressure to 20 0mbar G20 or 25 0mbarf or Groningen G25 after gas burner ignition fig 26 High Low heat injection pressure check Electronic board W4115D1024 There is one boardf...

Page 64: ...at Place the potentiometer called current on position Min Regulate thev alue of the minimum f low at 2 mbar for natural gas and at approximately 2 6 mbar f or Groningen gas by operating on the adjusti...

Page 65: ...BURNER Purge the pipe work near the connection on the ignition control Valve for af ew seconds Check that the unit s Treatment Fan Blower is running Set the control to ON This will priorities the gas...

Page 66: ...essary the valv e Inlet pressure to 20 0mbar G20 or 25 0mbarf or Groningen G25 after gas burner ignition fig 28 High Low heat injection pressure check Electronic board W4115D1024 There is one board pe...

Page 67: ...n Min Increase the current by turning this potentiometer until the desired maximum current is obtained here to reach 8 0mbar we must apply 105mA according to the curve below Adjusting minimum pressure...

Page 68: ...IOM FLEXY II 1007 E Page 66 60kW 120kW HEATING MODULATING GAS BURNER...

Page 69: ...IOM FLEXY II 1007 E Page 67 180kW 240kW HEATING MODULATING GAS BURNER...

Page 70: ...2 SENSOR 16 CO2 SENSOR 17 ANALOG DIRTY FILTER AND FAN PROVEN SWITCH 17 ANALOG DIRTY FILTER AND FAN PROVEN SWITCH 17 ANALOG DIRTY FILTER AND FAN PROVEN SWITCH 17 ANALOG DIRTY FILTER AND FAN PROVEN SWIT...

Page 71: ...2 MG21 2 2 HIGH PRESSURE SAFETY SWITCH MG21 MG22 COMPRESSOR MG21 MG22 B4 5 B46 GAS MANIFOLD 1 GAS MANIFOLD 2 R EGULATION KLIXON MR1 ECONOMISER DAMPER MOTOR B5 1 B52 COMPRESSOR MG11 12 MG21 2 2 LOW PRE...

Page 72: ...1007 E Page 70 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 ELECTRICAL DATA WI...

Page 73: ...IOM FLEXY II 1007 E Page 71 MAIN CURRENT DIAGRAM TRI 400V 50Hz T ELECTRICAL DATA WIRING DIAGRAMS...

Page 74: ...IOM FLEXY II 1007 E Page 72 CLIMATIC 50 CONTROLER ELECTRICAL DATA WIRING DIAGRAMS...

Page 75: ...IOM FLEXY II 1007 E Page 73 CLIMATIC 50 INPUT FCM FHM FGM FDM ELECTRICAL DATA WIRING DIAGRAMS...

Page 76: ...IOM FLEXY II 1007 E Page 74 CLIMATIC 50 OUTPUT FCM FHM FGM FDM ELECTRICAL DATA WIRING DIAGRAMS...

Page 77: ...IOM FLEXY II 1007 E Page 75 DAD SMOKE DETECTOR ELECTRICAL DATA WIRING DIAGRAMS...

Page 78: ...IOM FLEXY II 1007 E Page 76 GENERAL CUSTOMER CONNECTION TCB ELECTRICAL DATA WIRING DIAGRAMS...

Page 79: ...IOM FLEXY II 1007 E Page 77 GENERAL CUSTOMER CONNECTION WITH ADVANCED CONTROL PACK ADC ELECTRICAL DATA WIRING DIAGRAMS...

Page 80: ...IOM FLEXY II 1007 E Page 78 WIRING DIAGRAM GAS BURNER 60 kW and HOT WATER COIL ELECTRICAL DATA WIRING DIAGRAMS HOT WATER COIL...

Page 81: ...IOM FLEXY II 1007 E Page 79 WIRING DIAGRAM GAS BURNER 120kW ELECTRICAL DATA WIRING DIAGRAMS...

Page 82: ...IOM FLEXY II 1007 E Page 80 WIRING DIAGRAM GAS BURNER 180 240kW ELECTRICAL DATA WIRING DIAGRAMS...

Page 83: ...IOM FLEXY II 1007 E Page 81 WIRING DIAGRAM ELECTRIC HEATER ELECTRICAL DATA WIRING DIAGRAMS...

Page 84: ...IOM FLEXY II 1007 E Page 82 GENERAL CUSTOMER CONNECTION DIAGRAM ELECTRICAL DATA WIRING DIAGRAMS...

Page 85: ...gned 4 customized DO 3 to 6 C ustomized choose for each input 4 between those 7 possibilities Alarm Filters Alarm Blower Alarm Compressors Alarm Gas Alarm Electric Heater Alarm Hot Water Coil Freezing...

Page 86: ...22 24 24 26 35 63 56 21 24 23 13 34 03 54 20 27 22 04 32 49 52 19 33 20 99 31 01 50 18 43 19 98 29 57 48 17 55 19 28 19 46 16 70 18 05 26 86 44 15 89 17 14 25 57 42 15 10 16 26 24 33 40 14 34 15 42 2...

Page 87: ...RESSOR RUNNING UNLOADED BALANCE PRESSURE IS A FAILURE Likely situations where protection may activate Initial system charging or recharging after serv icing Compressor is run with too little sy stem c...

Page 88: ...RESSOR MG1 MG2 HIGH PRESSURE SAFETY SWITCH B51 B52 COMPRESSOR MG1 MG2 LOW PRESSURE SAFETY SWITCH B61 B62 COMPRESSOR MG1 MG2 HIGH PRESSURE CONTROL SWITCH MC1 MC2 CONDENSER MC1 MC2 FAN MOTOR MC3 MC4 CON...

Page 89: ...IOM FLEXY II 1007 E Page 87 FCM 150 FHM 150 PRINCIPLE SKETCHES...

Page 90: ...IOM FLEXY II 1007 E Page 88 FCM 170 FHM 170 PRINCIPLE SKETCHES...

Page 91: ...IOM FLEXY II 1007 E Page 89 FCM 200 230 FHM 200 230 PRINCIPLE SKETCHES...

Page 92: ...IOM FLEXY II 1007 E Page 90 HOT WATER COIL DIAGRAM PIPE DIAMETERS 1 ROW 2 ROWS 085 25 32 100 25 32 120 25 32 150 32 40 170 32 40 200 32 40 230 32 40 HOT WATER...

Page 93: ...lement by freezing the valv e and then heating the thermostatic element Replace thev alve if necessary Expansion valv e not adjusted properly Adjust the expansion Valv e Ice plug in the expansionv alv...

Page 94: ...ssibly blocked abnormal noisef rom the valv e low LP and increasing HP Check operation of thev alve by going through cy cle inv ersions Change if necessary Ref er to LP problems INDOOR FAN BLOWER FAUL...

Page 95: ...section bulkhead Water ingress in the f ilter compartment Water ingress through a leaking fresh air hood or when running 100 f resh air Check the seals andf langes in thef resh air hood Reduce the air...

Page 96: ...lan to keep a roof top unit in good working order Regular maintenance of y our rooftop will extend its operating life and reduce operatingf aults Symbols and Legend o Operation which can be carried ou...

Page 97: ...heckClimatic control set points and variables Refer to the commissioning sheet Check all set points are set according to this document 15 Checkclocksettings Checkthe ti me and date of the control o 5...

Page 98: ...ut of the heater module box and checkthe resistances of tr aces of corrosion R eplace resistance as required o 1h if replacement Checkanti vi bration mountings for wear and tear Visuall ycheckanti vi...

Page 99: ...y the owner f or these applications which has been recommended by a competent body not linked to the owner and after carry ing out a study of the site 5 Nev ertheless the LENNOX coating is highly resi...

Page 100: ...IOM FLEXY II 1007 E Page 98 LONGVIC SITE ISO 9001 2000 CERTIFICATE...

Page 101: ...IOM FLEXY II 1007 E Page 99 EC CONFORMITY DECLARATION...

Page 102: ...IOM FLEXY II 1007 E Page 100 DAD LOTUS CERTIFICATE...

Page 103: ...IOM FLEXY II 1007 E Page 101 GLASS WOOL INSULATION CERTIFICATE...

Page 104: ...IOM FLEXY II 1007 E Page 102 GLASS WOOL INSULATION CERTIFICATE...

Page 105: ...IOM FLEXY II 1007 E Page 103 F7 FILTER INSULATION CERTIFICATE...

Page 106: ...IOM FLEXY II 1007 E Page 104 G4 FILTER INSULATION CERTIFICATE...

Page 107: ...IOM FLEXY II 1007 E Page 105 FLEXY 60 120 180 240 KW GAS BURNER CERTIFICATE...

Page 108: ...IOM FLEXY II 1007 E Page 106 ROOFTOP PED CONFORMITY CERTIFICATE...

Page 109: ...IOM FLEXY II 1007 E Page 107 ROOFTOP PED CONFORMITY CERTIFICATE...

Page 110: ...tions 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 person...

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