Lennox ROOFTOP FLEXY FXK 55 Installation, Operating And Maintenance Manual Download | Manualshive

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IMPORTANT NOTICE – Safety instructions

FLEXYII_WSHP-IOM-1307-E

- 4 -

UV

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

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Summary of Contents for ROOFTOP FLEXY FXK 55

Page 1: ...lennoxemeia com FLEXY FCM FHM FGM FDM FWH FWM Installation operating and maintenance Air cooled and water cooled rooftop packaged units 85 234 kW FLEXYII WSHP IOM 1307 E...

Page 2: ......

Page 3: ...datory handling devices 6 Dimensions and weights 7 Lifting the units 9 INSTALLATION 10 Forklift protections 10 Minimum clearance around the unit 11 Duct connections 12 WATER CONDENSING water source he...

Page 4: ...FROM THE GAS BURNER EXHAUST PLEASE READ CAREFULLY THE MANUFACTURER S INSTRUCTIONS BEFORE STARTING THIS UNIT Switchgear must be installed on each unit in accordance with the Machine Directive and the...

Page 5: ...ver Replacing components 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 man...

Page 6: ...l 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 wh...

Page 7: ...15 The start up power is the maximum value likely to be achieved for the specified operational voltage The customer must have a suitable electrical supply It is therefore important to check whether t...

Page 8: ...TRANSPORT HANDLING FLEXYII_WSHP IOM 1307 E 6 Handling slings to guide the unit towards the roofcurb Vacuum lifting beam to position the unit COMPLIANT NON COMPLIANT MANDATORY HANDLING DEVICES...

Page 9: ...kg 990 1065 1141 1442 1505 1752 2052 Weight gas unit FGM Standard heat kg 1097 1172 1248 1683 1746 2016 2316 High heat kg 1167 1242 1318 1706 1769 2056 2356 WSHP FWH FWM 85 100 120 150 170 View F G b...

Page 10: ...1055 490 600 950 FXM030 4070 1635 1055 490 600 980 FXM035 4750 2255 1290 490 600 1400 FXM040 4750 2255 1290 490 600 1450 FXM055 4750 2255 1290 490 600 1600 FXM070 5050 2255 1725 890 600 1800 FXM085 50...

Page 11: ...TRANSPORT HANDLING FLEXYII_WSHP IOM 1307 E 9 LIFTING THE UNIT As shown on the picture below a lifting frame is necessary After lifting withdraw angle s feet and lifting lugs...

Page 12: ...ons and local applicable codes Check to ensure that the refrigerant lines do not rub against the cabinet or against other refrigerant lines In general make sure no obstacles walls trees or roof ledges...

Page 13: ...und the unit NOTE Ensure the fresh air inlet does not face prevailing wind direction A B C D FCM FHM FGM FDM FWH FWM F BOX 2200 1 2000 2000 2000 G BOX 2700 1 2000 2000 2000 H BOX 2700 1 2000 2000 2000...

Page 14: ...er 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 f...

Page 15: ...nits with open loops which can cause troubles with oxygenation or operation with untreated ground water Use of untreated or improperly treated water can cause deposits of scale algae and sludge or cau...

Page 16: ...tent The minimum volume of the rooftop water circuit must be determined If necessary install a buffer tank Proper operation of regulating and safety devices can only be ensured if the volume of water...

Page 17: ...WATER CONDENSING FLEXYII_WSHP IOM 1307 E 15 It is imperative to tighten the nuts evenly to avoid pinching the gasket...

Page 18: ...ing the water flow valve accordingly by a 0 10 Volts signal This option offers a second opportunity give the possibility to close the rooftop water loop when compressors are stopped Warning the valve...

Page 19: ...opening it Failure to observe these rules could lead to accidents and cause injury to service personal FWH FWM Exchanger Curve Filter Curve 85 C B 100 D B 120 D B 150 E C 170 E C Pressure Loss Heat pl...

Page 20: ...refrigerant circuit etc It s advised to fix curbs and roofcurbs to the unit As levels are adjustable observe the following recommendations when installing the equipment Above all ensure that all the a...

Page 21: ...sulation 2 figure 7 Check that the insulation is continuous counter flash and seal around the frame as shown in 1 figure 7 CAUTION To be effective the upstream must end below the drop edge 3 figure 7...

Page 22: ...ALLATION 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 havin...

Page 23: ...you need a pneumatic or electric device All parts must be sealed with polyurethan sealant during assembly Foam Insulation Installing Stick large foam pieces underneath the flat top Foam Gasket Instal...

Page 24: ...IOM 1307 E 22 STEP 1 Rooftop configuration SIZE Dimensions Weight A B C D E F F box 85 100 120 2146 2063 1422 367 1796 900 525 kg G box 150 170 2330 2247 1518 463 2170 900 635 kg H box 200 230 2516 24...

Page 25: ...COMMISSIONNING FLEXYII_WSHP IOM 1307 E 23 STEP 1 Rooftop configuration STEP 2 Lifting Remove lifting lug Remove corner sheet metal No Hood No panel 4 x...

Page 26: ...COMMISSIONNING FLEXYII_WSHP IOM 1307 E 24 STEP 3 Fitting STEP 4 Check SAME LEVEL 10 15 mm...

Page 27: ...COMMISSIONNING FLEXYII_WSHP IOM 1307 E 25 STEP 5 Fixing H box for each side F G box for each side F 8 x 4 8x25mm G 8 H 10 x 4 8x32mm 5 10 mm...

Page 28: ...COMMISSIONNING FLEXYII_WSHP IOM 1307 E 26 On top STEP 6 Masticate Apply mastic on side junctions and higher junction F 13 G 15 x 4 8x25mm H 15...

Page 29: ...FLEXYII_WSHP IOM 1307 E 27 STEP 7 Electrical wiring The Recovery module is sent with a power cable and a T lan cable Separate these 2 cables communication and power ones using the two holes Power cabl...

Page 30: ...IONNING FLEXYII_WSHP IOM 1307 E 28 Then fix the 2 cables on the grid of the extraction roofcurb and insert them in rooftop electrical panel Communication and power cables from the module should be sep...

Page 31: ...Modbus cable according to the bus connection wiring diagram it could be connected to the BE60 A1 connector in electrical rooftop panel or other options with bus communication Recovery module connecti...

Page 32: ...h Heat Recovery module option the extract air goes through the wheel that s why the economiser of the roofcurb has to be permanently fully closed If roofcurb economiser is not fully closed close it ma...

Page 33: ...pulleys 43 Airflow balancing 44 Filters 52 Air sock control 53 UV Light 54 REFRIGERATION CIRCUIT Electronic expansion valve 55 Advanced scroll temperature protection ASTP 56 HEATING OPTIONS Hot water...

Page 34: ...ked 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 Averaged Measured Amps rpm A Shaft Mechanical Power Refer to airflow...

Page 35: ...Phase 3 Temperatures Pressures 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 Refrigera...

Page 36: ...COMMISSIONNING REPORT FLEXYII_WSHP IOM 1307 E 34 COMMENTS...

Page 37: ...Site name Serial Number Site address Site operator Cooling load Refrigerant type Refrigerant quantity kg Unit manufacturer Year of installation Refrigerant additions Date Engineer Quantity kg Reason...

Page 38: ...REFRIGERANT TRANSACTION LOGBOOK FLEXYII_WSHP IOM 1307 E 36 Leak tests part 1 Date Engineer Test Result Follow up action required Follow up actions Date Engineer Related to test dated Action taken...

Page 39: ...gerant load according to model size Refrigerant Box Model Number of circuit Cooling only units Load kg BAC BAG Heat pump units Load kg BAH BAM R410A C 24 1 6 1 6 1 30 1 6 1 6 1 38 1 8 1 8 1 42 1 8 1 8...

Page 40: ...gravity exhaust dampers relieve the pressure when outside air is introduced into the system When large amount of fresh air is introduced into the system power exhaust fans can be used to equalise the...

Page 41: ...LY INCLUDES 3 PHASES Check the following wire connections for tightness Main switch connections mains wires linked to the contactors and circuit breakers and the cables in the 24V control supply circu...

Page 42: ...therefore all turn in either the right or wrong direction NOTE A compressor rotating in the wrong direction will fail If the fan turns in the wrong direction the right direction is shown on figure n 1...

Page 43: ...ect to the air pressure value Observe the response of the CLIMATIC menu 2332 Same procedure for detecting Missing Filter page menu 2334 or Air Flow Detection page menu 2333 Check the smoke detection f...

Page 44: ...d deflection is 20 mm per meter from centre to centre Check that according to the diagram below figure 12 the following ratio remains the same The belts should always be replaced when The disk is set...

Page 45: ...pulley in both hands and shake it vigorously to make sure everything is in place Fill the holes with grease for protection NOTE During installation the key should never protrude out of its groove Afte...

Page 46: ...power which may result in having 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...

Page 47: ...nit can be taken as 20 to 30 Pa PINT P filter coil P Inlet P Options Using the results from above the external static pressure ESP can then be estimated ESP PTOT Pd PINT Table_ 2 Motor information Mot...

Page 48: ...rmined that each motor pulley has a diameter of 114 2mm rpm FAN rpm MOTOR x DM DF 1465 x 114 2 200 836 rpm Using the fan curve the operating point can be located In order to facilitate the calculation...

Page 49: ...ormances 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...

Page 50: ...VENTILATION AIRFLOW BALANCING FLEXYII_WSHP IOM 1307 E 48 AT18 18S...

Page 51: ...VENTILATION AIRFLOW BALANCING FLEXYII_WSHP IOM 1307 E 49 ADH355L...

Page 52: ...VENTILATION AIRFLOW BALANCING FLEXYII_WSHP IOM 1307 E 50 ADH450L...

Page 53: ...VENTILATION AIRFLOW BALANCING FLEXYII_WSHP IOM 1307 E 51 ADH500L...

Page 54: ...34 50Pa by default Dirty Filter in page 2335 250Pa by default The actual pressure drop measured accross the coil can be read on the Climatic Display DS60 in menu 2332 The following faults may be ident...

Page 55: ...ependent actuator The return air damper is controlled by a spring return damper driven by the opposite signal delivered to the fresh air damper An auxiliary switch allows setting a minimum few of retu...

Page 56: ...ns 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 s...

Page 57: ...s selected or in Flexy EC F box G box Hbox Model designation 085 100 120 150 170 200 230 Reference E3V45 E3V45 E3V45 E3V45 E3V45 E3V55 E3V55 EEV adjustments EEV allows to control superheat in biflow o...

Page 58: ...heck for normal operation v DO NOT ASSUME A COMPRESSOR RUNNING UNLOADED BALANCE PRESSURE IS A FAILURE v Likely situations where protection may activate Initial system charging or recharging after serv...

Page 59: ...djust the control for Heating by reducing the simulated ambient temperature down to 10 C Check that the red indicators located under the valve actuator are moving correctly with the signal Fill the hy...

Page 60: ..._WSHP IOM 1307 E 58 Hot water coil connection F G H box Pipe Internal Diameters DN MAXIMUM WORKING PRESSURE 8 BARS MAXIMUM WORKING TEMPERATURE 110 C F085 F100 F120 F150 F170 F200 F230 S 25 25 25 32 32...

Page 61: ...4 kW Fully modulating Triac 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 Tria...

Page 62: ...12 5 12 5 12 5 18 8 18 8 25 25 For modulating gas we have just H power for F G H box The gas supply of a Rooftop gas unit must be realized according to Sound Engineering Practice and the local safety...

Page 63: ...ned the screw by one turn Check and adjust if necessary the valve Inlet pressure to 20 0mbar G20 or 25 0mbar for Groningen G25 or 37 0mbar for propane G31 after gas burner ignition fig 16 High Heat In...

Page 64: ...r for Groningue G25 15 3 mbar for propane G31 fig 18 After the adjustment of the low heat re verify the high heat re position the stoppers and close the pressure ports Pressure adjustments table for e...

Page 65: ...ned the screw by one turn Check and adjust if necessary the valve Inlet pressure to 20 0mbar G20 or 25 0mbar for Groningen G25 or 37 0mbar for propane G31 after gas burner ignition fig 20 High Heat In...

Page 66: ...ar for Groningen G25 12 6 mbar for propane G31 fig 22 After the adjustment of the low heat re verify the high heat re position the stoppers and close the pressure ports Pressure adjustments table for...

Page 67: ...e rooftop fig 24 The burner stops completely However No fault light will be displayed on the Gas ignition control block After 6 Minutes the CLIMATIC will display a fault Reset the CLIMATIC Ionisation...

Page 68: ...N Gas Control Valve Closes BURNER STOPS Gas Low Pressure Gas Ignition Control Block Signal Normal Operation 6 Minutes Delay Pre Ventilation 30 seconds Fire up Electrode 4s Gas Valve Open Ionisation 1s...

Page 69: ...n the Gas Ignition Control Block and on EF connection Board Check the Fan supply voltage Replace fan Replace EF connection board If necessary Extraction Fan is ON After 30 to 45 seconds pre ventilatio...

Page 70: ...ove the gas burner support bar avoiding 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 n...

Page 71: ...HEATING GAS BURNER FLEXYII_WSHP IOM 1307 E 69 60kW 120kW...

Page 72: ...HEATING GAS BURNER FLEXYII_WSHP IOM 1307 E 70 180kW 240kW...

Page 73: ...d or activated Compressor Heating Control Heating mode activated Dead Z Control Dead zone mode activated Cooling Control Cooling mode activated by BMS BMS Activated by BMS Sched A Schedule Mode A acti...

Page 74: ...Fresh Air Force the damper to minimum opening 40 50 F A Fresh Air Force the damper to minimum opening 50 All F A Fresh Air Force the damper to full opening 100 No FreeC Fresh Air Unloaded Free Coolin...

Page 75: ...not freeze this could indicate a problem with the distribution Liquid line drier blocked High temperature difference between inlet and outlet of the drier Change filter drier Contaminant in the expan...

Page 76: ...ircuit Ensure very low and slow vacuum for R407c Recharge the unit Condenser coil is obstructed Check the condenser coil and clean is necessary Water Filter is obstructed only for Water Cooled Rooftop...

Page 77: ...of the fan OUTDOOR AXIAL FAN FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Heat Pump mode Circuit breaker open High Amps due to a low voltage from the main supply Check the voltage drop when all componen...

Page 78: ...ress through a leaking fresh air hood or when running 100 fresh air Check the seals and flanges in the fresh air hood Reduce the airflow rate if necessary CLIMATIC DISPLAYS FAULT POSSIBLE CAUSE AND SY...

Page 79: ...o follow such a plan to keep a rooftop unit in good working order Regular maintenance of your rooftop will extend its operating life and reduce operating faults Symbols and Legend o Operation which ca...

Page 80: ...t and control 5 Check CLIMATIC control set points and variables Refer to the commissioning sheet Check all set points are set according to this document 15 Check clock settings Check the time and date...

Page 81: ...replace ment Check anti vibration mountings for wear and tear Visually check anti vibration mountings on compressors and centrifugal fan Replace if damaged O 1h if replace ment Check refrigeration ci...

Page 82: ...ation circuit 4720905K DML165S 4720907M DML167S 4720908N Non return valve NRV16S Refrigeration circuit 4720002H 4 way valve STF0715 Refrigeration circuit 4740101N STF1511 4740104T STF2506 4740105V STF...

Page 83: ...ber pipe Thickness 5 mm Fixings 4680360K Key Maintenance key 5880158T Ventilation Filtration components Designation Familly Code Filter EU3 625x500x50 Filters 4960118T Filter EU4 metal frame 625x500x5...

Page 84: ...n applied by the owner for these applications which has been recommended by a competent body not linked to the owner and after carrying out a study of the site 5 Nevertheless the LENNOX coating is hig...

Page 85: ...WARNING 85 ONE DC60 FOR ONE AND ONLY ONE ROOFTOP 86 TEMPERATURE MEASUREMENT 86 RELATIVE HUMIDITY MEASUREMENT 86 CONFIGURATION 87 INITIALIZATION 88 PRESENTATION 88 USE 90 LEVEL 2 ACTIVATION 92 DISPLAY...

Page 86: ...equipped with a temperature sensor The temperature sensor allows the acquisition of room temperature to control WARNING Separate as much as possible probes displays logical input cables from power cab...

Page 87: ...ield The cable length with power should not exceed 30m The cable length without power 24V external must not exceed 150m For a better electromagnetic protection Lennox recommends the use of LiYCY P cab...

Page 88: ...use the measure of the DC60 1 BM B12 or 2 BM B1 to use the remote probe Note for rooftop with a medium CLIMATIC 60 connect the remote sensor between points B12 and GND terminal block J18 for rooftop w...

Page 89: ...urn the knob to adjust the desired value Press again on the knob to confirm your choice The symbol is no longer displayed on the right side of the value The rotation of the knob is for select a new se...

Page 90: ...connection between the CLIMATIC 60 and the DC60 is correct Online to power up the screen displays only the symbol This phase allows the CLIMATIC 60 to set up the DC60 with options of rooftop After so...

Page 91: ...efly press the button To set the time press the button a few seconds The hour value flashes Turn the knob to adjust the desired value Press the knob to select your choice Then the minute value flashes...

Page 92: ...rotating the knob you can view or modify the following values This item can know the number of rooftop connected to the DC60 This item allows you to view and or modify the control temperature require...

Page 93: ...to 0 By this item it s possible to reset the alarm activated To do this set the value of the item to the value 0 This item indicates the measure temperature of the air outside This item indicates the...

Page 94: ...000 flashes Turn the knob to change the value to select the number 066 Then validate the code by pressing the knob If the code is wrong access the setup menu is not possible and the DC60 returns to th...

Page 95: ...ack on the back of the DM60 screen attach the front panel on the back using provided countersunk screws snap frame The display is connected to CLIMATIC DM60 on the screw terminals of the card DT50 The...

Page 96: ...t the connectors A and SC are not Displays connected to these ports are not powered If J14 and J15 are set differently the DT50 dispatcher DOESN T WORK and therefore connected displays don t work Term...

Page 97: ...nection with star is not recommended for optimum performance it is advisable to connect a maximum of two cables per unit The connection must be wired as follows For a length of 0 to 300 m AWG22 0 34 m...

Page 98: ...ged is displayed If after 5 seconds the display is not correct access a second time the setup mode by pressing the arrow enter and down arrow keys for at least 5 seconds up to the next screen press en...

Page 99: ...y I mode Day II mode If the unit is in alarm this symbol is displayed Small numerical value volatile set point temperature View and or modify the offset or set point of the desired temperature control...

Page 100: ...ressing the alarm button directs you to the alarm list display pressing the prg button directs you to the rooftop setup menus display pressing the esc button takes you to the selected rooftop choice d...

Page 101: ...set point visualization Alarm list History used to store the last 99 alarms occurred on the unit each alarm is stored on the date and time the fault occurred an active alarm is signified by the bell...

Page 102: ...tton it puts you on the next digit password or directs you to the selected function screen Pressing the down arrow button decreases the password digit value or selects the next function Setting Temper...

Page 103: ...g the enter button validates the selection then directs you to the rooftop setup menus display Pressing the down arrow button reverses the state View edit alarm and safety reset Pressing the alarm but...

Page 104: ...cted value View edit hour and minutes of each zone beginning View edit the zone operating mode The schedule is different each weekday You must set a schedule for monday tuesday and sunday The visualiz...

Page 105: ......

Page 106: ...LGIUM AND LUXEMBOURG FRANCE GERMANY ITALY NETHERLANDS POLAND PORTUGAL SALES OFFICES OTHER COUNTRIES Due to Lennox s ongoing commitment to quality the specifications ratings and dimensions are subject...

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