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1. Check electrical connections Yes No L Supply Temperature Return Temperature Outdoor Temperature Inlet Water Temp for Water Condensing Outlet Water Temp for Water Condensing 7 MIXING AIR DAMPERS CHECKS Dampers urs close freely Minimum FA Power exhaust checked Enthalpy sensor s checked Yes No L Yes No L Yes No L FLEXYII WSHP IOM 0212 E 32 COMMISSIONNING REPORT LENNOX gt 8 REFRIGERATION SECTION Outdoor Fan Motor Current Check Rotation Po tege Compressor Amps COOLING Pressures amp Temperatures Phase 1 Phase 2 Phase 3 Discharge Check Reversing valves Valve1 Yes L Valve3 Yes No L Valve2 Yes L No L Valve4 Yes No L Compressor Amps HEATING Pressures amp Temperatures Phase 1 Phase 2 Phase 3 HP cut out Refrigerant charge AMPS 1 stage 10 HOT WATER COIL SECTION Check Three Way Valve Movement Yes L 11 GAS HEATING SECTION Gas Burner N 1 Valve type ize Valve type Check manifold pressure Check manifold pressure High fire Low fire High fire Low fire Pressure cut out airflow press switch Pressure cut out airflow press switch mbar Pa mbar Pa 12 SETTINGS Using Wizard software edit the complete list of settings by Print function FLEXYII WSHP IOM 0212 E 33 COMMISSIONNING REPORT LENNOX COMMENTS FLEXYII WSHP IOM 0212 E 34 REFRIGERANT TRANS
2. Velocity Pressure Nim FLEXYII WSHP IOM 0212 E 48 VENTILATION AIRFLOW BALANCING LENNOX ADH355L sas DIAVETRO GIRANTE 355 mm WHEEL DIAMETER x 12Kg m oF 22 REND TOT V LA IMPELLER TOTAL EFF z 2 48 55 61 64 61 53 4 HR oH TOTAL PRESSURE 1600 1700 1000 1400 900 500 1200 1100 600 1000 AC 9 400 350 600 300 250 700 600 180 O 160 Lu 140 00 120 100 Portata Volume X1000 E boue d bb oan I 3 2 3 4 5 6 7 8 9 10 14 20 20 40 mh 2 4 56 78918 14 20 30 40 50 1 8 Velocts aria n uscita Air outlet velocity 2 3 4 5 T 10 20 30 50 70 100 200 300 5007001000 2000 gt Pressione dinarmca Velocity Pressure Nim FLEXYII WSHP IOM 0212 E 49 VENTILATION AIRFLOW BALANCING ADHA450L DIAMETRO GIRANTE 450 men WHEEL DIAMETER K LZ Z ZZ L 1 p 12 Kg m UE lt i REND TOT V LA IMPELLER TOTAL EFF 40 49 58 63 59 48 un 2400 Lippe 220 AE mL lt JR 1600 Z XZ 22 1600 ZAG PSY 1 1400 27 4274 EN 1200 E 1000 ad E lt 900 ETT 800 700 600 n 600 400 z 4 AGW Ty D 2 Lor 160 x P 140 iiti F lt 120 E y 5 j 3 T ATI 90 H p 50 05 0 7 l E Portata Volume X 1000 2
3. z p POTENZA CUSCINETTI ge 500 400 350 300 PRESSIONE TOTALE X 1000 5 2 A 6 7 91 14 20 pr 30 nvs 4 3 4 5 6 919 14 20 Velocta usota Ar gullet velocity 2 4 45 T 10 30 50 70 1 200 500 700 Pressione dinamica Velocity Pressure The performances of twin fan units 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 2 W x 2 15 fan speed Nb N x 1 05 Lws Lwsb Lws 3 dB FLEXYII WSHP IOM 0212 E 47 VENTILATION AIRFLOW BALANCING LENNOX AT18 18S aatis DIAMETRO GIRANTE 470 mm WHEEL DIAMETER uo p 12Kgim 55 2 REND TOT V LA IMPELLER TOTAL EFF 5 5 2 2000 5 62 68 70 67 57 Z E ALS 55 4 1600 Kw 77 Or 7 1400 Z 442 o v w wW 7 P 4 200 t 27 we le f 1000 2 lt 1100 13 45 900 ARN A Fas Al 1000 MI PS a 700 2 CU D 900 nola 1 10 14 00 8 12 400 300 2 10 250 1 9 200 amp 160 140 T 120 AYI ALLDATA V FT a LWIA Jin del PRESSIONE TOTALE amp e e X 1000 2 345 7 10 20 30 50 70 100 200 300 5007001000
4. 89 90 PRESEN ua UE ME 90 Pw 92 LEVEE Z ACTIA MON Mc E 94 DISPLAY DM60 epo oie 95 DM60 AND COMMUNICATION 5 97 98 mS 63819 724 OP THE DIGO rrr 98 FLEXYII WSHP IOM 0212 E 83 DISPLAY DC60 LENNOX The display DC60 is personalized for the user It allows an overview of operation of the unit and allows access to certain parameters The DC60 is designed to be remote connected of the rooftop The DC60 is equipped with a temperature sensor The temperature sensor allows the acquisition of room temperature to control INSTALLATION The DC60 has been designed for flush mount assembly on distribution boxes compliant with the standards in force CONNECTION e 84 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DC60 LENNOX Power supply The power of the DC60 can be 24Vac 10 15 50 60Hz or 24Vdc 22 35Vdc maximum current of 2VA LENNOX recommends a 24Vac supply provided by rooftop for installation of the display less within 30 meters of rooftop For connection of the display of over 30 meters a power supply close to the display 24Vac must be provided by the installer For an external connection to the rooftop 24V using a tr
5. Fig 19 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 FLEXYII WSHP IOM 0212 E LENNOX gt High Heat Injection Pressure Checks Check and adjust if necessary the valve OUTLET pressure to 8 0mbar G 20 10 4mbar for Groningen G25 amp 28 3 mbar for propane G31 fig 21 Fig 21 The out pressure must be measured on the pressure tap located on the gas injector support bar to avoid the pressure drop due to the elbow after the valve 63 HEATING GAS BURNER 180 amp 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 for Groningen G25 amp 12 6 mbar for propane G31 fig 22 FLEXYII WSHP IOM 0212 E LENNOX 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 each type of gas mbar Supply Low Heat High Heat categon jection G20 20 0 1 3 1 0 1 8 0 2 G25 Groningue 25 0 1 3 3 9 0 1 10 4 0 2 G31 GPL 37 0 1 9 12 6 0 3 28 3 0 6 64 HEATING GAS BURNER BURNER SAFETY CHECKS Smoke extractor pressure switch Test With the gas burner running disconnect the flexible tube fitted to the pressure taping on the pre
6. RATING PLATE The rating plate provides a complete reference for the model and ensures that the unit corresponds to the model ordered It states the electrical power consumption of the unit on start up its rated power and its supply voltage The supply voltage must not deviate beyond 10 15 96 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 the supply voltage stated on the unit s rating plate is compatible with that of the mains electrical supply The rating plate also states the year of manufacture as well as the type of refrigerant used and the required charge for each compressor circuit CODE TYPE FHM 200 N N AFFAIRE LIGNE 27483571 OF N UNIT 76088 1 2 ENNOX a zi LONG ve FRANCE _ 0 06 Unit type FHM 200 N Serial NR 274635_ 4 1 2 Nominal I Starting Capacities KU 1398 This product is used for Air Conditioning Contains fluorinabed greenhouse gases covered by the Kyoto protocol Hermetically sealed Fig 1 FLEXYII WSHP IOM 0212 E LENNOX STORAGE When units are delivered on site they are not always required immediately and are sometimes put into storage In the event of medium to long term storage we recommend the following procedures Ensure that there is no water in the hydrau
7. WATER FILTER REPLACEMENT ONLY FOR WATER SOURCE HEAT PUMP It is important that units are serviced regularly by a qualified technician at least once every year or every 1000 hours of operation CAUTION The water circuit may be pressurised Observe the usual precautions when depressurising the circuit before opening it Failure to observe these rules could lead to accidents and cause injury to service personal Access for cartridge cleaning FLEXYII WSHP IOM 0212 E 15 WATER CONDENSING LENNOX Pressure Loss Heat plate Exchanger 100 T n o o l o o 10 1 10 100 Water flow m3 h Pressure Loss WATER FILTER 10 0 x o o o o o 1 0 1 10 100 Water flow m3 h FLEXYII WSHP IOM 0212 E INSTALLATION ON A ROOFMOUNTING FRAME LENNOX CAUTION 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 It s advised to fix curbs and roofcurbs to the unit As levels are adjustable observe the following recommendations when installing the e
8. If the code is correct the level 2 is actif and symbol displayed to the right of the value The level 2 is turned off automatically every hour 92 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DM60 LENNOX The DM60 display is personalized for the user It allows an overview of unit operation and allows access to certain parameters The DM6O is designed for connection of remote roof top INSTALLATION The optional delivered DM60 is designed to be wall mounted position the cable through the rear fasten the rear wall using button head screws provided in the package connect the cable from the main board on the jack 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 connection must be wired as follows e for a length of 0 to 300 m AWG22 0 34 mm 2 two crossed pairs with screen for a length of 0 to 500 m LiYCY P 0 34 mm 2 two pairs shielded general The cable length should not exceed 500 m For a better protection of electromagnetic disturbances LENNOX recommends the icable LiYCY P installation DC60 DM60 ROOFTOP IOM 0212 E 24 DISPLAY DM60 LENNOX CONNECTION ON THE DT50 SPLITTER DT50 dispatcher installation guide The board is equipped with three RJ12 phone jacks and a screw connector SC Terminal Wire function Connections Earth Shield
9. 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 Hoods is folded during transportation to limit risks of damage and must be unfolded on site as shown on fig 9 EXTRACTION Installed with economiser assembly the gravity exhaust dampers relieve the pressure when outside air is introduce Fig 9 system When large amount of fresh 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 in operation The extraction fan runs when outdoor air dampers are at least 5096 open adjustable value It is overload protected NOTE When horizontal flow configuration is required the multidirectional roof curb will be installed MULTIDIRECTIONAL ROOFCURB FLEXY II PRINCIPLE SKETCH PRINCIPLE SKETCH a gt FRESH AIR m D RETURN AIR ITIIIIZD25 EXHAUST AIR SUPPLY AIR FLEXYII WSHP IOM 0212 E 38 COMMISSIONING LENNOX BEFORE STARTING THE UNIT THIS WORK MUST ONLY BE CARRIED OUT BY TRAINED REFRIGERATION ENGINEERS FILL THE COMMISSIONNING SHEET AS YOU GO ALONG ELECTRICAL CONNECTIONS Ensure that the power supply between the building and the unit meets local authority standards and that the cable specification satisfies the start up and operating conditions ENSURE T
10. FLEXYII WSHP IOM 0212 E 3 IMPORTANT NOTICE Safety instructions LENNOX 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 FLEXYII WSHP IOM 0212 E TRANSPORT HANDLING WARNING 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 lifting and handling equipment are suitable for the equipment and comply with the specifications of the handling instructions enclosed here in Accessories ordered for on site installation have been delivered and are in good working order The equipment supplied corresponds to the order and matches the delivery note If the product is damaged exact details must be confirmed in writing by registered post to the shipping company within 48 hours of delivery working days A copy of the letter must be addressed to Lennox and the supplier or distributor for information purposes Failure to comply will invalidate any claim against the shipping company
11. Fresh air set point value 4 0 20 100 Speed blower set point value level 20mA nominal level Control outside temperature by 4 20mA sensor Control room temperature by 4 20mA sensor Control outside relative humidity by 4 20mA sensor Control room relative humidity by 4 20mA sensor 271 2 CONTROL VARIABLES Digital inputs dry contacts Maximum 2 free input contacts on BM60 BM J4 ID4 BM J4 ID7 Not always available Not always available Maximum 4 free input contacts on BE60 BE J4 ID1 BE J4 ID2 BE J4 ID3 BE J4 ID4 always available always available always available always available Functions can be set among followings Power Reset Al Summer Winter Low Fan High Fan No F A 10 F A 20 F A 30 F A 40 F A 50 F A All F A No FreeC No FreeH No Air Q Defrost 50 No Cp amp Ht 50 Ht No Heat Prio Ht Tcb G Tcb B Tcb Y1 Tcb Y2 Tcb W1 Tcb W2 for BMS Sched A Sched B Sched C Sched D Sched BMS Power of the unit ON OFF Reset Alarm Control Unloaded heating mode Control Unloaded cooling mode Blower Force reduced flow low speed Blower Force nominal flow high speed Fresh Air Force the damper to close 096 Fresh Air Force the damper to minimum opening 10 Fresh Air Force the damper to minimum opening 20 Fresh Air Force the damper to minimum opening 3096 Fresh Air Force the damper t
12. Start unit in cooling mode Thermodynamic readings are possible on Climatic 60 or using manometers No rated values are given here These depend on the climatic conditions both outside and inside the building during operation However an experienced refrigeration engineer will be able to detect any abnormal machine operation Safety test Check Air pressure switch Dirty filter detection test vary the set point value menu page 2335 on DS60 in respect 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 function if fitted Check the Firestart by pressing the test button if fitted Disconnect the circuit breakers of the condensor fans and check the high pressure cut out points on different refrigerant circuits FLEXYII WSHP IOM 0212 E LENNOX gt Reverse cycle test This test is designed to check the good operation of the 4 way reversing valves 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 test menu 2222 41 VENTILATION BELT TENSION LENNOX 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
13. VRL 30 Vdc 1st pair A GND 2nd pair A Rx Tx 3rd pair A RX Tx 3rd pair B GND 2nd pair B VRL 30 Vdc 1st pair B Jumpers The displays are directly supplied by the Climatic board with a 30 VDC power supply Pay attention to the value of this voltage when multiple cards are used J14 and J15 closed or cut the power supply J14 and J15 set between 1 2 connectors A B C and SC are in parallel Power is available on all connectors e J14 and J15 set between 2 3 B and C connectors are supplied in parallel but the connectors 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 Display s ferrites protection To avoid appearance of RF interference that may cause destruction of components in the displays you need to equip the cable of a ferrite during its installation provided by LENNOX 94 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DM60 LENNOX DM60 AND COMMUNICATION MASTER SLAVES If the master slaves communication bus is connected between several rooftop maximum 8 The DM60 connected on this bus allows viewing alternatively information of all connected units MASTER SLAVES DM60 b et Tee afa Ed am L The inter bus boards CLIMATIC connects to connector J8 on the BM60 cards Connection with star is not recommen
14. 60 control the return temperature measurement If you want to control on a room temperature measure disconnect the return probe between points B1 and GND terminal block J13 Connect the remote sensor in place RELATIVE HUMIDITY MEASUREMENT If the rooftop is designed to manage humidity a box of combined sensors temperature and humidity supplied with the rooftop it must be placed in the conditioned area It s possible to use the temperature measurement DC60 86 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DC60 LENNOX CONFIGURATION To communicate with the CLIMATIC 60 this basic parameters of internal DC60 must to be settled Setup menu To do this when the DC60 is powered Simultaneously press the keys and After some seconds the text C o appears and the value 000 flashes Turn the knob to change the value to select the number 022 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 the previous If the code is correct the display shows Addr 2 buttons on the right simultaneously Parameter s choice By rotating of the knob you can view and modify the following parameters e Addr Address DC60 on the communication bus Always set to value 31 e GAUd Communication speed always set to value 2 e Backlight mode e bLIn Backilght ilntensity e FL AL Probe calibration e Cn St Screen contrast e 9 Di
15. Change the component ELECTRICAL HEATER High Temperature trip out on electric heater FLEXYII WSHP IOM 0212 E Low airflow rate Incorrect position of the Klixon Measure and estimate the airflow and pressure and compare with the specification from customer Check that the Klixon is positioned in the airflow relocate Klixon if necessary Check that there is no heat transfer from the Klixon support 75 MAINTENANCE DIAGNOSTIC LENNOX WATER LEAKS FAULT POSSIBLE CAUSE AND SYMPTOMS SOLUTION Water found in the ventilation section Water ingress in the filter compartment Cooling mode Water carried away from the coil because of excessive airflow and speed on the Coil Low air pressure in the compartment due to a high airflow rate or a high pressure drop before the fan Check seals around the ventilation section Water ingress through a leaking fresh air hood or when running 100 fresh air Estimate the airflow rate and check the speed is lower than 2 8 m s Check filter Reduce airflow rate Check the door seal Check for the presence of silicone seals in the corners of the door and at the bottom of the refrigeration section bulkhead Check the seals and flanges in the fresh air hood Reduce the airflow rate if necessary CLIMATIC DISPLAYS Nothing is written on the screen but it s enlightened Nothing occurs on the unit or an option disappeared The message no link appears All the
16. Climatic CSA oe uu OUO n e 76 MAINTENANCE PLAN 0 00000000000000 saos erac aas 77 SPAHEPAHRTLISIT u da x Jai EN RII xx uz uz mz 80 u 82 CONTROL MANUAL 83 FLEXYII WSHP IOM 0212 E 31 COMMISSIONNING REPORT LENNOX gt Site details Controller Site Model Unit Ref Serial No Installer Refrigerant 1 ROOF INSTALLATION Sufficient Access OK Condensate drain fitted Roofcurb Yes No Yes No OKL Not OK L 2 CONNECTIONS CHECK Phase check Yes L No O Voltage between Phases 3 CLIMATIC CONFIGURATION CHECK CLIMATIC 60 Configured according to the Options and Specifications Yes No 4 SUPPLY BLOWER SECTION Power displayed on plate Voltage displayed on plate Current displayed on plate Fan Type Forward Forward Backward Backward Displayed Belt Length Tension Checked Alignment Checked Yes No L Yes L No L Motor Pulley Diameter Dy Fan Pulley Diameter Dp Fan Speed Motor rom x Dv Averaged Measured Amps Shaft Mechanical Power Refer to airflow balancing Operating point checked Set Points Adjusted Yes No L If Yes enter new values 2333 2334 2339
17. Turn the knob to adjust the desired value Press the knob to select your choice After a few seconds DC60 communicates the new time to the CLIMATIC M 60 DC60 DM60 ROOFTOP IOM 0212 E 99 DISPLAY DC60 LENNOX USE Information available By rotating the knob you can view or modify the following values DC60 set in light mode set Volatile temperature set point current mode C Indoor Room temperature Set Volatile Temperature set point This item allows you to view and or modify the control temperature required for the Roof Top selected If this point is changed this value is used until the scheduling changes mode A B C D BMS At each change of the mode the CLIMATIC M 60 sets the value of this set point on the preset value in the mode concerned Indoor room temperature This item indicates the measured air temperature in the room conditioning The room temperature isn t available if the CLIMATIC 60 is configured to supply control DC60 set in full mode Unit Number of rooftop connected to the DC60 set Predetermined temperature set point current mode C set Volatile temperature set point current mode C e L Alarms code e t 04 Outdoor temperature C e t 54 Supply temperature C t In Indoor Room temperature C h In Indoor Room humidity Sehr Indoor Room Air quality ppm Opening of fresh air
18. The warranty will only apply if a maintenance contract has been signed starting from the date of commissioning and if the maintenance contract has actually been performed The maintenance contract must be made with a specialist competent company The sole effect of any repair modification or replacement of an item during the warranty period must be to extend the material s warranty period Maintenance must be carried out in accordance with regulations If a spare part is supplied after the expiry of the warranty period it shall be guaranteed for a period equal to the initial warranty period and will be subject to the same conditions We recommend for a contract four inspections per year every three months before the start of each season in order to check the operation of the equipment in the various operating modes FLEXYII WSHP IOM 0212 E 82 TABLE OF CONTENTS LENNOX CONTROL MANUAL DISPLAY DC60 USN 86 COIN ST IN m 86 IMPORTANT WARNING u uuu 87 ONE DC60 FOR ONE AND ONLY ONE ROOFTOP a 88 TEMPERATURE MEASUREMENT 88 RELATIVE HUMIDITY MEASUREMENI L a a 88 CONFIGURA
19. allows the air socks to be progressively filled with air on start up It takes up to 1 minute to go from 0 of air to full air flow START UP This option requires the economiser to be delivered inside the machine Both return air and fresh air damper are linked with and independent 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 return air opening before the fan is switched on Starting steps Both dampers are fully closed and Fan is OFF Rooftop is set to RUN by the schedule or the remote display order Return air damper move to the minimum position manually adjustable on the auxiliary switch Fresh air damper is OFF motor starts Return air damper goes to 10096 return air slowly during 1 minute allowing the duct to be smoothly inflated Finally the fresh air damper and return air damper return to adjusted fresh air ratio recorded in the climatic60 program The return air damper with its auxiliary switch FLEXYII WSHP IOM 0212 E 53 VENTILATION UV lights LENNOX 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 Mak
20. damper 96 Available if the option is enabled Available if the level 2 is activated set Adjustable with DC60 t Unit connected This item can know the number of rooftop connected to the DC60 90 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DC60 LENNOX USE Set Volatile temperature set point This item allows you to view and or modify the control temperature required for the rooftop selected If this point is changed this value is used until the scheduling changes mode A B C D BMS At each change of the mode the CLIMATIC M 60 sets the value of this set point on the preset value in the mode concerned S P t Predetermined temperature set point If level 2 is active this item allows you to view and or change the preset temperature control for the active mode AL Alarms code This item can see the code of different active alarms on the rooftop If the rooftop isn t in alarm this item is to O By this item it s possible to reset the alarm activated To do this set the value of the item to the value 0 t 0 u Outdoor temperature This item indicates the measure temperature of the air outside L 5 u Supply temperature This item indicates the measure of outlet air temperature of the rooftop t Inlndoor Room temperature This item indicates the measured air temperature in the room conditioning The room temperature isn t available if the 60 is configured to supply control h
21. display Pressing the esc button directs you to the rooftop menu setup display Pressing the up arrow button reverses the state e Pressing the enter button resets alarm if the reset word is selected then it directs you to the rooftop setup menus display Pressing the down arrow button reverses the state Setting rooftop On Off View edit On Off status of the unit Pressing the alarm button directs you to the alarm list display Pressing the esc button Esc directs you to the rooftop setup menus display Pressing the up arrow button Up Arrow reverses the state Pressing the enter button validates the selection then directs you to the rooftop setup menus display Pressing the down arrow button reverses the state DC60 DM60 ROOFTOP IOM 0212 E 101 DISPLAY DM60 LENNOX Setting Clock of CLIMATIC View edit hour minute day of month month and year of the CLIMATIC clock Pressing the alarm button directs you to the alarm list display Pressing the esc button directs you to the rooftop setup menus display Pressing the up arrow button increases the selected value Pressing the enter button commits the change and it puts you to the next value Pressing the down arrow button decreases the selected value Setting CLIMATIC schedule View edit hour and minutes of each zone beginning View edit the zone operating mode The schedule is differe
22. of belts is generally produced during the first 15 hours of operation Before adjusting the tension make sure that the pulleys are correctly aligned To tension the belt set the height of motor support plate by moving the plate adjustment screws The recommended 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 A mm P m The belts should always be replaced when The disk is set to maximum The belt rubber is worn or the wire is visible Replacement belts must have the same rated size as the ones they are replacing If a transmission system has several belts they must all be from the same NOTE An under tensioned belt will slip heat and wear prematurely On the other hand if a belt is over tensioned the pressure on the bearings will cause them to over heat and wear prematurely Incorrect alignment will also cause the belts to wear prematurely Fig 12 FLEXYII WSHP IOM 0212 E 42 VENTILATION PULLEYS MOUNTING AND ADJUSTING PULLEYS FAN PULLEY REMOVAL Remove the 2 screws and put one of them in the extraction threaded screw Screw in fully The hub and the pulley will separate from each other Remove the hub and the pulley by hand without damaging the machine FAN PULLEY INSTALLATION Clean and de grease the shaft hub and conical bore of the pulley Lubricate the screws and install the hub and p
23. pre Extraction ventilation the Continuous Ventilation without sparks Check injection pressure during start up Value for High Heat the gas Burner lonisation Probe It must not be Earthed fires up BUT 230V safety shutdown Measure the lonisation Current It must be from the Ignition higher than 1 5 microAmps Control Block Check the Type of GAS G20 G25 Gas of Groningue for example FLEXYII WSHP IOM 0212 E sp HEATING GAS BURNER DISASSEMBLING THE GAS BURNER FOR MAINTENANCE PURPOSES Preliminary Safety Recommendations solate the unit using the main isolator switch Close off the isolating gas valve located before the unit Disconnect the Pipe work Do not discard the seals PN m Ms ELI B i TA T 5 Disassembling the gas burner support bar Disconnect the Electrical Connector on the electric connection board EF47 Remove the two screws which hold the gas Bar in Place Carefully remove the gas burner support bar avoiding any damages to the electrodes FLEXYII WSHP IOM 0212 E LENNOX 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 box ATTENTION Check the correct position of the pressure tube used by the extraction pressure switch Required Equipment List for maintenance Adjustment and Start up An accurate ma
24. temperature rise Dt 6 for an air conditioning application Vmini 86 x Q N x Dt K Seopa tt stages Volume L FWH FWM 085 FWH FWM 100 FWH FWM 120 FWH FWM 150 FWH FWM 170 FLEXYII WSHP IOM 0212 E he WATER CONDENSING LENNOX WATER LOOP CONFIGURATION FOR WATER SOURCE HEAT PUMP Figures below show the 2 water configurations Figure 1 indicates all components used as standard e electronic water flow switch e water filter e pressure taps and drain valves e the automatic airvent The second figure shows rooftop water loop with Low Water Loop Temperature option Hydraulic Data Standard Low Water Loop Temperature Option Figure 1 Figure 2 All Victaulic Connections Inlet Water Filter 6 Stainless steel Exchanger Automatic Air Vent ElectroValve HP control option Electronic Flow Switch Low WATER LooP TEMPERATURE OPTION In order to operate with low water inlet temperature in cooling mode ie ground source water loops it is necessary to control the water flow rate in the heat exchanger to maintain a minimum condensing pressure in the refrigeration circuit In cooling mode the climatic 50 will control the water flow rate in the condenser by monitoring the condensing pressure and by closing 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
25. unit shall be isolated from the electrical supply by disconnection and locking using the main isolating switch e Workers shall wear the appropriate personal protective equipment helmet gloves glasses etc Work on the electrical system e Work on electric components shall be performed with the power off by employees having valid electrical qualification and authorisation Work on the refrigerating circuit s e Monitoring of the pressures draining and filling of the system under pressure shall be carried out using connections provided for this purpose and suitable equipment To prevent the risk of explosion due to spraying of coolant and oil the relevant circuit shall be drained and at zero pressure before any disassembly or unbrazing of the refrigerating parts takes place e There is a residual risk of pressure build up by degassing the oil or by heating the exchangers after the circuit has been drained Zero pressure shall be maintained by venting the drain connection to the atmosphere on the low pressure side The brazing shall be carried out by a qualified brazier The brazing shall comply with standard NF EN1044 minimum 30 silver Replacing components e n order to maintain CE marking compliance replacement of components shall be carried out using spare parts or using parts approved by Lennox e Only the coolant shown on the manufacturers nameplate shall be used to the exclusion of all other products mix of coolants hydroca
26. units are extinct FLEXYII WSHP IOM 0212 E Possible problem of units configuration Problem of addresses recognition Problem main board plan addressing Press on the three right hand side s buttons at the same time during a few seconds then reconfigure display address setting at 32 Check the instructions from 3811 to 3833 and reconfigure options if necessary Disconnect the DS from the unit and then reconnect it Disconnect then re plug disconnect each unit from the others then change all the plan addresses 76 MAINTENANCE PLAN LENNOX Rooftops are generally placed on the roof but can also be installed in technical rooms These units are very 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 carried in the air filters and must be cleaned or replaced These units are designed to produce cooled or heated air through the use of a refrigeration vapour compression system it is therefore imperative to monitor the refrigeration circuit operating pressures and check the pipe work for leaks The table below details a possible maintenance plan including the operations to be carried out and the periodicity at which they must be accomplished It is recommended to follow such a plan to keep a rooftop unit in good working order Regular maintenance of your rooftop will extend its operating li
27. 0 200 35000 43000 31 211 54 19 31 24 29 66 19 195 310 2700 7 105 24 8 14 48 18 17 26 6 84 195 230 39000 43000 31 211 54 19 31 24 26 29 66 19 195 30 FLEXYII WSHP IOM 0212 E 45 VENTILATION AIRFLOW BALANCING LENNOX 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 previous page and 2x 5 5 kW motors Motor rpm 1465 rpm Coso 0 79 Voltage 400V Current 9 00A per fan Pmech fan V x I x X COS X N mech motor X N Transmission 400 x 9 1 x V3 x 0 79 x 0 89 x 0 9 4 0 kW The unit is also fitted with 2 transmission kits 3 Fixed Fan pulley 200mm Motor adjustable pulley type 8550 opened 4 turns from fully closed or measured distance between pulley end plates is 29 1mm from table 1 it can be determined that each motor pulley has a diameter of 114 2mm rpm Fan rpm X Du De 1465 x 114 2 200 836 rpm 2 LEE S5 47 E REND FOT VLAS MPELLER TOTAL lt Using the fan curve the operating point can ESSA 0 s g be located 2000 2 25 55 RM 2 6 1 In order to facilitate the calculation you aes 04 x w won t
28. A ROOF MOUNTING FRAME LENNOX 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 NOTE frame assembly must be installed flat leveled within 5mm per linear meter in any direction Fig 8 UNIT FLOOR A UNIT FLOOR INSIJI ATION UNIT Support rail AIR DUCT ROOFCURB FLEXYII WSHP IOM 0212 E 19 TRANSITION CURB LENNOX 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 Therefore you need a pneumatic or electric device All parts must be sealed with polyurethan sealant during assembly Foam Insulation Installing e Stick large foam pieces underneath the flat top Foam Gasket Installing e Stick gasket all around the curb flange s top Let it free on 200 mm long to enable water drainage Spare parts 17 m 0 85 m 19 m 0 95 m 21 m 1 1 m 760 x 1960 1 39 m 920 x 1960 1 79m tbd FLEXYII WSHP IOM 0212 E 20 ENERGY RECOVERY INSTA
29. ACTION LOGBOOK General information LENNOX 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 for addition Refrigerant removal Date Engineer Quantity kg Reason for removal FLEXYII WSHP IOM 0212 E 35 REFRIGERANT TRANSACTION LOGBOOK Leak tests part 1 LENNOX Date Engineer Test Result Follow up action required Follow up actions Date Engineer Related to test dated Action taken FLEXYII WSHP IOM 0212 E 36 REFRIGERANT TRANSACTION LOGBOOK LENNOX Testing of automatic leak detection system if fitted Date Engineer Test result Comments Refrigerant load according to model size Number of Cooling only units Heat pump units Refrigerant circuit Load kg Load kg RAC IRAH DAMY FLEXYII WSHP IOM 0212 E zr ECONOMISER AND EXTRACTION LENNOX ECONOMISER Free cooling is provided through the use of fresh air which is more appropriate than excessive cooling amounts of return air
30. Control operating mode Label or clock Schedule mode Staus a 4 i Of amp 4 e 4 Day Compressor s e Defrost Im Day Condenser s CI Night P Heaters BMS Hidden to stop Visible running Blinking in fault 88 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DC60 LENNOX PRESENTATION Buttons Ventilation Control Not used Not used Clock E Standby Viewing or setting the time SS Knob Select or set of values USE 5 On Off unit By supporting a few seconds the button you can activate or not On Off the rooftop connected If the symbol OFF completed by the time is displayed the rooftop is stopped and the DC60 in sleep mode To restart the unit press the button a few seconds O Setting time At initialization of the DC60 the CLIMATIC 60 are synchronized time and day of week with the clock DC60 To view the time briefly press the button eo To set the time press the button C2 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 Turn the knob to adjust the desired value Press the knob to select your choice Hon Monday Tue Tuesday Wednesday THU Thursady F F I Friday 5 aT Saturday Sunday Then the weekday value flashes
31. HAT THE POWER SUPPLY 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 circuit PRELIMINARY CHECKS Ensure that all drive motors are secure Ensure that the adjustable pulley blocks are secure and that the belt is tensioned with the transmission correctly aligned Refer to the next section foe details Using the electrical wiring diagram check the conformity of the electrical safety devices circuit breaker settings presence and rating of fuses Check the temperature probe connections FLEXYII WSHP IOM 0212 E 39 COMMISSIONING STARTING THE UNIT At this point the unit circuit breakers should be open You will need a DS60 maintenance controller DS 60 Service Connecting the CLIMATIC displays RJ12 connector on the main board Close the 24V Control Circuit breakers gt TE 9 29 The CLIMATIC 60 starts after 30s Reset the DAD photo If fitted FLEXYII WSHP IOM 0212 E LENNOX Check and adjust the control settings Refer to the control section in this manual to adjust the different parameters POWERING THE UNIT Power up the unit by closing the isolator switch At this point the blower should start unless the climatic does not energise the contactor In this particular case the blower can be forced
32. HEWM 85 100 120 150 170 A 220 2200 2200 2200 2200 B 3350 3350 3350 4380 4380 D 360 360 360 450 450 Weight of standard units FWH 1026 1325 1388 Weight gas unit FWM Standarddheat kg 960 1046 1133 1566 169 FLEXYII WSHP IOM 0212 E f TRANSPORT HANDLING LENNOX DIMENSIONS AND WEIGHTS Fxko25 400 1635 105 40 60 950 FXK030 470 165 105 490 60 980 FXK035 470 255 1290 40 60 0 FXK040 4750 2255 1290 490 60 1450 mm mm FXK055 4750 225 1290 490 60 160 FXK070 550 255 1725 890 600 1800 FXK085 500 2255 1725 890 60 190 FxK100 550 2255 1725 890 60 200 FXKt10 550 2255 2000 860 2620 FXKi40 5650 2255 200 860 2620 FXKi70 550 255 20 860 2650 FLEXYII WSHP IOM 0212 E 8 TRANSPORT HANDLING LENNOX LIFTING THE UNIT As shown on the picture below a lifting frame is necessary After lifting withdraw angle s feet and lifting lugs FLEXYII WSHP IOM 0212 E 9 INSTALLATION FORKLIFT PROTECTIONS LENNOX NEVER LIFT THE UNIT WITHOUT FORKLIFT PROTECTIONS a REMOVE THE FORKLIFT PROTECTIONS BEFORE INSTALLATION PRELIMINARY CHECKS Before installing the equipment the following points MUST be checked Have the forklift protections been removed s t
33. Ice plug in the expansion valve Incorrect insulation of the thermostatic bulb of the expansion valve Low Pressure Switch cut out point too high LP cut out due to not enough defrost on heat pumps Measure the superheat and sub cooling Good if 5 C lt SC lt 10 C 5 C lt SH lt 10 C Bad if 5 gt 10 and SH too low Check superheat adjustment and charge unit a leak check must be carried out If too high check the coils are clean or check coil internal pressure drop between the liquid line and the suction line Good if 3bar Too high 3 bar coil blocked Stop the fan and create icing of the coil Check all circuits freeze evenly across the whole surface of the coil If some parts of the coil do not freeze this could indicate a problem with the distribution Change filter drier Attempt to free the valve adjusting element by freezing the valve and then heating the thermostatic element Replace the valve if necessary Adjust the expansion valve Heat the main body of the valve If the LP increases and then decreases gradually empty the circuit and replace the drier Superheat too low adjust superheat Move the thermostatic element along the pipe Insulate the Thermostatic element of the valve Check the cut out pressure of the Low Pressure switch It must be 0 7 0 2bar and must closes at 2 24 0 2 bar Adjust the CLIMATIC settings to extend the defrost cycles or shorten the time between defrost
34. Inlndoor Room relative humidity This item shows the measured relative humidity of the air in the room conditioning The room humidity isn t available if the option of humidity management isn t set Coz CO measurement This item indicates the measured rate of CO in conditioning room in ppm The measurement of CO isn t available if the option isn t set Eco Opening of fresh air damper This item indicates the measured value of the opening rate of the fresh air damper in mixture of outside air and return air This value is only available if the rooftop is equipped with this option Setting value If the value of the selected item is modified L To activate the modified value press the knob The S ET symbol appears on the right side of the value Turn 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 allows to select a new item DC60 DM60 ROOFTOP IOM 0212 E 91 DISPLAY DC60 LENNOX LEVEL 2 ACTIVATION 2 buttons on the right simultaneously Simultaneously press the keys and After some seconds the text C o dE appears and the value 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 the previous display
35. LENNOX Installation operating maintenance FLEX Y Rooftop units air cooled FLEXY WSHP Rooftop units water cooled 85 234 kW FLEXYII WSHP IOM 0212 E TABLE OF CONTENTS LENNOX gt INSTALLATION MANUAL IMPORTANT NOTICE Safety Instructions ccc 2 TRANSPORT HANDLING 2 0 000101 5 Bart E T P T TU UU m 5 ll lD f 5 siepe J 5 Maintenance KOy uuu uuu u mmt 5 SONS a SIR E L u u na T 5 Mandatory handling 6 Dimensions and NE 7 Lifting the UNITS EEE EE 9 INSTALLATION 10 Meo uuu ETT Am 10 Minimum clearance around the 11 ERR Um 12 WATER CONDENSING water source heat pump 19 Water CONNEC CUO 13 lil RN ETE D E 14 Water
36. LLATION LENNOX F box 85 100 120 _ G box 50170 200 230 No Hood FLEXYII WSHP IOM 0212 E 21 COMMISSIONNING LENNOX Remove lifting lug Remove corner sheet metal STEP 2 Lifting FLEXYII WSHP IOM 0212 E 22 COMMISSIONNING LENNOX STEP Fitting STEP 4 Check SAME LEVEL FLEXYII WSHP IOM 0212 E 23 COMMISSIONNING LENNOX STEP 5 Fixing H box for each side 04 8x32mm F amp G box for each side 04 8 25 FLEXYII WSHP IOM 0212 E 24 COMMISSIONNING LENNOX Ontop F 13 G 15 x 04 8 25 STEP 6 Masticate Apply mastic on side junctions higher junction FLEXYII WSHP IOM 0212 E 295 COMMISSIONNING LENNOX STEP 7 Electrical wiring The Recovery module is sent with a power cable and a T lan cable Modbus cable Power cable Separate these 2 cables communication and power ones using the two holes FLEXYII WSHP IOM 0212 E 26 COMMISSIONNING LENNOX Then fix the 2 cables on the grid of the extraction roofcurb and insert them in rooftop electrical panel be 14 1 L z f a Lit i t WM lets I eu mn SEDI m he n i Sp 4 4 qd 4 Communication and power cables from the module should be separ
37. ONS AND The gas supply of a Rooftop gas unit must be realized CAN ONLY BE USED IN PLANED INSTALLATION according to Sound Engineering Practice and the local CONDITIONS FOR OUTDOOR safety codes and rules PLEASE READ CAREFULLY THE MANUFACTURER S In any case the diameter of pipe work connected to each INSTRUCTIONS BEFORE STARTING A UNIT Rooftop must not be smaller than the diameter of the BEFORE COMMISSIONING A UNIT WITH GAS BURNER MORON Te s UM PEP IT IS MANDATORY TO ENSURE THAT THE GAS Make sure that shut off isolation valve has been DISTRIBUTION SYSTEM type of gas available installed before EAGH Rooftop Check the supply voltage to the exit of the power supply s transformer T3 of the burner it must be between 220 and 240V CHECK ACCESS AND CLEARANCE AROUND THE UNIT Make sure one can move freely around the unit A minimum one meter clearance must be left in front of the burnt gas exhaust flue Combustion air inlet and burnt gas exhaust s must NOT be obstructed in any way STARTING UP THE GAS BURNER SUPPLY NETWORK PIPE SYZING MALE THREADED CONNECTION FOR GAZ BURNER 3 4 Check that the gas supply line can provide the burners with the pressure and the gas flow rate necessary to provide the heating nominal output Number of male threaded connections 3 4 Purge the pipe work near the connection on the ignition control Valve for a few seconds Check that the unit s treatment Fa
38. R EXHAUST PLEASE READ CAREFULLY THE MANUFACTURER S INSTRUCTIONS BEFORE STARTING THIS UNIT owitchgear must be installed on each unit in accordance with the Machine Directive and the standard NF EN 60204 THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FOLLOWING CODES IR GR 18 In case these symbols are not displayed on the unit please refer to the technical documentation which will eventually detail any modifications required to the installation of the unit in a particular country All the technical and technological information contained in this manual including any drawing and technical descriptions provided by us remain the property of Lennox and must not be used except in operation of this product reproduced issued to or made available to third parts without the prior written agreement of Lennox The technical informations and specifications contained in this manual are for reference only The manufacturer reserves the right to modify these without warning and without obligation to modify equipment already sold FLEXYII WSHP IOM 0212 E IMPORTANT NOTICE Safety instructions LENNOX 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 following instructions may result in injury or serious accidents Work on the unit e The
39. SING LENNOX Antifreeze protection Use glycol water solution The glycol water solution must be sufficiently concentrated to ensure proper protection and prevent formation of ice at the lowest outdoor air temperatures expected on an installation Take precautions when using non passivated MEG antifreeze solutions Mono Ethylene Glycol or MPG Mono Propylene Glycol Corrosion can occur with these antifreeze solutions with oxygen m ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZING CC x AUTION Drain the installation To drain the circuit the drain cocks must be opened and an air inlet ensured Note air bleeders are not designed to admit air EVAPORATOR FREEZING DUE TO COLD WEATHER CONDITIONS IS NOT COVERED BY LENNOX WARRANTY za To enable drainage of the circuit make sure that drain cocks are installed at all the low points of the circuit CAUTION Minimum water content 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 is sufficient The theoretical volume of the water loop for a proper air conditioning operation can be calculated using the formulas hereafter WATER COOLED FLEXYII RANGE Vt gt Minimum water content of the installation Q gt Water capacity in kW N gt Number of control steps available in the unit Dt gt Maximum acceptable
40. SO42 sulphate ions can cause perforating corrosion 30 mg l No fluoride ions 0 1 mg l No Fe2 and Fe3 ions with dissolved oxygen Dissolved iron lt 5 mg l with dissolved oxygen lt 5 mg l Over those values it means a corrosion of steel which may generate a corrosion of copper parts under deposite of Fe this is mainly the case with shell and tube heat exchangers Dissolved silicon silicon is an acid element of water and can also lead to corrosion risks Content lt 1mg I e Water hardness TH gt 2 8 K Values between 10 and 25 can be recommended This will facilitate scale deposit that can limit corrosion of copper TH values that are too high can cause piping blockage over time TAC 100 e Dissolved oxygen Any sudden change in water oxygenation conditions must be avoided It is as detrimental to deoxygenate the water by mixing it with inert gas as it is to over oxygenate it by mixing it with pure oxygen The disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles Specific resistance electric conductivity the higher the specific resistance the slower the corrosion tendency Values above 3000 Ohm cm are desirable A neutral environment favours maximum specific resistance values For electric conductivity values in the order of 200 6000 S cm can be recommended e pH pH neutral at 20 C 7 lt pH lt 8 FLEXYII WSHP IOM 0212 E 13 WATER CONDEN
41. VERED BY THE WARRANTY Filling up and starting the system Adjust the control for Heating by reducing the simulated ambient temperature down to 10 Check that the red indicators located under the valve actuator are moving correctly with the signal ELECTROLYTIC CORROSION Attention is drawn to the corrosion problems resulting from electrolytic reaction created by unbalanced earth connections ANY COIL DAMMAGED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE WARRANTY Fill the hydraulic system and bleed the coil using the air vents Check incoming hot water Check the various connections for possible leaks FLEXYII WSHP IOM 0212 E 5 HEATING HOT WATER COIL LENNOX Hot water coil connection F G H box a L AA LL 1 Q TI 8 Hill L LIH WERL e i j Pipe Internal Diameters DN F085 F100 F120 F150 F170 F200 F230_ MAXIMUM WORKING PRESSURE 8 BARS MAXIMUM WORKING TEMPERATURE 110 C FLEXYII WSHP IOM 0212 E 58 HEATING ELECTRIC HEATER LENNOX GENERAL INFORMATIONS 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 This is provided as a standard feature on the electric heater with the electric power supply c
42. ables made of reticulated silicon rubber resistant to temperatures up to 200 C For any rooftop unit size three sizes of electric heater are available S standard M Medium and H high FLEXY 2 85 100 and 120 have Standard heat 30 kW 2 stages Medium Heat 54 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 Triac FLEXY 2 150 and 170 have Standard heat 72 kW 2 stages Medium Heat 108 kW Fully modulating Triac High Heat 162 kW Fully modulating Triac Capacity of the medium and high heat heater can be limited electronically to an exact value through the CLIMATIC M 60 To reduce installation time and hence cost electric heaters are always factory fitted fully wired and tested prior to shipment 380V 400V 415V Module size kW Current A Cap kW Current A Cap kW Current A Cap kW 734 44 76s ss s 9 _ 32 ss ss 600 45 FLEXYII WSHP IOM 0212 E 759 HEATING GAS BURNER LENNOX PRELIMINARY CHECKS BEFORE START UP GAS FLOW for G20 at 20mbar and 15 m h NOTE ANY WORK ON THE GAS SYSTEM MUST BE CARRIED H POWER OUT BY QUALIFIED PERSONNEL THIS UNIT MUST BE INSTALLED IN ACCORDANCE For modulating gas we have just H power for F G amp H box WITH LOCAL SAFETY CODES AND REGULATI
43. ansformer class 2 under 0 14 Communication The DC60 is controlled by a communication bus RS485 Cable features The connection of power and communication must be made by the following cable e 0 34 mm 2 pairs with general shield The cable length with power should not exceed 30m The cable length without power 24V external must not exceed 150m Fora better electromagnetic protection Lennox recommends the use of LiYCY P cable For extended networks fit a 120 Ohm resistor between RX TX and RX TX on the first and last device to avoid possible communication problems DC60 DM60 ROOFTOP IOM 0212 E e 85 DISPLAY DC60 LENNOX ONE DC60 FOR ONE AND ONLY ONE ROOFTOP The DC60 displays only the values and information of the Roof Top on which the DC60 is connected TEMPERATURE MEASUREMENT All LENNOX rooftop comes with a temperature sensor it must be placed in the conditioned area But if the DC60 is placed in the area conditioned by the rooftop that display is connected it is possible in this case to use the temperature measurement of the DC60 To indicate the CLIMATIC 60 your choice set the point 3213 e 128 to use the measure of the DC60 e 1 BM B12 or 2 BM B1 to use the remote probe Note e for rooftop with a medium 60 connect the remote sensor between points B12 and GND terminal block J18 for rooftop with a small CLIMATIC TM 60 by default the CLIMATIC
44. ated FLEXYII WSHP IOM 0212 E x27 COMMISSIONNING LENNOX Then connect the power cable from the module to the rooftop and the 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 Extraction roofcurb connection Recovery module connection Actuator roofcurb connection Be careful Check connections and connect male connections to good female one Roofcurb and recovery module connectors are the same To check the wiring please refer to Rooftop and Recovery Module electrical diagram FLEXYII WSHP IOM 0212 E 28 COMMISSIONNING LENNOX STEP 8 Roof curb economiser Adjustment With 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 manually Actuator roofcurb not connected FLEXYII WSHP IOM 0212 E 29 TABLE OF CONTENTS LENNOX FLEXYII WSHP IOM 0212 E 30 TABLE OF CONTENTS LENNOX SERVICE MANUAL COMMISSIONING OS lt erates are u uu l cores 32 Refrigerant transaction 35 Economiser and extraction 38 Be
45. by bridging the port NO11 and C4 on connector J15 on the Climatic Once the fan is running check the rotation direction Refer to the rotation arrow located on the fan The fans and compressors direction of rotation is checked during the end of line test They should 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 11 disconnect the main power supply to the machine at the building s mains switch reverse two phases and repeat the above procedure Close all circuit breakers and power up the unit remove the bridge on connector J15 if fitted If now only one of the components rotates in the wrong direction disconnect the power supply at the machine s isolator switch if fitted and reverse two of the component s phases on the terminal within the electrical panel Check the current drawn against the rated values in particular on the supply fan f the readings on the fan are outside the specified limits this usually indicates excessive air flow which will affect the life expectancy and the thermodynamic performances of the unit This will also increase the risks of water ingress into the unit Refer to the Air Flow Balancing section to correct the problem At this point attach the manometers to the refrigerant circuit Fig 11 40 COMMISSIONING RUN TEST
46. cty Pressure FLEXYII WSHP IOM 0212 E 51 FILTERS LENNOX FILTER 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 monitors the pressure drop across the filter The following set points can be adjusted depeding on the installation Airflow in page 2333 25Pa by default No filter in page 2334 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 identified Fault code 0001 AIRFLOW FAILURE if measured AP across the filter and coil is below the value set in page 2333 Fault code 0004 DIRTY FILTERS if measured AP across the filter and coil is above the value set in page 2335 Fault code 0005 MISSING FILTERS if measured AP across the filter and coil is below the value set in page 2334 Be Careful do the filters fire classification s choice according to the local regulations FLEXYII WSHP IOM 0212 E Dee VENTILATION AIR SOCK CONTROL LENNOX AIR SOCK CONTROL FANSTART 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
47. d outdoor temperature value visualization In the house e indoor humidity value visualization if enabled indoor temperature value visualization indoor air quality rate visualization if enabled 98 LENNOX gt DC60 DM60_ROOFTOP IOM 0212 E DISPLAY DM60 LENNOX J Heating mode set point visualization Cooling mode set point visualization Fresh air damper opening percentage visualization P Engaged compressor percentage visualization A Engaged heaters percentage visualization e pressing the alarm button directs you to the alarm list display e pressing the esc button takes you to the main display e pressing the arrow button directs you to the previous screen e pressing the down arrow button directs you to the next screen Alarm list History used to store the last 99 alarms occurred on the unit e each alarm is stored on the date and time the fault occurred an active alarm is signified by the bell symbol e anreseted alarm is signified by the symbol each alarm is signified by a 3 digit code To have the text of fault code position the cursor on the desired line by using the up arrow or down arrow and then confirm by pressing enter pressing the esc button takes you to the main display pressing the arrow button positions you in the list pressing the enter button takes you to the clear display of failure code pressing the down arrow but
48. ded for optimum performance it is advisable to connect a maximum of two cables per unit The connection must be wired as follows e For a length of 0 to 300 m AWG22 0 34 mm 2 a twisted pair shielded e For a length of 0 to 500 m LiYCY P 0 34 mm 2 a pair overall shield cable length should not exceed 500 m For better protection of electromagnetic disturbances Lennox recommends the installation of cable LiY CY P DC60 DM60 ROOFTOP IOM 0212 E egg DISPLAY DM60 LENNOX CONFIGURATION Brightness Contrast The display is equipped with a contrast but it can be adjusted manually For manual adjustment of contrast simultaneously press the alarm and keys and press arrow or down arrow buttons to increase or decrease the contrast Configuring the terminal s address The termminal s address DC60 or DM60 must be checked after putting the card to On access the setup mode by pressing the arrow enter and down arrow keys for at least 5 seconds press enter to place the cursor on setting with arrow or down arrow set the address of the display 31 of DM60 then confirm by pressing enter The screen display address changed 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 enter to place the cursor on setting press enter a s
49. e 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 A safety interlock is fitted to switch off the access doors to the lamps UV light Door opened Safety locks Filters COIL Sight Glass FLEXYII WSHP IOM 0212 E 54 REFRIGERATION CIRCUIT LENNOX Electronic expansion valve 2 electronic valves types can be fitted on ASHP only if the option is selected or in Flexy EC Model designation 085 100 120 150 170 200 230 Reference 45 45 E3V45 45 E3V45 55 E3V55 adjustments EEV allows to control superheat in biflow operation see climatic 60 sections E3V Welding instructions Electronic expansion valves are sensitive to dust strainers must be used in case of replacing FLEXYII WSHP IOM 0212 E ADVANCED SCROLL TEMPERATURE PROTECTION ASTP LENNOX OPERATION MODE EXPLANATION SERVICE A COMPRESSOR Protection is activated when Scroll Discharge Port What to do Reaches 150 C 17K e f a protected compressor is identified Stop the compressor Allow to cool thoroughly Restart pump amp check for normal operation NOT ASSUME A COMPRESSOR RUNNING e Protection mode balances discharge suction UNLOADED BALANCE PRESSURE IS A FAILURE Likely situations where protection may activate Motor heat b
50. econd time to place the cursor on the O board address line with arrow or down arrow replace by the address of the BM60 connected and confirm by pressing enter FUNCTIONALITY OF THE DM60 Rooftop selection A DM60 can be connected to 8 units per the pLan bus DM60 screens connected alternatively to one of BM60 The next screen allows selection of the unit to display Each of the 8 rooftops is represented by a number The selected rooftop is indicated by its number which is framed Each time you press the down arrow button it connects the display to the next rooftop Pressing enter key returns to the main screen 96 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DM60 LENNOX Main Top left in heating mode control in cooling mode Small numerical value volatile set point temperature View and or modify the offset or set point of the desired temperature control for the selected rooftop Pressing the arrow button increases the set point value Pressing the down arrow button decreases the set point value If the setpoint is changed this value is maintained as long as the rooftop scheduling doesn t change modes night day day 1 day Il BMS At each change of the mode the CLIMATIC M 60 sets the value of this setpoint on the preset value the mode concerned Big numerical value measured air temperature value in the conditioned space Top right ra 2 wlll Ven
51. ermostatique TGEL40 31 4720924M tectonic expansion EV48 4720928T Elemonicexpansonvae E3V55 Ref 4720155 GbE Ref 4720931X ver ev _ 4770717M_ DMS Rerig 4720907M_ Fitters Rerig 4720908N SF Rerig 4740104 S Refig 4740108V S Rerig 4740107X D 05 20barQuickOn Control 4770214X 2 800mm Hoses 4681044P INOX 1 5 8 0 850mm Hoses 4681025M D O Pipping 5680574 2 D40B42Pa Pipping 5680575N Casing Designation Familly Code Fresh air hood grille Fbox 7 Sheetmetal 4921087V po Fresh air hood grille 7 Sheetmetal 4921088W_ Handle dorr 1091 103 02 5880109W Handle Outdoor coil M443 140N 5880160W Charnieres clips 8576178 SNAP LINE 5880187L Outdoor fans Designation Familly Code FE071 4921080K 2 _ AGD8O0 AU0101F Gbox 4921099M FLEXYII WSHP IOM 0212 E 80 SPARE PART LIST LENNOX gt LLL A6D800 AUO101 Hbox Fan 4921098L Electrical amp control components Designation Familly Code Miscillaneous Designation Familly Code 4680360K cle double barre 5880158T Ventilation amp Filtration components Designation Familly Code ADHE 500 SupplyFan 4910093A 1 5 kW IE2 4521802L FLEXYII WSHP IOM 0212 E 81 WARRANTY LENNOX TERMS AND CONDITIONS In the absence of any other written agreement the guarantee shall only apply to design faults w
52. ers or missing Blower A Alarm Blower Comp A Alarm Circuit Compressor Gas A Alarm Gas burner Elec A Alarm Electrical heaters Frost A Alarm Supply to low Freeze protection Smoke A Alarm Smoke detection Defrost Circuit Defrosting cycle requested 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 activated Sched B Schedule Mode B activated Sched C Schedule Mode C activated Sched D Schedule Mode D activated Sched BMS Schedule Mode BMS activated Sched ZO Schedule Zone 0 activated Sched Z1 Schedule Zone 1 activated Sched Z2 Schedule Zone 2 activated Sched Z3 Schedule Zone 3 activated Sched Z4 Schedule Zone 4 activated Sched Z5 Schedule Zone 5 activated Sched Z6 Schedule Zone 6 activated FLEXYII WSHP IOM 0212 E BE J9 B1 Analog inputs NTC probe or 4 20mA signal No analog input on BM60 Maximum 4 free analog inputs on BE60 Not always available BE J9 B2 Not always available BE J10 B3 Not always available BE J10 B4 Not always available Power Ntc BMS Hr BMS Sp Temp Sp F Air Sp Speed T Out T Room Hr Out Hr Room Functions can be set among followings Power of the unit ON OFF BMS temperature NTC reading for BMS BMS relative humidity 4 20mA reading for BMS Control set point swift of the value 4mA 5K 20 5
53. fe and reduce operating faults Symbols and Legend O Operation which can be carried out by on site maintenance technicians Operation which must be carried out by qualified refrigeration personnel trained to operate on this type of equipment NOTE Times are given for information purpose only and may vary depending on the unit size and type of installation e Coil cleaning must be carried out by qualified personnel using appropriate methods that won t damage the fins or the tubes e t 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 e The access ports to the refrigeration circuits MUST be leak checked every time gauges are connected to the service ports FLEXYII WSHP IOM 0212 E ee MAINTENANCE PLAN Task Clean or replace filters disposable or metal frame theol level Visually check the oil level through the sight glass on the side of the compressor casing Position check of the Check the heating resistance is fitted properly and tight compressor crankcase heater around the compressor bod Belt tension check Centrifugal fan bearings check Check absorbed amps Check smoke detector Check CLIMATIC control set Refer to the commissioning sheet Check all set points points and var
54. fore starting the 39 Set re rer ret 40 RIETI 41 VENTILATION 2 RT T 42 Mo nting E E 43 Jede u DEEP TETTE 44 j SS E s 2 2 y s 52 nid ec L CONIO C E 2 I 9 54 REFRIGERATION CIRCUIT Fl cioniceexpansi yalyeu uu L Lu uuu 55 Advanced scroll temperature protection nnne nnne nnn nnn 56 HEATING OPTIONS Hot Water 57 59 Diss RR T 60 CONIROL 8 ze 71 MAINTENANCE DIAGNOSTI C nn rn errare sare saria 73 2 OVA MR 73 Aae ale 105 75 Outdoor adal TaN 75 u u 75 AIS RN 76
55. here sufficient space for the equipment s the surface on which the equipment is to be installed sufficiently solid to withstand its weight A detailed study of the frame must be made beforehand Do the supply and return ductwork openings excessively weaken the structure Are there any obstructing items which could hinder the operation of the equipment Does the electrical power available correspond to the equipment s electrical specifications Is drainage provided for the condensate Is there sufficient access for maintenance Installation of the equipment could require different lifting methods which may vary with each installation helicopter or crane Have these been evaluated Ensure that the unit is installed in accordance with the installation instructions 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 are obstructing the duct connections or hindering assembly and maintenance access FLEXYII WSHP IOM 0212 E INSTALLATION REQUIREMENTS The surface on which the equipment is to be installed must be clean and free of any obstacles which could hinder the flow of air to the condensers Avoid uneven surfaces Avoid installing two units side by side or close to each other as this may restrict the airflow to the condensers Before installing a packaged Rooftop u
56. hich 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 delivery of the Rooftop 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 The warranty shall not apply in the following cases 1 If the corrosion of the casing is caused by external damage to the protective layer such as scratches projections abrasion impacts etc 2 If the casing is not kept continually clean in the course of maintenance work or by a specialist company If the casing is not cleaned and maintained in accordance with regulations 4 Ifthe Rooftop units are installed on a site or in an environment which is known to be corrosive unless a special protective coating has been 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 highly resistant to corrosion the warranty will not be applied for rooftop installed at less than 1000m away from the sea Note With the exception of the casing the rest of the machine is covered by the warranty of our general terms of sale DO NOT CONFUSE THE WARRANTY WITH MAINTENANCE
57. iables are set according to this document Check clock settings Check the time and date of the control Check the position and tightness of refrigeration components Check airflow rate safety switch if fitted water coil Check three way valve on hot water coil Check economizer actuator operation Check refrigeration 4 way valve Check tightness of all electrical connections FLEXYII WSHP IOM 0212 E LENNOX Operating mode winter Yearly before Estimated time Replace filters with new ones if disposable Vacuum clean or blow the dirt Wash and dry carefully Replace media if necessary Blocked filter will reduce the performance of the unit THE UNIT MUST NOT OPERATE WITHOUT FILTERS Check belt tension information on installation manual Replace belt if necessary Isolate unit from the main power supply Push the fan wheel manually and check for abnormal noises Bearings are lubricated for life but may need replacement after 10000 hours Check absorbed amps on all the three phases Compare with the nominal value given in the electrical wiring diagram Start the unit Trigger the smoke detector by moving a magnet around the detector head Reset unit and control Check systematically all connections and fixings on the refrigeration circuit Check for oil traces eventually a leak test should be conducted Check operating pressures correspond to the ones indicated on the commiss
58. iameter 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 CONNECTION Vertical supply CONNECTION FLEXYII WSHP IOM 0212 E WATER CONDENSING LENNOX WATER SOURCE HEAT PUMP ONLY Water connections The water circulating pump will be preferably installed upstream so that the evaporator condenser will be subjected to positive pressure Inlet and Outlet water connections are indicated on the certified drawing sent with the unit or shown in the sales brochure The water pipes connected to the unit must not transmit any radial or axial force or any vibration to the heat exchangers It is important to follow non exhaustive recommendations hereunder e Comply with the water inlet and outlet connections shown on the unit Install manual or automatic air purge valves at all high points in the circuit Install a safety valve as well as an expansion tank to maintain the circuit pressure Install thermometers in both the inlet and outlet water connections Install drain connections at all low points to allow the whole circuit to be drained Install stop valves close to the inlet and outlet water connections Use flexible connections to reduce vibrations transmission After testing for leaks insulate all pipe work to reduce thermal leaks and to prevent condensation If the external water pipes are in an a
59. ignal Extraction Fan ON AIR Pressure Switch ON uL Pre Ventilation 30 seconds Fire up Electrode 4s Gas Control Valve Closes BURNER TOP Gas Valve Open dieci Gas Control Valve Closes BURNER STOPS Fault on Gas Control Block lonisation 1second after tha and nf Gas Valve remains Open 6 Minutes Delay Normal Operation Y NO Air Press Switch ON or Fault on CLIMATIC Pe WL H Signal from lonisation YES L m AAA NO FLEXYII WSHP IOM 0212 E 66 HEATING GAS BURNER LENNOX 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 gt 20 mbar when the Burners shut down Adjust the set points to priorities the burner Increase the value of the room temperature set point to a temperature higher than actual room temperature DIAGNOSTIC TABLE BALTIC GAS BURNER SAGE eec ACTION POSSIBLE SOLUTION ane Check connections on the blower blower Replace thermostat thermostat Heating xiraction fans sped gas Check valve s opening amp supply pressure Restore gas supply Requested start Fault on the superheat thermostat on the gas burner support bar After 10 seconds safety shutdown Check connect
60. ioning sheet Shut down supply fan The fault must be detected within 5 seconds Increase room set point 10 above the actual room temperature Check operation of the piston It must move away from the valve head Reset the control Check all fixings and transmission Stop the unit using the control The fresh air damper must close Start the unit The fresh air damper should open With the unit running in cooling mode increase the room set point temperature by 10 The unit should switch to heat pump mode Reset the control Power down the unit and check and tighten all screws terminal and electrical connections taking a particular attention to the power lines and low voltage control wires MAINTENANCE PLAN LENNOX s 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 29 bar 1 0 auto reset 22 bar 0 7 Reconnect fans Switch off the centrifugal supply fan and wait for the LP switch to cut out 0 5 bar 0 5 reset 1 5 bar 0 5 Check the fan blades conditions and all fan guards and guards protections Check the good positioning and operation of all sensors Check position of all sensors Check the values given in the control system Replace sensor if necessary Check the fresh air grilles if fitted If dirty or damaged Check and clean if necessary all remove from the unit and clean with high pressure water f
61. ions of the control block on by the ignition the gas valve control block Check superheat thermostat s operation Replace superheat after manual reset thermostat Repositioning of the control block on the valve Starting of Replace valve the Extraction Fans extraction are running fans Check the free movement of the fan wheel Check Electrical connection on the Gas Replace fan Nothing happens Ignition Control Block and on EF connection Replace EF connection Board board If necessary Check the Fan supply voltage Check the fire up electrode Check the pressure drop at the pressure Re position the pressure switch It must be higher than 165 Pa switch tube Fan is ON fire up frames Check the good operation of the pressure Change the pressure electrode switch using an Ohmmeter and by artificially switch electrode should spark creating a depression in the tube After 4 seconds Remove the air from the the GAS Burner Gas pipe work still not operating Adjust the injection and safety Remove the control box from the gas possum shutdown by the block value Continuous Ignition Control Change the Control Box seconds the and sparks gas burner Check the whole from fire up Within 4 seconds Check the Position and connection of the fires up electrical supply electrode Adjust the supply and injection pressure if gas is different from natural gas After 30 to 45 seconds
62. j EX z 1 2 j 4 5 6 7 6 310 14 20 30 4D Velocity ana in uscta Aur outlet velooty I f LEVELING T NE d CULT 2 3465 7 10 30 50 70 100 200 300 500 700 1000 Fressione dinamica Velocity Pressure FLEXYII WSHP IOM 0212 E Ea E Ge mh ms Pa POTENZA CUSCINETTI BEARING POWER LENNOX 50 VENTILATION AIRFLOW BALANCING LENNOX ADH500L DIANETRO GIRANTE 500 mm WHEEL DIAMETER EL i RA Kqgim i S L 5 gt 2400 LZ i ae KW Z LR Kt K 5 2000 23 NV VZ A 1800 X S NOA 1500 La Ls Es 1600 N lt PIE N RA 1400 24 23 132 17 J 152 7 22m 2 M SEES AE TA 22 27 104 182 A AN SS S IN 2 fim 1200 Ape INE mm of L PI 1000 1 gt sy la Lis 800 len ous i ALES EGET N 500 DH lo LOT UNA Un L w IAS 1 ED k u l4 250 j I VSS Leila E T1 160 I oM b 2 2 140 BE avi 5 120 TELA le 0 4 71 la te a OL rr 07 I 14 2 3 Portata X 1000 T 4 5 6 78910 14 20 30 42 mis Velocita ana n uscita Air outlet velocity 2 3 45 7 10 20 30 50 70 100 200 300 500 7001000 Pa gt Pressione donamica Vele
63. lic systems Keep the heat exchanger covers in position AQUILUX cover Keep protective plastic film in position Ensure the electrical panels are closed Keep all items and options supplied in a dry and clean place for future assembly before using the equipment MAINTENANCE KEY On delivery we recommend that you keep the key which is attached to an eyebolt in a safe and accessible place This allows you to open the panels for maintenance and installation work The locks are turn then tighter figure 2 Figure 2 CONDENSATE DRAINS The condensate drains are not assembled when delivered and are stored in the electrical panel with their clamping collars Fig 3 To assemble them insert them on the condensate tray outlets TRANSPORT HANDLING LENNOX MANDATORY HANDLING DEVICES Handling slings to guide the I unit towards the roofcurb wg Vacuum lifting beam to position the unit COMPLIANT NON COMPLIANT FLEXYII WSHP IOM 0212 E 6 TRANSPORT HANDLING LENNOX DIMENSIONS AND WEIGHTS F amp G BOX FLEXY2 FCMFHMFGMFDM 85 100 120 150_ H BOX A mm 2200 2200 2200 2200 2200 2200 2200 5 mm 3350 3350 3350 4380 4380 5533 5533 D M 9 imm 360 360 360 450 450 615 615 170 200 230 G BOX H BOX Weight of standard units FCM kg 990 1065 1141 1442 1505 1752 2052 Weight gas unit FGM we FW
64. loop OMI AU OM MEE 15 FSS SSO So S Tu 15 INSTALLATION A ROOF MOUNTING FRAME 1 1 7 4232422 21 17 LUN VS RNC 18 Non adjustable non assembled roof curb installation 19 Energy recovery 21 SERVICE MANUAL m 31 FLEXYII WSHP IOM 0212 E IMPORTANT NOTICE Safety instructions LENNOX 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 FDM 85 FDM 100 FDM 120 FDM 150 FDM 170 FDM 200 FDM 230 FGM 85 FGM 100 FGM 120 FGM 150 FGM 170 FGM 200 FGM 230 FWH 85 FWH 100 FWH 120 FWH150 FWH170 FWM 85 FWM 100 120 FWM150 FWM170 FXK 25 FXK 30 FXK 35 FXK 40 FXK 55 FXK 70 FXK 85 FXK 100 FXK 110 EXK 150 FXK 170 NOTES FOR UNIT FITTED WITH GAS BURNER THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL VENTILATED AREA IF MACHINE IS INCLUDING GAZ BURNER MINIMUM CLEARANCE AROUND THE UNIT MUST BE AT LEAST 8 TO ALLOW A PROPER GAZ FLUE DILUTION IF NOT POSSIBLE THE FRESH AIR INTAKE MUST BE DUCTED AT LEAST 8 M AWAY FROM THE GAS BURNE
65. make any mistake by considering lt 6 that the external static pressure available LU is the one calculated with one fan providing the half of the nominal flow here 15000m3 h It can be determined that the fan is providing approximately 15000 m3 h with a total pressure Prot 630 Pa pe The pressure losses in the unit are the sum of all pressure drops across the different parts of a unit Coil and filter measured 89 Pa Inlet into the unit 50 Pa Options 16 Pa for economiser and 15 Pa for electric heater H AP 89 16 15 50 170 The dynamic pressure at 15000m7 h is given at the bottom of the fan curve Pd 81 Pa ALE The external static pressure available is E therefore PRESSIOME TOT ESP Pror Pd APint 2630 91 170 369 6 7 amp 510 12 16 eh Pa 1000 i E 1 i n E TANN T 5 uv i n ach 10 H 10 4 BS ech rus oft I vua 1 1 n 4 24 19 d 20 JU TW WU CD HEU a Prose one a Velocity reste FLEXYII WSHP IOM 0212 E 46 VENTILATION AIRFLOW BALANCING LENNOX AT15 15G2L 747 DIAMETHO GRANTE 393 mm WHEEL DIAMETER p 1 2 Kg m REND TOT V LA s IMPELLER TOTAL ETT 4 60 67 gt m Pa BEARING POWER 5 5 TOTAL PRESSURE
66. n blower is running Set the control to ON This will priorities the gas burner Increase the set temperature room set point temperature to a temperature higher than the actual room temperature y Extractionfan Smoke extractionfan ON 30 to 45 seconds pre ventilation _ Fire up spark electrode 45 Opening of the gas valve High Heat lb ett ttt Flame propagation towards the ionisation poe eet LELLLLLLELELLLLLL If ionisation within 5s Normal running b mm EEE I block LTT climatic controller If incorrect sequence refer to the fault analysis table to identify the problem FLEXYII WSHP IOM 0212 E 60 HEATING GAS BURNER 60 amp 120 kW LENNOX PRESSURE ADJUSTMENTS ON HONEYWELL PRESSURE REGULATING VALVE TYPE VK 4125 P Pressure regulator adjustment with 300mbar gas supply High Heat Injection Pressure Checks Check and adjust if necessary the valve OUTLET pressure to 10 4mbar G 20 13 1mbar for Groningen G25 amp 34 3 mbar for propane G31 fig 17 The Burner must run in High Heat mode for this check Place the tube of the accurate manometer on the Inlet pressure port Figure 15 of the Gas Regulating Valve after having loosened the screw by one turn INLET PRESSURE MEASURING The out pressure must be measured on the pressure tap located on the gas injector
67. nit it is important to understand The direction of prevailing winds The direction and position of air flows The external dimensions of the unit and the dimensions of the supply and return air connections The arrangement of the doors and the space required to open them to access the various components CONNECTIONS Ensure that all the pipe work crossing walls or roofs are secured sealed and insulated To avoid condensation problems make sure that all pipes are insulated according to the temperatures of fluids and type of rooms NOTE The AQUILUX protection sheets fitted to the finned surfaces must be removed prior to start up 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 _ D PAN enr 7 ain H E Tri Ium ul o P nem iis W 3 Dill 11 non FCM FHM FGM FDM FWH FWM F BOX 1 Add 1 meter if the units are equipped with gas burner FLEXYII WSHP IOM 0212 E LENNOX 1 DUCT CONNECTIONS LENNOX RECOMMENDATIONS FOR DUCTS CONNECTIONS Some rules must be complied with for the connections between ducts and unit done on site Whatever the supply configuration is respect a minimal duct s length D of 2m before any elbow or any duct s d
68. nometer from 0 to 3500 Pa 0 to 350 mbar 0 1 full scale A Multimeter with Ohmmeter and Micro amps scale An Adjustable Spanner Tube Spanner Set 5 7 8 9 10 and 13 Flat spanner 5 7 8 amp 9 Flat Screwdrivers diameter 3 and 4 Fillips n 1 Vacuum cleaner Paint brush GAS BURNER SUPPORT BAR 68 lt LENNOX GAS BURNER HEATING 120kW 69 FLEXYII WSHP IOM 0212 E HEATING GAS BURNER LENNOX FLEXYII WSHP IOM 0212 E 70 CONTROL VARIABLES Function LENNOX The Climatic 60 has free inputs outputs on the main board BM60 and the expansion board BE60 to offer different possibilities to customize input output for remote control of the unit Description Free customized inoputs outputs number depends on added option Without any option expansion board BE60 is available with DCBO option Below not always available means that some inputs outputs could be used by options Refer to the electrical wiring diagram or to the CL60 IOM Digital outputs dry contacts NO Maximum 2 free output contacts on 60 BM J14 NO7 Not always available BM J15 NO12 Not always available Maximum 4 free output contacts on BE60 BE J5 NO1 Not always available BE J6 NO2 always available BE J7 NO3 always available BE J8 NO4 always available Functions can be set among followings Alarm Alarm General Minor A Alarm Minor Major A Alarm Major Filter A Alarm Dirty filt
69. nt each weekday You must set a schedule for monday tuesday and sunday The visualization of another weekday is done by pressing the prg button Pressing the alarm button directs you to the alarm list display e Pressing the prg button displays the next weekday Pressing the esc button directs you to rooftop setup menus display Pressing the up arrow button increases and validates the selected value Pressing the enter button commits the change and it puts you to the next value Pressing the down arrow button decreases and validates the selected value 102 DC60 DM60 ROOFTOP IOM 0212 E LENNOX www lennoxeurope com SALES OFFICES BELGIUM AND LUXEMBOURG 323 633 3045 FRANCE 33 1 64 76 23 23 GERMANY 39 02 495 26 200 NETHERLANDS 31 332 471 800 POLAND 48 22 58 48 610 PORTUGAL 351 229 066 050 4 RUSSIA 7 495 626 56 53 34 902 533 920 UKRAINE 380 44 461 87 79 UNITED KINGDOM AND IRELAND 44 1604 669 100 OTHER COUNTRIES LENNOX DISTRIBUTION 33 4 72 23 20 00 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 FLEXYII WSHP IOM 0212 E Installation and service must be performed b
70. o minimum opening 40 Fresh Air Force the damper to minimum opening 50 Fresh Air Force the damper to full opening 100 Fresh Air Unloaded Free Cooling mode Fresh Air Unloaded Free Heating mode Air Quality Unloaded control Circuit Defrosting cycle delayed Compressor Circuit Unloaded immediately 5096 of compressors running Circuit Unloaded all compressor Circuit Unloaded all compressor in heat pump mode Circuit and Heaters Unloaded all Heaters Unloaded immediately 50 of heaters running Heaters Unloaded all heaters Control Force the Priority of the heaters vs Compressors TCB G TCB B TCB W1 TCB W2 TCB Y1 TCB Y2 BMS input reading for BMS Schedule Force the Mode A Schedule Force the Mode B Schedule Force the Mode C Schedule Force the Mode D Schedule Force the Mode BMS FLEXYII WSHP IOM 0212 E LENNOX 72 MAINTENANCE DIAGNOSTIC LENNOX REFRIGERATION LP PROBLEMS AND LP CUT OUTS FLEXYII WSHP IOM 0212 E Refrigerant charge too low In Heat Pump Mode the temperature difference between T outdoor and Tevap Dew is too high 5 C lt Delta T lt 10 C excellent 10 Delta T 15 acceptable 15 C lt Delta T lt 25 C too high Refrigeration circuit blocked in distribution Liquid line drier blocked High temperature difference between inlet and outlet of the drier Contaminant in the expansion valve Expansion valve not adjusted properly
71. ol for protection use of a 3 way valve The hot water coil connections and against freezing valves are all tested at pressure of 15 bars Frost protection is provided by forcing the opening the 3 way valve when GLYCOL IS THE ONLY EFFECTIVE PROTECTION supply temperature from hot water coil falls below 8 C and AGAINST FREEZING by stopping the outdoor fan when that supply temperature falls below 6 C In addition to that the 3 ways is also The antifreeze must protect the unit and avoid icing under opened at 10 value if the outdoor temperature falls below winter conditions an adjustable value WARNING Mono ethylene glycol based fluids Hot water coils are always factory fitted wired and fully produce corrosive agents when mixed with air tested prior to shipment Hot water coil includes automatic purge system 2 Drain the installation EN You must ensure that the manual automatic air bleeders The hot water coil is fitted with a three way proportional have been installed on all high points in the system In valve and two isolating shut off valves Two spanners must order to drain the system check that all the drain cocks be used to tighten the connections One spanner must have been installed on all low points of the system maintain the valve body when connecting the pipe work to the main Failure to do so may damage the pipes joints and HOT WATER COILS FROZEN DUE TO LOW AMBIENT notes warranty CONDITIONS ARE NOT CO
72. quipment Above all ensure that all the adjustable returns are facing outward 1 figure 4 They are usually turned inside out for transport Place the roof mounting frame on the trimmer beam by first lining up the inlet and the outlet opening 2 figure 5 After levelling the frame secure the adjustable returns on the trimmer It is important to centre the unit on the roof frame FLEXYII WSHP IOM 0212 E zr INSTALLATION ON A ROOFMOUNTING FRAME LENNOX 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 Outside of frame must be insulated with rigid type insulation We recommend a minimum of 20 mm thick insulation 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 Where pipes and electrical conduits extend through the roof flashing must conform to local codes of practice Fig 7 Before installing the equipment make sure that seals are not damaged and check that the unit is secured to the mounting frame Once in position the bottom of the equipment must be horizontal The installer must comply with local authority standards and specifications FLEXYII WSHP IOM 0212 E 18 INSTALLATION ON
73. rbons etc CAUTION In the event of fire refrigerating circuits can cause an explosion and spray coolant gas and oil TRANSPORT HANDLING Never lift the unit without forklift protections Remove the forklift protection before installation 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 advised to fix curbs and roofcurbs to the unit Whatever the supply configuration is respect a minimal duct s length of 2m before any elbow or any duct s section change COMMISSIONING t must only be carried out by trained refrigeration engineers Don t forget to open the insulation valve on the liquid line before starting the unit FILTERS Do the filters fire classification s choice according to local regulations FANSTART Any adjustment has to be done power stopped GAS Any work on gas module must be carried out by qualified personnel A unit with gas module must be installed in accordance with local safety codes and regulations and can only be used in planed installation conditions for outdoor Before commissioning this type of unit its mandatory to ensure that the gas distribution system is compatible with the adjustment and settings of the unit
74. rea where the ambient temperature is likely to fall below 0 C insulate the piping and add an electric heater e Ensure full earthling continuity A drainage plug is located at the base of the evaporator A drainage pipe may be connected to this to enable drainage of evaporator water for service operations or for seasonal shut down Connections at the inlet and outlet are Victaulic type Water analysis The water must be analysed the water circuit installed must include all items necessary for water treatment filters additives intermediate exchangers bleed valves vents isolating valves etc depending on the results of the water analysis We do not advise operation of the units with open loops which can cause troubles with oxygenation or CAUTION operation with untreated ground water Use of untreated or improperly treated water can cause deposits of scale algae and sludge or cause corrosion and erosion It is advisable to call in a qualified water treatment specialist to determine what kind of treatment will be necessary The manufacturer cannot accept liability for damage caused by the use of untreated or improperly treated water salt water or brine Here are our non exhaustive recommendations given as an indication e No NH4 ammonium ions in the water they are very detrimental for copper 10mg l Cl Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture lt 10 mg l
75. resh air grilles cleaner Refit on unit once clean and dry EHE Visually check the coils for dirt If not too dirty cleaning Indoor with a light brush may be enough WARNING fins and T following local tubes are very fragile Any damage WILL reduce om hit regulations the performances of the unit If very dirty deep industrial cleaning cleaning is required using de greasing agents external contractors must be called winter Estimated time min Yearly before Check HP LP safety switches Isolate the unit Pull the electrical heater out of the heater Check electrical heater element module box and check the resistances of traces of for excessive corrosion corrosion Replace resistance as required Check anti vibration mountings Visually mountings on compressors th if osa aaj eat and centrifugal fan replace Replace if damaged ment Ep d d d tor Take a sample of oil from the refrigeration circuit traces of acid in the oil Check the glycol concentration in the pressurised water Check glycol concentration in the circuit a concentration of 3096 gives a protection down to hot water coil circuit approx 15 C Check the circuit pressure Switch the unit to heat pump mode Change the set point Check defrost cycle with 4 way to obtain the standard defrost mode and reduce the cycle valve inversion time to the minimum value Check the opera
76. s 73 MAINTENANCE DIAGNOSTIC LENNOX gt REFRIGERATION Heat pump mode Check the filter before the indoor coil measure and estimate the airflow rate Incorrect airflow rates increase the speed of the fan Cooling mode Check the condenser fan Amps Incorrect water flow rate Water cooled rooftop only Check water flow value Summer operation oeveral hours after the unit has stopped check the correspondence between the measured pressure and the outdoor temperature 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 refrigerant and vacuum the circuit Ensure very low and slow vacuum for R407c Recharge the unit HP PROBLEMS AND HP CUT OUTS Moisture or contaminants in the system Check the condenser coil and clean is necessary Condenser coil is obstructed Water Filter is obstructed Check the water filter and clean if only for Water Cooled Rooftop necessary Recycled Hot Air Check clearance around the condenser Incorrect adjustment of the expansion valve 3 bar Thermostatic 2 to 3 bar Thermostatic Low refrigerant charge Refer to LP problems and LP cut out Expansion Valve hunting Filter drier obstructed with gas bubbles section at the expansion valve inlet Moisture in the system Open the superheat adjustment on the Ver
77. sabling keys e FSul Password always to value 22 e rEar Realtime clock DC60 year e Realtime clock DC60 month e ndas Realtime clock DC60 day e udas Realtime clock DC60 weekday 1 Monday e Hour Realtime clock DC60 hour mins Realtime clock DC60 minute ESC Exits the settings mode Changing the parameters value To activate the modified mode value _ After selecting the desired parameter by rotating the knob Press the knob Thes et symbol appears on the right side of the value Turn the knob to adjust the desired value Press again on the knob to confirm your choice The t symbol is no longer displayed on the right side of the value The rotation of the knob is for select a new setting Mandatory values e Addr 31 bAUd 2 e PSul 22 DC60 DM60_ROOFTOP IOM 0212 E 87 DISPLAY DC60 LENNOX INITIALIZATION If the connection between the CLIMATIC 60 and the DC60 is not correct Offline screen displays only the symbol Cn In this case check e the connection between CLIMATIC 60 DC60 the setting of the DC60 e the power of CLIMATIC 60 If the connection between the CLIMATIC 60 and the DC60 is correct Online to power up the screen displays only the symbol I n i t This phase allows the CLIMATIC 60 to set up the DC60 with options of rooftop After some seconds DC60 is operational PRESENTATION Showing
78. ssure switch Fig 23 The Flame must disappear and the extraction fan must carry on running However NO fault will be displayed Gas ignition control block or CLIMATIC Fig 23 After reconnecting of the tube the Burner will restart after a period of 30 to 45 seconds pre ventilation Gas pressure switch test With the gas burner running close the shut off valve located before the rooftop fig 24 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 FLEXYII WSHP IOM 0212 E LENNOX lonisation Probe test With the gas burner running disconnect the terminal plug coming from the ionisation probe to the gas ignition control box The flame disappears The fan is still running and attempting to restart the burner restart cycle 30 to 45 seconds if the ignition probe is not reconnected at the end of the ignition sequence the burner will stop completely The fault light on the gas ignition control block is ON Manually reset the gas ignition control block to eliminate the fault IN CASE OF PROBLEMS REFER TO THE START UP SEQUENCE FLOWCHART NEXT PAGE 65 HEATING GAS BURNER LENNOX GAS BURNER FIRE UP SEQUENCE Operation from control thermostat GAZ Closed Supply Thermostat YES Gas Ignition Control Block S
79. support bar to avoid the pressure drop due to the elbow after the valve 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 Fig 17 FLEXYII WSHP IOM 0212 E 61 HEATING GAS BURNER 60 amp 120 kW 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 for Groningue G25 amp 15 3 mbar for propane G31 fig 18 FLEXYII WSHP IOM 0212 E LENNOX 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 each type of gas mbar oressure Injection min Injection G20 20 0 1 3 7 0 1 10 4 0 2 G25 Groningue 25 0 1 3 5 1 0 1 13 1 0 2 G31 GPL 37 0 1 9 15 3 0 3 34 3 0 6 Category 62 HEATING GAS BURNER 180 amp 240kW PRESSURE ADJUSTMENTS HONEYWELL PRESSURE REGULATING VALVE TYPE VR 4605P Pressure regulator adjustment with 300mbar gas supply The Burner must run in High Heat mode for this check Place the tube of the accurate manometer on the Inlet pressure port Figure 19 of the Gas Regulating Valve after having loosened the screw by one turn Inlet pressure meas uring port
80. then be estimated P meca fan P meca Motor X 1 Transmission ESP Pror Pd APint Pmeca fan Pelec X T meca motor X T Transmission Pmecafan V X X X 5 X N meca motor X N Transmission Table 2 Motor information This formula can be approximated in this way Motor Size T meca motor 0 75 KW 79 9 ads VETERE END With the fan rpm and the mechanical power at the fan shaft an operating point and the supplied airflow can be estimated using the fan curves 90kW 1467rpm 077 909 Table 3 Accessories pressure drops T Heat CA UV Electric Electric Electric Heating Adjustable Multidire Recovery z Heater Heater Heater Gaz ctional Filters Pie roofcurb Modul S M H fired H Roofcurb Fresh 12000 pt 7 9 8131516 41 7 2 164 15000 7 105 30 13 22 6 7 7 23 2 3 204 23000 38 1400015 94 2 n 19 6 v 8 2 3 30 19 100 18500 15 143 44 18 31 8 130 t 34 4 5t 22 23000 28 199 63 26 44 1 14 16 5 6 78 33 150001 7 105 30 13 2 7 8 9 2 27 3 24 120 20500 23000 150 18000 1 75 15 6 10 4 5 7 16 S 35 170 26000 12 130 33 12 19 9 10 13 33 6 72 25 35000 29 204 54 19 33 15 18 59 2 131 99 210001 5 94 21 8 4 8 9 10 2 4 49 198 170 30000 35000 2400
81. tilation state Bottom right State mode based on the schedule hour minute of CLIMATIC 7S Night mode 1 Day mode f Day Imode II mode Bottom left P If the unit is in alarm this symbol is displayed Pressing the alarm button directs you to the alarm list display Pressing the prg button directs you to rooftop setup menus display Pressing the esc button takes you to the selected rooftop choice display Pressing the arrow button increases the set point value Pressing the enter button takes you to the rooftop operation display Pressing the down arrow button decreases the set point value DC60 DM60 ROOFTOP IOM 0212 E 9 DISPLAY DM60 Rooftop off If the rooftop is Off this screen is activated pressing 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 display Rooftop operation pressing the alarm button directs you to the alarm list display pressing the esc button takes you to the main display pressing the arrow button directs you to the previous screen pressing the down arrow button directs you to the next screen View edit status of the unit On Off Pressing the prg button reverses the On Off state of the unit On the left of the house outdoor humidity value visualization if enable
82. tion of the defrost cycle Pull out the burner to access the tubes refer to Gas nl corrosion burner section in the installation manual Clean the in shot burners and the blower wheel lightly with a brush Sweep the flue and flue box Wipe off the Sweeping and cleaning the gas dust from the housing of the motor Clean combustion air inlet louver Pull out baffles from the tubes sweep the tubes CHECK FLUE BOX GASKET Gas supply Refer to gas burner section in the installation manual for oressures connections checks details Refer to gas burner section in the installation manual for Gas regulation valve settings d tails Tm RoR gas burner section in the installation manual for REN CAUTION the water circuit may be pressurized Observe the usual precautions when depressurizing the Check and clean water filter only circuit before opening it Failure to observe these rules for water cooled rooftop could lead to accidents and cause injury to service personal FLEXYII WSHP IOM 0212 E S49 burner SPARE PART LIST LENNOX Refrigeration components Designation Familly Code 4220432V ze KE Comp 4220433 ol 4310443M_ 4910472H OD 4310446R_ Ff tx 4310447T_ Col 4910448V 0 00x Col 4910449W ODHox Col 4910450X DC D tendeurthermostaique TGEL20 23 4720912V x x D tendeur th
83. 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 If the absorbed power is greater and the pressure lower than the rated values the ventilation system has a lower pressure drop than anticipated Reduce the flow by reducing the rpm If the system resistance is significantly lower than design there is a risk that the motor will overheat resulting in an emergency cut out If the absorbed power is lower and the pressure greater than the rated values your system has a higher pressure drop than anticipated Increase the flow by increasing the rpm At the same time you will increase the absorbed 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 4 Allen screw s on the pulley see figure 13 Pulley li Nb of turns Actual diameter DM or distance between faces for a given number of Pulley eternal from fully turns from fully closed with SPA belt in mm 999 Diameter py Mirco 55 Table 1 The easiest way to determine the fan rotation speed is to ALLEN WRENCH 4 use a Tachometer If not available the fan rpm can be estimated using the following two methods 12 Method with the pulley secured in place Measure the distance between the two o
84. ton positions you in the list DC60 DM60 ROOFTOP IOM 0212 E 99 DISPLAY DM60 LENNOX Setup menus Access to the setup menus is protected by a password The password must be entered digit by digit If the password is correct the lock opens and the selection of the function choice is active Pressing the alarm button directs you to alarm list display Pressing the esc button takes you to the main display Pressing the arrow button increases the password digit value or selects the previous function Pressing the enter button 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 Temperature View edit the current schedule mode of the heating mode setpoint e View edit the current schedule mode of the cooling mode setpoint Pressing the alarm button directs you to alarm list display Pressing the esc button directs you to rooftop menus setup display Pressing the up arrow button increases the set point value Pressing the enter button commits the changes then it puts you on the next or previous setpoint Pressing the down arrow button decreases the set point value 100 DC60 DM60 ROOFTOP IOM 0212 E DISPLAY DM60 LENNOX Setting Reset Alarms View edit alarm and safety reset Pressing the alarm button directs you to alarm list
85. uilds inside compressor e Initial system charging or recharging after servicing No refrigerant flow to carry motor heat away Compressor is run with too little system charge Very common on split system Compressor is protected as lt Unloaded gt but continues to run Motor protector opens Klyxon Will result in very low suction pressures 1 7 Bars Compressor turns off cools not disable low pressure cutouts while charging Motor protector resets compressor restarts Charge high side with liquid first e Field servicing system problem causes overheating Technician will observe Balanced pressures Risk of misdiagnosis as failed compressor Must stop pump cool thoroughly reset e Bi metal disk resets before motor protection e Cycle will continue until cause of overheat is fixed Temperature Behavior with ASTP Protection 180 150 120 9 9 ASTP Klyxon 1N 90 Discharge I l 65 I oL 40 Compressor Runs off i 0 20 40 66 80 100 120 140 I 160 Time Minutes PROTECTOR RESETS PUMP RESTARTS FULLY LOADED DISC OPENS MOTOR PROTECTOR SCROLLS UNLOAD OPENS PUMP TURNS OFF FLEXYII WSHP IOM 0212 E 50 HEATING HOT WATER COIL LENNOX FREEZE PROTECTION HYDRAULIC CONNECTIONS 1 Glycol for freeze protection Hot water coils offer fully modulating control through the Check the hydraulic system contains Glyc
86. ulley Position the screws without turning them Place the assembly on the shaft and screw in the screws alternatively and evenly Using a mallet or a hammer with a wooden wedge tap on the face of the hub to keep the assembly in place Torque the screws to 30 Nm Take the 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 After 50 operating hours check that the screws are still in place PULLEY INSTALLATION amp REMOVAL The pulley is held in position by the key and a screw located in the groove After unlocking removing this screw by pulling against the shaft spindle if necessary use a mallet and tap uniformly on the hub to remove it To assemble proceed in the reverse order after having cleaned and de greased the motor shaft and the pulley bore PULLEYS ALIGNMENT After adjusting one or both of the pulleys check the transmission alignment using a ruler placed on the inner face of the two pulleys NOTE The warranty may be affected if any major modification is made to the transmission without obtaining our agreement beforehand FLEXYII WSHP IOM 0212 E LENNOX 43 VENTILATION AIRFLOW BALANCING LENNOX The actual resistance of ductwork systems is not always identical to the calculated theoretical values To rectify this it may be necessary
87. utside faces of the pulley Using table 1 the motor pulley actual diameter can be estimated FLEXYII WSHP IOM 0212 E Ll C Y C C MM VENTILATION AIRFLOW BALANCING LENNOX 274 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 total motor pulley actual diameter pressure available Pror and the corresponding dynamic Record the fix fan pulley diameter DF pressure Pd can now be estimated for a specific Determine the fan speed using the following formulae operating point The next step consists in estimating the pressure losses PM ean across the unit This can be achieved using the dirty filter pressure sensor Where rpm motor from the motor plate or table 2 and the accessories pressure drop table table 3 from table 1 Also the pressure drop due to the duct inlet into the roof top Dr from machine unit can be taken as 20 to 30 Pa Once the pulleys are adjusted and the belt checked and tensioned start the fan motor and record the Amps and APint AP fiter col AP met AP options Voltage between the phases Using the measured data and table 2 Using the results from above the external static pressure Theoretical mechanical power at the fan shaft ESP can
88. y a qualified installer and servicing agency
89. y high superheat very hot expansion valve Very high discharge compressor Check the pressure drop on the filter temperature drier in the suction line Check operation of the valve by going through cycle inversions Change if necessary Hefer to LP problems High amps measured at compressor Four Way reversing valve possibly blocked abnormal noise from the valve low LP and increasing HP FLEXYII WSHP IOM 0212 E 74 MAINTENANCE DIAGNOSTIC LENNOX INDOOR FAN BLOWER High amps on action Fan motor High amps on reaction Fan motor Unstable running and high vibration Pressure drop in the ducting installation too low Pressure drop in the ducting installation too high Fan jumping from one operating point to the other Reduce the rotation speed of the fan Measure and estimate the airflow and pressure and compare with the specification from customer Reduce the rotation speed of the fan Measure and estimate the airflow and pressure and compare with the specification from customer Change rotation speed of the fan OUTDOOR AXIAL FAN Heat Pump mode Circuit breaker open High Amps due to a low voltage from the main supply High amps due to freezing of the coil Water ingress in the motor connection box Check the voltage drop when all components are running Change the circuit breaker for one with a higher rating Check the adjustable amps on the motor starter Adjust the defrost cycle set points

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