Lennox Baltic BCK 020 User manual

BALTIC
English
August 2003
INSTALLATION
OPERATING &
MAINTENANCE MANUAL

IOM / ROOFTOP BALTIC Series - 0803 - E Page 1
CONTENTS
The present manual applies to the following ROOFTOP versions :
BCK 020 - BCK 025- BCK 030- BCK 035- BCK 040- BCK 045- BCK 050
BHK 020 - BHK 025- BHK 030- BHK 035- BHK 040- BHK 045- BHK 050
BGK 020 - BGK 025- BGK 030- BGK 035- BGK 040- BGK 045- BGK 050
BDK 020 - BDK 025- BDK 030- BDK 035- BDK 040- BDK 045-BDK 050
The technical information 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.
IOM MANUAL
Ref. IOM-RT B/0803-E
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
VENTILLATED AREA.
PLEASE READ CAREFULLY THE MANUFACTURER'S INSTRUCTIONS
BEFORE STARTING THIS UNIT.
THIS MANUAL IS ONLY VALID FOR UNITS DISPLAYING THE FOLLOWING
CODES: GB IR GR DA NO FI IS
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.

Page 2 - IOM / ROOFTOPBALTIC Series - 0803 - E
CONTENTS
INSTALLATION
TRANSPORT - HANDLING ......................................................................................... 4
DIMENSIONS AND WEIGHTS ....................................................................................5
LIFTING THE UNITS ................................................................................................... 6
PRELIMINARY CHECKS ............................................................................................. 7
MINIMUM CLEARANCE AROUND THE UNIT ............................................................ 8
INSTALLATION ON ROOF MOUNTING FRAMES ......................................................9
Adjustable roofcurb .................................................................................................... 10
Multidirectional roofcurb ............................................................................................16
Non-adjustable Non-assembled roofcurb ..................................................................22
Curbing and flashing ..................................................................................................25
ECONOMISER AND EXTRACTION ..........................................................................26
COMMISSIONING 27
BEFORE CONNECTING THE POWER .................................................................... 27
CLIMATIC ..................................................................................................................27
POWERING THE UNIT .............................................................................................28
RUN TEST ................................................................................................................. 28
COMMISSIONING SHEET 29
VENTILATION 30
BELT TENSION .........................................................................................................32
MOUNTING & ADJUSTING PULLEYS ......................................................................33
AIRFLOW BALANCING ............................................................................................34
FILTERS ....................................................................................................................40
FAN STARTER ..........................................................................................................41
HEATING OPTIONS 42
HOT WATER COILS .................................................................................................. 42
ELECTRIC HEATER ..................................................................................................44
GAS BURNERS .........................................................................................................45
CLIMATIC CONTROLLER 55
COMMUNICATION LINKS ......................................................................................... 56
SOFTWARE FEATURES AND LOGIC ......................................................................57
OTHER FEATURES .................................................................................................. 59
CONTROL INTERFACES .......................................................................................... 60
DC50 COMFORT DISPLAY ....................................................................................... 60
DS50 SERVICE DISPLAY ........................................................................................62
DS50 MENU TREE .................................................................................................... 64
SAFETY AND ERROR CODES .................................................................................73
COMMISSIONING .....................................................................................................74
CONTROL INTERFACE CLIMALINK-CLIMALOOK 75
ELECTRICAL WIRING DIAGRAM 83
REFRIGERATION CIRCUIT 93
MAINTENANCE DIAGNOSTIC 95
MAINTENANCE PLAN 98
CONTENTS

IOM / ROOFTOP BALTIC Series - 0803 - E Page 3
IMPORTANT NOTICE
IMPORTANT NOTICE
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:
• The unit shall be isolated from the electrical supply by disconnection and locking using the
main isolating switch.
• Workers shall wear the appropriate personal protective equipment (helmet, gloves, glasses,
etc.).
Work on the electrical system:
• Work on electric components shall be performed with the power off (see below) by employees
having valid electrical qualification and authorisation.
Work on the refrigerating circuit(s):
• 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.
• 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 brazer. The brazing shall comply with the
standard NF EN1044 (minimum 30% silver).
Replacing components:
• In order to maintain CE marking compliance, replacement of components shall be carried out
using spare parts, or using parts approved by Lennox.
• Only the coolant shown on the manufacturer's nameplate shall be used, to the exclusion of all
other products (mix of coolants, hydrocarbons, etc.).
CAUTION:
In the event of fire, refrigerating circuits can cause an explosion and spray coolant gas and oil.
All Baltic units are compliant with the PED directive 97-23-CE.
The following note must be followed carefully.

Page 4 - IOM / ROOFTOPBALTIC Series - 0803 - E
TRANSPORT - HANDLING
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.
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 %. 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.
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 hydraulic 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 ¼ turn + then tighter (figure 2).
CONDENSATE DRAINS
The condensate drains are not assembled when delivered and
are stored
in the electrical panel with their clamping collars.
To assemble them, insert them on the condensate tray outlets
and use a screwdriver to tighten the collars (Figure 3).
Fig. 1
Fig. 2
Fig. 3

IOM / ROOFTOP BALTIC Series - 0803 - E Page 5
TRANSPORT - HANDLING
A
B
D
C
A
B
D
C
AB
D
C
B BOX
D BOX
C BOX
BALTIC BCK/BHK/BGK/BDK 020 025 030 035 040 045 050
View B BOX B BOX C BOX C BOX D BOX D BOX D BOX
Amm 2050 2050 1950 1950 1950 1950 1950
Bmm 1418 1418 1913 1913 2233 2233 2233
Cmm 1220 1220 1220 1220 1220 1220 1220
Dmm 478 478 418 418 418 418 418
Weight of standard units
without hood kg 377 428 501 503 626 630 638
with hood kg 400 451 529 531 659 663 671
Weight of gas units
Standard heat without hood kg 419 472 567 572 709 718 723
Standard heat with hood kg 442 495 595 600 742 751 756
High heat without hood kg 431 484 586 591 730 739 744
High heat with hood kg 454 507 614 619 763 772 777
DIMENSIONS AND WEIGHTS
Fig. 4

Page 6 - IOM / ROOFTOPBALTIC Series - 0803 - E
TRANSPORT - HANDLING
LIFTING B BOX RETRACTABLE LIFTING LUG
LIFTING C BOX LIFTING D BOX
1930 1700
(mini) (mini)
2250 1700
(mini) (mini)
1850 1410
(mini) (mini)
Fig. 5 Fig. 6
Fig. 7 Fig. 8

IOM / ROOFTOP BALTIC Series - 0803 - E Page 7
TRANSPORT - HANDLING
FORKLIFT PROTECTIONS
PRELIMINARY CHECKS
Before installing the equipment, the following points MUST
be checked :
-Have the forklift protections been removed ?
-Is there sufficient space for the equipment?
-Is 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.
REMOVE FORKLIFT PROTECTIONS
BEFORE INSTALLATION
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 unit 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.
Fig. 9

Page 8 - IOM / ROOFTOPBALTIC Series - 0803 - E
TRANSPORT - HANDLING
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.
A
D
B
C
A BCD
B box 1000(1) 1500(2) 1500 1000
C box 1200(1) 1500(2) 1500 1000
D box 1400(1) 1500(2) 1500 1000
(1)Add one meter to this distance if units is fitted with Gas Burner.
(2) Double distance if unit fitted with extraction.
Fig. 10

IOM / ROOFTOP BALTIC Series - 0803 - E Page 9
INSTALLATION ON A ROOF MOUNTING FRAMES
As levels are adjustable, observe the following
recommendations when installing the equipment.
Above all, ensure that all the adjustable returns are facing
outward ( figure 11). 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 12)
After levelling the frame, secure the adjustable returns on
the trimmer (figure 13).
It is important to centre the unit on the roof frame.
2
Fig. 12
Fig. 13
Fig. 11
1