Lennox ROOFTOP FLEXY FCA Series User manual

INSTALLATION
OPERATING &
MAINTENANCE MANUAL
ROOFTOP
FLEXY
English
Sept 2001

IOM / ROOF-TOP FLEXY™ Series - Page 1
CONTENTS
The present manual applies to the following ROOFTOP versions :
FCA 50 - FCA 60 - FCA 70 - FCA 85 - FCA 100 - FCA 120 - FCA 140 - FCA 160 - FCA 190
FCK 50 - FCK 60 - FCK 70 - FCK 85 - FCK 100 - FCK 120 - FCK 140 - FCK 160 - FCK 190
FHA 50 - FHA 60 - FHA 70 - FHA 85 - FHA 100 - FHA 120 - FHA 140 - FHA 160 - FHA 190
FHK 50 - FHK 60 - FHK 70 - FHK 85 - FHK 100 - FHK 120 - FHK 140 - FHK 160 - FHK 190
FDA 50 - FDA 60 - FDA 70 - FDA 85 - FDA 100 - FDA 120 - FDA 140 - FDA 160 - FDA 190
FDK 50 - FDK 60 - FDK 70 - FDK 85 - FDK 100 - FDK 120 - FDK 140 - FDK 160 - FDK 190
FGA 50 - FGA 60 - FGA 70 - FGA 85 - FGA 100 - FGA 120 - FGA 140 - FGA 160 - FGA 190
FGK 50 - FGK 60 - FGK 70 - FGK 85 - FGK 100 - FGK 120 - FGK 140 - FGK 160 - FGK 190
FXA 25 - FXA 30 - FXA 35 - FXA 40 - FXA 55 - FXA 70 - FXA 85 - FXA 100 - FXA 110 - FXA 140 - FXA 170
FXK 25 - FXK 30 - FXK 35 - FXK 40 - FXK 55 - FXK 70 - FXK 85 - FXK 100 - FXK 110 - FXK 140 - FXK 170
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.
Ref. IOM-RT F-0901-E
IOM MANUAL

Page 2 - IOM / ROOF-TOP FLEXY™Series
CONTENTS
INSTALLATION
TRANSPORT - HANDLING .............................................................................................. 3
INSTALLATION............................................................................................................... 10
INSTALLATION ON ROOF MOUNTING FRAME ........................................................... 11
INSTALLATION ON POSTS ........................................................................................... 13
COMMISSIONING .......................................................................................................... 14
OPERATION
AIR FLOW BALANCING ................................................................................................ 15
AIRFLOW BALANCING - FXA/FXK .............................................................................. 24
FILTERS .........................................................................................................................25
HOT WATER COILS....................................................................................................... 26
GAS BURNERS.............................................................................................................. 27
BELT TENSIONING........................................................................................................ 34
PULLEYS........................................................................................................................ 35
CONTROL FUNCTIONS
USING THE KP 17 COMFORT DISPLAY ...................................................................... 36
USING THE KP02 MAINTENANCE DISPLAY ............................................................... 37
USING THE KP07 REMOTE GRAPHICAL DISPLAY .................................................... 47
BMS CONTACTS KIT ..................................................................................................... 56
CLIMATIC™PARAMETERS .......................................................................................... 57
WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS ............................................................................... 63
ELECTRICAL WIRING DIAGRAMS LIST OF ITEMS .................................................... 74
TROUBLESHOOTING
SAFETY AND ERROR CODES ..................................................................................... 77
BEFORE CALLING FOR ASSISTANCE ........................................................................ 82
PLANNED MAINTENANCE............................................................................................ 84
WARRANTY ................................................................................................................... 87
CERTIFICATES
AFAQ CERTIFICATION .................................................................................................. 88
CE CERTIFICATION OF CONFORMITY........................................................................ 89
FILTERS FIRE CLASS ................................................................................................... 90
33 KW GAS BURNER CE CERTIFICATION OF CONFORMITY ................................... 91
60 KW GAS BURNER CE CERTIFICATION OF CONFORMITY ................................... 92
120 KW GAS BURNER CE CERTIFICATION OF CONFORMITY ................................. 93
180 kW GAS BURNER CE CERTIFICATION OF CONFORMITY ................................. 94
INSULATION FIRE CLASS ............................................................................................ 95

IOM / ROOF-TOP FLEXY™Series - Page 3
TRANSPORT - HANDLING
DELIVERY CHECKS
The equipment is shipped at the customers risk, and whose
responsiblity it is to ensure that the products are in good
working order on receipt by checking the following :
- 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 herein.
- Accessories ordered for on site installation have been
delivered and are in good working order.
- The equipment supplied corresponds with 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 %.
Thestart-uppoweristhe maximum value likelytobeachieved
forthespecifiedoperationalvoltage.Thecustomer 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 with the required volume
capacity of 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 (AKILUX
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 accesible place. This
allowsyoutoopenthe panels for maintenanceandinstallation
work.
The locks are ¼turn + then tighter (figure 2).
Figure 2
Figure 1
N˚ SERIE
SERIAL NUMBER
TYPE
UNITTYPE
Usine Dijon
Z.I. LONGVIC
21600 LONGVIC
FRANCE
ANNEE
YEAR
ALIMENTATION
ELEC. SUPPLY
A. MAXI
MAX. AMP.
REFRIGERANT
FLUIDE Kg/CIRC
C1 C3C2 C4
I. DEMARR.
START UP AMP.
C. COMMANDE.
CONTROL CIR.
V
V
A
Hz
FCK 190 2000
215 900-01/01
400 3 50
140 269 24
111111 11
R407C

Page 4 - IOM / ROOF-TOP FLEXY™Series
Model Length Rain Width Height Weight
Cover
mm mm mm mm kg
FC*/FH* 050 downflow 2150 - 1780 1090 750
FC*/FH* 050 upflow 2150 - 1780 1120 750
FC*/FH* 050 horizontal flow 2150 - 1780 1120 750
FGA/FDA/FGK/FDK 050 2200 - 1900 1090 850
FC*/FH* 060 downflow 2821 629 2254 1410 1000
FC*/FH* 060 upflow 2821 629 2254 1410 1000
FC*/FH* 060 side discharge 2821 629 2254 1410 1000
FC*/FH* 060 centrif. condensing fan 2821 629 2254 2000 1100
FGA/FDA/FGK/FDK 060 2821 629 2254 1410 1100
FC*/FH* 070 downflow 2821 629 2254 1410 1000
FC*/FH* 070 upflow 2821 629 2254 1410 1000
FC*/FH* 070 side discharge 2821 629 2254 1410 1000
FC*/FH* 070 centrif. condensing fan 2821 629 2254 2000 1100
FGA/FDA/FGK/FDK 070 2821 629 2254 1410 1150
FC*/FH* 085 downflow 3781 629 2254 1495 1200
FC*/FH* 085 upflow 3781 629 2254 1495 1200
FC*/FH* 085 side discharge 3781 629 2254 1495 1200
FC*/FH* 085 centrif. condensing fan 3782 629 2254 2010 1430
FGA/FDA/FGK/FDK 085 2821 629 2254 1495 1300
FC*/FH* 100 downflow 3781 629 2254 1495 1200
FC*/FH* 100 upflow 3781 629 2254 1495 1200
FC*/FH* 100 side discharge 3781 629 2254 1495 1200
FC*/FH* 100 centrif. condensing fan 3782 629 2254 2010 1430
FGA/FDA/FGK/FDK 100 2821 629 2254 1495 1480
FC*/FH* 120 downflow 3582 629 2254 1410 1500
FC*/FH* 120 upflow 3582 629 2254 1410 1500
FC*/FH* 120 side discharge 3582 629 2254 1410 1500
FC*/FH* 120 centrif. condensing fan. 3582 629 2254 1910 1550
FGA/FDA/FGK/FDK 120 4030 629 2254 1410 1750
FC*/FH* 140 downflow 3582 629 2254 1410 1600
FC*/FH* 140 upflow 3582 629 2254 1410 1600
FC*/FH* 140 side discharge 3582 629 2254 1410 1600
FC*/FH* 140 centrif. condensing fan 3582 629 2254 1910 1650
FGA/FDA/FGK/FDK 140 4030 629 2254 1410 1950
FC*/FH* 160 downflow 3590 900 2254 2050 2000
FC*/FH* 160 upflow 3590 900 2254 2050 2000
FC*/FH* 160 side discharge 3590 900 2254 2050 2000
FC*/FH* 160 centrif. condensing fan 3590 900 2254 2050 2150
FGA/FDA/FGK/FDK 160 4040 900 2254 2050 2500
FC*/FH* 190 downflow 3590 900 2254 2050 2250
FC*/FH* 190 upflow 3590 900 2254 2050 2250
FC*/FH* 190 side discharge 3590 900 2254 2050 2250
FC*/FH* 190 centrif. condensing fan 3590 900 2254 2050 2350
FGA/FDA/FGK/FDK 190 4040 900 2254 2050 2750
TRANSPORT - HANDLING
DIMENSIONS AND WEIGHTS

IOM / ROOF-TOP FLEXY™Series - Page 5
TRANSPORT - HANDLING
Model Length Side Ventil. Width Height Weight
louver louver
mm mm mm mm mm kg
FX* 25 4070 490 600 1633 1055 950
FX* 30 4070 490 600 1633 1055 980
FX* 35 4750 490 600 2254 1290 1400
FX* 40 4750 490 600 2254 1290 1450
FX* 55 4750 490 600 2254 1290 1600
FX* 70 5050 890 600 2254 1725 1800
FX* 85 5050 890 600 2254 1725 1900
FX* 100 5050 890 600 2254 1725 2000
FX* 110 5650 860 2254 2000 2300
FX* 140 5650 860 2254 2000 2400
FX* 170 5650 860 2254 2000 2600
HANDLING
The equipment can be moved using the lifting holes on the
top of the unit.
The "sling" length is the value that we recommend for safe
handling of the equipment.
Some units can only be supported by four slings at right-
angles. Others require different lengths (see figure 3).
It is essential that all lifting holes are used and that the slings
are all of the same size to avoid damaging the equipment.
Sling length = 1580 mm
for angle = 45°C
FC.../FH.../FD.../FG... 050
Sling length = 2210 mm
for angle = 45°C
FC.../FH.../FD.../FG... 060 & 070

Page 6 - IOM / ROOF-TOP FLEXY™Series
TRANSPORT - HANDLING
Sling length = 1855 mm
for angle = 45°C
FC.../FH.../FD.../FG... 060 & 070 with centrifugal fans
Sling length = 2590 mm
for angle = 45°C
Sling length = 2330 mm
for angle = 64,5°C
FC.../FH.../FD.../FG... 085 & 100
Sling length = 2430 mm
for angle = 45°C
FC.../FH.../FD.../FG... 085 & 100 with centrifugal fans
Sling length = 3230 mm
for angle = 45°C
Sling length = 2830 mm
for angle = 45°C
Sling length = 1870
mm
for angle = 45°C

IOM / ROOF-TOP FLEXY™Series - Page 7
TRANSPORT - HANDLING
Sling length = 2080 mm
for angle = 45°C
FC.../FH.../FD... 120 & 140
Sling length = 2700 mm
for angle = 45°C
Sling length = 2410 mm
for angle = 45°C
FC.../FH.../FD... 120 & 140 with centrifugal fans
Sling length = 2080 mm
for angle = 45°C
FG... 120 & 140 with gas burner
Sling length = 2700 mm
for angle = 45°C
Sling length = 3000 mm
for angle = 45°C
Sling length = 1880 mm
for angle = 45°C

Page 8 - IOM / ROOF-TOP FLEXY™Series
TRANSPORT - HANDLING
Sling length = 2700 mm
for angle = 45°C
FG... 120 & 140 with gas burner and centrifugal fans
Sling length = 3300 mm
for angle = 45°C
Sling length = 2080 mm
for angle = 45°C
Sling length = 2090 mm
for angle = 45°C
FC.../FH.../FD... 160 & 190
FC.../FH.../FD... 160 & 190 with centrifugal fans
Sling length = 2700 mm
for angle = 45°C
Sling length = 2320 mm
for angle = 45°C
FG... 160 & 190
FG... 160 & 190 with centrifugal fans
Sling length = 3000 mm
for angle = 45°C

IOM / ROOF-TOP FLEXY™Series - Page 9
TRANSPORT - HANDLING
FX 25 & 30
Sling length = 3000 mm
FX 35 - 40 - 55
Sling length = 3700 mm
Sling length = 3900 mm
FX 70 - 85 - 100
Sling length = 4300 mm
FX 110 - 140 - 170