Lennox FCM 85 User manual

Providing indoor climate comfort
FLEXY II
FLEXYII-IOM-0308-E
Installation, operating
and maintenance

IOM –FLEXY II –0308 –E Page 1
INSTALLATION
OPERATION
MAINTENANCE MANUAL
Ref. FLEXYII_IOM/0308-E
The present manual applies to the following ROOFTOP versions:
FCM 85 -FCM 100 -FCM 120 -FCM 150 -FCM 170 -FCM200 -FCM 230
FHM 85 -FHM 100 -FHM 120 -FHM 150 -FHM 170 -FHM200 - FHM 230
FDM 85 -FDM 100 -FDM 120 -FDM 150 -FDM 170 -FDM200 -FDM 230
FGM 85 -FGM 100 -FGM 120 -FGM 150 -FGM 170 -FGM 200 -FGM 230
FXK 25 -FXK 30 -FXK 35 -FXK 40 -FXK 55 -FXK 70 -FXK 85 -FXK 100 -FXK 110 -FXK 150 -FXK 170
NOTES FOR UNIT FITTED WITH GAS BURNER:
LENNOX have been providing environmental solutions since 1895, our range of Baltic TM rooftop continues to meet the
standards that have made LENNOX a household name. Flexible design solutions to meet YOUR needs and uncompromising
attention to detail. Engineered to last, simple to maintain and Quality that becomes a standard. Further Information on
www.lennoxeurope.com.
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 informationsand 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.
CONTENTS
THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH LOCAL
SAFETY CODES AND REGULATIONS AND CAN ONLY BE USED IN WELL
VENTILATED 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.
Switchgear must be installed on each unit in accordance with the Machine
Directive and the standard NF EN 60204.

IOM –FLEXY II –0308 –E Page 2
COMMISSIONING SHEET..............................................................................................................................6
INSTALLATION
Transport -Handling.................................................................................................................................10
Dimensions and weights...........................................................................................................................12
Lifting the units.........................................................................................................................................14
Preliminary checks...................................................................................................................................15
Minimum clearance around the unit...........................................................................................................16
Installation on roof mounting frame ..........................................................................................................17
Curbing and flashing ................................................................................................................................18
Duct connections......................................................................................................................................19
Non-adjustable non-assembled roof curb installation.................................................................................20
Non-adjustable non-assembled roof curb installation instructions...............................................................21
Adjustable roof curb .................................................................................................................................22
Non-adjustable Non-assembled roof curb .................................................................................................23
Multidirectional roof curb ..........................................................................................................................24
Return roof curb ......................................................................................................................................25
Return horizontal roof curb .......................................................................................................................26
Transition roof curb ..................................................................................................................................27
Energy Recovery......................................................................................................................................28
Economiser and extraction .......................................................................................................................29
COMMISSIONING
Before connecting the power ....................................................................................................................30
CLIMATIC................................................................................................................................................31
Powering the unit .....................................................................................................................................31
Run test...................................................................................................................................................32
VENTILATION
Belt tension ....................................................................................................................................................33
Mounting ans adjusting pulleys......................................................................................................................34
Airflow balancing............................................................................................................................................35
Filters .............................................................................................................................................................43
Air sock control.........................................................................................................................................44
UV Light...................................................................................................................................................45
HEATING OPTIONS
Hot water coils .........................................................................................................................................46
Electric heater..........................................................................................................................................48
Gas burners.............................................................................................................................................49
Modulating gas burners............................................................................................................................60
CONTENTS

IOM –FLEXY II –0308 –E Page 3
ELECTRICAL DATA: WIRING DIAGRAMS
Diagram reference legend ........................................................................................................................69
Main current diagram TRI/400V/50Hz + T……………………………………………………. ............................70
CLIMATIC 50 controller………………………………………………………………………….............................72
CLIMATIC 50 input……………………………………………………………………………………......................73
CLIMATIC 50 output…………………………………………………………………………………. ......................74
DAD smoke detector……………………………………………………………………………… ..........................75
General customer connection (TCB..........................................................................................................76
General customer connection with Advanced Control Pack (ADC) .............................................................77
Gas burner 60 kW and hot water coil.........................................................................................................78
Gas burner 120 kW .................................................................................................................................79
Gas burner 180/240 kW............................................................................................................................80
Electric heater..........................................................................................................................................81
General customer connection diagram......................................................................................................82
Electrical data control variables.................................................................................................................83
REFRIGERATION CIRCUIT
R410A .....................................................................................................................................................84
Advanced scroll temperature protection (ASTP)........................................................................................85
Principle sketches....................................................................................................................................86
HOT WATER COIL.........................................................................................................................................90
MAINTENANCE DIAGNOSTIC.......................................................................................................................91
MAINTENANCE PLAN...................................................................................................................................94
WARRANTY...................................................................................................................................................97
CERTIFICATES..............................................................................................................................................98
CONTENTS

IOM –FLEXY II –0308 –E Page 4
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:
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 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 brazier. The brazing shall comply with 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.
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…
- It’s 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:
- It 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 modulemust 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, it’s mandatory to ensure that the gas distribution system is compatible with the
adjustment and settings of the unit.
IMPORTANT NOTICE –Safety instructions

IOM –FLEXY II –0308 –E Page 5
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
IMPORTANT NOTICE –Safety instructions

IOM –FLEXY II –0308 –E Page 6
Site details
Site
Unit Ref
Installer
………………………………………
……………………………………....
………………………………………
Controller
Model
Serial No
Refrigerant
………………………………….
……………….…………………
…………………………………
…………………………………
(1) ROOF INSTALLATION
Sufficient Access OK
Yes No Condensate drain fitted Yes No Roofcurb OK Not OK
(2) CONNECTIONS CHECK
Phase checkYes No Voltage between
Phases 1 / 2 ………………. 2 / 3 ………………. 1 / 3 ……………….
(3)CLIMATIC CONFIGURATION CHECK
CLIMATIC 50 Configured according to the Options and Specifications:
Yes No
(4) SUPPLY BLOWER SECTION
Type :
Power displayed on plate:
Voltage displayed on plate:
Current displayed on plate:
KW
V
A
N°1
……………………
……………………
……………………
N°2
……………………
……………………
……………………
Fan Type : Forward
Backward Forward Backward
Displayed Belt Length : mm …………………… ……………………
Tension Checked: Yes No Yes No
Alignment Checked : Yes No Yes No
Motor Pulley Diameter: DMmm …………………… ……………………
Fan Pulley Diameter: DPmm …………………… ……………………
Fan Speed = Motor rpm x DM/ DP
Averaged Measured Amps : rpm A …………………… …………………… …………………… ……………………
Shaft Mechanical Power (Refer to airflow balancing) W …………………… ……………………
Operating point checked : Yes No Yes No
Estimated Airflow m3/h …………………… ……………………
(5) AIRFLOW PRESS. SENSOR CHECK
Measured pressure drop…………………………… mbar Set Points Adjusted: Yes No
If Yes enter new values:
3410: ………… 3411: ………… 3412: …………
(6) EXTERNAL SENSOR CHECKS Check and record temp. in menu 2110
Yes Non
Check electrical connections :
Yes No 100% Fresh Air 100% return Air
Supply Temperature ………………………..°C ………………………..°C
Return Temperature ………………………..°C ………………………..°C
Outdoor Temperature ………………………..°C ………………………..°C
(7) MIXING AIR DAMPERS CHECKS
Dampers open & close freely
OK % Minimum FA: Power exhaust checked Enthalpy sensor(s) checked
Yes No ……………..% Yes No Yes No
COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 7
(8) REFRIGERATION SECTION
Outdoor Fan Motor Current: Check Rotation
Motor 1 / Moteur 1 L1 ……..A L2 ……..A L3 ……A Yes No
Motor 2 / Moteur 2 L1 ……..A L2 ……..A L3 ……A Yes No Compressor Voltage
Motor 3 / Moteur 3 L1 ……..A L2 ……..A L3 ……A Yes No Comp1: …….. V
Motor 4 / Moteur 4 L1 ……..A L2 ……..A L3 ……A Yes No Comp2: …….. V
Motor 5 / Moteur 5 L1 ……..A L2 ……..A L3 ……A Yes No Comp3: …….. V
Motor 6 / Moteur 6 L1 ……..A L2 ……..A L3 ……A Yes No Comp4: …….. V
Compressor Amps COOLING Pressures & Temperatures
Temperatures Pressures
Phase 1 Phase 2 Phase 3 Suction Discharge LP/ BP HP / HP
Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Check Reversing valves :
Valve1: Yes No Valve2: Yes No Valve3: Yes No Valve4: Yes No
Compressor Amps HEATING Pressures & Temperatures
Temperatures Pressures
Phase 1 Phase 2 Phase 3 Suction Discharge LP/ BP HP / HP
Comp 1 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 2 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 3 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
Comp 4 …..… A …..… A …..… A ……… °C ……… °C ……… Bar ……… Bar
HP cut out ……Bar LP cut out ………..…... Bar
Refrigerant charge C1 : ………..kg C2 : ………..kg C3 : ………..kg C4 : ………..kg
(8)ELECTRIC HEATER SECTION
Type : …………………………………………………. Serial No.:………………………..
AMPS 1st stage (Baltic) AMPS 2nd stage (Baltic)
1 ………………. 2 ………………. 3 ………………. 1 ………………. 2 ………………. 3 ……………….
(9) HOT WATER COIL SECTION
Check Three Way Valve Movement : Yes No
(10) GAS HEATING SECTION
Gas Burner N°1 Gas Burner N°2
Size :
………………………. Valve type : ……………………. Size : ………………………. Valve type : …………………….
Pipe size: Gas type : G……. Pipe size Gas type : G…….
Line pressure :
……………………… Drop test Yes No line pressure : ……………………… Drop test Yes No
Check manifold pressure:
High fire …….…Low fire ……….. Check manifold pressure: High fire …….…... Low fire ………..
Pressure cut out airflow press switch :
……………………mbar /Pa Pressure cut out airflow press switch : ……………………mbar /Pa
Motor amps :
……….A
Flue temp.
……… °C
CO2 %:
………%
CO ppm:
………%
Motor Amps:
……….A
Flue temp.
………. °C
CO2 %:
………%
CO ppm:
………%
(11) REMOTE CONTROL BMS CHECK
Type :
………………………….. Sensor type ……………………………….. KP07 KP/17 checked: Yes No Interconnect wiring checked: Yes No
COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 8
It is recommended that you fill the two tables below before transferring the zone settings to the Climatic 50 controller.
Refer to control section page 55 / Se référer à la section régulation page 55
Time Zones / Zones Horaires
Hour 0
1
2 3 4
5
6
7 8 9 10
11
12
13 14
15
16
17 18
19
20
21
22
23
Example UNO
7h15
ZA
11h00 ZB
14h00 ZC
19h00 UNO
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Variables to adjust for each time zone / Consignes à renseigner pour chaque zone horaire
Start z.A Start z.B Start z.C Start UNO
hour (3211)
min (3212)
hour (3213)
min (3214)
hour (3215)
min (3216) hour (3217)
min (3218)
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Description
Unit
Menu
Min Max Zone A Zone B Zone C UNOC
Sp Room °C 3311 8 35
Mini.Air % 3312 0 100
Sp Dyna °C 3321 0 99.9
Sp Cool °C 3322 8 35
Sp Heat °C 3323 8 35
Swap Heater On/Off
3324 ~ ~
Activation On/Off
3331 ~ ~
Swap Heater On/Off
3332 ~ ~
Sp.Dehu % 3341 0 100
Sp.Humi % 3342 0 100
Fan On/Off On/Off
3351 ~ ~
Fan Dead On/Off
3352 ~ ~
F.Air On/Off
3353 ~ ~
CO2 On/Off
3354 ~ ~
Comp.Cool. On/Off
3355 ~ ~
Comp.Heat. On/Off
3356 ~ ~
AuxHeat On/Off
3357 ~ ~
Humidif. On/Off
3358 ~ ~
Low Noise On/Off
3359 ~ ~ N/A N/A N/A
COMMISSIONING REPORT

IOM –FLEXY II –0308 –E Page 9
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COMMISSIONING REPORT